service and maintenance procedures

1

Infinity ICS --- Model 58MVC, Direct Vent 4---Way MultipoiseCondensing Gas Furnace With IdealComfortt IdealHumidityt

Service and Maintenance ProceduresNOTE: Read the entire instruction manual before starting theinstallation.

ELECTRICAL SHOCK, FIRE OR EXPLOSIONHAZARD

Failure to follow warnings could result in personal injury,death, or property damage.

Improper servicing could result in dangerous operation,serious injury, death, or property damage.

--Before servicing, disconnect all electrical power tofurnace.

--When servicing controls, label all wires prior todisconnecting. Reconnect wires correctly.

--Verify proper operation after servicing.

! WARNING

ELECTRICAL SHOCK, FIRE OR EXPLOSIONHAZARD

Failure to follow this warning could result in propertydamage, personal injury, or death.

The ability to properly perform maintenance on thisequipment requires certain expertise, mechanical skills,tools, and equipment. If you do not possess these, do notattempt to perform any maintenance on this equipmentother than those procedures recommended in the User’sManual.

! WARNING

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personalinjury, death, or property damage.

Never store anything on, near, or in contact with thefurnace, such as:

1. Spray or aerosol cans, rags, brooms, dust mops, vacuumcleaners, or other cleaning tools.

2. Soap powders, bleaches, waxes or other cleaningcompounds, plastic or plastic containers, gasoline, kerosene,cigarette lighter fluid, dry cleaning fluids, or other volatilefluids.

3. Paint thinners and other painting compounds, paper bags,or other paper products.

! WARNING

amaCERTIFIED

As an ENERGY STAR® Partner,Carrier Corporation has determinedthat this product meets the ENERGYSTAR® guidelines for energy effi-ciency.

REGISTERED

ISO 9001:2000

SAFETY CONSIDERATIONSRecognize safety information. This is the safety--alert symbol

. When you see this symbol on the unit and in instructions ormanuals, be alert to the potential for personal injury.

Understand the signal words DANGER, WARNING,CAUTION, and NOTE. These words are used with thesafety--alert symbol. DANGER identifies the most serioushazards which will result in severe personal injury or death.WARNING signifies hazards which could result in personalinjury or death. CAUTION is used to identify unsafe practiceswhich may result in minor personal injury or product andproperty damage. NOTE is used to highlight suggestions whichwill result in enhanced installation, reliability, or operation.

Untrained personnel can perform basic maintenance functionsdescribed in User’s Information Manual such as cleaning andreplacing air filters. All other operations must be performed bytrained service personnel. When working on heating equipment,observe precautions in the literature, on tags, and on labelsattached to or shipped with the unit and other safety precautionsthat may apply.

CUT HAZARD

Failure to follow this caution may result in personal injury.

Be careful of sharp metal edges, etc. Use care and wearprotective clothing, gloves, and safety glasses whenremoving parts.

CAUTION!

Installing and servicing heating equipment can be hazardous dueto gas and electrical components. Only trained and qualifiedservice agency personnel should install, repair, or service heatingequipment.

Follow all safety codes including the National Fuel Gas Code(NFGC) NFPA 54--2006/ANSI Z223.1--2006 in the USA, CSAB149.1--05 National Standard of Canada, Natural Gas andPropane Installation Codes (NSCNGPIC) in Canada, and theInstallation Standards, Warm Air Heating and Air ConditioningSystems (NFPA 90B) ANSI/NFPA 90B. Wear safety glasses andwork gloves. Have a fire extinguisher available during start--upand adjustment procedures and service calls.

2

A05085

Fig. 1 -- Multipoise Furnace in Upflow Orientation

GENERALThis furnace can be installed as a direct vent (2--pipe) or anoptional ventilated combustion air condensing gas furnace. Theseinstructions are written as if the furnace is installed in an upflowapplication. An upflow furnace application is where the blower islocated below the combustion and controls section of the furnace,and conditioned air is discharged upward. Since this furnace canbe installed in any of the 4 positions shown in Fig. 2, you mayneed to revise your orientation to component locationaccordingly.

UPFLOW

DOWNFLOW

HORIZONTALLEFT

AIRFLOW AIRFLOW

AIRFLOW

AIRFLOW

HORIZONTALRIGHT

A93041

Fig. 2 -- Multipoise Orientation

ELECTROSTATIC DISCHARGE (ESD)PRECAUTIONS

UNIT DAMAGE HAZARD

Failure to follow this caution may damage furnacecomponents.

Failure to follow this caution may damage furnacecomponents. Electrostatic discharge can affect electroniccomponents. Take precautions during furnace installationand servicing to protect the furnace electronic control.Precautions will prevent electrostatic discharges frompersonnel and hand tools which are held during theprocedure. These precautions will help to avoid exposingthe control to electrostatic discharge by putting the furnace,the control, and the person at the same electrostaticpotential.

CAUTION!

1. Disconnect all power to the furnace. DO NOT TOUCHTHE CONTROL OR ANY WIRE CONNECTED TOTHE CONTROL PRIOR TO DISCHARGING YOURBODY’S ELECTROSTATIC CHARGE TO GROUND.

2. Firmly touch a clean, unpainted, metal surface of thefurnace chassis which is close to the control. Tools held ina person’s hand during grounding will be satisfactorilydischarged.

3. After touching the chassis, you may proceed to service thecontrol or connecting wires as long as you do nothing thatrecharges your body with static electricity (for example;DO NOT move or shuffle your feet, DO NOT touchungrounded objects, etc.).

4. If you touch ungrounded objects (recharge your body withstatic electricity), firmly touch furnace again beforetouching control or wires.

5. Use this procedure for installed and uninstalled(ungrounded) furnaces.

6. Before removing a new control from its container,discharge your body’s electrostatic charge to ground toprotect the control from damage. If the control is to beinstalled in a furnace, follow items 1 through 5 beforebringing the control or yourself into contact with thefurnace. Put all used AND new controls into containersbefore touching ungrounded objects.

7. An ESD service kit (available from commercial sources)may also be used to prevent ESD damage.

CARE AND MAINTENANCEFor continuing high performance and to minimize possiblefurnace failure, it is essential that maintenance be performedannually. Consult your local dealer for maintenance andmaintenance contract availability.

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personalinjury or death.

Turn off the gas and electrical supplies to the unit beforeperforming any maintenance or service. Follow theoperating instructions on the label attached to the furnace.

! WARNING

58MVC

3

WASHABLEFILTER

FILTERSUPPORT

FILTERRETAINER

WASHABLE FILTER ORDISPOSABLE MEDIA FILTERIN FILTER CABINET

A00232

Fig. 3 -- Bottom Filter Arrangement

The minimum maintenance that should be performed on thisequipment is as follows:

1. Check and clean or replace air filter each month as needed.

2. Check blower motor and wheel for cleanliness annually.

3. Check electrical connections for tightness and controls forproper operation each heating season. Service asnecessary.

4. Check for proper condensate drainage. Clean as necessary.

5. Check for blockages in combustion--air and vent pipesannually.

6. Check burners for cleanliness annually.

A. CLEANING AND/OR REPLACING AIR FILTERThe air filter arrangement may vary depending on the applicationor orientation.

CARBONMONOXIDE POISONING HAZARD


Never operate unit without a filter or with the blower accesspanel removed. Operating a unit without a filter or with theblower access door removed could cause damage to thefurnace blower motor. Dust and lint on internal parts offurnace can cause a loss of efficiency.

! WARNING

NOTE: If the filter has an airflow direction arrow, the arrowmust point toward the blower.To clean or replace filters, proceed as follows:If filter is installed in filter cabinet adjacent to furnace:

1. Turn off electrical supply to furnace.

2. Remove filter cabinet door.

3. Slide filter out of cabinet.

4. If equipped with permanent, washable filter, clean filter byspraying cold tap water through filter in opposite directionof airflow. Rinse filter and let dry. Oiling or coating of thefilter is not recommended.

5. If equipped with factory specified disposable media filter,replace only with a factory specified media filter of thesame size.

FILTERRETAINER

WASHABLEFILTER

IN FURNACE

WASHABLE FILTER ORDISPOSABLE MEDIAFILTER IN FILTER CABINET

A00233

Fig. 4 -- Filter Installed for Side Inlet

6. Slide filter into cabinet.

7. Replace filter cabinet door.

8. Turn on electrical supply to furnace.

If filter is installed in furnace blower compartment:


2. Remove main furnace door and blower access panel.

3. Release filter retainer wire. (See Fig. 3 or 4.)

NOTE: Filters shown in Fig. 3 and 4 can be in furnace blowercompartment or in filter cabinet, but not in both.

4. Slide filter out of furnace.

5. Furnaces are equipped with permanent, washable filter(s).Clean filter by spraying cold tap water through filter inopposite direction of airflow.

6. Rinse filter and let dry. Oiling or coating filter is notrecommended.

7. Slide filter into furnace.

8. Recapture filter retaining wire.

9. Replace blower access panel and main furnace door.

10. Turn on electrical supply to furnace.

B. BLOWER MOTOR AND WHEEL MAINTENANCETo ensure long life, economy, and high efficiency, cleanaccumulated dirt and grease from blower wheel and motorannually.

The inducer and blower motors are pre--lubricated and require noadditional lubrication. These motors can be identified by theabsence of oil ports on each end of the motor.

The following items should be performed by a qualified servicetechnician.

58MVC

4

PLUG

CAP

COLLECTOR BOX DRAIN TUBE (BLUE &

WHITE STRIPED)

INDUCER HOUSING (MOLDED) DRAIN

TUBE (BEHIND COLLECTOR BOX

DRAIN TUBE)

COLLECTOR BOX TUBE (PINK)

COLLECTOR BOX DRAIN TUBE (BLUE)

COLLECTOR BOX TUBE (GREEN ,

ROUTES BEHIND INDUCER)

FIELD- INSTALLED FACTORY- SUPPLIED

DRAIN TUBE COUPLING (LEFT

DRAIN OPTION)


DRAIN TUBE

FIELD- INSTALLED FACTORY- SUPPLIED ½ - IN. CPVC STREET

ELBOWS (2) FOR LEFT DRAIN OPTION


DRAIN TUBE COUPLING (LEFT

DRAIN OPTION)

CONDENSATE TRAP

A07274

Fig. 5 -- Factory--Shipped Upflow Tube Configuration (Shown with Blower Access Panel Removed)

Clean blower motor and wheel as follows:


2. Remove main furnace door and blower access panel.

3. Disconnect wiresAll factory wires can be left connected, but fieldthermostat connections may need to be disconnecteddepending on their length and routing.

4. Position control box, transformer, and door switchassembly to right side of furnace casing.

5. If condensate trap is located in left-- or right--hand side offurnace casing, proceed to item 6. Otherwise remove trapand tubing as described below (See Fig. 5.):

a. Disconnect field drain connection from condensate trap.

b. Disconnect drain and relief port tubes from condensatetrap.

c. Remove condensate trap from blower shelf.

6. Remove screws securing blower assembly to blower shelfand slide blower assembly out of furnace. Detach groundwire and disconnect blower motor harness plugs fromblower motor.

NOTE: Blower wheel is fragile. Use care.

7. Clean blower wheel and motor by using a vacuum withsoft brush attachment. Be careful not to disturb balanceweights (clips) on blower wheel vanes. Do not bend wheelor blades as balance will be affected.

8. If greasy residue is present on blower wheel, removewheel from the blower housing and wash it with anappropriate degreaser. To remove wheel:

a. Mark blower wheel location on shaft before disassemblyto ensure proper reassembly.

b. Loosen setscrew holding blower wheel on motor shaft.

NOTE: Mark blower mounting arms and blower housing soeach arm is positioned at the same hole location duringreassembly.

c. Mark blower wheel orientation and cutoff plate locationto ensure proper reassembly.

d. Remove screws securing cutoff plate and remove cutoffplate from housing.

e. Remove bolts holding motor mounts to blower housingand slide motor and mounts out of housing.

f. Remove blower wheel from housing.

g. Cleanwheel per instructions on degreaser cleaner.Do notget degreaser in motor.

9. Reassemble motor and blower wheel by reversing items8b through 8f. Ensure wheel is positioned for properrotation.

NOTE: Be sure to attach ground wire and reconnect blowerharness plugs to blower motor.

10. Reinstall blower assembly in furnace.

11. Reinstall condensate trap and tubing if previouslyremoved.

a. Reinstall condensate trap in hole in blower shelf.

b. Connect condensate trap drain tubes. See Fig. 5 or tubingdiagram on main furnace door for proper tube location.

(1.) Connect 1 tube (blue or blue andwhite striped) fromcollector box.

(2.) Connect 1 tube (violet or unmarked) from inducerhousing.

(3.) Connect one tube (relief port, green or pink) fromcollector box.

c. Connect field drain to condensate trap.

NOTE: Ensure tubes are not kinked or pinched, as this willaffect operation.

12. Reinstall control box, transformer, and door switchassembly on blower shelf.

13. Reconnect wires.

a. Refer to furnace wiring diagram and connect thermostatleads if previously disconnected. (See Fig. 21.)

58MVC

5



Blower access panel door switch opens 115--v power tofurnace control. No component operation can occur.Caution must be taken when manually closing this switchfor service purposes.

! WARNING

14. Turn on electrical supply. Manually close blower accesspanel door switch. Use a piece of tape to hold switchclosed. Check for proper rotation and speed changesbetween heating and cooling by jumpering R to G and Rto Y/Y2 on furnace control thermostat terminals. (See Fig.15.)

15. If furnace is operating properly, release blower accesspanel door switch, replace blower access panel, andreplace main furnace door.

C. CLEANING BURNERSThe following items should be performed by a qualified servicetechnician. If the burners develop an accumulation of light dirt ordust, they may be cleaned by using the following procedure:

1. Turn off gas and electrical supplies to furnace.

2. Remove main furnace door.

3. Remove burner box cover.

4. Using backup wrench, disconnect gas supply pipe fromfurnace gas control valve.

UNIT DAMAGE HAZARD

Failure to follow this caution may result in furnacecomponent damage.

Label all wires prior to disconnection when servicingcontrols. Wiring errors can cause improper and dangerousoperation.

CAUTION!

5. Remove wires from gas valve. Note location forreassembly.

6. Remove burner box pressure tube from gas valve regulatorfitting.

7. Unplug igniter from harness.

8. Remove igniter leads from slot in manifold grommet.

9. Remove screws that secure manifold to burner box. (SeeFig. 6.)

NOTE: Do not remove burner box from cell panel.

10. Remove manifold, orifices, and gas valve as 1 assembly.

11. Remove screws attaching burner assembly in burner box.

NOTE: Use care when removing and reinstalling burners not tostrike the hot surface igniter.

12. Remove burner assembly from burner box. NOTE: Allburners are attached to burner bracket and can be removedas 1 assembly.

13. Clean burners with soft brush and vacuum.

14. Reinstall manifold, orifice, and gas valve assembly inburner box. Ensure manifold seal grommet is installedproperly and burners fit over orifices.

15. Reinsert the igniter wires in the slot in the manifoldgrommet, dressing the wires to ensure there is no tensionon the igniter itself. (See Fig. 7.)



Igniter wires must be securely placed in slot in manifoldgrommet or else they could become pinched or severed andelectrically shorted.

! WARNING

16. Reconnect wires to gas valve and igniter. Refer to furnacewiring diagram for proper wire location.

17. Reinstall burner box pressure tube to gas valve regulatorfitting.

18. Reinstall gas supply pipe to furnace gas control valveusing backup wrench on gas valve to prevent rotation andimproper orientation.

GAS CONTROL

VALVE

THROTTLING VALVE

MANIFOLD

GASKET

CELLPANEL

MANIFOLD MOUNTING SCREWS

GAS VALVE REGULATOR FITTING

A07562

Fig. 6 -- Burner Box Assembly

58MVC

6

IGNIT ER WIRES MUST BE PLACED IN THIS SLOT

A05074

Fig. 7 -- Igniter Wire Placement

PRIMARY HXINLET OPENINGS

A96305

Fig. 8 -- Cleaning Inlet Openings ofPrimary Heat Exchangers

PAM

RTV

A93087

Fig. 9 -- Combustion--air IntakeHousing Gasket Repair

58MVC

7

A07563

Fig. 10 -- Furnace Pressure and Drain Tubing Diagram

��BURNER FLAME

BURNER

MANIFOLD

A89020

Fig. 11 -- Burner Flame

NOTE: Use propane gas resistant pipe dope to prevent gas leaks.DO NOT use Teflon tape.

FIRE, EXPLOSION, UNIT DAMAGE HAZARD

Failure to follow this warning could result in personalinjury, death, or property damage,.

Gas valve switch MUST be facing forward or tilted slightly.

! WARNING


Failure to follow this warning could result in personalinjury or death or property damage.

Never test for gas leaks with an open flame. Use acommercially available soap solution made specifically forthe detection of leaks to check all connections.

! WARNING58MVC

8

19. Replace burner box cover.

20. Turn on gas and electrical supplies to furnace.

21. Check for gas leaks.

22. Replace main furnace door.

D. CLEANING HEAT EXCHANGERSThe following items should be performed by a qualified servicetechnician.

Primary Heat Exchangers

If the heat exchangers get an accumulation of light dirt or dust onthe inside, they may be cleaned by the following procedure:

NOTE: If the heat exchangers get a heavy accumulation of sootand carbon, both the primary and secondary heat exchangersshould be replaced rather than trying to clean them thoroughlydue to their intricate design. A build--up of soot and carbonindicates that a problem exists which needs to be corrected, suchas improper adjustment of manifold pressure, insufficient or poorquality combustion air, improper vent termination, incorrect sizeor damaged manifold orifice(s), improper gas, or a restricted heatexchanger (primary or secondary). Action must be taken tocorrect the problem.



UNIT DAMAGE HAZARD


Label all wires prior to disconnection when servicingcontrols. Wiring errors can cause improper and hazardousoperation.

CAUTION!

3. Disconnect wires or connectors to flame rollout switch,gas valve, igniter, and flame sensor.

4. Disconnect combustion--air intake pipe from intakehousing.

5. Remove the pressure switch tube from intake housing.

6. Remove screws attaching intake housing to burner box,and rotate intake housing away from burner box forremoval.

7. Using backup wrench, disconnect gas supply pipe fromfurnace gas control valve.

8. Disconnect pressure tubing from gas valve.

9. Remove two screws attaching top filler panel and rotateupwards to gain access to screws attaching burner box tocell panel.

10. Remove screws attaching burner box to cell panel. (SeeFig. 6.)

NOTE: Burner box, cover, manifold, gas valve, and burnerassembly should be removed as one assembly.

11. Clean heat exchanger openings with a vacuum and a softbrush. (See Fig. 8.) NOTE: After cleaning, inspect the heatexchangers to ensure they are free of all foreign objectsthat may restrict flow of combustion products.

12. Reverse items 4 through 10 for reassembly.

NOTE: Be sure burner box gasket is installed between burnerbox and cell panel. (See Fig. 6.) If gasket is damaged, replace it.

NOTE: Inspect combustion--air intake housing. If foamed gasketwas removed, check for any damage. If gasket is damaged in anyway, it must be repaired. To repair, remove damaged gasketsection, apply sealant releasing agent such as PAM cooking sprayor equivalent (must not contain corn nor canola oil, halogenatedhydrocarbons nor aromatic content, to prevent inadequate seal

from occurring) to burner box and apply a small bead of G.E.RTV 162, G.E. RTV 6702, or Dow--Corning RTV 738 sealant toedge of combustion--air intake housing. (See Fig. 9.)

UNIT MAY NOT OPERATE

Failure to follow this caution may result in improper unitoperation.

Failure to attach ground wire to an adequate casing groundmay cause the furnace control to lock out. The ground wirefrom the gas valve MUST be attached to the burner boxattachment screw.

CAUTION!

13. Refer to furnace wiring diagram and reconnect wires toflame rollout switch, gas valve, igniter, and flame sensor.

14. Reconnect pressure switch tubes to gas valve and intakehousing. Refer to tube routing label on main furnace doorfor proper tube location. (See Fig. 10.) Be sure tubes arenot kinked.


16. Check furnace operation through 2 complete heatoperating cycles. Look through sight glass in burnerenclosure to check burners. Burner flames should be clearblue, almost transparent. (See Fig. 11.)



Failure to follow this warning could result in personalinjury, death, or property damage.


! WARNING


E. Secondary Heat ExchangersNOTE: The condensing side (inside) of the secondary heatexchangers CANNOT be serviced or inspected. A small numberof bottom outlet openings can be inspected by removing theinducer assembly. See Flushing Collector Box and DrainageSystem section for details on removing inducer assembly.

F. FLUSHING COLLECTOR BOX AND DRAINAGESYSTEM1. Turn off gas and electrical supplies to furnace.


3. Disconnect inducer motor and pressure switch wires orconnectors.

4. Disconnect pressure switch tubes.

5. Disconnect vent pipe from inducer housing outlet byloosening coupling clamp on inducer outlet.

6. Disconnect drain tube from inducer housing. (See Fig.10.)

NOTE: Ensure the drain tube disconnected from the inducerhousing is higher than the collector box opening or water willflow out of tube.

7. Remove inducer housing assembly by removing 4 boltsattaching assembly to cell panel.

58MVC

9

UNIT DAMAGE HAZARD


DO NOT use wire brush or other sharp object to inspect ordislodge materials in secondary heat exchangers as cuttingof the secondary heat exchanger protective coating mayoccur. Flush with water only.

CAUTION!

8. Flush inside of collector box with water until dischargefrom condensate trap is clean and runs freely.

9. Inspect inside area of collector box for any pieces offoreign materials and remove them if present.

10. Reassemble inducer assembly by reversing items 5--7.Tighten the vent coupling clamp screw(s) to 15 in.--lb oftorque.

NOTE: If seal between the inducer housing and the collectorbox is damaged in any way, it must be repaired. To repair, applysealant releasing agent such as PAM cooking spray or equivalent(must not contain corn nor canola oil, halogenated hydrocarbonsnor aromatic content, to prevent inadequate seal from occurring)to inducer housing. (See Fig. 12.) Apply a small bead of G.E.RTV 162, G.E. RTV 6702, or Dow--Corning RTV 738 sealant togroove in collector box.

11. Refer to furnace wiring diagram and reconnect wires toinducer motor and pressure switches or connectors.

12. Reconnect pressure tubes to pressure switches. Seediagram on main furnace door for proper location of tubes.Be sure tubes are not kinked. (See Fig. 10.)


14. Check furnace operation through two complete heatoperating cycles. Check area below inducer housing, ventpipe, and condensate trap to ensure no condensate leaksoccur. If leaks are found, correct the problem.



RTV

PAM

A93081

Fig. 12 -- Gasket on Collector Box

FIRE AND EXPLOSION HAZARD

Failure to follow this warning could result in personalinjury, death or property damage.


! WARNING

G. SERVICING HOT SURFACE IGNITER

BURN HAZARD

Failure to follow this caution may result in personal injury.

Allow igniter to cool before removal. Normal operatingtemperatures exceed 2000_.

CAUTION!

The igniter does NOT require annual inspection. Check igniterresistance before removal.



3. Disconnect igniter wire connection.

4. Check igniter resistance. Igniter resistance is affected bytemperature. Only check resistance when the igniter is atroom temperature.

a. Using an ohm meter, check resistance across both igniterleads in connector.

b. Cold reading should be between 40 ohms and 70 ohms.

5. Remove igniter assembly.

a. Remove burner box cover.

b. Remove igniter wires from slot in manifold grommet.(See Fig. 7.)

c. Using a 1/4--in. driver, remove the single screw securingthe igniter bracket to the burnerbox bracket (See Fig. 13.)and carefully withdraw the igniter and bracket assemblythrough the front of the burner box without striking theigniter on surrounding parts. Note that the igniter brackethas a handle that extends to the front of the burner boxto aid in handling. (See Fig. 13.)

d. Inspect igniter for signs of damage or failure.

BRACKET

IGNITER

9/16˝

11/16˝

EXTENDED IGNITERBRACKET HANDLE

IGNITER BRACKETMOUNTING SCREW

A05075

Fig. 13 -- Igniter Bracket

58MVC

10

UNIT DAMAGE HAZARD

Failure to follow this caution may result in prematurefailure of the igniter.

The igniter is fragile. DO NOT allow it to hit burner boxparts while removing or replacing it.

CAUTION!

e. If replacement is required, replace igniter on igniterbracket and then install assembly into burnerbox to avoiddamage to the igniter.

6. To replace igniter and bracket assembly, reverse items 5athrough 5d.

7. Reconnect igniter wire connection and insert the igniterwires in the slot in the manifold grommet, dressing theigniter wires to ensure there is no tension on the igniteritself. (See Fig.7.)

ELECTRICAL OPERATION HAZARD


Igniter wires must be securely placed in slot in manifoldgrommet or else they could become pinched or severed andelectrically shorted.

! WARNING

2-5/32˝A04181

Fig. 14 -- Igniter

8. Reinstall burner box cover.


10. Verify igniter operation by initiating control boardself--test feature or by cycling thermostat.


H. ELECTRICAL CONTROLS AND WIRING



There may be more than 1 electrical supply to the unit.Check accessories and cooling unit for additional electricalsupplies.

! WARNING

The electrical ground and polarity for 115--v wiring must bemaintained properly. Refer to Fig. 15 for field wiring informationand to Fig. 21 for unit wiring information.

NOTE: If the polarity is not correct or furnace is not properlygrounded, the STATUS LED on the furnace control will flashrapidly and prevent the furnace from operating. The controlsystem also requires an earth ground for proper operation of thefurnace control and flame sensor.The 24--v circuit contains an automotive--type, 3--amp fuselocated on the furnace control. (See Fig. 16.) Any direct shorts ofthe 24--v wiring during installation, service, or maintenance willcause this fuse to blow. If fuse replacement is required, use ONLYa fuse of identical size. The furnace control LED will flash statuscode 24 when fuse needs to be replaced.With power to the unit disconnected, check all electricalconnections for tightness. Tighten all screws on electricalconnections. If any smoky or burned connections are found,disassemble the connection, clean all parts, strip wire, andreassemble properly and securely.Reconnect electrical supply to unit and observe unit through 1complete operating cycle and check for proper operation.

I. CHECKING HEAT TAPE OPERATION(IF APPLICABLE)

In applications where the ambient temperature around the furnaceis 32_F or lower, freeze protection measures are required. If thisapplication is where heat tape has been applied, check to ensure itwill operate when low temperatures are present.

NOTE: Heat tape, when used, should be wrapped around thecondensate drain trap and drain line. There is no need to use heattape within the furnace casing. Most heat tapes are temperatureactivated, and it is not practical to verify the actual heating of thetape. Check the following:

1. Check for signs of physical damage to heat tape such asnicks, cuts, abrasions, gnawing by animals, etc.

2. Check for discolored heat tape insulation. If any damageor discolored insulation is evident, replace heat tape.

3. Check that heat tape power supply circuit is on.

UNIT AND PROPERTY DAMAGE HAZARD

Failure to follow this caution may result in furnacecomponent failures or water property damage.

If this furnace is to be operated in an unconditioned spacewhere the ambient temperatures may be 32_F (0_C) orlower, freeze protection measures must be taken. SeeCONDENSATE DRAIN PROTECTION section ofInstallation, Start--up, and Operating Instructions. (See Fig.17.)

CAUTION!

58MVC

11

115-VOLT FIELD-SUPPLIED

FUSEDDISCONNECT

JUNCTIONBOX

CONTROLBOX

24-VOLTTERMINALBLOCK

THREE-WIREHEATING-

ONLY

FIVEWIRE

NOTE 2

NOTE 1

1-STAGETHERMOSTATTERMINALS

FIELD-SUPPLIEDFUSED DISCONNECT

CONDENSINGUNIT

FURNACE

COM

R

W C Y R G

GND

GND

FIELD 24-VOLT WIRINGFIELD 115-, 208/230-, 460-VOLT WIRINGFACTORY 24-VOLT WIRINGFACTORY 115-VOLT WIRING

Connect Y/Y2-terminal as shown for proper operation.Some thermostats require a "C" terminal connection as shown.If any of the original wire, as supplied, must be replaced, usesame type or equivalent wire.

208/230- OR460-VOLTTHREEPHASE

208/230-VOLTSINGLEPHASE

WHT

BLK

WHT

BLK

A95236

W/W1

W2

Y/Y2

G

NOTES: 1.2.3.

A95236

Fig. 15 -- Field Wiring

J. WINTERIZING

UNIT DAMAGE HAZARD


Freezing condensate left in the furnace may damage thefurnace.

CAUTION!

If the furnace will be off for an extended period of time in astructure where the temperature will drop to 32_F (0_C) orbelow, winterize as follows:



3. Disconnect upper inducer housing drain connection capfrom inducer housing. (See Fig. 18.)

4. Connect field--supplied 1/2--in. I.D. inducer housing tubeto upper inducer housing drain connection.

5. Insert funnel in tube and pour one quart of antifreeze,propylene glycol (RV, swimming pool antifreeze, orequivalent) into funnel/tube until it is visible at pointwhere condensate enters open drain. (See Fig. 19.)

UNIT DAMAGE HAZARD

Failure of plastic components may occur.

Do not use ethylene glycol (Prestone II antifreeze/coolant orequivalent automotive type).

CAUTION!

6. Replace drain connection cap and clamp to inducerhousing.


8. Propylene glycol need not be removed before restartingfurnace.

WIRING DIAGRAMSSee Fig. 15, 16 and 21 for the Deluxe 4--Way Multipoise Furnacewiring diagrams.

TROUBLESHOOTINGUse the troubleshooting guide, the status code LED on thefurnace control and the component test to isolate furnaceoperation problems.

A more detailed troubleshooting guide is available from yourdistributor.

For an explanation of status codes, refer to service label locatedon back of main furnace door (See Fig. 20.)

The furnace control stores all status codes for a period of 72hours, regardless of 115--v or 24--v power interruption.

NOTE: Removing blower access panel opens blower accesspanel door switch and terminates 115--v power to furnace control.Before removing blower access panel or turning off 115--v power,look into blower access panel sight glass for current LED status.

1. To retrieve status code, proceed with the following:

NOTE: NO thermostat signal may be present at furnace controland all blower time delay periods must be completed.

a. Leave 115--v power to furnace turned on.

b. Remove main furnace door.

c. Look into bloweraccesspanel sight glass for currentLEDstatus code.

d. Remove blower access panel.

e. Turn setup switch SW1--1 to ON position. (See Fig. 16or 21 for location.)

f. Manually close blower access panel door switch. Use apiece of tape to hold switch closed.

58MVC

12

ELECTRICAL SHOCK, UNIT MAY NOT OPERATEHAZARD


Blower access panel door switch opens 115--v power tofurnace control. No component operation can occur unlessswitch is closed. Caution must be taken when manuallyclosing this switch for service purposes.

! WARNING

g. TheAMBER LEDwill flash the status codes in the orderof occurence. Record status codes until status code 11flashes (1 short and 1 long).

h. After status code #11 flashes, the status codes will repeatuntil setup switch SW1--1 is turned off.

i. Remove tape to release blower access panel door switchand replace blower access panel.

j. Operate furnace through 1 heat cycle to test for properoperation and check LED status.

k. If furnace is operating properly and LEDs indicateproperoperation, replace main furnace door.

2. Status codes are erased after 72 hours or they can bemanually erased by performing the following procedure:

a. Look into bloweraccesspanel sight glass for currentLEDstatus code.

b. Remove blower access panel.

c. Turn setup switch SW1--1 to ON position. (See Fig. 16or 21 for location.)

d. Jumper thermostat terminals R, W/W1, and Y/Y2 onfurnace control.

e. Manually close blower access panel door switch. Use apiece of tape to hold switch closed.

f. After status code 11 flashes for at least 2 times, removeR, W/W1, and Y/Y2 jumpers.

g. Turn setup switch SW1--1 to OFF position.

h. Remove tape to release blower access panel door switchand replace blower access panel.

i. Operate furnace through 1 heat cycle to check for properoperation and check LED status.

j. If furnace is operating properly and LEDs indicateproperoperation, replace main furnace door.

3. The control can also assist in troubleshooting byperforming a Component Test. The Component Test willfunctionally operate all furnace components, except thegas valve.

NOTE: The component test feature will not operate if thefurnace control is receiving any thermostat signals or until alltime delays have expired.

a. To initiate Component Test proceed with the following:

(1.) Leave 115--v power to furnace turned on.

(2.) Remove main furnace door.

(3.) Remove blower access panel.

(4.) Turn setup switch SW1--6 to ON position.

(5.) Manually close blower access panel door switch.Use a piece of tape to hold switch closed.

b. When items (1) through (5) above have been completed,the following will occur:

(1.) Inducer motor operates at medium speed throughstep (3), then turns off.

(2.) After waiting for 15 sec, hot surface igniter isenergized for 15 sec, then de--energized.

(3.) Main blowermotor operates atmidrange airflow for15 sec, then turns off.

(4.) After component operation test is completed, 1 ormore fault codes (11, 25, 41, or 42) will flash. Seeservice label on back of main furnace door or Fig.20 for explanation of codes.

NOTE: To repeat component test, turn setup switch SW1--6 toOFF and then back to ON.

c. After component test, perform the following:

(1.) Remove tape to release blower access panel doorswitch and turn setup switch SW1--6 to OFFposition.

(2.) Replace blower access panel.

(3.) Operate furnace through 1 heat cycle to check forproper operation and check LED status.

(4.) If furnace is operating properly and LEDs indicateproper operation, replace main furnace door.

58MVC

13

24-V THERMOSTAT TERMINALS

PL2 – HOT SURFACE IGNITER & INDUCER

MOTOR CONNECTOR

115-VAC (L2) NEUTRAL CONNECTIONS

115-VAC (L1) LINE VOLTAGE CONNECTIONS

EAC-1 TERMINAL (115 -VAC 1.0 AMP MAX.)

PL1 – LOW VOLTAGE MAIN HARNESS CONNECTOR

PL3 – ECM BLOWER HARNESS

CONNECTOR

TRANSFORMER 24-VAC CONNECTIONS

3-AMP FUSE

STATUS AND COMM LED LIGHTS

SW1 SETUP SWITCHES AND BLOWER OFF-

DELAY

MODEL PLUG CONNECTOR

AIR CONDITIONING (A/C) AIRFLOW

SETUP SWITCHES

USER INTERFACE OR ADVANCED

PRODUCT MONITOR

CONNECTOR

CONTINUOUS FAN (CF) AIRFLOW

SETUP SWITCHES OAT

CONNECTOR

HUMIDIFIER TERMINAL (24-VAC

0.5 AMP MAX.

ACRDJ – AIR CONDITIONING RELAY DISABLE

JUMPER

FLASH UPGRADE

CONNECTOR (FACTORY

ONLY)

SW4 SETUP SWITCHES

BOARD SERIAL NUMBER

EXAMPLE: V12 HK42FZ022 3407

SOFTWARE VERSION NUMBER

DATE CODE

PART NUMBER

A07422

Fig. 16 -- Variable Capacity Furnace Control

58MVC

14

32oF MINIMUM INSTALLEDAMBIENT OR FREEZEPROTECTION REQUIRED

A93058

Fig. 17 -- Freeze Protection

A99118

Fig. 18 -- Inducer Housing Drain Tube

A99119

Fig. 19 -- Funnel in Drain Tube and AntifreezeRunning Through Trap

58MVC

15

A07564

Fig. 20 -- Service Label

58MVC

16

A06677

Fig. 21 -- Wiring Diagram

58MVC

17

Is A

MBE

R LE

D s

tat

us li

ght o

n?

Is th

ere

24V

at S

EC-1

and

SEC

-2?

Is th

ere

115V

at L

1 an

d L2

?

Repl

ace

furn

ace

cont

rol.

Is d

oor s

witc

h cl

osed

?

Repl

ace

tran

sfor

mer

.

Repl

ace

door

sw

itch.

Is th

ere

115V

goi

ng to

sw

itch?

Clos

e do

or s

witc

h.

Is c

ircui

t bre

aker

clo

sed?

Chec

k fo

r con

tinui

ty in

wire

from

circ

uit

brea

ker t

o fu

rnac

e.

Clos

e ci

rcui

t bre

aker

and

go

back

to

STA

RT.

Is A

MBE

R LE

D s

tatu

s li

ght b

linki

ng

rapi

dly

with

out a

pau

se?

Chec

k fo

r cor

rect

line

vol

tage

pol

arity

. If

units

are

twin

ned,

che

ck fo

r pro

per l

ow-

volta

ge (2

4V) t

rans

form

er p

hasi

ng.

Is A

MBE

R LE

D s

tatu

s li

ght b

linki

ng

ON

/OFF

slo

wly

with

a c

ombi

natio

n of

Det

erm

ine

stat

us c

ode.

The

sta

tus

code

dete

rmin

ed b

y th

e nu

mbe

r of s

hort

To re

call

prev

ious

sta

tus

code

s di

scon

nect

the

R th

erm

osta

t con

nect

ion,

rese

t pow

er, a

nd p

ut s

etup

sw

itch

SW1-

1 in

the

ON

pos

ition

. Th

e A

MBE

R LE

D

will

repe

at.

Stat

us c

odes

ar

e er

ased

aft

er 7

2 ho

urs

or c

an b

e m

anua

lly e

rase

d by

put

ting

setu

p sw

itch

SW1-

1 in

the

ON

pos

ition

an

d ju

mpe

ring

R, W

/W1,

and

Y/Y

2 si

mul

tane

ousl

y

setu

p sw

itch

SW1-

1 in

the

OFF

pos

ition

.

Was

ther

e a

prev

ious

sta

tus

code

oth

er

than

#11

?

Go

to s

ectio

n be

low

for t

he s

tatu

s co

de

Doe

s th

e co

ntro

l res

pond

to W

/W1,

W2,

Y1

, Y/Y

2, a

nd G

(24V

) th

erm

osta

t si

gnal

s?

Run

syst

em th

roug

h a

low

-hea

t, m

ediu

m-

heat

, hig

h-he

at, o

r coo

ling

cycl

e to

che

ck

oper

atio

n. S

tatu

s co

des

are

eras

ed a

fter

72

hou

rs o

r can

be

man

ually

era

sed

by

putt

ing

setu

p sw

itch

SW1-

1 in

the

ON

po

sitio

n an

d ju

mpe

ring

R, W

/W1,

and

Y/

Y2 s

imul

tane

ousl

y un

til s

tatu

s co

de

Is 2

4V p

rese

nt a

t W/W

1, W

2, Y

1, Y

/Y2

or

G th

erm

osta

t ter

min

als

on th

e fu

rnac

e co

ntro

l?

Chec

k ro

om th

erm

osta

t or

inte

rcon

nect

ing

cabl

e.

Dis

conn

ect a

ll th

e th

erm

osta

t wire

s fr

om

the

furn

ace

cont

rol.

Doe

s th

e pr

oble

m re

peat

whe

n us

ing

a ju

mpe

r wire

? Re

plac

e fu

rnac

e co

ntro

l.

The

ther

mos

tat i

s no

t com

patib

le w

ith th

e fu

rnac

e co

ntro

l. E

ither

inst

all a

bal

last

re

sist

or, c

onne

ct th

e Co

m24

V th

erm

osta

t te

rmin

al to

the

ther

mos

tat,

or re

plac

e th

e th

erm

osta

t.

YES

NO

YES

YES

YES

YES

YES

S

EY

S

EY

S

EY

YES

STA

RT

YES

YES

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

Trou

bles

hoot

ing

Gui

de

A07581

58MVC

18

11

NO

PRE

VIO

US

COD

E –

Stat

us c

odes

are

er

ased

aft

er 7

2 ho

urs

or c

an b

e m

anua

lly

eras

ed b

y pu

ttin

g se

tup

switc

h SW

1-1

in

the

ON

pos

ition

and

jum

perin

g R,

W/W

1,

and

Y/Y2

sim

ulta

neou

sly

until

sta

tus

code

#1

1 is

flas

hed.

Run

sys

tem

thro

ugh

a lo

w-

heat

, hig

h-he

at, o

r coo

ling

cycl

e to

che

ck

syst

em.

12

BLO

WER

ON

AFT

ER P

OW

ER U

P –

(115

V O

R 24

V) –

Nor

mal

ope

ratio

n.

Blow

er ru

ns fo

r 90

seco

nds,

if u

nit i

s po

wer

ed u

p du

ring

a ca

ll fo

r hea

t (R-

W/W

1 cl

osed

) or w

hen

(R-W

/W1

open

s)

durin

g th

e bl

ower

on-

dela

y pe

riod.

13

LIM

IT C

IRCU

IT L

OCK

OU

T –

Lock

out

occu

rs if

the

limit

or

flam

e ro

llout

sw

itch

is

open

long

er th

an 3

min

utes

or 1

0 su

cces

sive

lim

it tr

ips

occu

rred

dur

ing

high

-he

at.

Cont

rol w

ill a

uto-

rese

t aft

er 3

hou

rs.

See

code

33.

14

IGN

ITIO

N L

OCK

OU

T –

Syst

em fa

iled

to

igni

te g

as a

nd p

rove

flam

e in

4 a

ttem

pts.

Co

ntro

l will

aut

o-re

set a

fter

3 h

ours

. Se

e st

atus

cod

e 34

.

21

GA

S H

EATI

NG

LO

CKO

UT

– Tu

rn o

ff po

wer

and

wai

t 5 m

inut

es to

retr

y. C

heck

fo

r:

- St

uck

clos

ed g

as v

alve

rela

y on

con

trol

.

- M

isw

ire o

r sho

rt to

gas

val

ve w

ire.

22

ABN

ORM

AL

FLA

ME-

PRO

VIN

G S

IGN

AL

Flam

e is

pro

ved

whi

le g

as v

alve

is d

e-en

ergi

zed.

Ind

ucer

will

run

until

faul

t is

clea

red.

Che

ck fo

r:

- St

uck

open

or l

eaky

gas

val

ve.

23

PRES

SURE

SW

ITCH

DID

NO

T O

PEN

–

Chec

k fo

r: -

Obs

truc

ted

pres

sure

tube

. -

Pres

sure

sw

itch

stuc

k cl

osed

.

24

SECO

ND

ARY

VO

LTA

GE

FUSE

IS O

PEN

Ch

eck

for:

-

Shor

t circ

uit i

n se

cond

ary

volta

ge (2

4V)

wiri

ng in

clud

ing

ther

mos

tat l

eads

. D

isco

nnec

t the

rmos

tat l

eads

to is

olat

e sh

ort c

ircui

t.

32

LOW

-HEA

T PR

ESSU

RE S

WIT

CH D

ID

NO

T CL

OSE

OR

REO

PEN

ED –

If o

pens

du

ring

blow

er o

n-de

lay

perio

d, b

low

er w

ill

com

e on

for t

he s

elec

ted

blow

er o

ff-de

lay.

If

open

s w

ithin

5 m

inut

es a

fter

igni

tion

the

next

hea

ting

cycl

e w

ill b

e re

stric

ted

to

high

-hea

t. C

heck

for:

-

Prop

er v

ent s

izin

g.

- Lo

w in

let g

as p

ress

ure

(if L

GPS

use

d).

- Re

stric

ted

com

bust

ion

air s

uppl

y.

- D

isco

nnec

ted

or o

bstr

ucte

d pr

essu

re

tubi

ng.

- D

efec

tive

or m

isw

ired

pres

sure

sw

itche

s -

Exce

ssiv

e w

ind.

If p

robl

em p

ersi

sts

turn

se

tup

switc

h SW

1-3

ON

. -

Plug

ged

cond

ensa

te d

rain

. -

Wat

er in

ven

t pip

ing,

pos

sibl

e sa

ggin

g pi

pe.

33

LIM

IT C

IRCU

IT F

AU

LT –

Indi

cate

s th

e lim

it or

flam

e ro

llout

sw

itch

is o

pen

or th

e fu

rnac

e is

ope

ratin

g in

hig

h-he

at o

nly

mod

e du

e to

2 s

ucce

ssiv

e lo

w- o

r m

ediu

m-h

eat l

imit

trip

s. B

low

er w

ill ru

n fo

r 4

min

. or u

ntil

open

sw

itch

rem

akes

w

hich

ever

is lo

nger

. If

open

long

er th

an 3

m

in.,

code

cha

nges

to lo

ckou

t #13

. If

open

less

than

3 m

in.

sta

tus

code

#33

co

ntin

ues

to fl

ash

until

blo

wer

shu

ts o

ff.

Flam

e ro

llout

sw

itch

requ

ires

man

ual

rese

t. C

heck

for:

-

Prop

er re

ar a

ir ba

ffle.

-

Loos

e bl

ower

whe

el.

- D

efec

tive

switc

h or

con

nect

ions

. -

Impr

oper

low

- or m

ediu

m-h

eat g

as in

put

adju

stm

ent.

- Im

prop

er o

r mis

alig

ned

limit

and/

or li

mit

shie

ld.

- St

uck

high

-hea

t sol

enoi

d in

gas

val

ve.

34

IGN

ITIO

N P

ROVI

NG

FA

ILU

RE –

If fl

ame

is

not s

ense

d du

ring

the

tria

l for

igni

tion

perio

d, th

e co

ntro

l will

repe

at th

e ig

nitio

n se

quen

ce 3

mor

e tim

es b

efor

e lo

ckou

t #14

oc

curs

. If

flam

e si

gnal

is lo

st d

urin

g th

e bl

ower

on-

dela

y pe

riod,

blo

wer

will

com

e on

fo

r the

sel

ecte

d bl

ower

off-

dela

y. C

heck

th

e fo

llow

ing

item

s fir

st b

efor

e pr

ocee

ding

to

the

next

ste

p.

-

Gas

val

ve tu

rned

off.

-

Man

ual s

hut-

off v

alve

. -

Gre

en/Y

ello

w w

ire M

UST

be

conn

ecte

d to

furn

ace

shee

t met

al.

- Fl

ame

sens

or m

ust n

ot b

e gr

ound

ed.

To d

eter

min

e w

heth

er th

e pr

oble

m is

in th

e ga

s va

lve,

igni

ter,

or fl

ame

sens

or th

e sy

stem

can

be

oper

ated

in c

ompo

nent

test

m

ode.

To

chec

k th

e ig

nite

r rem

ove

the

R th

erm

osta

t con

nect

ion

from

the

cont

rol,

rese

t pow

er, a

nd p

ut s

etup

sw

itch

SW1-

6 in

th

e O

N p

ositi

on to

sta

rt th

e co

mpo

nent

test

. D

oes

the

igni

ter g

low

ora

nge/

whi

te b

y th

e en

d of

the

15 s

econ

d w

arm

-up

perio

d?

Unp

lug

igni

ter h

arne

ss fr

om c

ontr

ol a

nd

repe

at c

ompo

nent

test

by

turn

ing

setu

p sw

itch

SW1-

6 O

FF a

nd th

en b

ack

ON

. Ch

eck

for 1

15V

betw

een

pin

3 an

d N

EUTR

AL-

L2 o

n th

e co

ntro

l. W

as 1

15V

pres

ent f

or th

e 15

sec

ond

perio

d?

Chec

k co

nnec

tions

and

retr

y.

If cu

rren

t is

near

typi

cal v

alue

(4

.0-6

.0 n

omin

al) a

nd b

urne

rs

will

not

sta

y on

, rep

eat c

heck

in

hig

h-he

at.

If bu

rner

s w

ill

still

not

sta

y on

repl

ace

cont

rol.

If b

urne

rs o

pera

te in

hi

gh-h

eat t

hen

switc

h to

m

ediu

m-h

eat,

chec

k m

anifo

ld

pres

sure

. If

OK,

che

ck

burn

er c

arry

over

and

flam

e se

nsor

loca

tion.

Clea

n fla

me

sens

or w

ith fi

ne s

teel

woo

l an

d re

chec

k cu

rren

t. N

omin

al c

urre

nt is

4.

0 to

6.0

mic

roam

ps.

Is c

urre

nt n

ear t

ypic

al v

alue

?

Repl

ace

elec

trod

e.

Will

mai

n bu

rner

s ig

nite

and

sta

y on

? Re

plac

e fu

rnac

e co

ntro

l.

Fixe

d.

NO

YES

YES

YES

NO

NO

15

BLO

WER

MO

TOR

LOCK

OU

T –

Indi

cate

s th

e bl

ower

faile

d to

reac

h 25

0 RP

M o

r the

bl

ower

faile

d to

com

mun

icat

e w

ithin

30

seco

nds

afte

r bei

ng tu

rned

ON

in tw

o su

cces

sive

hea

ting

cycl

es.

Cont

rol w

ill

auto

-res

et a

fter

3 h

ours

. Se

e co

de 4

1.

45

CON

TRO

L CI

RCU

ITRY

LO

CKO

UT

Aut

o-re

set

afte

r 1 h

our l

ocko

ut d

ue

to:

- Fl

ame

circ

uit f

ailu

re.

- G

as v

alve

rela

y st

uck

open

.-

Soft

war

e ch

eck

erro

r. Re

set p

ower

to c

lear

lo

ckou

t. R

epla

ce c

ontr

ol

if co

de re

peat

s.

Repl

ace

furn

ace

cont

rol.

Chec

k fo

r con

tinui

ty in

the

harn

ess

and

igni

ter.

Rep

lace

de

fect

ive

com

pone

nt.

Reco

nnec

t the

R th

erm

osta

t lea

d an

d se

t th

erm

osta

t to

call

for h

eat.

Con

nect

vo

ltmet

er a

cros

s ga

s va

lve

conn

ectio

ns.

Doe

s ga

s va

lve

rece

ive

24V?

Doe

s ga

s va

lve

open

and

allo

w g

as to

flo

w?

Do

the

mai

n bu

rner

s ig

nite

?

Do

the

mai

n bu

rner

s st

ay o

n?

Allo

w u

nit t

o dr

op to

low

-hea

t, an

d ch

eck

man

ifold

pre

ssur

e.

Repe

at te

st to

che

ck fo

r in

term

itten

t ope

ratio

n.

Chec

k th

at a

ll ga

s va

lves

are

tu

rned

on.

Rep

lace

val

ve.

Chec

k co

nnec

tions

. If

OK,

re

plac

e co

ntro

l.

Chec

k fo

r: -

Inad

equa

te fl

ame

carr

yove

r or

roug

h ig

nitio

n.

- Lo

w in

let g

as p

ress

ure.

-

Prop

er fi

ring

rate

. -

Air

leak

age

arou

nd ig

nite

r br

acke

t.

Repe

at c

all f

or h

eat a

nd c

heck

flam

e se

nsor

cur

rent

dur

ing

tria

l for

igni

tion

perio

d. I

s th

e D

C m

icro

amps

bel

ow 0

.5?

YES

YES

YES

YES

YES

NO

NO

NO

NO

NO

NO

43

LOW

-HEA

T PR

ESSU

RE S

WIT

CH O

PEN

W

HIL

E M

EDIU

M-H

EAT

PRES

SURE

SW

ITCH

IS C

LOSE

D -

Che

ck fo

r: -

Low

-hea

t pre

ssur

e sw

itch

stuc

k op

en.

- D

isco

nnec

ted

or o

bstr

ucte

d pr

essu

re

tubi

ng.

- Im

prop

er p

ress

ure

switc

h w

iring

. -

Low

inle

t gas

pre

ssur

e (if

LG

PS u

sed)

. -

Plug

ged

cond

ensa

te d

rain

. -

Wat

er in

ven

t pip

ing,

pos

sibl

e sa

ggin

g pi

pe.

A07582

58MVC

19

25

INVA

LID

MO

DEL

SEL

ECTI

ON

OR

SETU

P ER

ROR

– If

stat

us c

ode

25 o

nly

flash

es 4

tim

es o

n po

wer

-up

the

cont

rol i

s m

issi

ng it

s m

odel

plu

g PL

4 an

d is

de

faul

ting

to th

e m

odel

sel

ectio

n st

ored

in

mem

ory.

If s

tatu

s co

de 2

5 fla

shes

co

ntin

uous

ly it

cou

ld in

dica

te a

ny o

f the

fo

llow

ing:

- M

odel

plu

g PL

4 is

mis

sing

and

ther

e is

no

val

id m

odel

sto

red

in p

erm

anen

t m

emor

y. T

his

will

hap

pen

if yo

u fo

rget

to

inst

all t

he m

odel

plu

g PL

4 on

a

serv

ice

repl

acem

ent c

ontr

ol.

-

Ther

mos

tat c

all w

ith S

W1-

1 O

N.

-

Ther

mos

tat c

all w

ith S

W1-

6 O

N.

-

SW1-

1 an

d SW

1-6

both

ON

.

- Tw

o di

ffere

nt fu

rnac

e m

odel

s tw

inne

d.

-

Serv

ice

repl

acem

ent c

ontr

ol d

oes

not

reco

gniz

e ne

w m

odel

plu

gs H

K70E

Z017

th

ru H

K70E

Z021

. N

eed

boar

d so

ftw

are

vers

ion

V12

or la

ter.

31

MED

IUM

-HEA

T PR

ESSU

RE S

WIT

CH O

R H

PSR

RELA

Y D

ID N

OT

CLO

SE O

R RE

OPE

NED

- Ch

eck

for:

-

HPS

R re

lay

may

be

defe

ctiv

e.

-

See

stat

us c

ode

32.

41

BLO

WER

MO

TOR

FAU

LT –

Indi

cate

s th

e bl

ower

faile

d to

reac

h 25

0 RP

M o

r the

bl

ower

faile

d to

com

mun

icat

e w

ithin

the

pres

crib

ed ti

me

limits

. Th

irty

seco

nds

afte

r bei

ng tu

rned

ON

or t

en s

econ

ds

durin

g st

eady

-sta

te o

pera

tion.

Tur

n po

wer

off

and

che

ck th

e fo

llow

ing

item

s fir

st

befo

re p

roce

edin

g to

the

next

ste

p.

-

Rubb

ing

blow

er w

heel

.

- Lo

ose

blow

er w

heel

.

- W

iring

from

furn

ace

cont

rol t

o bl

ower

m

otor

.

Rem

ove

the

R th

erm

osta

t con

nect

ion

from

th

e fu

rnac

e co

ntro

l, di

scon

nect

bot

h co

nnec

tors

from

the

blow

er m

otor

PL1

3 an

d PL

14.

Doe

s th

e bl

ower

whe

el tu

rn

free

ly?

Repl

ace

the

blow

er c

ontr

ol m

odul

e at

tach

ed to

th

e bl

ower

mot

or.

Follo

w th

e in

stru

ctio

ns w

ith

the

blow

er c

ontr

ol m

odul

e to

mak

e su

re th

e en

tire

blow

er m

otor

doe

s no

t nee

d to

be

repl

aced

.

Turn

pow

er b

ack

on.

Is th

ere

115V

AC

at

PL14

-5 a

nd P

L14-

4?

You

have

an

open

wire

or b

ad

term

inal

on

eith

er th

e BL

ACK

or

WH

ITE

pow

er le

ads

betw

een

the

furn

ace

cont

rol a

nd th

e bl

ower

mot

or.

If yo

u ha

ve a

po

wer

cho

ke d

isco

nnec

t it a

nd

chec

k co

ntin

uity

.

YES

YES

NO

NO

Is th

ere

12-V

DC

at P

L13-

1 RE

D (+

) and

PL

13-4

GRE

EN (-

)?

YES

NO

Is th

ere

12-V

DC

at P

L3-1

RED

(+) a

nd

PL3-

2 G

REEN

(-)?

Repl

ace

the

furn

ace

cont

rol.

NO

You

have

an

open

wire

or b

ad

term

inal

on

eith

er th

e RE

D o

r G

REEN

wire

bet

wee

n th

e fu

rnac

e co

ntro

l and

the

blow

er

mot

or.

YES

Is th

ere

5-VD

C at

PL1

3-2

YELL

OW

(+)

and

PL13

-4 G

REEN

(-)?

Is th

ere

5-VD

C at

PL3

-3

YELL

OW

(+) a

nd P

L3-2

G

REEN

(-)?

NO

NO

You

have

an

open

wire

or b

ad

term

inal

on

the

YELL

OW

wire

be

twee

n th

e fu

rnac

e co

ntro

l and

th

e bl

ower

mot

or.

YES

YES

The

volta

ge ju

st m

easu

red

shou

ld b

e ve

ry s

tabl

e an

d sh

ould

not

fluc

tuat

e m

ore

than

.02-

VDC.

If t

he v

olta

ge fl

uctu

ates

m

ore

than

this

get

a d

iffer

ent v

oltm

eter

be

fore

pro

ceed

ing.

Turn

pow

er o

ff, d

isco

nnec

t PL1

3 an

d PL

14 fr

om th

e bl

ower

mot

or, t

hen

turn

po

wer

bac

k on

. Co

nnec

t a D

C vo

ltmet

er

acro

ss P

L13-

3 BL

UE

(+) a

nd P

L13-

4 G

REEN

(-).

The

vol

tage

sho

uld

be n

ear

0-VD

C bu

t it w

ill fl

uctu

ate

brie

fly s

ever

al

times

a s

econ

d. I

f you

hav

e an

ana

log

voltm

eter

the

need

le w

ill b

riefly

go

high

se

vera

l tim

es a

sec

ond.

If y

ou h

ave

a di

gita

l vol

tmet

er w

ith a

bar

gra

ph it

will

sh

ow a

larg

e ch

ange

in m

agni

tude

on

the

bar g

raph

sev

eral

tim

es a

sec

ond.

If y

ou

have

a s

tand

ard

digi

tal v

oltm

eter

it w

ill

show

a b

rief fl

uctu

atio

n in

vol

tage

and

the

mag

nitu

de m

ay v

ary

depe

ndin

g on

the

voltm

eter

use

d.

Doe

s th

e vo

ltage

fluc

tuat

e as

des

crib

ed in

the

prev

ious

ste

p?

Conn

ect a

DC

voltm

eter

acr

oss

PL3-

4 BL

UE

(+) a

nd P

L3-2

GRE

EN (-

). D

oes

the

volta

ge

fluct

uate

as

desc

ribed

two

step

s ba

ck?

You

have

an

open

wire

or b

ad te

rmin

al o

n th

e BL

UE

wire

bet

wee

n th

e fu

rnac

e co

ntro

l and

the

blow

er m

otor

.

NO

Repl

ace

the

furn

ace

cont

rol.

YES

Turn

pow

er o

ff, re

conn

ect P

L13

and

PL14

to th

e bl

ower

mot

or, t

hen

turn

po

wer

bac

k on

. Co

nnec

t a D

C vo

ltmet

er

acro

ss P

L3-3

YEL

LOW

(+) a

nd P

L3-2

G

REEN

(-).

Doe

s th

e vo

ltage

fluc

tuat

e m

ore

than

it d

id in

the

prev

ious

ste

p?

NO

YES

YES

NO

Repl

ace

the

blow

er c

ontr

ol m

odul

e at

tach

ed to

th

e bl

ower

mot

or.

Follo

w th

e in

stru

ctio

ns w

ith

the

blow

er c

ontr

ol m

odul

e to

mak

e su

re th

e en

tire

blow

er m

otor

doe

s no

t nee

d to

be

repl

aced

.

42

IND

UCE

R M

OTO

R FA

ULT

– In

dica

tes

the

indu

cer m

otor

has

not

sta

rted

with

in 2

0 se

cond

s af

ter a

cal

l for

hea

t, th

e in

duce

r m

otor

RPM

is o

utsi

de it

s va

lid ra

nge

of

oper

atio

n, o

r the

indu

cer R

PM s

igna

l was

lo

st fo

r 5 s

econ

ds d

urin

g op

erat

ion.

Ch

eck

for:

-

Prop

er v

ent s

izin

g.

-

Faile

d in

duce

r mot

or.

-

Rest

ricte

d co

mbu

stio

n ai

r sup

ply.

- Im

prop

er m

otor

wiri

ng.

A07583

58MVC

20

SERVICE TRAINING

Packaged Service Training programs are an excellent way to increase yourknowledge of the equipment discussed in this manual, including: • Unit Familiarization • Maintenance • Installation Overview • Operating SequenceA large selection of product, theory, and skills programs is available, using popularvideo-based formats and materials. All include video and/or slides, plus companionbook.

Classroom Service Training plus "hands-on" the products in our labs can meanincreased confidence that really pays dividends in faster troubleshooting, fewercallbacks. Course descriptions and schedules are in our catalog.

CALL FOR FREE CATALOG 1-800-644-5544

[ ] Packaged Service Training [ ] Classroom Service Training

Copyright 2007 Carrier Corp. S 7310 W. Morris St. S Indianapolis, IN 46231

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

Catalog No: 58MVC---01SMReplaces: New

Printed in U.S.A. Edition Date: 07/07

58MVC

service and maintenance procedures

Documents