1
58MCB
4 --- W a y M u l t i p o i s e F i x e d --- C a p a c i t y
Co ndensing Gas Furnace
Service and Maintenance Instructions
For Sizes 040-- 120, Series 110 & 120
NOTE: Read the entire instruction manual before starting the
installation.
TABLE OF CONTENTS
PAGE
SAFETY CONSIDERATIONS 1.........................
GENERAL 2.........................................
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS 2...
CARE AND MAINTENANCE 3.........................
Cleaning and/or Replacing Air Filter 3....................
Blower Motor and Wheel Maintenance 4..................
Cleaning Burners 6...................................
Cleaning Heat Exchangers 7............................
Primary Heat Exchangers 6............................
Secondary Heat Exchangers 7..........................
Flushing Collector Box and Drainage System 8.............
Servicing Hot Surface Igniter 10.........................
Electrical Controls and Wiring 11........................
Checking Heat Tape Operation (If Applicable) 11...........
Winterizing 13......................................
WIRING DIAGRAM 13................................
TROUBLESHOOTING 13..............................
Status Codes 13.....................................
Component Tests 14..................................
ELECTRICAL SHOCK, FIRE, OR EXPLOSION
HAZARD
Failure to follow safety warnings exactly could result in
dangerous operation, personal injury, death, or property
damage.
-- Before servicing, disconnect all electrical power to furnace.
--When servicing controls, label all wires prior to
disconnecting. Reconnect wires correctly.
-- Verify proper operation after servicing.
!
WARNING
SAFETY CONSIDERATIONS
Recognize safety information. This is the safety--alert symbol .
When you see this symbol on the furnace and in instructions or
manuals, be alert to the potential for personal injury.
Understand the signal words DANGER, WARNING, and
CAUTION. These words are used with the safety--alert symbol.
DANGER identifies the most serious hazards which will result in
severe personal injury or death. WARNING signifies a hazard
which could result in personal injury or death. CAUTION is used
to identify unsafe practices which may result in minor personal
injury or product and property damage. NOTE is used to highlight
suggestions which will result in enhanced installation, reliability, or
operation.
ELECTRICAL SHOCK, FIRE, OR EXPLOSION
HAZARD
Failure to follow this warning could result in possible
damage to this equipment, personal injury, or death.
The ability to properly perform maintenance on this
equipment requires certain expertise, mechanical skills,
tools, and equipment. If you do not possess these, do not
attempt to perform any maintenance on this equipment
other than those procedures recommended in the User’s
Manual.
!
WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could property damage,
personal injury, or death.
Never store anything on, near, or in contact with the furnace,
such as:
1. Spray or aerosol cans, rags, brooms, dust mops, vacuum
cleaners, or other cleaning tools.
2. Soap powders, bleaches, waxes or other cleaning
compounds, plastic or plastic containers, gasoline, kerosene,
cigarette lighter fluid, dry cleaning fluids, or other volatile
fluids.
3. Paint thinners and other painting compounds, paper bags,
or other paper products.
!
WARNING
2
A05078
Fig. 1 -- Furnace in Upflow Orientation
ama
REGISTERED
ISO 9001:2000
CERTIFIED
Installing and servicing heating equipment can be hazardous due to
gas and electrical components. Only trained and qualified
service agency personnel should install, repair, or service
heating equipment. Untrained personnel can perform basic
maintenance functions described in User’s Information
Manual such as cleaning and replacing air filters. All other
operations must be performed by trained service personnel. When
working on heating equipment, observe precautions in the
literature, on tags, and on labels attached to or shipped with the
unit and other safety precautions that may apply.
Follow all safety codes including the National Fuel Gas Code
(NFGC) NFPA 54--2006/ANSI Z223.1--2006 in the USA, CSA
B149.1--05 National Standard of Canada, Natural Gas and Propane
Installation Codes (NSCNGPIC) in Canada, and the Installation
Standards, Warm Air Heating and Air Conditioning Systems
(NFPA 90B) ANSI/NFPA 90B. Wear safety glasses and work
gloves. Have a fire extinguisher available during start--up and
adjustment procedures and service calls.
UNIT DAMAGE HAZARD
Failure to follow this caution may result in damage to
furnace.
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and dangerous
operation.
CAUTION
!
GENERAL
This furnace can be installed as a direct vent (2--pipe) or non--direct
vent (1--pipe) condensing gas furnace. These instructions are
written as if the furnace is installed in an upflow application. An
upflow furnace application is where the blower is located below
the combustion and controls section of the furnace, and
conditioned air is discharged upward. Since this furnace can be
installed in any of the 4 positions shown in Fig. 2, you may need to
revise your orientation to component location accordingly.
UPFLOW
DOWNFLOW
HORIZONTAL
LEFT
AIRFLOW
AIRFLOW
AIRFLOW
AIRFLOW
HORIZONTAL
RIGHT
A93041
Fig. 2 -- Multipoise Orientation
ELECTROSTATIC DISCHARGE (ESD)
PRECAUTIONS
UNIT DAMAGE HAZARD
Failure to follow this caution may damage furnace
components.
Electrostatic discharge can affect electronic components.
Take precautions during furnace installation and servicing
to protect the furnace electronic control. Precautions will
prevent electrostatic discharges from personnel and hand
tools which are held during the procedure. These
precautions will help to avoid exposing the control to
electrostatic discharge by putting the furnace, the control,
and the person at the same electrostatic potential.
CAUTION
!
1. Disconnect all power to the furnace. DO NOT TOUCH
THE CONTROL OR ANY WIRE CONNECTED TO THE
CONTROL PRIOR TO DISCHARGING YOUR BODY’S
ELECTROSTATIC CHARGE TO GROUND.
2. Firmly touch a clean, unpainted, metal surface of the fur-
nace chassis which is close to the control. Tools held in a
58MCB
3
person’s hand during grounding will be satisfactorily dis-
charged.
3. After touching the chassis, you may proceed to service the
control or connecting wires as long as you do nothing that
recharges your body with static electricity (for example; DO
NOT move or shuffle your feet, DO NOT touch ungroun-
ded objects, etc.).
4. If you touch ungrounded objects (recharge your body with
static electricity), firmly touch furnace again before touch-
ing control or wires.
5. Use this procedure for installed and uninstalled (ungroun-
ded) furnaces.
6. Before removing a new control from its container, discharge
your body’s electrostatic charge to ground to protect the
control from damage. If the control is to be installed in a
furnace, follow items 1 through 5 before bringing the con-
trol or yourself into contact with the furnace. Put all used
AND new controls into containers before touching un-
grounded objects.
7. An ESD service kit (available from commercial sources)
mayalsobeusedtopreventESDdamage.
CARE AND MAINTENANCE
For continuing high performance and to minimize possible furnace
failure, it is essential that maintenance be performed annually.
Consult your local dealer for maintenance and maintenance
contract availability.
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
Turn off the gas and electrical supplies to the unit before
performing any maintenance or service. Follow the operating
instructions on the label attached to the furnace.
!
WARNING
The minimum maintenance that should be performed on this
equipment 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 for
proper operation each heating season. Service as necessary.
4. Check for proper condensate drainage. Clean as necessary.
5. Check for blockages in combustion--air and vent pipes an-
nually.
6. Check burners for cleanliness annually.
CUT HAZARD
Failure to follow this caution may result in personal injury.
Be careful of sharp metal edges, etc. Use care and wear
protective clothing, gloves, and safety glasses when
removing parts.
CAUTION
!
Step 1 — Cleaning and/or Replacing Air Filter
The air filter arrangement may vary depending on the application
or orientation. See Table 1 or 2 for filter size and type.
FILTER
FILTER
SUPPORT
FILTER
RETAINER
A08586
Fig. 3 -- Bottom Filter Arrangement
FILTER
RETAINER
FILTER
A08587
Fig. 4 -- Filter Installed for Side Inlet
FIRE, CARBON MONOXIDE POISONING
HAZARD
Failure to follow this warning could result in personal injury,
death or property damage.
Never operate unit without a filter or with the blower access
panel removed. Operating a unit without a filter or with the
blower access door removed could cause damage to the
furnace blower motor. Dust and lint on internal parts of
furnace can cause a loss of efficiency.
!
WARNING
NOTE: If the filter has an airflow direction arrow, the arrow must
point toward the blower.
To clean or replace filters, proceed as follows:
If filter is installed in filter cabinet adjacent to furnace:
58MCB
4
Table 1 – Furnace Air Filter Table
FURNACE CASING WIDTH
IN (MM)
FILTER QUANTITY AND SIZE *
FILTER TYPE*SIDE RETURN*
IN (MM)
BOTTOM RETURN*
IN (MM)
17---1/2 (445)
(1) 16 x 25 x 3/4
(406 x 635 x 19)
(1) 16 x 25 x 3/4
(406 x 635 x 19)
3/4” (19 mm ) thick washable
21 (533 )
(1) 16 x 25 x 3/4
(406 x 635 x 19)
(1) 20 x 25 x 3/4
(508 x 635 x 19)
3/4” (19 mm ) thick washable
24---1/2 (610)
(1) 16 x 25 x 3/4
(406 x 635 x 19)
(1) 24 x 25 x 3/4
(610 x 635 x 19)
3/4” (19 mm ) thick washable
Table 2 – Air Filter Located in Filter Cabinet
FILTER CABINET HEIGHT --- IN (MM) F I LT E R S I Z E --- I N ( M M ) FILTER TYPE
16 (406)
(1) 16 x 25 x 3/4*
(406 x 635 x 19) or
(1) 16 x 25 x 4--- 5/16
(406 x 635 x 110)
washable
20 (508)
(1) 20 x 25 x 3/4*
(508 x 635 x 19) or
(1) 20 x 25 x 4--- 5/16
(508 x 635 x 110)
washable
24 (610)
(1) 24 x 25 x 3/4*or
(610 x 635 x 19) or
(1) 24 x 25 x 4--- 5/16
(610 x 635 x 110)
washable
* Filters with a side return--air may have a different filter size. Measure the filter to obtain the correct size.
COLLECTOR BOX
TUBE (PINK)
COLLECTOR BOX
TUBE (GREEN)
INDUCER HOUSING
(MOLDED) DRAIN
TUBE (BEHIND
COLLECTOR BOX
DRAIN TUBE)
COLLECTOR BOX
DRAIN TUBE (BLUE)
FIELD-INSTALLED
FACTORY-SUPPLIED
DRAIN TUBE
COUPLING (LEFT
DRAIN OPTION)
FIELD-INSTALLED
FACTORY-SUPPLIED
DRAIN TUBE
FIELD-INSTALLED
FACTORY-SUPPLIED
1
⁄
2
-IN. CPVC STREET
ELBOWS (2) FOR
LEFT DRAIN OPTION
FIELD-INSTALLED
FACTORY-SUPPLIED
DRAIN TUBE
COUPLING (RIGHT
DRAIN OPTION)
CAP
COLLECTOR BOX
DRAIN TUBE (BLUE
& WHITE STRIPED)
PLUG
CONDENSATE
TRAP
A05110
Fig. 5 -- Factory--Shipped Upflow Tube Configuration
(Shown with Blower Access Panel Removed)
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 by
spraying cold tap water through filter in opposite direction
of airflow. Rinse filter and let dry. Oiling or coating of the
filter is not recommended.
5. If equipped with factory specified disposable media filter,
replace only with a factory specified media filter of the same
size.
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:
1. Turn off electrical supply to furnace.
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 blower
compartment or in filter cabinet, but not in both.
4. Slide filter out of furnace.
5. If furnaces are equipped with permanent, washable filter(s),
clean filter by spraying cold tap water through filter in op-
posite direction of airflow.
6. Rinse filter and let dry. Oiling or coating filter is not recom-
mended.
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.
Step 2 — Blower Motor and Wheel Maintenance
To ensure long life, economy, and high efficiency, clean
accumulated dirt and grease from blower wheel and motor
annually.
The inducer and blower motors are pre--lubricated and require no
additional lubrication. These motors can be identified by the
absence of oil ports on each end of the motor.
The following items should be performed by a qualified service
technician.
Clean blower motor and wheel as follows:
58MCB
5
1. Turn off electrical supply to furnace.
2. Remove main furnace door and blower access panel.
3. Disconnect wires
All factory wires can be left connected, but field thermostat
connections may need to be disconnected depending on
their length and routing.
4. Remove control box mounting screws, and position control
box, transformer, and door switch assembly to right side of
furnace casing.
5. If condensate trap is located in left-- or right--hand side of
furnace casing, proceed to item 6. Otherwise remove trap
and tubing as described below (See Fig. 5.):
a. Disconnect field drain connection from condensate trap.
b. Disconnect drain and relief port tubes from condensate
trap.
c. Remove condensate trap from blower shelf.
6. Remove screws securing blower assembly to blower shelf
and slide blower assembly out of furnace. Detach ground
wire and disconnect blower motor harness plugs from
blower motor.
NOTE: Blower wheel is fragile. Use care.
7. Clean blower wheel and motor by using a vacuum with soft
brush attachment. Be careful not to disturb balance weights
(clips) on blower wheel vanes. Do not bend wheel or blades
as balance will be affected.
8. If greasy residue is present on blower wheel, remove wheel
from the blower housing and wash it with an appropriate
degreaser. To remove wheel:
a. Mark blower wheel location on shaft before disassembly
to ensure proper reassembly.
b. Loosen setscrew holding blower wheel on motor shaft.
NOTE: Mark blower mounting arms and blower housing so each
arm is positioned at the same hole location during reassembly.
c. Mark blower wheel orientation and cutoff plate location
to ensure proper reassembly.
d. Remove screws securing cutoff plate and remove cutoff
plate from housing.
e. Remove bolts holding motor mounts to blower housing
and slide motor and mounts out of housing. Disconnect
capacitor and ground wire attached to blower housing
before removing motor. Motor mounts need not be
removed from motor.
f. Remove blower wheel from housing.
UNIT DAMAGE HAZARD
Failure to follow this caution may result in noise or furnace
component failure.
The blower wheel should not be dropped or bent as balance
will be affected.
CAUTION
!
g. Clean wheel per instructions on degreaser cleaner. Do
not get degreaser in motor.
9. Reassemble motor and blower wheel by reversing items 8b
through 8f. Ensure wheel is positioned for proper rotation.
Be sure to reattach ground wire. Tighten setscrew to 140 to
160 in--lb torque.
NOTE: Be sure to attach ground wire to blower housing.
10. Reinstall blower assembly in furnace.
11. Reinstall control box, transformer, and door switch as-
sembly on blower shelf.
12. Reinstall condensate trap and tubing if previously removed.
a. Reinstall condensate trap in hole in blower shelf.
b. Connect condensate trap drain tubes. See Fig. 5 or
tubing diagram on main furnace door for proper tube
location.
NOTE: Ensure tubes are not kinked or pinched, as this will affect
operation.
(1.) Connect one tube (blue or blue and white striped)
from collector box.
(2.) Connect one tube (violet or unmarked) from in-
ducer housing.
(3.) Connect one tube (relief port, green or pink) from
collector box.
c. Connect field drain to condensate trap.
NOTE: Ensure tubes are not kinked or pinched, as this will affect
operation.
13. Reinstall control box, transformer, and door switch as-
sembly on blower shelf.
14. Reconnect wires. Refer to furnace wiring diagram and con-
nect thermostat leads if previously disconnected. (See Fig.
21.)
NOTE: Refer to Table 3 for motor speed lead reconnection if
leads were not identified before disconnection.
UNIT DAMAGE HAZARD
Failure to adjust the heating speed may shorten heat
exchanger life.
Heating speed selection MUST be adjusted to provide
proper temperature rise as specified on the rating plate.
CAUTION
!
Table 3 – Speed Selection
COLOR SPEED
FACTORY
ATTACHED TO
Black High Cool
Yellow (When Present) Medium High Spare
Blue Medium Low Heat
Red Low Fan
White Common Com
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Blower access panel door switch opens 115--v power to
furnace control. No component operation can occur.
Caution must be taken when manually closing this
switch for service purposes.
!
WARNING
15. Turn on electrical supply. Manually close blower access
panel door switch. Use a piece of tape to hold switch closed.
Check for proper rotation and speed changes between heat-
ing and cooling by jumpering R to G and R to Y/Y2 on
furnace control thermostat terminals. (See Fig. 15.)
16. If furnace is operating properly, release blower access panel
door switch, replace blower access panel, and replace main
furnace door.
58MCB
6
MANIFOLD
MOUNTING
SCREWS
MANIFOLD
GAS VALVE
REGULATOR
FITTING
GAS
CONTROL
VALVE
CELL
PANEL
GASKET
A02312
Fig. 6 -- Burner Box Assembly
Step3—CleaningBurners
The following items should be performed by a qualified service
technician. If the burners develop an accumulation of light dirt or
dust, 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 from fur-
nace gas control valve.
UNIT DAMAGE HAZARD
Failure to follow this caution may result in furnace
component damage.
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and dangerous
operation.
CAUTION
!
5. Remove wires from gas valve. Note location for reassembly.
6. Remove burner box pressure tube from gas valve regulator
fitting.
7. Unplug igniter from harness.
8. Remove igniter leads from slot in manifold grommet.
9. Remove screws that secure manifold to burner box. (See
Fig. 6.)
NOTE: Do not remove burner box from cell panel.
10. Remove manifold, orifices, and gas valve as one assembly.
11. Remove screws attaching burner assembly in burner box.
NOTE: Use care when removing and reinstalling burners not to
strike the hot surface igniter.
IGNIT ER WIRES MUST
BE PLACED IN THIS SLOT
A05074
Fig. 7 -- Igniter Wire Placement
12. Remove burner assembly from burner box.
NOTE: All burners are attached to burner bracket and can be
removed as one assembly.
13. Clean burners with soft brush and vacuum.
14. Reinstall manifold, orifice, and gas valve assembly in burn-
er box. Ensure manifold seal grommet is installed properly
and burners fit over orifices.
15. Reinsert the igniter wires in the slot in the manifold grom-
met, dressing the wires to ensure there is no tension on the
igniter itself. (See Fig. 7.)
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Igniter wires must be securely placed in slot in manifold
grommet or else they could become pinched or severed
and electrically shorted.
!
WARNING
16. Reconnect wires to gas valve and igniter. Refer to furnace
wiring diagram for proper wire location.
17. Reinstall burner box pressure tube to gas valve regulator fit-
ting.
18. Reinstall gas supply pipe to furnace gas control valve using
backup wrench on gas valve to prevent rotation and im-
proper orientation.
NOTE: Use propane gas resistant pipe dope to prevent gas leaks.
DO NOT use Teflon tape.
58MCB
7
FIRE, EXPLOSION, UNIT DAMAGE HAZARD
Failure to follow this warning could result in personal
injury, death, or property damage.
Gas valve switch MUST be facing forward or tilted
slightly.
!
WARNING
19. Replace burner box cover.
20. Turn on gas and electrical supplies to furnace.
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death or property damage.
Never test for gas leaks with an open flame. Use a
commercially available soap solution made specifically
for the detection of leaks to check all connections.
!
WARNING
21. Check for gas leaks.
22. Replace main furnace door.
Step 4 — Cleaning Heat Exchangers
The following items should be performed by a qualified service
technician.
Primary Heat Exchangers
If the heat exchangers get an accumulation of light dirt or dust on
the inside, they may be cleaned by the following procedure:
NOTE: If the heat exchangers get a heavy accumulation of soot
and carbon, both the primary and secondary heat exchangers
should be replaced rather than trying to clean them thoroughly due
to their intricate design. A build--up of soot and carbon indicates
that a problem exists which needs to be corrected, such as improper
adjustment of manifold pressure, insufficient or poor quality
combustion air, improper vent termination, incorrect size or
damaged manifold orifice(s), improper gas, or a restricted heat
exchanger (primary or secondary). Action must be taken to correct
the problem.
1. Turn off gas and electrical supplies to furnace.
2. Remove main furnace door.
UNIT DAMAGE HAZARD
Failure to follow this caution may result in furnace
component damage.
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and hazardous
operation.
CAUTION
!
3. Disconnect wires or connectors to flame rollout switch, gas
valve, igniter, and flame sensor.
4. Disconnect combustion--air intake pipe from intake hous-
ing.
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 for removal.
7. Using backup wrench, disconnect gas supply pipe from fur-
nace gas control valve.
8. Disconnect pressure tubing from gas valve.
9. Remove two screws attaching top filler panel and rotate up-
wards to gain access to screws attaching burner box to cell
panel.
10. Remove screws attaching burner box to cell panel. (See Fig.
6.)
NOTE: Burner box, cover, manifold, gas valve, and burner
assembly should be removed as one assembly.
11. Clean heat exchanger openings with a vacuum and a soft
brush. (See Fig. 8.)
NOTE: After cleaning, inspect the heat exchangers to ensure they
are free of all foreign objects that may restrict flow of combustion
products.
PRIMARY HX
INLET OPENINGS
A96305
Fig. 8 -- Cleaning Inlet Openings of Primary
Heat Exchangers
UNIT MAY NOT OPERATE
Failure to follow this caution may result in improper or
intermittent unit operation.
The ground wire from the gas valve MUST be attached to
the burner box attachment screw.
CAUTION
!
12. Reverse items 3 through 10 for reassembly.
NOTE: Be sure burner box gasket is installed between burner box
and cell panel. (See Fig. 6.) If gasket is damaged, replace it.
NOTE: Inspect combustion--air intake housing. If foamed gasket
was removed, check for any damage. If gasket is damaged in any
way, it must be repaired. To repair, remove damaged gasket
section, apply sealant releasing agent such as PAM cooking spray
or equivalent (must not contain corn nor canola oil, halogenated
hydrocarbons 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 to edge
of combustion--air intake housing. (See Fig. 9.)
58MCB
8
PAM
RTV
A93087
Fig. 9 -- Combustion--Air Intake Housing
Gasket Repair
13. Refer to furnace wiring diagram and reconnect wires to
flame rollout switch, gas valve, igniter, and flame sensor.
14. Reconnect pressure switch tubes to gas valve and intake
housing. Refer to tube routing label on main furnace door
for proper tube location. (See Fig. 10.) Be sure tubes are not
kinked.
15. Turn on gas and electrical supplies to furnace.
16. Check furnace operation through two complete heat operat-
ing cycles. Look through sight glass in burner enclosure to
check burners. Burner flames should be clear blue, almost
transparent. (See Fig. 11.)
17. Check for gas leaks.
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death or property damage.
Never test for gas leaks with an open flame. Use a
commercially available soap solution made specifically
for the detection of leaks to check all connections.
!
WARNING
18. Replace main furnace door.
Secondary Heat Exchangers
NOTE: The condensing side (inside) of the secondary heat
exchangers CANNOT be serviced or inspected. A small number of
bottom outlet openings can be inspected by removing the inducer
assembly. See Flushing Collector Box and Drainage System
section for details on removing inducer assembly.
Step 5 — Flushing Collector Box and Drainage
System
1. Turn off gas and electrical supplies to furnace.
2. Remove main furnace door.
3. Disconnect inducer motor and pressure switch wires or con-
nectors.
4. Disconnect pressure switch tubes.
5. Disconnect vent pipe from inducer housing outlet by
loosening coupling clamp on inducer outlet.
6. Disconnect drain tube from inducer housing. (See Fig. 10.)
NOTE: Ensure the drain tube disconnected from the inducer
housing is higher than the collector box opening or water will flow
out of tube.
7. Remove inducer housing assembly by removing 4 bolts at-
taching assembly to cell panel.
58MCB
9
Furnace is shipped from factory in upflow configuration. Pressure tube and drain tube routing MUST match the diagrams below.
Tube location when used in DOWNFLOW application
Tube location when used on
HORIZONTAL - RIGHT application
PLUG
CAP
COLLECTOR BOX DRAIN TUBE
(BLUE & WHITE STRIPED)
COLLECTOR BOX TUBE
(PINK)
COLLECTOR BOX DRAIN TUBE
(BLUE)
INDUCER HOUSING DRAIN TUBE
(VIOLET)
COLLECTOR BOX TUBE
(PINK)
COLLECTOR BOX DRAIN
TUBE
(BLUE & WHITE STRIPED)
COLLECTOR BOX DRAIN TUBE
(BLUE)
INDUCER HOUSING (MOLDED) DRAIN TUBE
(BEHIND COLLECTOR BOX DRAIN TUBE)
FIELD-INSTALLED
FACTORY-SUPPLIED DRAIN TUBE
COUPLING (LEFT DRAIN OPTION)
FIELD-INSTALLED FACTORY-SUPPLIED
DRAIN TUBE
FIELD-INSTALLED
FACTORY-SUPPLIED 1/2-IN.
CPVC STREET ELBOWS (2)
FOR LEFT DRAIN OPTION
COLLECTOR BOX TUBE
(GREEN)
CONDENSATE TRAP
CAP
Condensate Trap; Factory Installed
in Blower Shelf
CONDENSATE TRAP
COLLECTOR BOX TUBE (GREEN)
Condensate Trap on LEFT
Side Optional
CAP
PLUG
COLLECTOR BOX
DRAIN TUBE (BLUE)
PLUGGED END
COLLECTOR BOX DRAIN TUBE
(BLUE & WHITE STRIPED)
COLLECTOR BOX
TUBE (GREEN)
COLLECTOR BOX
TUBE (PINK)
COLLECTOR BOX
EXTENSION TUBE
CONDENSATE TRAP
INDUCER HOUSING DRAIN TUBE (VIOLET)
COLLECTOR BOX
EXTENSION TUBE
COLLECTOR BOX TUBE
(PINK)
COLLECTOR BOX DRAIN TUBE
(BLUE)
COLLECTOR BOX TUBE
(GREEN)
CONDENSATE TRAP
INDUCER HOUSING DRAIN
TUBE (VIOLET)
COLLECTOR BOX EXTENSION TUBE
COLLECTOR BOX DRAIN
TUBE
(BLUE & WHITE STRIPED)
Condensate Trap on
RIGHT Side
COLLECTOR BOX
EXTENSION DRAIN TUBE
DRAIN TUBE COUPLING
GAS VALVE
DRAIN TUBES ROUTED IN
FRONT OF GAS VALVE
PLUG
CAP
COLLECTOR BOX DRAIN TUBE
(BLUE & WHITE STRIPED)
CONDENSATE TRAP
COLLECTOR BOX
EXTENSION TUBE
COLLECTOR BOX
TUBE (GREEN)
INDUCER HOUSING
DRAIN TUBE
(VIOLET)
COLLECTOR BOX TUBE (PINK)
RELOCATE TUBE BETWEEN BLOWER
SHELF AND INDUCER HOUSING FOR
040,060, AND 080 HEATING INPUT
FURNACES
CAP
PLUG
COLLECTOR BOX DRAIN TUBE
(BLUE)
COLLECTOR BOX EXTENSION TUBE
COLLECTOR BOX TUBE (PINK)
COLLECTOR BOX
TUBE (GREEN)
COLLECTOR BOX DRAIN TUBE
(BLUE AND WHITE STRIPED)
INDUCER HOUSING DRAIN TUBE (VIOLET)
CONDENSATE TRAP
Condensate Trap on
LEFT Side
COLLECTOR BOX
DRAIN TUBE (BLUE)
PLUG
Tube location when used in UPFLOW application
Tube location when used on
HORIZONTAL - LEFT application
CAP
PLUG
COLLECTOR BOX
EXTENSION TUBE
DRAIN TUBE
COUPLING
COLLECTOR BOX EXTENSION DRAIN TUBE
(Blower access panel removed)
1. All tubing must be connected securely and routed to avoid kinks and traps.
2. Pressure tubing must always slope away from pressure switch to collector box connection as shown.
3. HORIZONTAL-LEFT installations require the collector box pressure tube to be relocated between the inducer housing and the blower shelf to
prevent a trap. Refer to the Installation Instructions for further details.
NOTE:
324999-201 REV. C
FIELD-INSTALLED
FACTORY-SUPPLIED
DRAIN TUBE COUPLING
(RIGHT DRAIN OPTION)
BURNER ENCLOSURE
PRESSURE REFERENCE
TUBE ASSEMBLY
BURNER ENCLOSURE
PRESSURE REFERENCE
TUBE ASSEMBLY
BURNER ENCLOSURE PRESSURE
REFERENCE TUBE ASSEMBLY
BURNER ENCLOSURE
PRESSURE REFERENCE
TUBE ASSEMBLY
BURNER ENCLOSURE
PRESSURE REFERENCE
TUBE ASSEMBLY
BURNER ENCLOSURE PRESSURE
REFERENCE TUBE ASSEMBLY
TUBE ROUTING
AUXILIARY "J" BOX RELOCATED HERE
A00308
Fig. 10 -- Furnace Pressure and Drain Tubing Diagram
8. Flush inside of collector box with water until discharge
from condensate trap is clean and runs freely.
9. Inspect inside area of collector box for any pieces of foreign
materials and remove them if present.
UNIT DAMAGE HAZARD
Failure to follow this caution may result in furnace
component damage.
DO NOT use wire brush or other sharp object to inspect or
dislodge materials in secondary heat exchangers as cutting
of the secondary heat exchanger protective coating may
occur. Flush with water only.
CAUTION
!
10. Reassemble inducer assembly by reversing items 3--7.
Tighten the vent coupling clamp screw(s) to 15 in.--lb of
torque.
NOTE: If seal between the inducer housing and the collector box
is damaged in any way, it must be repaired. To repair, apply sealant
releasing agent such as PAM cooking spray or equivalent (must not
contain corn nor canola oil, halogenated hydrocarbons nor
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 to groove
in collector box.
11. Refer to furnace wiring diagram and reconnect wires to in-
ducer motor and pressure switches or connectors.
12. Reconnect pressure tubes to pressure switches. See diagram
on main furnace door for proper location of tubes. Be sure
tubes are not kinked. (See Fig. 10.)
13. Turn on gas and electrical supplies to furnace.
14. Check furnace operation through two complete heat operat-
ing cycles. Check area below inducer housing, vent pipe,
and condensate trap to ensure no condensate leaks occur. If
leaks are found, correct the problem.
15. Check for gas leaks.
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death or property damage.
Never test for gas leaks with an open flame. Use a
commercially available soap solution made specifically for
the detection of leaks to check all connections.
!
WARNING
58MCB
10
16. Replace main furnace door.
Step 6 — Servicing Hot Surface Igniter
The igniter does NOT require annual inspection. Check igniter
resistance before removal.
1. Turn off gas and electrical supplies to furnace.
BURN HAZARD
Failure to follow this caution may result in personal injury.
Allow igniter to cool before removal. Normal operating
temperatures exceed 2000_F (1093_C).
CAUTION
!
2. Remove main furnace door.
3. Disconnect igniter wire connection.
4. Check igniter resistance. Igniter resistance is affected by
temperature. Only check resistance when the igniter is at
room temperature.
a. Using an ohm meter, check resistance across both ig-
niter leads 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 securing
the igniter bracket to the burner box bracket (See Fig.
13.) and carefully withdraw the igniter and bracket as-
sembly through the front of the burner box without
striking the igniter on surrounding parts. Note that the
igniter bracket has a handle that extends to the front of
the burner box to aid in handling. (See Fig. 13.)
d. Inspect igniter for signs of damage or failure.
UNIT DAMAGE HAZARD
Failure to follow this caution may result in premature
failure of the igniter.
The igniter is fragile. DO NOT allow it to hit burner box
parts while removing or replacing it.
CAUTION
!
e. If replacement is required, replace igniter on igniter
bracket and then install assembly into burner box to
avoid damage to the igniter.
6. To replace igniter and bracket assembly, reverse items 5a
through 5c.
7. Reconnect igniter wire connection and insert the igniter
wires in the slot in the manifold grommet, dressing the ig-
niter wires to ensure there is no tension on the igniter itself.
(See Fig.7.)
8. Reinstall burner box cover.
9. Turn on gas and electrical supplies to furnace.
10. Verify igniter operation by initiating control board self--test
feature or by cycling thermostat.
11. Replace main furnace door.
BURNER FLAME
BURNER
MANIFOLD
A89020
Fig. 11 -- Burner Flame
RTV
PAM
A93081
Fig. 12 -- Gasket on Collector Box
BRACKET
IGNITER
9/16˝
11/16˝
EXTENDED IGNITER
BRACKET HANDLE
IGNITER BRACKET
MOUNTING SCREW
A05075
Fig. 13 -- Igniter Bracket
58MCB
11
2-5/32˝
(55 mm)
A04181
Fig. 14 -- Igniter
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Igniter wires must be securely placed in slot in manifold
grommet or else they could become pinched or severed and
electrically shorted.
!
WARNING
Step 7 — Electrical Controls and Wiring
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
There may be more than one electrical supply to the unit.
Check accessories and cooling unit for additional electrical
supplies.
!
WARNING
The electrical ground and polarity for 115--v wiring must be
maintained properly. Refer to Fig. 15 for field wiring information
and to Fig. 21 for unit wiring information.
NOTE: If the polarity is not correct or furnace is not properly
grounded, the STATUS LED on the furnace control will flash
rapidly and prevent the furnace from operating. The control system
also requires an earth ground for proper operation of the furnace
control and flame sensor.
The 24--v circuit contains an automotive--type, 3--amp fuse located
on the furnace control. (See Fig. 16.) Any direct shorts of the 24--v
wiring during installation, service, or maintenance will cause this
fuse to blow. If fuse replacement is required, use ONLY a fuse of
identical size. The furnace control LED will flash status code 24
when fuse needs to be replaced.
With power to the unit disconnected, check all electrical
connections for tightness. Tighten all screws on electrical
connections. If any smoky or burned connections are found,
disassemble the connection, clean all parts, strip wire, and
reassemble properly and securely.
Reconnect electrical supply to unit and observe unit through one
complete operating cycle and check for proper operation.
Step 8 — Checking Heat Tape Operation
(If Applicable)
In applications where the ambient temperature around the furnace
is 32_F(0_C) or lower, freeze protection measures are required. If
this application is where heat tape has been applied, check to
ensure it will operate when low temperatures are present.
NOTE: Heat tape, when used, should be wrapped around the
condensate drain trap and drain line. There is no need to use heat
tape within the furnace casing. Most heat tapes are temperature
activated, and it is not practical to verify the actual heating of the
tape. Check the following:
1. Check for signs of physical damage to heat tape such as
nicks, cuts, abrasions, gnawing by animals, etc.
2. Check for discolored heat tape insulation. If any damage or
discolored insulation is evident, replace heat tape.
3. Check that heat tape power supply circuit is on.
58MCB
12
115-V FIELD-
SUPPLIED
DISCONNECT
AUXILIARY
J-BOX
24-V
TERMINAL
BLOCK
THREE-WIRE
HEATING-ONLY
FIVE WIRE
NOTE 1
NOTE 2
FIELD-SUPPLIED
DISCONNECT
CONDENSING
UNIT
TWO
WIRE
FURNACE
C
O
N
T
R
O
L
R
G
COM
WCR GY
GND
GND
FIELD 24-V WIRING
FIELD 115-, 208/230-, 460-V WIRING
FACTORY 24-V WIRING
FACTORY 115-V WIRING
208/230- OR
460-V
THREE
PHASE
208/230-V
SINGLE
PHASE
BLOWER DOOR SWITCH
WHT
BLK
WHT
BLK
NOTES: Connect Y-terminal in furnace as shown for proper blower operation.
Some thermostats require a "C" terminal connection as shown.
If any of the original wire, as supplied, must be replaced, use
same type or equivalent wire.
W
Y
GND
THERMOSTAT
TERMINALS
1.
2.
3.
A02174
Fig. 15 -- Field Wiring
BLW
NUETRAL
STATUS CODE LED
SEC-2 SEC-1
EAC-2 L2
FUSE 3-AMP
0.5 AMP@24VAC
HUM
TEST/TWIN
G Com W Y R
24V
120 180
90 150
BLOWER OFF-DELAY
PLT 1
COOL HEAT
SPARE-1 SPARE-2
EAC-1
1-AMP@
115VAC
PR-1
L1
PL2 1
24-V THERMOSTAT
TERMINALS
3-AMP FUSE
LED OPERATION &
DIAGNOSTIC LIGHT
115-VAC(L2)NEUTRAL
CONNECTIONS
COOL
HEAT
SPARE-1
SPARE-2
BLOWER SPEED
SELECTION TERMINALS
EAC-1 TERMINAL
(115-VAC 1.0 AMP MAX.)
115 VAC (L1) LINE
VOLTAGE CONNECTION
PL2-HOT SURFACE
IGNITER & INDUCER
MOTOR CONNECTOR
PL1-LOW VOLTAGE MAIN
HARNESS CONNECTOR
TRANSFORMER 24-VAC
CONNECTIONS
HUMIDIFIER TERMINAL
(24-VAC 0.5 AMP MAX.)
TWINNING AND/OR
COMPONENT TEST
TERMINAL
BLOWER OFF-DELAY
J2
J2 JUMPER
PLT
A02100
Fig. 16 -- Control Center
58MCB
13
UNIT AND PROPERTY DAMAGE
Failure to follow this caution may result in furnace
component failures or water property damage.
Operating a unit without a filter or with the blower access
door removed could cause damage to the furnace blower
motor. Dust and lint on internal parts of furnace can cause a
loss of efficiency. If this furnace is to be operated in an
unconditioned space where the ambient temperatures may
be 32_F(0_C)or lower, freeze protection measures must be
taken. See CONDENSATE DRAIN PROTECTION section
of Installation, Start--up, and Operating Instructions. (See
Fig. 17.)
CAUTION
!
Step 9 — Winterizing
UNIT DAMAGE HAZARD
Failure to follow this caution may result in furnace
component damage.
Freezing condensate left in the furnace may damage the
furnace.
CAUTION
!
If the furnace will be off for an extended period of time in a
structure where the temperature will drop to 32_F(0_C)or below,
winterize as follows:
1. Turn off electrical supply to furnace.
2. Remove main furnace door.
3. Disconnect upper inducer housing drain connection cap
from inducer housing. (See Fig. 18.)
4. Connect field--supplied 1/2--in. I.D. inducer housing tube to
upper inducer housing drain connection.
5. Insert funnel in tube and pour one quart of antifreeze, pro-
pylene glycol (RV, swimming pool antifreeze, or equival-
ent) into funnel/tube until it is visible at point where con-
densate enters open drain. (See Fig. 19.)
UNIT DAMAGE HAZARD
Failure to follow this caution may result in unit component
damage.
Do not use ethylene glycol (Prestone II antifreeze/coolant or
equivalent automotive type).
CAUTION
!
6. Replace drain connection cap and clamp to inducer housing.
7. Replace main furnace door.
8. Propylene glycol need not be removed before restarting fur-
nace.
A07911
Fig. 17 -- Freeze Protection
WIRING DIAGRAMS
See Fig. 21 for wiring diagram.
TROUBLESHOOTING
Use the troubleshooting guide, the status code LED on the furnace
control and the component test to isolate furnace operation
problems.
Status Codes
For an explanation of status codes, refer to service label located on
back of main furnace door or Fig. 20.
NOTE: Removing the blower access door will open the blower
access door switch and terminate 115--v power to the control.
To read current status code, remove main furnace door. The status
code LED can be viewed through the sight glass on the blower
access door.
NOTE: NO thermostat signals may be present at control and all
blower off delays must be completed to view previous codes.
UNIT DAMAGE HAZARD
Failure to follow this caution may result in damage to unit
components.
Make sure limit switch or flame rollout switch wire does
not contact any metal component, such as gas valve. If wire
is shorted, 3--amp fuse on furnace control board will open
and unit will not operate.
CAUTION
!
To retrieve previous codes, remove one of the red main limit or
flame rollout switch wires for 1 to 4 sec until the LED light goes
out, then reconnect it. (Do not leave red wire disconnected for
longer periods of time as the control will assume an
overtemperature condition exists and will respond with blower
operation.) This places the control in the status recall mode and
displays the last code stored in memory.
Record the code. After the last code is displayed the control will
perform the component test, and then return to normal standby
mode.
58MCB
14
A99118
Fig. 18 -- Inducer Housing Drain Tube
Component Test
NOTE: The furnace control component test allows all
components to run for a short time; except the gas valve and
humidifier terminal HUM are not energized for safety reasons. The
EAC--1 terminal is energized when the blower is energized. This
feature helps diagnose a system problem in case of a component
failure. The component test feature will not operate if any
thermostat signal is present at the control and not until all time
delays are completed.
NOTE: Record the status code BEFORE opening the blower
access door and before shutting off power to furnace. Opening the
blower access door will open the blower door switch and shut off
power within the furnace. When power to the furnace is shut off by
either method, the status code will be lost because the code is not
stored while power is removed for any reason.
To Begin Component Self--Test:
ELECTRICAL SHOCK AND UNIT MAY NOT
OPERATE HAZARD
Failure to follow this warning could result in electrical shock,
personal injury, or death.
Blower access panel door switch opens 115--v power to
control board. No component operation can occur. Caution
must be taken when manually closing this switch for service
purposes.
!
WARNING
1. Remove blower access door.
2. Disconnect the thermostat R lead from furnace control
board.
3. Manually close blower door switch.
4. For approximately 2 sec, short (jumper) the COM--24v ter-
minal on control to the TEST/TWIN 3/16--in. quick--con-
nect terminal on control until LED turns off. Remove jump-
er from terminals. (See Fig. 16.)
NOTE: If TEST/TWIN and COM--24v terminals are jumpered
longer than 2 sec, LED will flash rapidly and ignore component
test request.
A99119
Fig. 19 -- Funnel in Drain Tube and Antifreeze
Running Through Trap
Component test sequence for single--stage furnace is as follows:
a. LED will display status code 11 four times.
b. Inducer motor starts and continues to run until Step f. of
component test sequence.
c. After 7 sec the hot surface igniter is energized for 15
sec, then off.
d. Blower motor operates on HEAT speed for 10 sec.
e. Blower motor operates on COOL speed for 10 sec.
f. Inducer motor stops.
5. Reconnect R lead to furnace control board, remove tape
from blower door switch, and reinstall blower door.
6. Operate furnace per instruction on outer door.
7. Verify furnace shut down by lowering thermostat setting be-
low room temperature.
8. Verify that furnace restarts by raising thermostat setting
above room temperature.
Use the Component Test to check furnace components for proper
operation. To initiate the component self--test sequence, shut off the
room thermostat or disconnect the “R” thermostat lead. Briefly
(approximately 2 sec) short the TWIN/TEST terminal to the COM
24V terminal. The status LED will turn off. The test sequence will
be as follows:
1. LED flashes last status code, or code 11, 4 times. Record
this status code for further troubleshooting.
2. The inducer will start and continue to run until test is over.
3. Hot surface igniter (HSI) is energized for 15 sec, then de--
energized.
4. Blower operates on continuous FAN speed for 10 sec, then
turns off.
5. The blower motor operates on HEATING speed for 10 sec,
then turns off.
6. The blower motor operates on COOLING speed for 10 sec,
then turns off.
7. Inducer turns off.
8. The gas valve and humidifier terminal HUM are not ener-
gized for safety reasons.
58MCB
15
SERVICE
To initiate the component test sequence, shut OFF the room thermostat or disconnect
the "R" thermostat lead. Briefly short the TEST/TWIN terminal to the "Com 24V" ter-
minal. Status LED will flash code and then turn ON the inducer motor. The inducer
motor will run for the entire component test. The hot surface ignitor, blower motor
FAN speed (AMBER LED boards only) blower motor HEAT speed, and blower motor
COOL speed will be turned ON for 10-15 seconds each. Gas Valve and Humidifier
will not be turned on.
CONTINUOUS OFF - Check for 115VAC at L1 & L2, & 24VAC at SEC-1 & SEC-2.
CONTINUOUS ON - Control has 24VAC power.
RAPID FLASHING - Line voltage (115VAC) polarity reversed. If twinned,
refer to twinning kit instructions.
LED CODE
EACH OF THE FOLLOWING STATUS CODES IS A TWO DIGIT NUMBER WITH THE FIRST
DIGIT DETERMINED BY THE NUMBER OF SHORT FLASHES AND THE SECOND DIGIT BY
THE NUMBER OF LONG FLASHES.
STATUS
11 NO PREVIOUS CODE - Stored status code is erased automatically after 72
hours. On RED LED boards stored status codes can also be erased when power
(115 VAC or 24 VAC) to control is interrupted.
12 BLOWER ON AFTER POWER UP (115 VAC or 24 VAC) -Blower runs for 90
seconds, if unit is powered up during a call for heat (R-W closed) or R-W opens
during blower on-delay.
13 LIMIT CIRCUIT LOCKOUT - Lockout occurs if the limit or flame rollout switch is
open longer than 3 minutes.
- Control will auto reset after three hours. - Refer to #33.
14 IGNITION LOCKOUT - Control will auto-reset after three hours. Refer to #34.
21 GAS HEATING LOCKOUT - Control will NOT auto reset.
Check for: - Mis-wired gas valve -Defective control (valve relay)
22 ABNORMAL FLAME-PROVING SIGNAL - Flame is proved while gas valve is
de-energized. Inducer will run until fault is cleared. Check for:
- Leaky gas valve - Stuck-open gas valve
23 PRESSURE SWITCH DID NOT OPEN Check for:
- Obstructed pressure tubing. - Pressure switch stuck closed.
24 SECONDARY VOLTAGE FUSE IS OPEN Check for:
- Short circuit in secondary voltage (24VAC) wiring.
31 PRESSURE SWITCH DID NOT CLOSE OR REOPENED - If open longer than
five minutes, inducer shuts off for 15 minutes before retry. Check for:
- Excessive wind - Proper vent sizing - Defective inducer motor
- Low inducer voltage (115VAC) - Defective pressure switch
- Inadequate combustion air supply - Restricted vent
- Disconnected or obstructed pressure tubing
- Low inlet gas pressure (if LGPS used)
If it opens during blower on-delay period, blower will come on for the selected
blower off-delay.
33 LIMIT CIRCUIT FAULT - Indicates a limit, or flame rollout is open. Blower will
run for 4 minutes or until open switch remakes whichever is longer. If open
longer than 3 minutes, code changes to lockout #13. If open less than 3 minutes
status code #33 continues to flash until blower shuts off. Flame rollout switch
requires manual reset. Check for: - Restricted vent
- Proper vent sizing - Loose blower wheel - Excessive wind
- Dirty filter or restricted duct system.
- Defective blower motor or capacitor. - Defective switch or connections.
- Inadequate combustion air supply (Flame Roll-out Switch open).
34 IGNITION PROVING FAILURE - Control will try three more times before lockout
#14 occurs. If flame signal lost during blower on-delay period, blower will come
on for the selected blower off-delay. Check for: - Control ground continuity
- Flame sensor must not be grounded
- Oxide buildup on flame sensor (clean with fine steel wool).
- Proper flame sense microamps (.5 microamps D.C. min., 4.0 - 6.0 nominal).
- Gas valve defective or gas valve turned off - Manual valve shut-off
- Defective Hot Surface Ignitor
- Low inlet gas pressure
- Inadequate flame carryover or rough ignition
- Green/Yellow wire MUST be connected to furnace sheet metal
45 CONTROL CIRCUITRY LOCKOUT Auto-reset after one hour lockout due to;
- Gas valve relay stuck open - Flame sense circuit failure
- Software check error
Reset power to clear lockout. Replace control if status code repeats.
If status code recall is needed, briefly remove then reconnect one main limit wire to display
stored status code. On RED LED boards do not remove power or blower door before initiat-
ing status code recall. After one status code recall is completed component test will occur.
COMPONENT TEST
327884-101 REV. B
A02270
Fig. 20 -- Service Label
58MCB
16
PCB
TRAN
FRS
NOTE #11
LS
PRS
(WHEN USED)
LGPS
FUSED OR CIRCUIT BREAKER
DISCONNECT SWITCH (WHEN REQ’D)
NOTE #2
JB
L1
L1
BLWR
TO 115VAC FIELD DISCONNECT
NOTE #2
EQUIPMENT GROUND
SPARE-1
HEAT
COOL
HSIR
EAC-1
START
OL
HI
MED HI
MED LO
LO
BLWM
SCHEMATIC DIAGRAM
(NATURAL GAS & PROPANE)
1
1
HSI
2
PL3
2
PL2
115VAC
PR1
TRAN
24VAC
M
IDR
TEST/TWIN
F U 1
NOTE #6
IDM
OL
AUX
CAP - 2
CAP-1
L2
FRS
LS
LGPS
(WHEN USED)
NOTE #11
PRS
FSE
9
1
5
CPU
PCB
Y
G
C
R
W
SEC-1
GVR-1
NOTES:
328150-101 REV. A
OM
10
4
6
2
PL4
2
3
1
NEUTRAL
ILK
FU2
L1
ILK
GND
RED
BLU
ORN
WHT
RED
RED
ORN
RED
RED
GRN/YEL
YEL
BLU
BLU
RED
WHT
BLK
LED 1
12345678910
BLOWER OFF DELAY
JUMPER SELECT
YEL
OL
START
BLK
WHT
WHT
BRN
IDM
BRN
CAP -2
AUX
OL
M
HSI
WHT
BLK
BLK
WHT
WHT (COM)
BLK
BLK
WHT
WHT
2
1
PL2
WHT
BLK
BLK
BLWM
CAP -1
SPARE 1
SPARE 2
EAC-1
PR1
SEC-2
SEC-1
EAC-2
SEC-2
8
7
3
PL1
2
1
PL3
3
2
1
PL4
BRN
BRN
RED (LO)
WHT
(COM)
YEL
BLU
(MED LO)
COM
HUM
(MED HI)
HI/LO
11
WHT
PL1
11
L2
GRN/YEL
GRN/YEL
GRN/YEL
GND
NOTE #3
GV
M
C
NOTE #3
GV
M
C
GRN/YEL
GRN/YEL
FSE
NOTE #10
WHT
R
Y
W
C
HUM
om
TEST/TWIN
24V
FU1
J1
180
150
120
90
G
NOTE #6
EAC-2
L2
NEUTRAL
NOTE #8
BLW
L1
BHT/CLR BLWR
COOL
HEAT
BLK (HI)
L
E
G
E
N
D
BHT/CLR BLOWER MOTOR SPEED CHANGE RELAY, SPDT
BLWR BLOWER MOTOR RELAY, SPST-(N.O.)
BLWM BLOWER MOTOR, PERMANENT-SPLIT-CAPACITOR
CAP 1,2 CAPACITOR
CPU MICROPROCESSOR AND CIRCUITRY
EAC-1 ELECTRONIC AIR CLEANER CONNECTION (115 VAC 1.0 AMP MAX.)
EAC-2 ELECTRONIC AIR CLEANER CONNECTION (COMMON)
FRS FLAME ROLLOUT SW. -MANUAL RESET, SPST-(N.C.)
FSE FLAME-PROVING ELECTRODE
FU 1 FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE, FACTORY INSTALLED
FU 2 FUSE OR CIRCUIT BREAKER CURRENT INTERRUPT DEVICE
(FIELD INSTALLED & SUPPLIED)
GND EQUIPMENT GROUND
GV GAS VALVE-REDUNDANT
GVR 1, 2 GAS VALVE RELAY, DPST-(N.O.)
HSI HOT SURFACE IGNITER (115 VAC)
HSIR HOT SURFACE IGNITER RELAY, SPST-(N.O.)
HUM 24VAC HUMIDIFIER CONNECTION (0.5 AMP. MAX.)
IDM INDUCED DRAFT MOTOR, PSC
IDR INDUCED DRAFT MOTOR RELAY, SPST-(N.O.)
ILK BLOWER ACCESS PANEL INTERLOCK SWITCH, SPST-(N.O.)
J1 BLOWER - OFF DELAY JUMPER SELECTOR
J2 COOLING - OFF DELAY JUMPER
JB JUNCTION BOX
LED LIGHT-EMITTING DIODE FOR STATUS CODES - RED
LGPS LOW GAS PRESSURE SWITCH, SPST-(N.O.)
LS LIMIT SWITCH, AUTO-RESET, SPST (N.C.)
OL AUTO-RESET INTERNAL MOTOR OVERLOAD
TEMPERATURE SWITCH (N.C.)
PCB PRINTED CIRCUIT BOARD CONTROL
PL1 11-CIRCUIT PCB CONNECTOR
PL2 2-CIRCUIT CONNECTOR
PL3 2-CIRCUIT HSI, CONNECTOR
PL4 3-CIRCUIT IDM EXTENSION CONNECTOR
PRS PRESSURE SWITCH, SPST-(N.O.)
TEST/TWIN COMPONENT TEST & TWIN TERMINAL
TRAN TRANSFORMER-115VAC/24VAC
JUNCTION
UNMARKED TERMINAL
PCB CONTROL TERMINAL
FACTORY WIRING (115VAC)
FACTORY WIRING (24VAC)
FIELD WIRING (115VAC)
FIELD WIRING (24VAC)
CONDUCTOR ON CONTROL PCB
FIELD WIRING SCREW TERMINAL
FIELD EARTH GROUND
EQUIPMENT GROUND
FIELD SPLICE
PLUG RECEPTACLE
1. If any of the original equipment wire is replaced use wire rated for 105°C.
2. Use only copper wire between the disconnect switch and the furnace junction box (JB).
3. This wire must be connected to furnace sheet metal for control to prove flame.
4. Symbols are electrical representation only.
5. Solid lines inside PCB are printed circuit board conductors and are not included in legend.
6. Replace only with a 3 amp fuse.
7. Inducer (IDM) and blower (BLWM) motors contain internal auto-reset thermal overload switches (OL).
8. Neutral connections are interchangeable within the NEUTRAL connector block.
9. Blower motor speed selections are for average conditions, see installation instructions for details on
optimum speed selection.
10. YELLOW lead not on all motors.
11. Factory connected when LGPS is not used.
12. Ignition-lockout will occur after four consecutive unsuccessful trials-for-ignition. Control will
auto-reset after three hours.
13. Blower-on delay: gas heating 60 seconds, cooling or heat pump 2 seconds.
14. Blower-off delay: gas heating selections are 90, 120, 150 or 180 seconds, cooling or heat pump
90 seconds or 5 seconds when J2 is cut.
NOTE #10
PRINTED CIRCIUT BOARD
PRINTED CIRCIUT BOARD
NOTE #5
SPARE-2
J2
24V
A02271
Fig. 21 -- Wiring Diagram
58MCB
17
Is LED status light on?
Is LED status light blinking rapidly without a
pause?
Is LED status light blinking ON/OFF slowly
with a combination of short and long flashes?
Determine status code.
The status code is a
2 digit number with the first digit determined
by the number of shor
t flashes
and the second
digit by the number of long flashes?
Go to section below for the status code that
was flashed.
Is there 115V at L1 and L2?
Is there 24V at SEC-1 and SEC-2?
Replace furnace control.
Check for correct line voltage polarity and ground-
ing. If units are twinned, check for proper low-
voltage (24V) transformer phasing.
To recall status code briefly remove and reconnect one RED wire from the Limit
Switch or Flame Rollout switch to display stored status code. On RED LED
control do not remove power or blower access panel before initiating status
code recall. You can also recall the previous status code by momentarily shorting
the
TEST/TWIN terminal to Com24V terminal until the LED goes out. LED will
flash the previous status code or status code #11 (1 short and 1 long flash) if
there was no pre
vious code.
After the control repeats the code 4 times, the
control will go through
a brief component test sequence.
The inducer will start
and r
un for the entire component test.
The HSI, b
lower motor F
AN speed
(AMBER LED boards only) HEA
T speed, and COOL speed will run f
or 10 – 15
seconds each. Gas valve and humidifier will not be turned on.
Was there a previous status code
other than #11?
Is door switch closed?
Is there 115V going to switch?
Replace door s
witch.
Replace transformer.
Does the control
respond to
W, Y1 (if present),
Y/Y2, and G (24V) thermostat signals?
R
un system
through
a
heating
or
cooling
cycle
to chec
k operation.
Status codes are erased
after 72 hours
.
On RED LED boards stored
status codes can also be erased whene
ver
(115V or 24V) is interr
upted.
Replace furnace control.
Close door switch and go back to START.
Is circuit breaker closed?
Check for continuity in wire from circuit breaker
to furnace.
Close circuit breaker and go back to START.
Check room ther
mostat or
interconnecting cab
le
.
Is 24V present at
W,
Y
1 (if present), Y/Y2 or
G thermostat terminals on
the
furnace
control?
Disconnect all the thermostat wires from the
fur
nace control.
Does the prob
lem repeat when using
a jumper wire?
The thermostat is not compatible with the
fur
nace
control.
Either i
nstall a
ballast resistor
,
connect the Com24V ther
mostat terminal to
the thermostat, or replace the thermostat.
NO
YES
YES
NO
NO
YES
YES
YES
YES
NO
YES
YES
NO
YES
NO
YES
NO
NO
NO
YES
NO
YES
NO
START
TROUBLESHOOTING GUIDE
NO
A05107
58MCB
18
11
NO PREVIOUS CODE – Stored codes
are erased after 72 hours. On RED LED
boards stored status codes can also be
erased whenever power (115V or 24V)
is interr
upted. Run system through a
heating or cooling cycle to
check system.
12 BLO
WER ON AFTER PO
WER UP –
(115V OR 24V) – Normal operation.
Bl
ow
er r
uns for 90 seconds, if unit is
powered up during a call for heat (R-W
closed) or when (R-W opens) during th
e
blower on-delay period.
13 LIMIT CIRCUIT LOCKOUT – Lockout
occurs if the limit or flame rollout switch is
open longer than 3 minutes. Control will
auto-r
eset after 3 hours.
See code 33
.
14 IGNITION LOCKOUT – System failed to
ignite gas and prove flame in 4
attempts.
Control will auto-reset after 3 hours.
See status code 34.
21 GAS HEATING LOCKOUT – Tur
n off
power and wait 5 minutes to retry.
Chec
k for:
- Stuck closed gas valve relay
on control.
- Miswire or short to gas valve wire.
22 ABNORMAL FLAME-PRO
VING SIGNAL
Flame is proved while gas valve is de-
energiz
ed.
Inducer will run until fault is
cleared. Chec
k for:
- Stuck open or leaky gas valve.
23 PRESSURE SWITCH DID NOT OPEN
Check for:
- Obstructed pressure tube.
- Pressure switch stuck closed.
24
SECONDARY VOLTAGE FUSE IS OPEN
Check for:
-Shor
t circuit in secondary
vo
ltage (24V)
wiring including thermostat leads.
D
isconnect thermostat leads to isolate
short circuit.
31 PRESSURE SWITCH DID NOT CLOSE
OR REOPENED – If open longer than 5
minutes, inducer shuts off for 15 minutes
before retry. If opens during blower on-
delay period, blower will come on for the
selected blower off-delay. Check for:
- Proper vent sizing.
- Low inducer voltage (115V).
- Low inlet
gas pressure
(if LGPS used).
- Inadequate comb
ustion air supply.
-D
isconnected or obstr
ucted pressure
tubing.
-D
efective inducer motor.
-D
efective pressure switch.
- Excessive wind.
-R
estr
icted vent.
33 LIMIT CIRCUIT FAU
LT – Indicates the
limit or flame rollout switch
is
open.
Blower
will run for 4 minutes or until open sw
itc
h
remakes whiche
ver is longer. If open
longer than 3 minutes, code changes to
lockout #13. If open less than 3 min.
status code #33 continues to flash until
blower shuts off. Flame rollout switch
requires manual reset. Check for:
- Dirty filter or restricted duct system.
- Loose b
lower wheel.
- Defective switch or connections.
-D
efectiv
e blower motor or capacitor.
-
Inadequate combustion air supply
(flame rollout s
witch open).
-R
estricted vent.
- Proper vent sizing.
- Excessive wind.
- Blower motor on incorrect speed tap.
- Input rate to fur
nace set too high.
34 I
GNITION PROVING FAILURE – If
flame
is not sensed during the trial f
or ignition
per
iod,
the control will repeat the ignition
sequence 3 more times before lo
ck
out
#14 occurs. If flame signal is lost during
the blower on-delay period, blower wil
l
come on for the selected blower off-delay.
Check the following items first before
proceeding to the next step.
- Gas valve turned off.
- Manual shut-off valve.
-G
reen/Yellow
wire
MUST be connected
to furnace sheet metal.
- Flame sensor must not be grounded.
To determine whether the problem is in
the gas valve,
igniter, or flame sensor the
system can be operated in the component
test mode to chec
k the igniter. First
remove the R thermostat connection from
the control and initiate the component
test sequence. Does the igniter glow
orange/white by the end of the 15 second
warm-up period?
Unplug igniter harness from control and initiate
another component test sequence. Check
for 115V between pin 1 and NEUTRAL-L2 on
the control. Was 115V present for the 15
second per
iod?
Reconnect the R thermostat lead and set
ther
mostat to call for heat. Connect voltmeter
across gas va
lve
connections. Does gas valve
receiv
e 24V?
Does gas valv
e open and allow gas to flow?
Do the main burners ignite?
Do the main b
urners stay on?
Repeat call f
or heat and check flame sensor
current dur
ing trial for ignition period. Is the
DC microamps bel
ow 0.5?
Is current near typical value?
Will main b
urners ignite and stay on?
Fix
ed.
Clean flame sensor with fine steel wool and
recheck current. Nominal current is 4.0 to 6.0
microamps.
45 CONTROL CIRCUITRY LOCKOUT
Auto-reset after 1 hour lockout due to:
- Flame circuit failure.
- Gas valve relay stuck open.
- Software check error.
Reset power to clear lockout. Replace
control if code repeats.
Replace furnace control.
Check for continuity in the harness and
igniter.
Replace defective component.
Check connections. If OK, replace control.
Check that all gas valves are turned on.
Replace v
al
ve.
Check for:
-
Inadequate flame carr
yov
er or rough
ignition.
- Low inlet gas pressure.
- Proper firing rate.
Allow blow
er to come on and repeat test to
check for intermittent operation.
Chec
k connections and retry. If current is
near typical
value (4.0-6.0 nominal) and
burners will not stay on, replace control.
Replace electrode.
Replace furnace control.
YES
YES
YES
YES
NO
YES
YES
YES
NO
YES
NO
NO
NO
YES
NO
NO
NO
NO
A05096
58MCB
19
SERVICE TRAINING
Packaged Service Training programs are an excellent way to increase your
knowledge of the equipment discussed in this manual, including:
• Unit Familiarization • Maintenance
• Installation Overview • Operating Sequence
A large selection of product, theory, and skills programs is available, using popular
video-based formats and materials. All include video and/or slides, plus companion
book.
Classroom Service Training plus "hands-on" the products in our labs can mean
increased confidence that really pays dividends in faster troubleshooting, fewer
callbacks. Course descriptions and schedules are in our catalog.
CALL FOR FREE CATALOG 1-800-644-5544
[ ] Packaged Service Training [ ] Classroom Service Training
A94328
58MCB
20
Copyright 2009 Carrier Corp. S 7310 W. Morris St. S Indianapolis, IN 46231 Printed in U.S.A. Edition Date: 10/09
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
Catalog No: 58MCB---4SM
Replaces: 58MCB --- 3SM
58MCB
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Carrier Furnace 58MCB User manual
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