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58UVBDedicated UpflowVariable---CapacityCondensing Gas Furnace
Service and Maintenance InstructionsFor Sizes 060--120, Series 100
NOTE: Read the entire instruction manual before starting theinstallation.
TABLE OF CONTENTSPAGE
SAFETY CONSIDERATIONS 1. . . . . . . . . . . . . . . . . . . . . . . .
GENERAL 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS 3. .
CARE AND MAINTENANCE 3. . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and/or Replacing Air Filter 3. . . . . . . . . . . . . . . . .
Blower Motor and Wheel Maintenance 4. . . . . . . . . . . . . . .
Cleaning Burners 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning Heat Exchangers 6. . . . . . . . . . . . . . . . . . . . . . . . .
Flushing Collector Box and Drainage System 7. . . . . . . . . .
Servicing Hot Surface Igniter 7. . . . . . . . . . . . . . . . . . . . . . .
Electrical Controls and Wiring 9. . . . . . . . . . . . . . . . . . . . . .
Checking Heat Tape Operation (If Applicable) 10. . . . . . . .
Winterizing 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAMS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SHOCK, FIRE, OR OPERATIONHAZARD
Failure to follow safety warnings exactly could result indangerous operation, serious injury, death, or propertydamage.
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 possibledamage to this equipment, serious personal injury, ordeath.
The ability to properly perform maintenance on thisequipment requires certain expertise, mechanical skills,tools, and equipment. If you do not possess these, donot attempt to perform any maintenance on thisequipment other than those procedures recommended inthe User’s Manual.
! WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could cause corrosion ofheat exchanger, fire, personal injury, or death.
Never store anything on, near, or in contact with thefurnace, such as:1. Spray or aerosol cans, rags, brooms, dust mops,vacuum cleaners, or other cleaning tools.2. Soap powders, bleaches, waxes or other cleaningcompounds, plastic or plastic containers, gasoline,kerosene, cigarette lighter fluid, dry cleaning fluids, orother volatile fluids.3. Paint thinners and other painting compounds, paperbags, or other paper products.
! WARNING
SAFETY CONSIDERATIONSRecognize safety information. This is the safety--alert symbol
. When you see this symbol on the furnace and ininstructions or manuals, be alert to the potential for personalinjury.
Understand the signal words DANGER, WARNING, andCAUTION. These words are used with the safety--alert symbol.DANGER identifies the most serious hazards which will result insevere personal injury or death. WARNING signifies a hazardwhich could result in personal injury or death. CAUTION is usedto identify unsafe practices which may result in minor personalinjury or product and property damage. NOTE is used to
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highlight suggestions which will result in enhanced installation,reliability, or operation.
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.
A05069
Fig. 1 --- Furnace in Upflow Orientation
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!
Follow all safety codes including the National Fuel Gas Code(NFGC) NFPA 54--2002/ANSI Z223.1--2002 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.
GENERALThis furnace must be installed as a direct vent (2--pipe) orventilated combustion air condensing gas furnace (see installationinstructions for details). This furnace must be installed in anupflow application. An upflow furnace application is where theblower is located below the combustion and controls section ofthe furnace, and conditioned air is discharged upward. (See Fig.1 and 2.)
UPFLOW
AIRFLOW
A06340
Fig. 2 --- Approved Orientation
ELECTROSTATIC DISCHARGE (ESD)PRECAUTIONS
UNIT DAMAGE HAZARD
Failure to follow this caution may damage furnacecomponents.
Electrostatic discharge can affect electronic components.Take precautions during furnace installation and servicingto protect the furnace electronic control. Precautions willprevent electrostatic discharges from personnel and handtools which are held during the procedure. Theseprecautions will help to avoid exposing the control toelectrostatic 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 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 the fur-nace chassis which is close to the control. Tools held in aperson’s hand during grounding will be satisfactorily dis-charged.
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 touch un-grounded objects, etc.).
4. If you touch ungrounded objects (recharge your body withstatic electricity), firmly touch furnace again before touch-ing control or wires.
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5. Use this procedure for installed and uninstalled (un-grounded) furnaces.
6. Before removing a new control from its container, dis-charge your body’s electrostatic charge to ground to pro-tect 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 the fur-nace. Put all used AND new controls into containers be-fore 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 thefurnace.
! WARNING
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 as neces-sary.
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.
Step 1—Cleaning and/or Replacing Air FilterThe air filter arrangement may vary depending on the applicationor orientation.
FIRE, CARBON MONOXIDE AND POISONINGHAZARD
Failure to follow this warning could result in a fire,personal injury, or death.
Never operate unit without a filter or with the bloweraccess panel removed. Operating a unit without a filteror with the blower access door removed could causedamage to the furnace blower motor. Dust and lint oninternal parts of furnace 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 direction
of 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.
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.)
WASHABLEFILTER
FILTERSUPPORT
FILTERRETAINER
WASHABLE FILTER ORDISPOSABLE MEDIA FILTERIN FILTER CABINET
A00232
Fig. 3 --- Bottom Filter Arrangement
FILTERRETAINER
WASHABLEFILTER
IN FURNACE
WASHABLE FILTER ORDISPOSABLE MEDIAFILTER IN FILTER CABINET
A00233
Fig. 4 --- Filter Installed for Side Inlet
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 in op-posite direction of airflow.
6. Rinse filter and let dry. Oiling or coating filter is not rec-ommended.
7. Slide filter into furnace.
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COLLECTOR BOX TUBE(PINK)
COLLECTOR BOX DRAIN TUBE(BLUE)
INDUCER HOUSING (MOLDED) DRAIN TUBE(BEHIND COLLECTOR BOX DRAIN TUBE)
FIELD-INSTALLEDFACTORY-SUPPLIED DRAIN TUBECOUPLING (LEFT DRAIN OPTION)
FIELD-INSTALLED FACTORY-SUPPLIED DRAIN TUBE
FIELD-INSTALLEDFACTORY-SUPPLIED1/2-IN. CPVC STREET
ELBOWS (2) FOR LEFTDRAIN OPTION
FIELD-INSTALLEDFACTORY-SUPPLIED DRAIN
TUBE COUPLING (RIGHTDRAIN OPTION)
COLLECTOR BOX TUBE (GREEN)
CONDENSATE TRAP
CAP
BURNER ENCLOSURE PRESSUREREFERENCE TUBE ASSEMBLY
PLUG
A06449
Fig. 5 --- Factory--Shipped Upflow Tube Configuration(Shown with Blower Access Panel Removed)
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 WheelMaintenanceTo 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.
Clean blower motor and wheel as follows:
1. Turn off electrical supply to furnace.
2. Remove main furnace door and blower access panel.
3. Disconnect wiresAll factory wires can be left connected, but field thermo-stat connections may need to be disconnected dependingon their length and routing.
4. Position control box, transformer, and door switch assem-bly 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 condensatetrap.
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 balance
weights (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 an ap-propriate degreaser. To remove wheel:
a. Mark blower wheel location on shaft beforedisassembly to 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 platelocation to ensure proper reassembly.
d. Remove screws securing cutoff plate and removecutoff plate from housing.
e. Remove bolts holding motor mounts to blowerhousing and slide motor and mounts out of housing.
f. Remove blower wheel from housing.
g. Clean wheel per instructions on degreaser cleaner. Donot get degreaser in motor.
9. Reassemble motor and blower wheel by reversing items8b through 8f. Ensure wheel is positioned for proper rota-tion.
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 previously re-moved.
a. Reinstall condensate trap in hole in blower shelf.
b. Connect condensate trap drain tubes. See Fig. 5 ortubing diagram on main furnace door for proper tubelocation.
(1.) Connect 1 tube (blue or blue and white striped)from collector box.
(2.) Connect 1 tube (violet or unmarked) from inducerhousing.
(3.) Connect 1 tube (relief port, green or pink) fromcollector box.
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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 switch assem-bly on blower shelf.
13. Reconnect wires.Refer to furnace wiring diagram and connect thermostatleads if previously disconnected. (See Fig. 21.)
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in electricalshock, personal injury, or death.
Blower access panel door switch opens 115--v power tofurnace control. No component operation can occur.Caution must be taken when manually closing thisswitch for 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 changes be-tween heating and cooling by jumpering R to G and R toY/Y2 on furnace control thermostat terminals. (See Fig.15.)
15. If furnace is operating properly, release blower access pan-el door switch, replace blower access panel, and replacemain furnace door.
Step 3—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 for reassemb-ly.
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.
MANIFOLDMOUNTINGSCREWS
MANIFOLD
GAS VALVEREGULATORFITTING
GASCONTROLVALVE
CELLPANEL
GASKET
A02312
Fig. 6 --- Burner Box Assembly
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 beremoved as 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 manifold grom-met, dressing the wires to ensure there is no tension on theigniter itself. (See Fig. 7.)
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ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in electricalshock, personal injury, or death.
Igniter wires must be securely placed in slot in manifoldgrommet or else they could become pinched or severedand electrically 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 valve us-ing backup wrench on gas valve to prevent rotation andimproper orientation.
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 propertydamage, personal injury, or death.
Gas valve switch MUST be facing forward or tiltedslightly.
! WARNING
19. Replace burner box cover.
20. Turn on gas and electrical supplies to furnace.
21. Check for gas leaks.
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warnings exactly couldresult in serious injury, death or property damage.
Never test for gas leaks with an open flame. Use acommercially available soap solution made specificallyfor the detection of leaks to check all connections.
! WARNING
22. Replace main furnace door.
Step 4—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.
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 furnacecomponent damage.
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 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 re-moval.
7. Using backup wrench, disconnect gas supply pipe fromfurnace gas control valve.
8. Disconnect pressure tubing from gas valve.
9. Remove 2 screws attaching top filler panel and rotate up-wards to gain access to screws attaching burner box to cellpanel.
10. Remove screws attaching burner box to cell panel. (SeeFig. 6.)
NOTE: Burner box, cover, manifold, gas valve, and burnerassembly should be removed as 1 assembly.
11. Clean heat exchanger openings with a vacuum and a softbrush. (See Fig. 8.)
NOTE: After cleaning, inspect the heat exchangers to ensurethey are free of all foreign objects that may restrict flow ofcombustion products.
12. Reverse items 4 through 10 for reassembly.
PRIMARY HXINLET OPENINGS
A96305
Fig. 8 --- Cleaning Inlet Openings of PrimaryHeat Exchangers
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UNIT MAY NOT OPERATE
Failure to attach ground wire to an adequate casing groundmay cause the furnace control to lock out.
The ground wire from the gas valve MUST be attached tothe burner box attachment screw.
CAUTION!
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 sealfrom 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.)
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.
15. Turn on gas and electrical supplies to furnace.
16. Check furnace operation through 2 complete heat operat-ing cycles. Look through sight glass in burner enclosure tocheck burners. Burner flames should be clear blue, almosttransparent. (See Fig. 11.)
17. Check for gas leaks.
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warnings exactly couldresult in serious injury, death or property damage.
Never test for gas leaks with an open flame. Use acommercially available soap solution made specificallyfor 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 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.
Step 5—Flushing Collector Box and DrainageSystem
1. Turn off gas and electrical supplies to furnace.
2. Remove main furnace door.
3. Disconnect inducer motor and pressure switch wires orconnectors.
4. Disconnect pressure switch tubes.
5. Disconnect vent pipe from inducer housing outlet by loos-ening coupling clamp on inducer outlet.
PAM
RTV
A93087
Fig. 9 --- Combustion--Air Intake HousingGasket Repair
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.
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 of for-eign materials and remove them if present.
UNIT DAMAGE HAZARD
Failure to follow this caution may result in furnacecomponent damage.
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!
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 to in-ducer motor and pressure switches or connectors.
12. Reconnect pressure tubes to pressure switches. See dia-gram 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 2 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.
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A06460
Fig. 10 --- Furnace Pressure and Drain Tubing Diagram
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warnings exactly couldresult in serious injury, death or property damage.
Never test for gas leaks with an open flame. Use acommercially available soap solution made specificallyfor the detection of leaks to check all connections.
! WARNING
16. Replace main furnace door.
Step 6—Servicing Hot Surface Igniter
BURN HAZARD
Failure to follow this caution may result in minor personalinjury.
Allow igniter to cool before removal. Normal operatingtemperatures exceed 2000_F.
CAUTION!
The igniter does NOT require annual inspection. Check igniterresistance before removal.
1. Turn off gas and electrical supplies to furnace.
2. Remove main furnace door.
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 bothigniter leads in connector.
b. Cold reading should be between 40 ohms and 70ohms.
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 screwsecuring the igniter bracket to the burner box bracket(See Fig. 13.) and carefully withdraw the igniter andbracket assembly through the front of the burner boxwithout striking the igniter on surrounding parts. Notethat the igniter bracket has a handle that extends to thefront of the burner box to aid in handling. (See Fig.13.)
d. Inspect igniter for signs of damage or failure.
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����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 IGNITERBRACKET HANDLE
IGNITER BRACKETMOUNTING SCREW
A05075
Fig. 13 --- Igniter Bracket
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 burner box toavoid damage 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 the ig-niter wires to ensure there is no tension on the igniter it-self. (See Fig.7.)
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in electricalshock, personal injury, or death.
Igniter wires must be securely placed in slot in manifoldgrommet or else they could become pinched or severedand electrically shorted.
! WARNING
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. If furnace failes to ignite properly, verify position of igni-ter (See Fig. 14) by removing the burner box assembly ac-cording to instructions in Step 4. After verifying and/oradjusting the location, re--install the burner box assemblyaccording to the instructions in Step 4. Repeat igniter op-eration test in item 10.
12. Replace main furnace door.
Step 7—Electrical Controls and Wiring
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ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personalinjury or death.
There may be more than 1 electrical supply to the unit.Check accessories and cooling unit for additionalelectrical supplies.
! 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.
A06522
Fig. 14 --- Igniter
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.
Step 8—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.
UNIT AND PROPERTY DAMAGE
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 or lower,freeze protection measures must be taken. SeeCONDENSATE DRAIN PROTECTION section ofInstallation, Start--up, and Operating Instructions. (See Fig.17.)
CAUTION!
Step 9—Winterizing
UNIT DAMAGE HAZARD
Failure to follow this caution may result in furnacecomponent damage.
Freezing condensate left in the furnace may damage thefurnace.
CAUTION!
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.
If the furnace will be off for an extended period of time in astructure where the temperature will drop to 32_F or below,winterize as follows:
1. Turn off electrical supply to furnace.
2. Remove main furnace door.
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, pro-pylene glycol (RV, swimming pool antifreeze, or equiva-lent) into funnel/tube until it is visible at point where con-densate enters open drain. (See Fig. 19.)
58UVB
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
W/W1
W2
Y/Y2
G
NOTES: 1.2.3.
A95236
Fig. 15 --- Field Wiring
FLASH UPGRADE
CONNECTOR (FACTORY
ONLY)
ACRDJ AIR CONDITIONING RELAY DISABLE
JUMPER
HUMIDIFIER TERMINAL (24-VAC
0.5 AMP MAX.
CONTINUOUS FAN (CF) AIRFLOW
SETUP SWITCHES
COMMUNICATION CONNECTOR
AIR CONDITIONING (A/C) AIRFLOW
SETUP SWITCHES
MODEL PLUG CONNECTOR
SW1 SETUP SWITCHES AND BLOWER OFF-
DELAY
STATUS AND COMM LED LIGHTS
3-AMP FUSE
TRANSFORMER 24-VAC CONNECTIONS
PL3 ECM BLOWERHARNESS
CONNECTOR
PL1 LOW VOLTAGE MAINHARNESS CONNECTOR
EAC-1 TERMINAL (115-VAC 1.0 AMP MAX.)
115-VAC (L1) LINE VOLTAGE CONNECTIONS
115-VAC (L2) NEUTRAL CONNECTIONS
PL2 HOT SURFACE IGNITER & INDUCER
MOTOR CONNECTOR
24-V THERMOSTAT TERMINALS
FUTURE APPLICATIONS
DA
TE C
OD
E X
XX
XN
A06494
Fig. 16 --- Variable Capacity Furnace Control
12
32°F MINIMUM INSTALLED�AMBIENT OR FREEZE�PROTECTION REQUIRED
A93058
Fig. 17 --- Freeze Protection
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 inducer hous-ing.
7. Replace main furnace door.
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 blower access panel sight glass for currentLED status code.
d. Remove blower access panel.
e. Turn setup switch SW1--1 to ON position. (See Fig.16 or 21 for location.)
f. Manually close blower access panel door switch. Use apiece of tape to hold switch closed.
ELECTRICAL SHOCK, UNIT MAY NOTOPERATE HAZARD
Failure to follow this warning could result in electricalshock, personal injury, or death.
Blower access panel door switch opens 115--v power tofurnace control. No component operation can occurunless switch is closed. Caution must be taken whenmanually closing this switch for service purposes.
! WARNING
g. The AMBER LED will flash the status codes in theorder of occurence. Record status codes until statuscode 11 flashes (1 short and 1 long).
h. After status code #11 flashes, the status codes willrepeat until setup switch SW1--1 is turned off.
i. Remove tape to release blower access panel doorswitch and 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 indicateproper operation, replace main furnace door.
2. Status codes are erased after 72 hours or they can bemanually erased by performing the following procedure:
a. Leave 115--v power to furnace turned on.
b. Remove main furnace door.
c. Look into blower access panel sight glass for currentLED status code.
d. Remove blower access panel.
e. Turn setup switch SW1--1 to ON position. (See Fig.16 or 21 for location.)
f. Jumper thermostat terminals R, W/W1, and Y/Y2 onfurnace control.
g. Manually close blower access panel door switch. Use apiece of tape to hold switch closed.
58UVB
58UVB
13
h. After status code 11 flashes for at least 2 times, removeR, W/W1, and Y/Y2 jumpers.
A06456
Fig. 18 --- Inducer Housing Drain TubeA06457
Fig. 19 --- Funnel in Drain Tube and AntifreezeRunning Through Trap
14
A06562
Fig. 20 --- Service Label
i. Turn setup switch SW1--1 to OFF position.
j. Remove tape to release blower access panel doorswitch and replace blower access panel.
k. Operate furnace through 1 heat cycle to check forproper operation and check LED status.
l. If furnace is operating properly and LEDs indicateproper operation, replace main furnace door.
3. The control can also assist in troubleshooting by perform-ing a Component Test. The Component Test will function-ally operate all furnace components, except the gas 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 thefollowing:
(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.
58UVB
15
(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 beencompleted, 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 blower motor operates at midrange airflowfor 15 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.
LEGEND
JUNCTION
TERMINAL
CONTROL TERMINAL
FACTORY POWER
WIRING (115VAC)
FACTORY CONTROL
WIRING (24VAC)
FIELD CONTROL
WIRING (24VAC)
CONDUCTOR ON
CONTROL
FIELD WIRING
SCREW TERMINAL
EQUIPMENT
GROUND
PLUG RECEPTACLE
NOTES:
3327
10-1
01 R
EV. A1. 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. Inductor is used with 3/4 hp and 1 hp ECM Blower motors.8. Factory connected when (LGPS) not used.9. Blower off-delay, gas heating selections are (90, 120, 150, 180) seconds, cooling or heat pump
90 seconds or 5 seconds when dehumidify call is active.10. Ignition lockout will occur after four consecutive unsuccessful trials for ignition. Control will
auto-reset after three hours.11. Any of the 5 wires shown within the NEUTRAL L2 box can be connected to any terminal within the box.12. Blower motor (BLWM) and Inducer motor (IDM) are locked-rotor overload protected by redundant
electronic control circuits.
A/C Air Conditioning (Adjustable Airflow -CFM)ACR Air Conditioning Relay, SPST (N.O.)ACRDJ Air Conditioning Relay Defeat JumperBLWM Blower Motor (ECM)CF Continuous Fan (Adjustable Airflow -CFM)COMMR Communication Relay, SPDTCPU Microprocessor / CircuitryDHUM DHUM Connection (24VAC )EAC-1 Electronic Air Cleaner Connection
(115VAC 1.0 Amp Max.)EAC-2 Electronic Air Cleaner Connection (Common)FRS Flame Rollout Switch, Man. Reset, SPST(N.C.)FSE Flame-Proving Sensor ElectrodeFUSE Fuse, 3 Amp, Automotive Blade Type,
Factory InstalledGV Gas ValveGVR Gas Valve Relay, DPST (N.O.)HPS High-Heat Pressure Switch, SPST (N.O.)HPSR High-Heat Pressure Switch Relay, SPST (N.C.)HSI Hot Surface Igniter (115VAC)HSIR Hot Surface Igniter Relay, SPST (N.O.)HUM 24VAC Humidifier Connection (0.5 Amp Max.)HUMR Humidifier Relay, SPST (N.O.)IDM Inducer Draft Motor, 2-Speed, Shaded PoleIDR Inducer Motor Relay, SPST (N.O.)IHI/LOR Inducer Motor Speed Change Relay, SPDTILK Blower Door Interlock Switch, SPST (N.O.)
IND Inductor (Note #7)LED Light Emitting Diode for Status CodesLGPS Low Gas Pressure Switch, SPST (N.O.)LPS Low-Heat Pressure Switch, SPST (N.O.)LS Limit Switch, Auto-Reset, SPST (N.C.)PCB Printed Circuit BoardPL1 12-Circuit ConnectorPL2 4-Circuit HSI & IDM ConnectorPL3 4-Circuit ECM BLWM ConnectorPL4 4-Circuit Model Plug ConnectorPL7 4-Circuit Communication ConnectorPL9 2-Circuit OAT ConnectorPL10 2-Circuit HSI ConnectorPL11 IDM Connector (12-Circuit)PL12 1-Circuit Inductor Splice ConnectorPL13 16-Circuit ECM Blower Ctrl. ConnectorPL14 5-Circuit ECM Blower Power ConnectorSW1-1 Manual Switch, Status Code Recall, SPST (N.O.)SW1-2 Manual Switch, Low-Heat Only, SPST(N.O.)SW1-3 Manual Switch, Low-Heat Rise Adj. SPST (N.O.)SW1-4 Manual Switch, Comfort/Efficiency Adjustment,
SPST (N.O.)SW1-5 Manual Switch, Cooling CFM/Ton, SPST (N.O.)SW1-6 Manual Switch, Component Test, SPST (N.O.)SW1-7,8 Manual Switches, Blower Off-Delay, SPST(N.O.)SW4-1 Manual Switch, Twinning Main (OFF) / Sec. (ON)SW4-2&3 FOR FUTURE USETRAN Transformer, 115VAC / 24VAC
GV
M
C HI
NOTE #3
BLU
BRN
HPS
GRN/YEL
FRSLS
NOTE #8
GRY
RED RED RED
LPS
(WHEN USED)LGPSBRN
FSEWHT
PL31
4
HSI
L1
FUSED OR CIRCUITBREAKER DISCONNECTSWITCH (WHEN REQ'D)
NOTE #2
GND
NEUTRAL
FU2
BLK
ILKPL10
JB
1
2
BLK
WHT
PL1
TRAN
BLWM
L1
EAC
-1
PL12
INDNOTE #7PL12
4
HSI
PL2
VS
BLK
WHTWHT
BLU
SEC
-2
CODE
SEC
-1HUM
FUSE
3-A
MP
W/W1DHUM G24VomCW2 Y/Y2 RY1 STATUS
LEDS
COMM
ACRD
J
PL8
PL9
OAT
SW4
PL7
A B C D
CF
AC
SW1PL
4
GRN/YEL
1. Default A/C airflow when A/C switches are in OFF position2. Default cont. fan airflow when CF switches are in OFF position
A/C OR CF AIRFLOW SELECTION CHART BASED ON 350 CFM/TON
1HSI2
SCHEMATIC DIAGRAM
IDR
TO 115VAC FIELD-DISCONNECT SWITCH
ILKEQUIPMENT GROUND
12
3HSIR
IHI/LOR
PL2
L2
L2
FU1
NOTE #6
PL1-8
R
PL1-6
L2
PL10
4
CPU
NOTE #5 PCB
PL31 2 3 4
BLWM
PL13
101617
54
321
EAC-1PL14
PL12INDNOTE #7
PL12
L1
EAC EAC-2
TRAN
115VACL1 L2
SEC2SEC1
24VAC
PL1-12
HPSR
GV
LPS
NOTE #8
LGPS(WHEN USED)
HPS
HI
PL1-2
PL1-4
PL1-3
PL1-10
PL1-5
W/W1
CPU
GVR
DHUMW2
Y/Y2G
Y1
COM NOTE #3C
M
PL1-1 FSENOTE #5
ACRCOMMR
PCB
1
1
1
2 210017501400
122512251225
1225
1050
1050
875
875
700
700
525
1205T080,100
DEF.DEF.
DEF.0603.5T080
SIZEMODEL
1 2 3
OFF
1 2 3
OFF
1 2 3
OFF
1 2 3
OFF
1 2 3
OFF
1 2 3
OFF
1 2 3
OFF
1 2 3
OFF
ORN
BLK
GRN/YEL
516 1 710
BLUYELG
RNRED
PL13 PL14
BLK
YEL
CONNECTION DIAGRAM
BLK
WHT
YEL
14 3 2
BLUYELG
RNRED
SW1-7,8BLOWER OFF DELAY
SELECTION
90SEC120SEC150SEC180 SEC
OFF
OFF
OFF
OFF
7 87 8
7 87 8
11
2
1
1
AC
RDJ
PRINTED
CIRC
IUT BOA
RD
PRINTED
CIRC
IUT BOA
RD
HUMRHUM
RED
MODEL MODELSIZE PLUG
HK70EZ
PIN RESISTANCE K
1 - 4 2 - 3060
3.5T0805T-080
100
057058059060
24242424
91120150180
PL4 - MODEL PLUG CHART
120 061 24 220
2700 875 1050 1225 1400 11750 1750
IDM
GRN/YEL
BRN
ORNYEL
WHTBLK
BLK
WHT
FRS LS
IDM
PL11
PL1-9PL1-11PL1-7
L2
NOTE #11
NEUTRAL - L2
EAC
-2
WHTRED
42
101
126 4
210
1
126
* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * ** * * * * * * * * * * * * * * * * ** * * * * * * * * * * * * * * * ** * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * ** * * * * * * * * * * * * * * * * ** * * * * * * * * * * * * * * * *
* * *
* *
* ** * * * * * *
* * * *
* *
* * * * * * *
* * *
** * * * * * * *
* * * * * * * *
* * *
* * * * *
* * * * * * *
* * * * * * ** * * * * * * * * * * * * * * * * * * * * * * ** * * * * * * * * * * * * * * * * * * * * * * * * * * * * * *
* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * ** * * * * * * * * * * * * * * * * ** * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * ** * * * * * * * * * * * * * * * * ** * * * * * * * * * * * * * * * * *
* * *
* *
* ** * * * * * *
* * * *
* *
* * * * * * *
* * *
** * * * * * * *
* * * * * * * *
* * *
* * * * *
* * * * * *
* * * * * * ** * * * * * * * * * * * * * * * * * * * * * * ** * * * * * * * * * * * * * * * * * * * * * * * * * * * * * *
A06459
Fig. 21 --- Wiring Diagram58UVB
58UVB
16
Is A
MB
ER
LE
D s
tatu
s lig
ht b
linki
ng O
N/O
FF
slow
ly w
ith a
com
bin
atio
n o
f sh
ort
and
long fla
shes?
Is A
MB
ER
LE
D s
tatu
s lig
ht blin
king
rapid
ly w
ithout a p
ause
?
Is A
MB
ER
LE
D s
tatu
s lig
ht on?
Dete
rmin
e s
tatu
s co
de.
The s
tatu
s co
de is
a 2
digi
t num
ber w
ith th
e fir
st d
igit
dete
rmin
edby
the n
um
ber
of sh
ort
fla
shes
and the
seco
nd d
igit
by th
e n
um
ber
of l
ong fl
ash
es?
Go to s
ect
ion b
elo
w fo
r th
e s
tatu
s co
de
that w
as
flash
ed.
YE
S
NO
YE
S
To r
eca
ll pre
vious
statu
s co
des
dis
connect
the R
therm
ost
at co
nnect
ion, re
set pow
er,
and p
ut se
tup s
witc
h S
W1-1
in the O
Nposi
tion.
The A
MB
ER
LE
D w
ill fla
sh the
statu
s co
des
in the o
rder
of occ
urr
ence
.R
eco
rd s
tatu
s co
des
until
sta
tus
code #
11
flash
es
(1 s
hort
and 1
long fl
ash
). A
fter st
atu
sco
de #
11 fl
ash
es
the s
tatu
s co
des
will
repeat.
Sta
tus
codes
are
era
sed a
fter
72 h
ours
or
can b
e m
anually
era
sed b
y puttin
g s
etu
psw
itch S
W1-1
in the O
N p
osi
tion a
nd
jum
perin
g R
, W/W
1, a
nd Y
/Y2 s
imulta
neousl
yuntil
sta
tus
code #
11 is
fla
shed.
When d
one
put se
tup s
witc
h S
W1-1
in the O
FF
posi
tion.
Check
for
corr
ect
line v
olta
ge p
ola
rity
.If u
nits
are
tw
inned, ch
eck
for
pro
per
low
-volta
ge (
24V
) tr
ansf
orm
er
phasi
ng.
Was
there
a p
revi
ous
statu
s co
de o
ther
than #
11?
Is d
oor
switc
h c
lose
d?
Is there
115V
goin
g to s
witc
h?
Repla
ce d
oor
switc
h.
Repla
ce tra
nsf
orm
er.
Does
the c
ontr
ol r
esp
ond to W
/W1, W
2, Y
1,
Y/Y
2, and G
(24V
) therm
ost
at si
gnals
?
Repla
ce furn
ace
contr
ol.
NO
NO
NO
NO
Is 2
4V
pre
sent
at W
/W1, W
2, Y
1, Y
/Y2 o
r G
therm
ost
at
term
inals
on t
he f
urn
ace
contr
ol?
NO
YE
S
YE
S
Repla
ce furn
ace
contr
ol.
Is there
24V
at S
EC
-1 a
nd S
EC
-2?
Is there
115V
at L1 a
nd L
2?
YE
S
NO
YE
S
YE
S
NO
YE
S
NO
YE
S
Run s
yste
m thro
ugh a
low
-heat, h
igh-h
eat,
or
coolin
g c
ycle
to c
heck
opera
tion.
Sta
tus
codes
are
era
sed a
fter
72 h
ours
or
can b
em
anually
era
sed b
y puttin
g s
etu
p s
witc
hS
W1-1
in the O
N p
osi
tion a
nd ju
mpering R
,W
/W1, a
nd Y
/Y2 s
imulta
neousl
y until
sta
tus
code #
11 is
fla
shed.
YE
S
NO
Clo
se c
ircu
it bre
ake
r and g
o b
ack
to S
TAR
T.
Check
for
contin
uity
in w
ire f
rom
circu
itbre
ake
r to
furn
ace
.
Is c
ircu
it bre
ake
r cl
ose
d?
Clo
se d
oor
switc
h.
Check
room
therm
ost
at
or
inte
rconnect
ing c
able
.
NO
YE
S
YE
S
NO
The t
herm
ost
at
is n
ot
com
patib
le w
ith t
he
furn
ace
cont
rol.
Eith
er in
stal
l a b
alla
st re
sist
or,
connect
the C
om
24V
therm
ost
at te
rmin
al t
oth
e t
herm
ost
at,
or
repla
ce t
he t
herm
ost
at.
Does
the p
roble
m r
epeat
when u
sing
a ju
mper
wire?
Dis
connect
all
the ther
furn
ace
contr
ol.
STA
RT
TR
OU
BLE
SH
OO
TIN
G G
UID
E -
VA
RIA
BLE
SP
EE
D
A02350a
58UVB
17
11
NO
PR
EV
IOU
S C
OD
E –
Sta
tus
cod
es
are
era
sed a
fter
72 h
ours
or
can b
e m
anua
llyera
sed
by
puttin
g s
etu
p s
witc
h S
W1-1
inth
eO
N p
osi
tion
and
jum
pe
rin
g R
,W
/W1,
an
d Y
/Y2 s
imu
ltan
eo
usl
y u
ntil
sta
tus
code
#11 is
flash
ed. R
un s
yste
m thro
ugh a
low
-h
ea
t, h
igh
-he
at,
or
coo
ling
cycl
e t
och
eck
syst
em
.
12
BLO
WE
R O
N A
FT
ER
PO
WE
R U
P –
(115V
OR
24V
) – N
orm
al o
pera
tion.
Blo
wer
runs
for
90
seco
nds,
if u
nit
ispow
ere
d u
p d
uri
ng
a c
all
for
heat (R
-W
/W1
close
d)
or
wh
en
(R
-W/W
1 o
pens)
duri
ng
the b
low
er
on-d
ela
yperiod.
13
LIM
IT C
IRC
UIT
LO
CK
OU
T –
Lo
cko
ut
occ
urs
ifth
e li
mit
or
flam
e r
ollo
ut sw
itch is
op
en
lon
ge
rth
an 3
min
ute
s o
r 1
0su
ccess
ive li
mit
trip
s occ
urr
ed d
uring h
igh-
heat.
Contr
ol w
ill a
uto
-rese
t after
3 h
ours
.S
ee c
ode
33.
14
IGN
ITIO
N L
OC
KO
UT
– S
yste
mfa
iled
toig
nite
gas
and p
rove
fla
me
in 4
attem
pts
.C
ontr
ol w
ill a
uto
-rese
t after
3 h
ours
. S
ee
statu
s co
de
34.
21
GA
S H
EAT
ING
LO
CK
OU
T –
Turn
off
pow
er
and w
ait
5 m
inute
sto
retr
y. C
heck
for:
-S
tuck
clo
sed
gas
valv
e r
ela
y o
n c
on
trol.
-M
isw
ire
or
sho
rt t
og
as
valv
ew
ire.
22
AB
NO
RM
AL F
LA
ME
-PR
OV
ING
SIG
NA
LF
lam
e is
pro
ved w
hile
gas
valv
e is
de-
energ
ize
d.
Induce
r w
ill r
un u
ntil
fault
iscl
ea
red.
Ch
eck
for:
-S
tuck
op
en o
r le
aky
gas
valv
e.
23
PR
ES
SU
RE
SW
ITC
H D
ID N
OT
OP
EN
–C
heck
for:
-O
bst
ruct
ed p
ress
ure
tube.
-P
ress
ure
switc
h s
tuck
clo
sed.
24
SE
CO
ND
AR
Y V
OLT
AG
E F
US
EIS
OP
EN
Check
for:
-S
hort
circ
uit
inse
condary
volta
ge (
24V
)w
irin
g in
cludin
gth
erm
ost
at le
ads.
Dis
connect
therm
osta
tle
ads
tois
ola
tesh
ort
circu
it.
32
LO
W-H
EAT
PR
ES
SU
RE
SW
ITC
H D
IDN
OT
CLO
SE
OR
RE
OP
EN
ED
– If opens
duri
ng b
low
er
on-d
ela
y peri
od,bl
ow
er
will
com
e o
nfo
r th
ese
lect
ed b
low
er
off-d
ela
y.If o
pens
with
in 5
min
ute
s after
igniti
on
the
nex
t heatin
gcy
cle
will
be r
est
rict
ed
tohig
h-h
eat.
Che
ckfo
r:-
Pro
per
vent si
zing.
-Low
inle
t gas
pre
ssure
(if
LG
PS
use
d).
-R
est
rict
ed
co
mbu
stio
na
ir s
up
ply
.-
Dis
connect
ed o
r obst
ruct
ed p
ress
ure
tubin
g.
-D
efe
ctiv
e o
r m
isw
ired p
ress
ure
sw
itches
- E
xcess
ive
win
d. *
- P
lugged
condensa
tedra
in.
-W
ate
rin
vent pip
ing, poss
ible
sagg
ing
pipe
33
LIM
IT C
IRC
UIT
FA
ULT
– I
nd
ica
tes
the
limit
or
flam
e r
ollo
ut
switc
his
open o
r th
efu
rnac
eis
op
era
ting
inh
igh
-he
at
on
lym
ode d
ue to 2
succ
ess
ive lo
w-h
eat lim
ittr
ips.
Blo
wer
will
run fo
r 4 m
in. o
r until
open
switc
h r
em
ake
s w
hic
hev
er
is lo
nger.
Ifopen
longer
than 3
min
., c
ode c
hanges
to lo
ckou
t #13.
If o
pen le
ssth
an 3
min
.st
atu
s co
de
#3
3 c
on
tinu
es
tofla
shu
ntil
blow
er
shuts
off.
Fla
me r
ollo
utsw
itch
req
uires
ma
nu
al r
ese
t. C
he
ckfo
r:-
Pro
per
rear
air b
affle
.-
Loose
blo
wer
wheel.
-D
efe
ctiv
e s
witc
h o
rco
nnect
ions.
-Im
pro
per
low
-heat gas
input
adju
stm
ent.
-Im
pro
per
or
mis
alig
ned li
mit
and/o
r lim
itsh
ield
.-
Stu
ck h
igh-h
eatso
lenoid
in g
as
valv
e.
34
IGN
ITIO
N P
RO
VIN
G F
AIL
UR
E –
Iffla
me is
no
t se
nse
dd
uri
ng t
he
tria
l for
ign
itio
np
eri
od
,th
e c
ontr
ol w
illre
pe
at
the
ign
itio
nse
quence
3 m
ore
times
befo
re lo
ckout
#14
occ
urs
.If
flam
esi
gnal i
s lo
st d
uri
ng
the
blow
er
on-d
ela
y peri
od, bl
ow
er
will
com
e o
nfo
r th
e s
ele
cte
dbl
ow
er
off
-de
lay.
Ch
eck
the
follo
win
gite
ms
first
be
fore
pro
cee
din
gto
the n
ext st
ep.
-G
as
valv
e turn
ed
off.
- M
anual
shut-
off
valv
e.
-G
ree
n/Y
ello
w w
ire
MU
ST
be
con
nect
ed
tofu
rnac
e s
he
et
me
tal.
-F
lam
e s
enso
r m
ust
no
t b
e g
rou
nd
ed
.To
dete
rmin
e w
heth
er
the
pro
blem
is in
the
gas
valv
e, ig
nite
r, o
r fla
me
senso
rth
esy
stem
can
be o
pera
ted
in c
om
ponent te
stm
ode.
To
check
the ig
nite
r re
move
the R
the
rmos
tat
con
ne
ctio
nfr
om
th
e c
ont
rol,
rese
t pow
er,
and
putse
tup
switc
h S
W1-6
inth
e O
Nposi
tion to s
tart
the c
om
ponent te
st.
Does
the ig
nite
rglo
w o
range/w
hite
by
the
end o
fth
e 1
5se
cond w
arm
-up p
eri
od?
Un
plu
g ig
nite
r h
arn
ess
fro
mco
ntr
ol a
nd
repeat co
mponentte
st b
y tu
rnin
gse
tup
switc
h S
W1-6
OF
F a
nd then b
ack
ON
.C
heck
for
115V
betw
een p
in 3
and
NE
UT
RA
L-L
2 o
nth
e c
ontr
ol.
Was
115V
pre
sentfo
r th
e 1
5se
cond p
eri
od?
Ch
eck
co
nn
ect
ion
s a
nd
retr
y.If c
urr
ent is
near
typic
al v
alu
e(4
.0-6
.0 n
om
inal) a
nd b
urn
ers
will
not
stay
on, re
peatch
eck
in h
igh-h
eat.
If b
urn
ers
will
still
notst
ay o
n r
epla
ceco
ntr
ol.
If
bu
rne
rso
pe
rate
inh
igh
-he
at
the
nsw
itch
to
low
-h
ea
t, c
heck
ma
nifo
ldp
ress
ure
. I
f O
K,ch
eck
burn
er
carr
yove
r a
nd
fla
me
senso
rlo
catio
n.
Cle
an fla
me
senso
r w
ith fin
est
eel w
ool
and r
ech
eck
curr
ent.
Nom
inalcu
rrent is
4.0
to 6
.0 m
icro
am
ps.
Iscu
rre
nt
ne
ar
typ
ica
l valu
e?
Re
pla
ce e
lect
rod
e.
Will
main
burn
ers
ignite
and s
tay
on?
Repla
ce furn
ace
contr
ol.
NO
YE
S
YE
S
YE
S
NO
NO
15
BLO
WE
R M
OT
OR
LO
CK
OU
T –
Indic
ate
sth
ebl
ow
er
faile
dto
reach
250 R
PM
or
the
blow
er
faile
d to
com
munic
ate
with
in 3
0se
conds
after
bein
g turn
ed
ON
in tw
osu
ccess
ive h
eatin
gcy
cles.
Contr
ol w
illauto
-rese
t after
3 h
ours
. S
ee c
ode
41.
45 C
ON
TR
OL
CIR
CU
ITR
YLO
CK
OU
T A
uto
-rese
tafter
1 h
our
lock
out due
to:
-F
lam
eci
rcu
itfa
ilure
.-
Ga
s va
lve
re
lay
stuck
open.
- S
oft
wa
rech
eck
err
or.
Rese
t pow
er
tocl
ear
lock
ou
t. R
ep
lace
co
ntr
ol
if co
de
repeats
.
Repla
ce furn
ace
contr
ol.
Ch
eck
for
contin
uity
in t
he
ha
rne
ssa
nd
ign
iter.
Re
pla
ced
efe
ctiv
e c
om
po
ne
nt.
Reco
nnect
the R
therm
ost
at le
ad
and
set
therm
ost
at
to c
all
for
heat. C
onnect
voltm
ete
r acr
oss
gas
valv
e c
onnect
ions.
Does
gas
valv
e r
ece
ive 2
4V
?
Do
es
gas
valv
e o
pe
n a
nd
allo
w g
as
toflo
w?
Do the m
ain
burn
ers
ignite
?
Do the m
ain
burn
ers
stay
on?
Allo
w b
low
er
toco
me o
n a
nd
repeat te
stto
check
for
inte
rmitt
ent opera
tion.
Check
that all
gas
valv
es
are
turn
ed
on
. R
ep
lace
valv
e.
Check
connect
ions.
IfO
K,
repla
ce c
ontr
ol.
Check
for:
- I
nadequa
tefla
me
carr
yove
ror
rough ig
niti
on.
-Low
inle
t gas
pre
ssure
.-
Pro
pe
rfir
ing
rate
.
Repeatca
llfo
r h
eat and c
heck
flam
ese
nso
rcu
rrent during tri
alf
or
igniti
on
pe
rio
d.
Isth
e D
Cm
icro
am
ps
be
low
0.5
?
YE
S
NO
43
LO
W-H
EAT
PR
ES
SU
RE
SW
ITC
H O
PE
NW
HIL
E H
IGH
-HE
AT
PR
ES
SU
RE
SW
ITC
H IS
CLO
SE
D -
Check
for:
-Low
-he
at
pre
ssu
re s
witc
h s
tuck
op
en.
-D
isco
nnect
ed o
r obst
ruct
ed p
ress
ure
tubin
g.
-Im
pro
per
pre
ssure
switc
h w
irin
g.
-Low
inle
t gas
pre
ssure
(if
LG
PS
use
d).
-P
lugged
condensa
tedra
in.
-W
ate
rin
vent pip
ing, poss
ible
saggin
gpip
e.
YE
S
YE
S
YE
S
YE
S
NO
NO
NO
NO
Fix
ed.
NO
*Se
t u
p s
witc
h S
W1
-3 t
o b
e O
N if
pro
ble
m p
ers
ists
.
A05076
58UVB
18
25IN
VALI
D M
OD
EL
SE
LEC
TIO
N O
RS
ET
UP
ER
RO
R –
If s
tatu
s co
de 2
5 on
lyfla
shes
4 ti
mes
on
pow
er-u
p th
e co
ntro
lis
mis
sing
its
mod
el p
lug
PL4
and
isde
faul
ting
to th
e m
odel
sel
ectio
n st
ored
in m
emor
y. I
f sta
tus
code
25
flash
esco
ntin
uous
ly it
cou
ld in
dica
te a
ny o
f the
follo
win
g:-
Mod
el p
lug
PL4
is m
issi
ng a
nd th
ere
is n
o va
lid m
odel
sto
red
in p
erm
anen
tm
emor
y. T
his
will
hap
pen
if yo
u fo
rget
to in
stal
l the
mod
el p
lug
PL4
on
ase
rvic
e re
plac
emen
t con
trol
.-
The
rmos
tat c
all w
ith S
W1-
1 O
N.
-T
herm
osta
t cal
l with
SW
1-6
ON
.-
SW
1-1
and
SW
1-6
both
ON
.-
Two
diffe
rent
furn
ace
mod
els
twin
ned.
31H
IGH
-HE
AT P
RE
SS
UR
E S
WIT
CH
OR
RE
LAY
DID
NO
T C
LOS
E O
RR
EO
PE
NE
D -
Che
ck fo
r:-
Con
trol
rel
ay m
ay b
e de
fect
ive.
-G
as v
alve
is m
isw
ired.
-S
ee s
tatu
s co
de 3
2.
41B
LOW
ER
MO
TOR
FA
ULT
– In
dica
tes
the
blow
er fa
iled
to r
each
250
RP
M o
r th
ebl
ower
faile
d to
com
mun
icat
e w
ithin
the
pres
crib
ed ti
me
limits
. T
hirt
y se
cond
saf
ter
bein
g tu
rned
ON
or
ten
seco
nds
durin
g st
eady
-sta
te o
pera
tion.
Tur
n po
wer
off a
nd c
heck
the
follo
win
g ite
ms
first
befo
re p
roce
edin
g to
the
next
ste
p.-
Rub
bing
blo
wer
whe
el.
-Lo
ose
blow
er w
heel
.-
Wiri
ng fr
om fu
rnac
e co
ntro
l to
blow
erm
otor
.R
emov
e th
e R
ther
mos
tat c
onne
ctio
nfro
m th
e fu
rnac
e co
ntro
l, di
scon
nect
bot
hco
nnec
tors
from
the
blow
er m
otor
PL1
3an
d P
L14.
Doe
s th
e bl
ower
whe
el tu
rnfr
eely
?
Rep
lace
the
blow
er c
ontr
ol m
odul
e at
tach
edto
the
blow
er m
otor
. Fo
llow
the
inst
ruct
ions
with
the
blow
er c
ontr
ol m
odul
e to
mak
e su
reth
e en
tire
blow
er m
otor
doe
s no
t nee
d to
be
repl
aced
.
You
have
an
open
wire
or
bad
term
inal
on
the
BLU
E w
ire b
etw
een
the
furn
ace
cont
rol a
ndth
e bl
ower
mot
or.
Rep
lace
the
furn
ace
cont
rol.
Con
nect
a D
C v
oltm
eter
acr
oss
PL3
-4 B
LUE
(+)
and
PL3
-2 G
RE
EN
(-)
. D
oes
the
volta
geflu
ctua
te a
s de
scrib
ed tw
o st
eps
back
?
Doe
s th
e vo
ltage
fluc
tuat
e as
des
crib
ed in
the
prev
ious
ste
p?
Rep
lace
the
blow
er c
ontr
ol m
odul
e at
tach
edto
the
blow
er m
otor
. Fo
llow
the
inst
ruct
ions
with
the
blow
er c
ontr
ol m
odul
e to
mak
e su
reth
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
PL1
4-5
and
PL1
4-4?
Is th
ere
12-V
DC
at P
L13-
7 R
ED
(+) a
nd P
L13-
1 G
RE
EN
(-)
?
Is th
ere
12-V
DC
at P
L3-1
RE
D (
+) a
nd P
L3-
2 G
RE
EN
(-)
?
Rep
lace
the
furn
ace
cont
rol.
Is th
ere
5-V
DC
at P
L13-
16 Y
ELL
OW
(+) a
ndP
L13-
1 G
RE
EN
(-)
?
The
vol
tage
just
mea
sure
d sh
ould
be
very
stab
le a
nd s
houl
d no
t flu
ctua
te m
ore
than
.02-
VD
C.
If th
e vo
ltage
fluc
tuat
es m
ore
than
this
get
a d
iffer
ent v
oltm
eter
bef
ore
proc
eedi
ng.
Turn
pow
er o
ff, r
econ
nect
PL1
3 an
d P
L14
toth
e bl
ower
mot
or, t
hen
turn
pow
er b
ack
on.
Con
nect
a D
C v
oltm
eter
acr
oss
PL3
-3Y
ELL
OW
(+)
and
PL3
-2 G
RE
EN
(-)
. D
oes
the
volta
ge fl
uctu
ate
mor
e th
an it
did
in th
epr
evio
us s
tep?
Turn
pow
er o
ff, d
isco
nnec
t PL1
3 an
d P
L14
from
the
blow
er m
otor
, the
n tu
rn p
ower
bac
kon
. C
onne
ct a
DC
vol
tmet
er a
cros
s P
L13-
16 B
LUE
(+)
and
PL1
3-1
GR
EE
N (
-).
The
volta
ge s
houl
d be
nea
r 0-
VD
C b
ut it
will
fluct
uate
brie
fly s
ever
al ti
mes
a s
econ
d. I
fyo
u ha
ve a
n an
alog
vol
tmet
er th
e ne
edle
will
brie
fly g
o hi
gh s
ever
al ti
mes
a s
econ
d. I
f you
have
a d
igita
l vol
tmet
er w
ith a
bar
gra
ph it
will
sho
w a
larg
e ch
ange
in m
agni
tude
on
the
bar
grap
h se
vera
l tim
es a
sec
ond.
If y
ouha
ve a
sta
ndar
d di
gita
l vol
tmet
er it
will
sho
wa
brie
f flu
ctua
tion
in v
olta
ge a
nd th
em
agni
tude
may
var
y de
pend
ing
on th
evo
ltmet
er u
sed.
You
have
an
open
wire
or
bad
term
inal
on
eith
er th
e B
LAC
K o
r 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
pow
er c
hoke
dis
conn
ect
it an
d ch
eck
cont
inui
ty.
You
have
an
open
wire
or
bad
term
inal
on
eith
er th
e R
ED
or
GR
EE
N w
ire b
etw
een
the
furn
ace
cont
rol a
nd th
e bl
ower
mot
or.
Is th
ere
5-V
DC
at P
L3-3
YE
LLO
W (
+) a
ndP
L3-2
GR
EE
N (
-)?
You
have
an
open
wire
or b
ad te
rmin
al o
n th
eY
ELL
OW
wire
bet
wee
n th
e fu
rnac
e co
ntro
lan
d th
e bl
ower
mot
or.
YE
S
NO
NO
NO
YE
S
YE
S
YE
S
YE
S
YE
S
YE
S
NO
NO
NO
NO
NO
YE
S
YE
S
NO
42IN
DU
CE
R M
OTO
R F
AU
LT-
Indi
cate
s th
ein
duce
r m
otor
has
not
sta
rted
with
in 2
0se
cond
s af
ter
a ca
ll fo
r he
at, t
he in
duce
rm
otor
RP
M is
out
side
its
valid
ran
ge o
fop
erat
ion,
or t
he in
duce
r RP
M s
igna
l was
lost
for
5 se
cond
s du
ring
oper
atio
n.C
heck
for:
-P
rope
r ve
nt s
izin
g.-
Faile
d in
duce
r m
otor
.-
Res
tric
ted
com
bust
ion
air
supp
ly-
Impr
oper
mot
or w
iring
.
- S
ervi
ce r
epla
cem
ent c
ontr
ol d
oes
not
re
cogn
ize
new
mod
el p
lugs
HK
70E
Z05
7
thru
HK
70E
Z06
1. C
ontr
ol b
oard
with
da
te c
ode
3106
or
late
r re
quire
d.
A06461
58UVB
19
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 TrainingA94328
Copyright 2006 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:58UVB--1SM
Replaces:New
Printed in U.S.A. Edition Date: 08/06
58UVB