Carrier 58MSA Series Installation and user guide

58MSA

4-Way Multipoise Fixed-Capacity

Condensing Gas Furnace

Service and Maintenance Instructions

For Sizes 040—120, Series 110

NOTE: Read the entire instruction manual before performing any

service or maintenance.

This symbol →indicates a change since the last issue.

Index Page

SAFETY CONSIDERATIONS..................................................1-2

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS........2

GENERAL......................................................................................2

CARE AND MAINTENANCE................................................2-10

Cleaning and/or Replacing Air Filter.......................................3

Blower Motor and Wheel Maintenance................................3-4

Cleaning Burners...................................................................4-5

Cleaning Heat Exchangers....................................................5-6

Primary Heat Exchangers ................................................5-6

Secondary Heat Exchangers................................................6

Flushing Collector Box and Drainage System.....................6-7

Servicing Hot Surface Ignitor...............................................7-8

Electrical Controls and Wiring.................................................8

Troubleshooting...................................................................8-10

Checking Heat Tape Operation (If Applicable).................9-10

Winterizing..............................................................................10

WIRING DIAGRAM...................................................................12

SERVICE LABEL .......................................................................13

TROUBLESHOOTING GUIDE............................................14-15

SAFETY CONSIDERATIONS

Installing and servicing heating equipment can be hazardous due to

gas and electrical components. Only trained and qualified person-

nel should install, repair, or service heating equipment.

Untrained personnel can perform basic maintenance functions

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. In the United States, follow all safety

codes including the National Fuel Gas Code (NFGC) NFPA

54-1996/ANSI Z223.1-1996 and the Installation Standards, Warm

Air Heating and Air Conditioning Systems (NFPA 90B)

ANSI/NFPA 90B. In Canada, refer to the CAN/CGA-B149.1- and

.2-M95 National Standard of Canada, Natural Gas and Propane

Installation Codes (NSCNGPIC). Wear safety glasses and work

gloves. Have a fire extinguisher available during start-up and

adjustment procedures and service calls.

Recognize safety information. This is the safety-alert symbol .

When you see this symbol on the unit and in instructions or

manuals, be alert to the potential for personal injury.

Understand the signal words DANGER, WARNING, and CAU-

TION. These words are used with the safety-alert symbol. DAN-

GER identifies the most serious hazards which will result in severe

personal injury or death. WARNING signifies hazards which

could result in personal injury or death. CAUTION is used to

identify unsafe practices which would 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.

A93040

ama

CANADIAN GAS ASSOCIATION

APPROVED

As an ENERGY STAR®

Partner, Carrier Corporation

has determined that this prod-

uct meets the ENERGY

STAR® guidelines for energy

efficiency. A98306

REGISTERED QUALITY SYSTEM

→Fig. 1—Multipoise Furnace in Upflow Orienta-

tion

Visit www.carrier.com

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

Book 1 4

Tab 6a 8a PC 101 Catalog No. 535-744 Printed in U.S.A. Form 58MSA-3SM Pg 1 5-99 Replaces: 58MSA-2SM

The ability to properly perform maintenance on this equip-

ment 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. FAILURE

TO FOLLOW THIS WARNING COULD RESULT IN

POSSIBLE DAMAGE TO THIS EQUIPMENT, SERIOUS

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 com-

pounds, 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.

Failure to follow this warning can cause corrosion of the heat

exchanger, fire, personal injury, or death.

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

Electrostatic discharge can affect electronic components.

Take precautions during furnace installation and servicing to

protect the furnace electronic control. Precautions will pre-

vent 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.

1. Disconnect all power to the furnace. DO NOT TOUCH THE

CONTROL OR ANY WIRE CONNECTED TO THE CON-

TROL PRIOR TO DISCHARGING YOUR BODY’S ELEC-

TROSTATIC CHARGE TO GROUND.

2. Firmly touch a clean, unpainted, metal surface of the furnace

chassis which is close to the control. Tools held in a person’s

hand during grounding will be satisfactorily discharged.

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 ungrounded

objects, etc.).

4. If you touch ungrounded objects (recharge your body with

static electricity), firmly touch furnace again before touching

control or wires.

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

furnaces.

6. Before removing a new control from its container, discharge

your body’s electrostatic charge to ground to protect the

control from damage. If the control is to be installed in a

furnace, follow items 1 through 5 before bringing the control

or yourself into contact with the furnace. Put all used AND

new controls into containers before touching ungrounded

objects.

7. An ESD service kit (available from commercial sources) may

also be used to prevent ESD damage.

GENERAL

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. Therefore,

since this furnace can be installed in any of the 4 positions shown

in Fig. 2, you must revise your orientation to component location

accordingly.

CARE AND MAINTENANCE

For continuing high performance and to minimize possible equip-

ment failure, it is essential that maintenance be performed annually

on this equipment. Consult your local dealer for maintenance and

maintenance contract availability.

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. Failure to

follow this warning could result in personal injury or death.

The minimum maintenance that should be performed on this

equipment is as follows:

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

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 annu-

ally.

6. Check burners for cleanliness annually.

Personal injury could result from sharp metal edges, etc. Use

care when removing parts.

Fig. 2—Multipoise Orientations A93041

UPFLOW

DOWNFLOW

HORIZONTAL

LEFT

AIRFLOW AIRFLOW

AIRFLOW

HORIZONTAL

RIGHT

Step 1—Cleaning and/or Replacing Air Filter

The air filter arrangement may vary depending on the application

or orientation.

Never operate unit without a filter or with the blower access

panel removed. Failure to follow this warning could result in

a fire or personal injury.

To clean or replace the filters, proceed as follows:

1. Turn off electrical supply to furnace.

2. Remove main furnace door and blower access panel.

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

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

opposite direction of airflow.

6. Rinse filter and let dry. Oiling or coating of filter is not

recommended.

7. Place filter in furnace.

8. Replace blower access panel and main furnace door.

9. Turn on electrical supply to furnace.

NOTE: If the filter has cross-mesh binding, the binding must face

the blower. If the filter has an air direction arrow, the arrow must

point toward the blower.

Step 2—Blower Motor and Wheel Maintenance

To ensure long life, economy, and high efficiency, clean accumu-

lated 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:

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. 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.

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.

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 capaci-

tor and ground wire attached to blower housing before

removing motor.

f. Remove blower wheel from housing.

g. Clean wheel per instructions on degreaser cleaner.

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.

10. Reinstall blower assembly in furnace.

Fig. 3—Bottom Filter Arrangement A93046

WASHABLE

FILTER

FILTER

SUPPORT FILTER

RETAINER

Fig. 4—Filter Installed for Side Inlet A93045

FILTER

RETAINER

WASHABLE

FILTER

11. 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. 8 or tubing

diagram on main furnace door for proper tube location.

(1.) Connect 1 tube (blue or blue and white striped) from

collector box.

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

housing.

(3.) Connect 1 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.

12. Reinstall control box, transformer, and door switch assembly

on blower shelf.

13. Reconnect wires.

Refer to furnace wiring diagram, and connect thermostat leads

if previously disconnected. (See Fig. 15.)

NOTE: Refer to Table 1 for motor speed lead relocation if leads

were not identified before disconnection.

Heating speed selection MUST be adjusted to provide proper

temperature rise as specified on the rating plate. Failure to

adjust the heating speed may shorten heat exchanger life.

14. 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 heating and

cooling by jumpering R to G and R to Y on control center

thermostat terminals. (See Fig. 11.)

Blower access panel door switch opens 115-v power to

control center. No component operation can occur. Caution

must be taken when manually closing this switch for service

purposes. Failure to follow this warning could result in

electrical shock, personal injury, or death.

15. If furnace is operating properly, release blower access panel

door switch, replace blower access panel, and replace main

furnace door.

Step 3—Cleaning Burners

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 gas

valve.

5. Remove wires from gas valve. Note location for reassembly.

Label all wires prior to disconnection when servicing con-

trols. Wiring errors can cause improper and dangerous

operation.

6. Remove burner box pressure tube from gas valve regulator

fitting.

7. Remove screws that secure manifold to burner box. (See Fig.

5.)

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

9. Remove screws attaching burner assembly in burner box.

10. Remove burner assembly from burner box.

NOTE: All burners are attached to burner bracket and can be

removed as 1 assembly.

11. Clean burners with soft brush and vacuum.

12. Reinstall manifold, orifice, and gas valve assembly in burner

box. Ensure manifold seal grommet is installed properly and

burners fit over orifices.

13. Reconnect wires to gas valve. Refer to furnace wiring diagram

for proper wire location.

14. Reinstall burner box pressure tube to gas valve regulator

fitting.

15. Reinstall gas supply pipe to gas valve using backup wrench on

gas valve to prevent rotation and improper orientation.

NOTE: Use propane gas resistant pipe dope to prevent gas leaks.

DO NOT use Teflon tape.

Gas valve switch or knob MUST be facing forward or tilted

upward. Failure to follow this warning could result in

property damage, personal injury, or death.

16. Replace burner box cover.

17. Turn on gas and electrical supplies to furnace.

18. Check for gas leaks.

Table 1—Speed Selector

COLOR SPEED FACTORY

ATTACHED TO

Black High Cool

Yellow (When Present) Medium High Spare

Blue Medium Low Heat

Red Low Spare

White Common Com

Fig. 5—Burner Box Assembly A93295

MANIFOLD

MOUNTING

SCREW

MANIFOLD

GAS VALVE

REGULATOR

FITTING

GAS VALVE

Never use matches, candles, flame, or other sources of

ignition to check for gas leakage. Use a soap-and-water

solution. Failure to follow this warning could result in a fire,

personal injury, or death.

19. 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.

3. Disconnect wires or connectors to rollout switch, gas valve,

ignitor, and flame sensor.

Label all wires prior to disconnection when servicing con-

trols. Wiring errors can cause improper and dangerous

operation.

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

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 gas

valve.

8. Disconnect pressure tubing from gas valve.

9. Remove 2 screws attaching top filler panel and rotate upwards

to gain access to screws attaching burner box to cell panel.

10. Remove screws attaching burner box to cell panel. (See Fig.

5.)

NOTE: Burner box cover, manifold, gas valve, and burner

assembly should be removed as 1 assembly.

11. Clean heat exchanger openings with a vacuum and a soft

brush. (See Fig. 6.)

NOTE: After cleaning, inspect the heat exchangers to ensure they

are free of all foreign objects that may restrict flow of combustion

products.

12. Reverse items 4 through 10 for reassembly.

The ground wire from the gas valve MUST be attached to the

burner box attachment screw. Failure to attach this ground

wire to an adequate casing ground will cause the furnace

control to lock out.

NOTE: Be sure burner box gasket is installed between burner box

and cell panel. 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 or canola oil, aromatic or

halogenated hydrocarbons or inadequate seal may occur) 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. 7.)

13. Refer to furnace wiring diagram and connect wires to rollout

switch, gas valve, ignitor, 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. Be sure tubes are not kinked. (See Fig.

8.)

15. Turn on gas and electrical supplies to furnace.

16. Check furnace operation through 2 complete heat operating

cycles. Look through sight glass in burner enclosure to check

burners. Burner flames should be clear blue, almost transpar-

ent. (See Fig. 9.)

17. Check for gas leaks.

Fig. 6—Cleaning Inlet Openings of Primary Heat

Exchangers

A93080

PRIMARY HX

INLET OPENINGS

Fig. 7—Combustion-Air Intake Housing Gasket

Repair

A93087

PAM

RTV

→

Never use matches, candles, flame, or other sources of

ignition to check for gas leakage. Use a soap-and-water

solution. Failure to follow this warning could result in a fire,

personal injury, or death.

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

connectors.

→Fig. 8—Furnace Pressure and Drain Tubing Diagram A99102

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)

FORLEFTDRAINOPTION

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

AUXILIARY "J" BOX RELOCATED HERE

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 BOXTUBE (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. A

(LIT. BOTTOM)

FIELD-INSTALLED

FACTORY-SUPPLIED

DRAIN TUBE COUPLING

(RIGHT DRAIN OPTION)

BURNER ENCLOSURE

PRESSURE REFERENCE

TUBE ASSEMBLY

BURNER ENCLOSURE

PRESSURE REFERENCE

TUBE ASSEMBLY

BURNER ENCLOSUREPRESSURE

REFERENCE TUBE ASSEMBLY

BURNER ENCLOSURE

PRESSURE REFERENCE

TUBE ASSEMBLY

BURNER ENCLOSURE

PRESSURE REFERENCE

TUBE ASSEMBLY

BURNER ENCLOSUREPRESSURE

REFERENCE TUBE ASSEMBLY

TUBE ROUTING

Fig. 9—Burner Flame A89020



BURNER FLAME

BURNER

MANIFOLD

4. Disconnect pressure switch tubes.

5. Disconnect vent pipe from inducer housing outlet by loosen-

ing coupling clamp on inducer outlet.

6. Disconnect drain tube from inducer housing. (See Fig. 8.)

7. Remove inducer housing assembly by removing 4 bolts

attaching assembly to cell panel.

8. Flush inside of collector box with water until discharge from

condensate trap is clean and runs freely.

NOTE: Ensure the drain tube disconnected from the inducer

housing is higher than the collector box opening or water will flow

out tube.

9. Inspect inside area of collector box for any pieces of foreign

materials and remove if present.

DO NOT use wire brush or other sharp object to inspect or

dislodge materials in secondary heat exchangers as failure of

the secondary heat exchanger will occur. Flush with water

only.

10. Reassemble inducer assembly by reversing items 5 through 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 or canola oil, aromatic or halogenated

hydrocarbons or inadequate seal may occur) to inducer housing.

(See Fig. 10.) 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 connect wires to inducer

motor and pressure switch or connectors.

12. Reconnect pressure tubes to pressure switch. See diagram on

main furnace door for proper location of tubes. Be sure tubes

are not kinked. (See Fig. 8.)

13. Turn on gas and electrical supplies to furnace.

14. Check furnace operation through 2 complete heat operating

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.

Never use matches, candles, flame, or other sources of

ignition to check for gas leakage. Use a soap-and-water

solution. Failure to follow this warning could result in a fire,

personal injury, or death.

16. Replace main furnace door.

Step 6—Servicing Hot Surface Ignitor

The ignitor does NOT require annual inspection. Check ignitor

resistance before removal.

1. Turn off gas and electrical supplies to furnace.

2. Remove main furnace door.

3. Disconnect ignitor wire connection.

4. Check ignitor resistance.

a. Using an ohm meter, check resistance across both ignitor

leads in connector.

b. Cold reading should be between 45 ohms and 90 ohms.

c. If ohm reading is higher than 110 ohms, ignitor is cracked

and must be replaced.

5. Remove ignitor assembly.

Allow ignitor to cool before removal. Normal operation

temperatures exceed 2000°F.

a. Do not remove ignitor from bracket while assembly is in

furnace. Using a 1/4 in. nutdriver, remove screw securing

bracket and ignitor assembly to bottom of burner box. The

screw in the bracket is always located toward outside of

burner box. The screw may be hidden by inlet box or inlet

pipe, but can be removed without removing either. After

removing screw, slide ignitor and bracket toward outside of

burner box and pull straight out.

The ignitor is fragile. DO NOT allow it to hit the side of the

burner box opening while removing or replacing it.

b. Inspect ignitor for a white area indicating a crack may be

present. If found, replace ignitor.

NOTE: A small crack cannot be seen on a new ignitor. After a

period of operation, a white area will be visible around the crack.

c. If replacement is required, replace ignitor on ignitor

bracket external to furnace to avoid damage as the silicon

portion is very brittle and will easily crack or shatter.

d. To remove ignitor from ignitor bracket, remove screw

holding ignitor ceramic block to bracket and pull ceramic

block out of bracket.

6. To replace ignitor/ignitor assembly, reverse items 5a through

5d.

7. Reconnect ignitor wire connection.

8. Turn on gas and electrical supplies to furnace.

9. Verify ignitor operation by initiating control board self-test

feature or by cycling thermostat.

Fig. 10—Gasket on Collector Box A93081

RTV

PAM

→

10. Replace main furnace door.

Step 7—Electrical Controls and Wiring

There may be more than 1 electrical supply to the unit. Check

accessories and cooling unit for additional electrical supplies.

The electrical ground and polarity for 115-v wiring must be

maintained properly. Refer to Fig. 11 for field wiring information

and to Fig. 15 for unit wiring information.

NOTE: If the polarity is not correct, the STATUS LED on the

control center will flash rapidly and prevent the furnace from

operating. The control system also requires an earth ground for

proper operation of the control center and flame sensing.

The 24-v circuit contains an automotive-type, 3-amp fuse located

on the control center. (See Fig. 12.) 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.

With power to the unit disconnected, check all electrical connec-

tions 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 1

complete operating cycle. Electrical controls are difficult to check

without proper instrumentation; if there are any discrepancies in

the operating cycle, contact your dealer and request service.

Step 8—Troubleshooting

For an explanation of fault codes, refer to service label located on

back of main furnace door or Fig. 16, and the Troubleshooting

Guide.

The control center stores 1 fault code (the last fault to occur) for a

period of 48 hrs or until the 115- or 24-v power is interrupted.

NOTE: Removing blower access panel will open blower access

panel door switch and terminate 115-v power to control center, and

fault code will be erased. Look into blower access panel sight glass

for current LED status.

The unit’s component test is a useful troubleshooting tool since it

displays the current status (fault code) of the furnace and func-

tionally operates all furnace components except the gas valve. The

component test and methods to initiate it are described below.

COMPONENT TEST SEQUENCE

NOTE: All components are functionally operated except the gas

valve.

When component test is initiated, the following sequence of events

occurs:

1. LED flashes a fault code 4 times.

2. Inducer motor starts and continues to run for remainder of

component test.

3. Hot surface ignitor is energized for 15 sec, then de-energized.

4. Main blower operates at cooling speed for 10 sec, then turns

off.

5. Main blower operates at heating speed for 10 sec, then turns

off.

6. Inducer motor stops.

Component test can be initiated by one of the following proce-

dures.

INITIATING COMPONENT TEST AND RETRIEVING STA-

TUS CODE BY REMOVING MAIN LIMIT SWITCH WIRE

NOTE: NO thermostat signal may be present at control center

and all blower time delay off periods must be completed.

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

2. Remove main furnace door.

3. Look into blower access panel sight glass for current LED

status.

NOTE: Leave blower access panel installed to maintain power to

control center to view current LED status.

→Fig. 11—Field Wiring A98209

115-V

FIELD-SUPPLIED

DISCONNECT

AUXILIARY

J-BOX

CONTROL

BOX

24-V

TERMINAL

BLOCK

THREE-WIRE

HEATING-

ONLY

FIVE

WIRE

NOTE 1

NOTE 2 FIELD-SUPPLIED

DISCONNECT

CONDENSING

UNIT

TWO

WIRE

FURNACE

WCR GY

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

WHT

BLK

WHT

BLK

NOTES: Connect Y-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, use

same type or equivalent wire.

GND

THERMOSTAT

TERMINALS

2.

→

4. BRIEFLY remove either wire from the main limit switch until

the LED goes out, then reconnect it.

Make sure limit switch wire does not contact any metallic

component such as the gas valve. If wire is shorted, 3-amp

fuse on control center will blow.

NOTE: If wire to main limit is disconnected longer than 4 sec, the

control senses limit circuit is open. Main blower will start and

retrieval request will be ignored.

5. When above items have been completed, the component test

sequence will occur as described in the Component Test

Sequence section above.

NOTE: Be sure to record the fault code which is flashed 4 times

at start of component test for further troubleshooting.

6. After component test is completed and LED is ON continu-

ously indicating the furnace is ready to operate when a signal

from the thermostat is received, replace main furnace door.

INITIATING COMPONENT TEST AND RETRIEVING STA-

TUS CODE BY JUMPERING CONTROL TEST TERMINAL

1. Remove main furnace door.

2. Remove blower access panel.

3. Manually close blower access panel door switch. Use a piece

of tape to hold switch closed.

Blower access panel door switch opens 115-v power to

control center. No component operation can occur. Caution

must be taken when manually closing this switch for service

purposes. Failure to follow this warning could result in

electrical shock, personal injury, or death.

4. BRIEFLY short (jumper) TEST, 1/4-in. quick-connect termi-

nal on control center (adjacent to the LED diagnostic light)

and the COM terminal on thermostat connection block. (See

Fig. 12.)

NOTE: If TEST to COM terminals are jumpered longer than 2 sec,

LED will flash rapidly, and retrieval request will be ignored.

5. When above items have been completed, the component test

sequence will occur as described in the Component Test

Sequence section above.

NOTE: Be sure to record the fault code which is flashed 4 times

at start of component test for further troubleshooting.

6. After component test is completed and furnace is operating

properly, release blower access panel door switch, replace

blower access panel, and replace main furnace door.

Step 9—Checking Heat Tape Operation (If Applicable)

In applications where the ambient temperature around the furnace

is 32°F 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:

Fig. 12—Control Center A95086



24V



HUM

GRYW

3-AMP FUSE

HUMIDIFIER TERMINAL

(24-VAC 0.5 AMP MAX)

LED OPERATION &

DIAGNOSTIC LIGHT

HARNESS CONNECTOR

24-V TRANSFORMER SEC-2

SPARE-1

SPARE-2

EAC-1

EAC-ELECTRONIC AIR CLEANER

TERMINALS (115-VAC 1.5 AMP MAX)

EAC-2

115-VAC (L2) NEUTRAL

CONNECTION

24-V THERMOSTAT

TERMINALS

BLOWER SPEED

SELECTION TERMINALS

INDUCER MOTOR

CONNECTOR

115-VAC (L1)

POWER SUPPLY

HOT SURFACE

IGNITOR CONNECTOR

HEAT

COOL

SEC-1

TEST/TWIN

→

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.

Step 10—Winterizing

Freezing condensate left in the furnace will damage the

equipment.

If the furnace will be off for an extended period of time in a

structure 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 drain tube from inducer housing. (See Fig. 13.)

4. Insert funnel in drain tube and pour antifreeze, propylene

glycol (RV, swimming pool antifreeze, or equivalent) into

furnace until it is visible at point where condensate enters open

drain. (See Fig. 14.)

5. Reconnect drain tube to inducer housing.

6. Replace main furnace door.

Do not use ethylene glycol (Prestone II antifreeze/coolant or

equivalent automotive type). Failure of plastic components

will occur.

If this furnace is installed in an unconditioned space where

the ambient temperatures may be 32°F or lower, freeze

protection measures must be taken.

A93058

32°F MINIMUM INSTALLED

AMBIENT OR FREEZE

PROTECTION REQUIRED

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