Carrier Furnace 58MEC User Manual

58MEC  
D E L U X E 4 --- WAY M U LT I P O I S E 2 --- S TA G E  
CONDENSING GAS FURNACE  
SIZES 060 TO 120  
Service and Maintenance Instructions  
NOTE: Read the entire instruction manual before starting the  
installation.  
SAFETY CONSIDERATIONS  
Recognize safety information. This is the safety--alert symbol  
.
When you see this symbol on the furnace and in instructions or  
manuals, be alert to the potential for personal injury.  
TABLE OF CONTENTS  
Understand the signal words DANGER, WARNING, and  
CAUTION. These words are used with the safety--alert symbol.  
DANGER identifies the most serious hazards which will result in  
severe personal injury or death. WARNING signifies a hazard  
which could result in personal injury or death. CAUTION is used  
to identify unsafe practices which may result in minor personal  
injury or product and property damage. NOTE is used to highlight  
suggestions which will result in enhanced installation, reliability, or  
operation.  
Installing and servicing heating equipment can be hazardous due to  
gas and electrical components. Only trained and qualified service  
agency personnel should install, repair, or service heating  
equipment.  
PAGE  
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 1  
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS . . . 2  
CARE AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . 3  
Cleaning and/or Replacing Air Filter . . . . . . . . . . . . . . . . . . . . 3  
Blower Motor and Wheel Maintenance . . . . . . . . . . . . . . . . . . 3  
Cleaning Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  
Cleaning Heat Exchangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  
Primary Heat Exchangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  
Secondary Heat Exchangers . . . . . . . . . . . . . . . . . . . . . . . . . . 7  
Flushing Collector Box and Drainage System . . . . . . . . . . . . . 8  
Servicing Hot Surface Igniter . . . . . . . . . . . . . . . . . . . . . . . . . 10  
Electrical Controls and Wiring . . . . . . . . . . . . . . . . . . . . . . . . 11  
Checking Heat Tape Operation (If Applicable) . . . . . . . . . . . 11  
Winterizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11  
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13  
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13  
Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13  
Component Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14  
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . 17  
!
WARNING  
ELECTRICAL SHOCK, FIRE, OR EXPLOSION  
HAZARD  
Failure to follow this warning could result in personal  
injury, death or property damage.  
The ability to properly perform maintenance on this  
equipment requires certain expertise, mechanical skills,  
tools, and equipment. If you do not possess these, do not  
attempt to perform any maintenance on this equipment  
other than those procedures recommended in the User’s  
Manual.  
!
WARNING  
FIRE OR EXPLOSION HAZARD  
!
WARNING  
Failure to follow this warning could result in property  
damage, personal injury, or death.  
ELECTRICAL SHOCK, FIRE, OR EXPLOSION  
HAZARD  
Never store anything on, near, or in contact with the furnace,  
such as:  
1. Spray or aerosol cans, rags, brooms, dust mops, vacuum  
cleaners, or other cleaning tools.  
2. Soap powders, bleaches, waxes or other cleaning  
compounds, plastic or plastic containers, gasoline, kerosene,  
cigarette lighter fluid, dry cleaning fluids, or other volatile  
fluids.  
3. Paint thinners and other painting compounds, paper bags,  
or other paper products.  
Failure to follow safety warnings exactly could result in  
dangerous operation, personal injury, death, or property  
damage.  
-- Before servicing, disconnect all electrical power to furnace  
and install lock out tag.  
--When servicing controls, label all wires prior to  
disconnecting. Reconnect wires correctly.  
-- Verify proper operation after servicing.  
1
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1. Disconnect all power to the furnace. DO NOT TOUCH  
THE CONTROL OR ANY WIRE CONNECTED TO THE  
CONTROL PRIOR TO DISCHARGING YOUR BODY’S  
ELECTROSTATIC CHARGE TO GROUND.  
Step 1 — Cleaning and/or Replacing Air Filter  
The air filter arrangement may vary depending on the application  
or orientation.  
information.  
See Tables 1 and 2 for filter size and type  
2. Firmly touch a clean, unpainted, metal surface of the fur-  
nace chassis which is close to the control. Tools held in a  
person’s hand during grounding will be satisfactorily dis-  
charged.  
!
WARNING  
FIRE, CARBON MONOXIDE POISONING  
HAZARD  
3. After touching the chassis, you may proceed to service the  
control or connecting wires as long as you do nothing that  
recharges your body with static electricity (for example; DO  
NOT move or shuffle your feet, DO NOT touch ungroun-  
ded objects, etc.).  
Failure to follow this warning could result in personal injury,  
death or property damage.  
Never operate unit without a filter or with the blower access  
panel removed. Operating a unit without a filter or with the  
blower access door removed could cause damage to the  
furnace blower motor. Dust and lint on internal parts of  
furnace can cause a loss of efficiency.  
4. If you touch ungrounded objects (recharge your body with  
static electricity), firmly touch furnace again before touch-  
ing control or wires.  
5. Use this procedure for installed and uninstalled (ungroun-  
ded) furnaces.  
NOTE: If the filter has an airflow direction arrow, the arrow must  
6. Before removing a new control from its container, discharge  
your body’s electrostatic charge to ground to protect the  
control from damage. If the control is to be installed in a  
furnace, follow items 1 through 5 before bringing the con-  
trol or yourself into contact with the furnace. Put all used  
AND new controls into containers before touching un-  
grounded objects.  
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.  
7. An ESD service kit (available from commercial sources)  
may also be used to prevent ESD damage.  
4. If equipped with permanent, washable filter, clean filter by  
spraying cold tap water through filter in opposite direction  
of airflow. Rinse filter and let dry. Oiling or coating of the  
filter is not recommended.  
CARE AND MAINTENANCE  
For continuing high performance and to minimize possible furnace  
failure, it is essential that maintenance be performed annually.  
Consult your local dealer for maintenance and maintenance  
contract availability.  
5. If equipped with factory specified disposable media filter,  
replace only with a factory specified media filter of the same  
size.  
6. Slide filter into cabinet.  
7. Replace filter cabinet door.  
!
WARNING  
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.)  
ELECTRICAL SHOCK EXPLOSION HAZARD  
Failure to follow this warning could result in personal injury,  
death or property damage.  
Turn off the gas and electrical supplies to the unit and install  
lock out tags before performing any maintenance or service.  
Follow the operating instructions on the label attached to the  
furnace.  
NOTE: Filters shown in Fig. 3 and 4 can be in furnace blower  
compartment or in filter cabinet, but not in both.  
4. Slide filter out of furnace.  
5. Furnaces are equipped with permanent, washable filter(s).  
Clean filter by spraying cold tap water through filter in op-  
posite direction of airflow.  
The minimum maintenance that should be performed on this  
equipment is as follows:  
1. Check and clean or replace air filter each month as needed.  
2. Check blower motor and wheel for cleanliness annually.  
3. Check electrical connections for tightness and controls for  
proper operation each heating season. Service as necessary.  
6. Rinse filter and let dry. Oiling or coating filter is not recom-  
mended.  
7. Slide filter into furnace.  
8. Recapture filter retaining wire.  
9. Replace blower access panel and main furnace door.  
10. Turn on electrical supply to furnace.  
4. Check for proper condensate drainage. Clean as necessary.  
5. Check for blockages in combustion--air and vent pipes an-  
nually.  
6. Check burners for cleanliness annually.  
Step 2 — Blower Motor and Wheel Maintenance  
To ensure long life, economy, and high efficiency, clean  
accumulated dirt and grease from blower wheel and motor  
annually.  
!
CAUTION  
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.  
CUT HAZARD  
Failure to follow this caution may result in personal injury.  
Be careful of sharp metal edges, etc. Use care and wear  
protective clothing, gloves, and safety glasses when  
removing parts.  
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
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Table 1 – Furnace Air Filter Table  
FILTER QUANTITY AND SIZE *  
FURNACE CASING WIDTH  
IN (MM)  
FILTER TYPE  
IN (MM)*  
SIDE RETURN{*  
BOTTOM RETURN*  
IN (MM)  
IN (MM)  
(1) 16 x 25 x 3/4 {  
(406 x 635 x 19) {  
(1) 16 x 25 x 3/4  
(406 x 635 x 19)  
(1) 16 x 25 x 3/4  
(406 x 635 x 19)  
(1) 16 x 25 x 3/4  
(406 x 635 x 19)  
(1) 20 x 25 x 3/4 {  
(508 x 635 x 19) {  
(1) 24 x 25 x 3/4 {  
(610 x 635 x 19) {  
17---1/2 (445)  
21 (533 )  
3/4 (19 mm) thick washable  
3/4 (19 mm) thick washable  
3/4 (19 mm) thick washable  
24---1/2 (610)  
Table 2 – Air Filter Located in Filter Cabinet  
FILTER CABINET HEIGHT --- IN (MM)  
F I LT E R S I Z E --- I N ( M M )  
FILTER TYPE  
(1) 16 x 25 x 3/4*  
(406 x 635 x 19) or  
(1) 16 x 25 x 4---5/16  
(406 x 635 x 110)  
16 (406)  
Washable  
(1) 20 x 25 x 3/4*  
(508 x 635 x 19) or  
(1) 20 x 25 x 4---5/16  
(508 x 635 x 110)  
(1) 24 x 25 x 3/4*or  
(610 x 635 x 19) or  
(1) 24 x 25 x 4---5/16  
(610 x 635 x 110)  
20 (508)  
24 (610)  
Washable  
Washable  
* Filters with a side return--air may have a different filter size. Measure the filter to  
NOTE: Blower wheel is fragile. Use care.  
obtain the correct size.  
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.  
{
Factory--provided with furnace.  
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.  
WASHABLE  
FILTER  
NOTE: Mark blower mounting arms and blower housing so each  
arm is positioned at the same hole location during reassembly.  
FILTER  
SUPPORT  
c. Mark blower wheel orientation and cutoff plate location  
to ensure proper reassembly.  
FILTER  
RETAINER  
d. Remove screws securing cutoff plate and remove cutoff  
plate from housing.  
e. Remove bolts holding motor mounts to blower housing  
and slide motor and mounts out of housing. Disconnect  
capacitor and ground wire attached to blower housing  
before removing motor. Motor mounts do not need to  
be removed from motor.  
WASHABLE FILTER OR  
DISPOSABLE MEDIA FILTER  
IN FILTER CABINET  
A00232  
Fig. 3 -- Bottom Filter Arrangement  
f. Remove blower wheel from housing.  
WASHABLE  
FILTER  
IN FURNACE  
3. Disconnect blower motor wires from furnace control. Field  
thermostat connections may need to be disconnected de-  
pending on their length and routing.  
FILTER  
RETAINER  
4. Remove control box mounting screws and position control  
box, transformer, and door switch assembly to right side of  
furnace casing.  
5. If condensate trap is located in left-- or right--hand side of  
furnace casing, proceed to item 6, otherwise remove trap  
and tubing as described below (See Fig. 5):  
a. Disconnect field drain connection from condensate trap.  
b. Disconnect drain and relief port tubes from condensate  
trap.  
WASHABLE FILTER OR  
DISPOSABLE MEDIA  
c. Remove condensate trap from blower shelf.  
FILTER IN FILTER CABINET  
6. Remove screws securing blower assembly to blower shelf  
and slide blower assembly out of furnace. Detach ground  
wire and disconnect blower motor harness plugs from  
blower motor.  
A00233  
Fig. 4 -- Filter Installed for Side Inlet  
4
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(1.) Connect 1 tube (blue or blue and white striped)  
from collector box.  
(2.) Connect 1 tube (violet or unmarked) from inducer  
housing.  
PLUG  
CAP  
(3.) Connect 1 tube (relief port, green or pink) from  
collector box.  
COLLECTOR BOX  
DRAIN TUBE (BLUE  
& WHITE STRIPED)  
NOTE: Ensure tubes are not kinked or pinched, as this will affect  
operation.  
c. Connect field drain to condensate trap.  
13. Reconnect wires.  
COLLECTOR BOX  
TUBE (PINK)  
Refer to furnace wiring diagram and connect thermostat leads if  
previously disconnected. (See Fig. 16.)  
NOTE: Refer to Table 3 for motor speed lead reconnection if  
COLLECTOR BOX  
TUBE (GREEN)  
leads were not identified before disconnection.  
INDUCER HOUSING  
(MOLDED) DRAIN  
TUBE (BEHIND  
COLLECTOR BOX  
DRAIN TUBE)  
!
CAUTION  
UNIT DAMAGE HAZARD  
Failure follow this caution may result in unit component  
damage.  
COLLECTOR BOX  
DRAIN TUBE (BLUE)  
CONDENSATE  
TRAP  
Heating air speed selection MUST be adjusted to provide  
proper temperature rise as specified on the rating plate.  
FIELD-INSTALLED  
FACTORY-SUPPLIED  
DRAIN TUBE  
COUPLING (LEFT  
DRAIN OPTION)  
Table 3 – Speed Selection  
FACTORY  
ATTACHED TO  
Cool  
Spare  
High---Heat  
Spare  
COLOR  
SPEED  
FIELD-INSTALLED  
FACTORY-SUPPLIED  
DRAIN TUBE  
Gray  
Yellow  
Blue  
5
4
3
2
FIELD-INSTALLED  
FIELD-INSTALLED  
FACTORY-SUPPLIED  
DRAIN TUBE  
COUPLING (RIGHT  
DRAIN OPTION)  
FACTORY-SUPPLIED  
Orange  
1
2-IN. CPVC STREET  
ELBOWS (2) FOR  
Low Heat/Cont  
Fan  
Red  
1
LEFT DRAIN OPTION  
A01030  
Fig. 5 -- Factory--Shipped Upflow Tube Configuration  
(Shown with Blower Access Panel Removed)  
!
WARNING  
ELECTRICAL SHOCK HAZARD  
Failure to follow this warning could result in personal injury  
or death.  
!
CAUTION  
Blower access door switch opens 115--v power to furnace  
control. No component operation can occur. Caution must be  
taken when manually closing this switch for service purposes.  
UNIT DAMAGE HAZARD  
Failure to follow this caution may result in noise or furnace  
component failure.  
The blower wheel should not be dropped or bent as balance  
will be affected.  
14. Turn on electrical supply. Manually close blower access  
door switch. Use a piece of tape to hold switch closed.  
Check for proper rotation and speed changes by performing  
a component self--test as shown at the bottom of Service la-  
bel. (See Fig. 21.)  
g. Clean wheel per instructions on degreaser cleaner. Do  
not get degreaser in motor.  
9. Reassemble motor and blower wheel by reversing items 8b  
through 8f. Ensure wheel is positioned for proper rotation.  
Tighten setscrew to between 140--160 in.--lb torque.  
15. If furnace is operating properly, remove tape to release  
blower access door switch, replace blower access door, and  
replace main furnace door.  
NOTE: Be sure to attach ground wire to blower housing.  
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:  
10. Reinstall blower assembly in furnace.  
11. Reinstall control box, transformer, and door switch as-  
sembly on blower shelf.  
12. Reinstall condensate trap and tubing if previously removed.  
a. Reinstall condensate trap in hole in blower shelf.  
1. Turn off gas and electrical supplies to furnace.  
2. Remove main furnace door.  
b. Connect condensate trap drain tubes. See Fig. 5 or  
tubing diagram on main furnace door for proper tube  
location.  
3. Remove burner box cover.  
4. Using backup wrench, disconnect gas supply pipe from fur-  
nace gas control valve.  
5
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!
CAUTION  
UNIT DAMAGE HAZARD  
Failure to follow this caution may result in damage to furnace.  
Label all wires prior to disconnection when servicing controls.  
Wiring errors can cause improper and dangerous operation.  
5. Remove wires from gas valve. Note location for reassembly.  
6. Remove burner box pressure tube from gas valve regulator  
fitting.  
7. Unplug igniter from harness.  
8. Remove igniter leads from slot in manifold grommet.  
9. Remove screws that secure manifold to burner box. (See  
Fig. 6.)  
NOTE: Do not remove burner box from cell panel.  
10. Remove manifold, orifices, and gas valve as 1 assembly.  
11. Remove screws attaching burner assembly in burner box.  
IGNITER WIRES MUST  
BE PLACED IN THIS SLOT  
NOTE: Use care when removing and reinstalling burners not to  
strike the hot surface igniter.  
A05074  
Fig. 7 -- Igniter Wire Placement  
12. Remove burner assembly from burner box. NOTE: All  
burners are attached to burner bracket and can be removed  
as 1 assembly.  
13. Clean burners with soft brush and vacuum.  
!
CAUTION  
14. Reinstall burner assembly, manifold, orifice, and gas valve  
assembly in burner box. Ensure manifold seal grommet is  
installed properly and burners fit over orifices.  
15. Reinsert the igniter wires in the slot in the manifold grom-  
met, dressing the wires to ensure there is no tension on the  
igniter itself. (See Fig. 7.)  
UNIT COMPONENT ELECTRICAL SHORT HAZARD  
Failure to follow this caution may result in unit component  
damage.  
Igniter wires must be securely placed in slot in manifold  
grommet or else they could become pinched or severed and  
electrically shorted.  
CELL  
PANEL  
MANIFOLD  
MOUNTING  
SCREW  
16. Reconnect wires to gas valve and igniter. Refer to furnace  
wiring diagram for proper wire location.  
17. Reinstall burner box pressure tube to gas valve regulator fit-  
ting.  
18. Reinstall gas supply pipe to furnace gas control valve using  
backup wrench on gas valve to prevent rotation and im-  
proper orientation.  
NOTE: Use propane gas resistant pipe dope to prevent gas leaks.  
DO NOT use Teflon tape.  
!
WARNING  
MANIFOLD  
FIRE, EXPLOSION, UNIT DAMAGE HAZARD  
GAS VALVE  
REGULATOR  
FITTING  
Failure to follow this warning could result in property damage,  
personal injury, or death.  
Gas valve switch MUST be facing forward or tilted upward.  
GAS VALVE  
A96304  
Fig. 6 -- Burner Box Assembly  
19. Replace burner box cover.  
20. Turn on gas and electrical supplies to furnace.  
!
WARNING  
FIRE OR EXPLOSION HAZARD  
Failure to follow this warning could result in personal injury,  
death, or property damage.  
Never test for gas leaks with an open flame. Use a  
commercially available soap solution made specifically for the  
detection of leaks to check all connections.  
6
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21. Check for gas leaks.  
9. Remove 2 screws attaching top filler panel and rotate up-  
wards to gain access to screws attaching burner box to cell  
panel.  
22. Replace main furnace door.  
Step 4 — Cleaning Heat Exchangers  
The following items should be performed by a qualified service  
technician.  
10. Remove screws attaching burner box to cell panel. (See Fig.  
6).  
NOTE: Burner box, cover, manifold, gas valve, and burner  
assembly should be removed as one assembly.  
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:  
11. Clean heat exchanger openings with a vacuum and a soft  
brush. (See Fig. 8.)  
NOTE: If 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 orifices(s), improper gas, or a restricted heat  
exchanger (primary or secondary). Action must be taken to correct  
the problem.  
NOTE: After cleaning, inspect the heat exchanger to ensure they  
are free of all foreign objects that may restrict flow of combustion  
products.  
12. Reverse items 4 through 10 for reassembly.  
!
CAUTION  
UNIT MAY NOT OPERATE  
Failure to attach this ground wire to an adequate casing  
ground may cause the furnace control to lock out.  
1. Turn off gas and electrical supplies to furnace.  
2. Remove main furnace door.  
The ground wire from the gas valve MUST be attached to the  
burner box attachment screw.  
!
CAUTION  
NOTE: Be sure burner box gasket is installed between burner box  
UNIT DAMAGE HAZARD  
and cell panel. (See Fig. 6.) If gasket is damaged, replace it.  
Failure to follow this caution may result in furnace component  
damage.  
NOTE: Inspect combustion--air intake housing. If foamed gasket  
was removed, check for any damage. If gasket is damaged in any  
way, it must be repaired. To repair, remove damaged gasket  
section, apply sealant releasing agent such as PAM cooking spray  
or equivalent (must not contain corn nor canola oil, halogenated  
hydrocarbons nor aromatic content, to prevent inadequate seal  
from occurring) to burner box and apply a small bead of G.E. RTV  
162, G.E. RTV 6702, or Dow--Corning RTV 738 sealant to edge  
of combustion--air intake housing. (See Fig. 9.)  
Label all wires prior to disconnection when servicing controls.  
Wiring errors can cause improper and hazardous operation.  
3. Disconnect wires or connectors to flame rollout switch, gas  
valve, igniter, and flame sensor.  
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  
13. Refer to furnace wiring diagram and reconnect wires to  
flame rollout switch, gas valve, igniter, and flame sensor.  
rotate intake housing away from burner box for removal.  
14. Reconnect pressure switch tubes to gas valve and intake  
housing. Refer to tube routing label on main furnace door  
or Fig. 10 for proper tube location. Be sure tubes are not  
kinked.  
7. Using backup wrench, disconnect gas supply pipe from fur-  
nace gas control valve.  
8. Disconnect pressure tubing from gas valve.  
15. Turn on gas and electrical supplies to furnace.  
PRIMARY HX  
INLET OPENINGS  
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  
transparent. (See Fig. 11.)  
!
WARNING  
FIRE OR EXPLOSION HAZARD  
Failure to follow this safety warning could result in personal  
injury, death, or property damage.  
Never test for gas leaks with an open flame. Use a  
commercially available soap solution made specifically for the  
detection of leaks to check all connections.  
17. Check for gas leaks.  
18. Replace main furnace door.  
A96305  
Fig. 8 -- Cleaning Inlet Openings of Primary  
Heat Exchangers  
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  
7
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inducer assembly. See Flushing Collector Box and Drainage  
System section for details on removing inducer assembly.  
inducer housing. Apply a small bead of G.E. RTV 162, G.E. RTV  
6702, or Dow--Corning RTV 738 sealant to groove in collector  
box. (See Fig. 12.)  
Step 5 — Flushing Collector Box and Drainage  
System  
11. Refer to furnace wiring diagram and reconnect wires to in-  
ducer motor and pressure switches or connectors.  
1. Turn off gas and electrical supplies to furnace.  
2. Remove main furnace door.  
12. Reconnect pressure tubes to pressure switches. See diagram  
on main furnace door for proper location of tubes. Be sure  
tubes are not kinked. (See Fig. 10.)  
3. Disconnect inducer motor and pressure switch wires or con-  
nectors.  
13. Turn on gas and electrical supplies to furnace.  
4. Disconnect pressure switch tubes.  
5. Disconnect vent pipe from inducer housing outlet by  
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.  
loosening coupling clamp on inducer outlet.  
6. Disconnect drain tube from inducer housing. (See Fig. 10.)  
NOTE: Ensure the drain tube disconnected from the inducer  
housing is higher than the collector box opening or water will flow  
out of tube.  
!
WARNING  
FIRE OR EXPLOSION HAZARD  
7. Remove inducer housing assembly by removing 4 bolts at-  
taching assembly to cell panel.  
Failure to follow this warning could result in personal injury,  
death, or property damage.  
8. Flush inside of collector box with water until discharge  
from condensate trap is clean and runs freely.  
Never test for gas leaks with an open flame. Use a  
commercially available soap solution made specifically for the  
detection of leaks to check all connections.  
9. Inspect inside area of collector box for any pieces of foreign  
materials and remove them if present.  
!
CAUTION  
UNIT DAMAGE HAZARD  
Failure to follow this caution may result in furnace component  
damage.  
RTV  
DO NOT use wire brush or other sharp object to inspect or  
dislodge materials in secondary heat exchangers as cutting the  
secondary heat exchanger protective coating may occur. Flush  
with water only.  
PAM  
10. Reassemble inducer assembly by reversing items 5-7. Tight-  
en vent coupling clamp screw(s) to 15 in.-lb of torque.  
A93087  
Fig. 9 -- Combustion-Air Intake Housing  
Gasket Repair  
NOTE: If seal between the inducer housing and the collector box  
is damaged in any way, it must be repaired. To repair, apply  
sealant releasing agent such as PAM cooking spray or equivalent  
(must not contain corn nor canola oil, halogenated hydrocarbons  
nor aromatic content, to prevent inadequate seal from occurring) to  
15. Check for gas leaks.  
16. Replace main furnace door.  
8
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TUBE ROUTING  
Furnace is shipped from factory in upflow configuration. Pressure tube and drain tube routing MUST match the diagrams below.  
Condensate Trap on LEFT  
Condensate Trap; Factory Installed  
Tube location when used in UPFLOW application  
Side Optional  
in Blower Shelf  
BURNER ENCLOSURE  
PRESSURE REFERENCE  
TUBE ASSEMBLY  
BURNER ENCLOSURE  
PRESSURE REFERENCE  
TUBE ASSEMBLY  
(Blower access panel removed)  
CAP  
CAP  
COLLECTOR BOX TUBE  
(PINK)  
PLUG  
PLUG  
COLLECTOR BOX TUBE  
COLLECTOR BOX TUBE  
(GREEN)  
(PINK)  
COLLECTOR BOX DRAIN  
TUBE  
COLLECTOR BOX TUBE (GREEN)  
(BLUE & WHITE STRIPED)  
COLLECTOR BOX DRAIN TUBE  
(BLUE & WHITE STRIPED)  
INDUCER HOUSING (MOLDED) DRAIN TUBE  
(BEHIND COLLECTOR BOX DRAIN TUBE)  
CONDENSATE TRAP  
COLLECTOR BOX DRAIN TUBE  
(BLUE)  
COLLECTOR BOX DRAIN TUBE  
(BLUE)  
FIELD-INSTALLED  
FACTORY- SUPPLIED  
DRAIN TUBE COUPLING  
(RIGHT DRAIN OPTION)  
CONDENSATE TRAP  
FIELD-INSTALLED  
INDUCER HOUSING DRAIN TUBE  
(VIOLET)  
FACTORY-SUPPLIED DRAIN TUBE  
COUPLING (LEFT DRAIN OPTION)  
FIELD-INSTALLED  
FACTORY-SUPPLIED 1/2-IN.  
CPVC STREET ELBOWS (2)  
FOR LEFT DRAIN OPTION  
FIELD-INSTALLED FACTORY-SUPPLIED  
DRAIN TUBE  
Condensate Trap on  
LEFT Side  
Condensate Trap on  
Tube location when used in DOWNFLOW application  
RIGHT Side  
T
PLUG  
COLLECTOR BOX  
DRAIN TUBE (BLUE)  
PLUGGED END  
CAP  
CAP  
COLLECTOR BOX DRAIN TUBE  
(BLUE)  
COLLECTOR BOX DRAIN  
TUBE  
(BLUE & WHITE STRIPED)  
COLLECTOR BOX  
TUBE (GREEN)  
COLLECTOR BOX TUBE  
(PINK)  
PLUG  
COLLECTOR BOX DRAIN TUBE  
(BLUE & WHITE STRIPED)  
COLLECTOR BOX TUBE  
(GREEN)  
INDUCER HOUSING DRAIN  
TUBE (VIOLET)  
COLLECTOR BOX  
EXTENSION TUBE  
COLLECTOR BOX EXTENSION TUBE  
BURNER ENCLOSURE PRESSU  
REFERENCE TUBE ASSEMBL  
COLLECTOR BOX  
EXTENSION TUBE  
CONDENSATE TRAP  
DRAIN TUBE COUPLING  
CONDENSATE TRAP  
COLLECTOR BOX  
TUBE (PINK)  
BURNER ENCLOSURE PRESSURE  
REFERENCE TUBE ASSEMBLY  
DRAIN TUBES ROUTED IN  
FRONT OF GAS VALVE  
COLLECTOR BOX  
EXTENSION DRAIN TUBE  
GAS VALVE  
INDUCER HOUSING DRAIN TUBE (VIOLET)  
Tube location when used on  
HORIZONTAL - LEFT application  
Tube location when used on  
HORIZONTAL - RIGHT application  
AUXILIARY "J" BOX  
COLLECTOR BOX DRAIN TUBE  
COLLECTOR BOX DRAIN TUBE  
(BLUE & WHITE STRIPED)  
COLLECTOR BOX EXTENSION TUBE  
(BLUE)  
COLLECTOR BOX TUBE (PINK)  
PLUG  
CAP  
AUXILIARY "J" BOX RELOCATED HERE  
PLUG  
COLLECTOR BOX  
TUBE (GREEN)  
BURNER ENCLOSURE  
PRESSURE REFERENCE  
TUBE ASSEMBLY  
INDUCER HOUSING  
DRAIN TUBE  
(VIOLET)  
CAP  
COLLECTOR BOX  
BURNER ENCLOSURE  
PRESSURE REFERENCE  
TUBE ASSEMBLY  
EXTENSION TUBE  
COLLECTOR BOX  
DRAIN TUBE (BLUE)  
CONDENSATE TRAP  
COLLECTOR BOX  
EXTENSION TUBE  
COLLECTOR BOX  
TUBE (GREEN)  
DRAIN TUBE  
COUPLING  
COLLECTOR BOX TUBE (PINK)  
RELOCATE TUBE BETWEEN BLOWER  
SHELF AND INDUCER HOUSING FOR  
060 AND 080 HEATING INPUT  
FURNACES  
COLLECTOR BOX EXTENSION DRAIN TUBE  
COLLECTOR BOX DRAIN TUBE  
(BLUE AND WHITE STRIPED)  
CONDENSATE TRAP  
INDUCER HOUSING DRAIN TUBE (VIOLET)  
NOTE:  
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.  
326476-201 REV. B  
(lit-bottom)  
A01052  
Fig. 10 -- Furnace Pressure and Draining Tube Diagram  
9
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BURNER FLAME  
!
CAUTION  
BURNER  
BURN HAZARD  
Failure to follow this caution may result in personal injury.  
Allow igniter to cool before removal. Normal operating  
temperatures exceed 2000°F (1093°C).  
a. Remove burner box cover.  
b. Remove igniter wires from slot in manifold grommet.  
(See Fig. 7.)  
c. Using a 1/4 in. driver, remove the single screw securing  
the igniter bracket to the burner box bracket (See Fig.  
13.) and carefully withdraw the igniter and bracket as-  
sembly through the front of the burner box without  
striking the igniter on surrounding parts. Note that the  
igniter bracket has a handle that extends to the front of  
the burner box to aid in handling (See Fig. 13.).  
MANIFOLD  
A89020  
Fig. 11 -- Burner Flame  
d. Inspect igniter for signs of damage or failure.  
!
CAUTION  
PAM  
UNIT DAMAGE HAZARD  
Failure to follow this caution may result in unit component  
damage.  
RTV  
The igniter is fragile. DO NOT allow it to hit the side of the  
burner box parts while removing or replacing it.  
e. If replacement is required, replace igniter on igniter  
bracket and then install assembly to burner box to avoid  
damage to the igniter.  
6. To replace igniter and bracket assembly, reverse items 5a  
through 5d.  
7. Reconnect igniter wire connection and insert the igniter  
wires in the slot in the manifold grommet, dressing the ig-  
niter wires to ensure there is no tension on the igniter itself.  
(See Fig. 7.)  
A93081  
!
Fig. 12 -- Gasket on Collector Box  
CAUTION  
UNIT COMPONENT ELECTRICAL SHORT HAZARD  
Step 6 — Servicing Hot Surface Igniter  
The igniter does NOT require annual inspection. Check igniter  
resistance before removal.  
Failure to follow this caution may result in unit component  
damage.  
Igniter wires must be securely placed in slot in manifold  
grommet or else they could become pinched or severed and  
electrically shorted.  
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 affect by tem-  
perature. Only check resistance when the igniter is at room  
temperature.  
8. Reinstall burner box cover.  
9. Turn on gas and electrical supplies to furnace.  
d. Using an ohm meter, check resistance across both ig-  
niter leads in connector.  
10. Verify igniter operation by initiating furnace control board  
self-test feature or by cycling thermostat.  
e. Cold reading should be between 40 ohms and 70 ohms.  
5. Remove igniter assembly.  
11. Replace main furnace door.  
10  
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!
CAUTION  
UNIT AND PROPERTY DAMAGE HAZARD  
Failure to follow this caution may result in furnace component  
or property damage.  
If this furnace is to be operated in an unconditioned space  
where the ambient temperatures may be 32_F (0_C) or lower,  
freeze protection measures must be taken. (See Fig. 18). See  
CONDENSATE DRAIN PROTECTION section of  
Installation, Start--up, and Operating Instructions.  
A05075  
Fig. 13 -- Igniter Bracket  
Step 8 — Checking Heat Tape Operation (If  
Applicable)  
In applications where the ambient temperature around the furnace  
is 32°F (0_C) or lower, freeze protection measures are required. If  
this application is where heat tape has been applied, check to  
ensure it will operate when low temperatures are present.  
NOTE: Heat tape, when used, should be wrapped around the  
condensate drain trap and drain line. There is no need to use heat  
tape within the furnace casing. Most heat tapes are temperature  
activated, and it is not practical to verity the actual heating of the  
tape. Check the following:  
1. Check for signs of physical damage to heat tape such as  
nicks, cuts, abrasions, gnawing by animals, etc.  
2-5/32˝  
2. Check for discolored heat tape insulation. If any damage or  
(55 mm)  
discolored insulation is evident, replace heat tape.  
A04181  
3. Check that heat tape power supply circuit is on.  
Fig. 14 -- Igniter  
Step 9 — Winterizing  
Step 7 — Electrical Controls and Wiring  
!
CAUTION  
!
WARNING  
UNIT DAMAGE HAZARD  
Failure to follow this caution may result in furnace component  
damage.  
ELECTRICAL SHOCK HAZARD  
Failure to follow this warning could result in personal injury  
or death.  
Freezing condensate left in the furnace may damage the  
furnace.  
There may be more than 1 electrical supply to the unit. Check  
accessories and cooling unit for additional electrical supplies.  
If the furnace will be off for an extended period of time in a  
structure where the temperature will drop to 32°F (0_C)or below,  
winterize as follows:  
The electrical ground and polarity for 115-v wiring must be  
maintained properly. Refer to Fig. 15 or 16 for field wiring  
information and to Fig. 22 for unit wiring information.  
1. Turn off electrical supply to furnace.  
2. Remove main furnace door.  
NOTE: If the polarity is not correct or the furnace is not  
grounded, the STATUS LED on the furnace control board will  
flash rapidly and prevent the furnace from operating. The control  
system also requires an earth ground for proper operation of the  
furnace control board and flame sensor.  
3. Disconnect cap from unused drain tap on inducer housing.  
(See Fig. 19.)  
4. Connect field-supplied 1/2-in. (13 mm) I.D. tube to upper  
inducer housing drain connection.  
The 24-v circuit contains an automotive-type, 3-amp fuse located  
on the control. (See Fig. 17.) 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 3 amp fuse. The  
control LED will display status code 24 when fuse needs to be  
replaced.  
!
CAUTION  
UNIT DAMAGE HAZARD  
Failure of plastic components may occur.  
Do not use ethylene glycol (Prestone II antifreeze/coolant or  
equivalent automotive type).  
With power to the unit disconnected, check all electrical  
connections for tightness. Tighten all screws on electrical  
connections. If any smoky or burned connections are found,  
disassemble the connection, clean all parts, strip wire, and  
reassemble properly and securely.  
Reconnect electrical supply to unit and observe unit through 1  
complete operating cycle for proper operation.  
11  
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FIELD 24-V WIRING  
FIELD 115-, 208/230-, 460-V WIRING  
FACTORY 24-V WIRING  
FACTORY 115-V WIRING  
1-STAGE THERMOSTAT TERMINALS  
W
Y
R
G
C
FIVE  
WIRE  
FIELD-SUPPLIED  
FUSED DISCONNECT  
TWO-WIRE  
HEATING-  
ONLY  
208/230- OR  
460-V  
THREE  
PHASE  
W2  
BLK  
BLK  
GND  
GND  
GND  
COM  
W/W1  
WHT  
WHT  
208/230-V  
SINGLE  
PHASE  
GND  
GND  
Y/Y2  
115-V FUSED  
DISCONNECT  
SWITCH  
JUNCTION  
BOX  
GND  
R
G
CONTROL  
CONDENSING  
UNIT  
(WHEN REQUIRED)  
BOX  
24-V  
TERMINAL  
BLOCK  
NOTES: 1. Connect Y-terminal as shown for proper operation.  
FURNACE  
2. Some thermostats require a "C" terminal connection as shown.  
3. If any of the original wire, as supplied, must be replaced,  
use same type or equivalent wire.  
A99071  
Fig. 15 -- Field Wiring  
FIELD 24-V WIRING  
FIELD 115-, 208/230-, 460-V WIRING  
FACTORY 24-V WIRING  
FACTORY 115-V WIRING  
2-STAGE THERMOSTAT TERMINALS  
W2 W1 Y2  
R
G
Y1  
C
SEVEN  
WIRE  
FIELD-SUPPLIED  
FUSED DISCONNECT  
THREE-WIRE  
208/230- OR  
HEATING-  
ONLY  
460-V  
THREE  
PHASE  
W2  
COM  
W/W1  
BLK  
BLK  
GND  
C
GND  
GND  
WHT  
WHT  
208/230-V  
SINGLE  
PHASE  
GND  
GND  
Y/Y2  
115-V FUSED  
DISCONNECT  
SWITCH  
JUNCTION  
BOX  
Y1  
Y2  
GND  
R
G
CONTROL  
2-SPEED  
CONDENSING  
UNIT  
(WHEN REQUIRED)  
BOX  
24-V  
TERMINAL  
BLOCK  
NOTES: 1. Connect Y-terminal as shown for proper operation.  
FURNACE  
2. Some thermostats require a "C" terminal connection as shown.  
3. If any of the original wire, as supplied, must be replaced,  
use same type or equivalent wire.  
A99072  
Fig. 16 -- Field Wiring  
12  
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SET UP SWITCHES  
LOW HEAT ONLY  
AND BLOWER  
OFF-DELAY  
TWINNING AND/OR  
COMPONENT TEST  
TERMINAL  
ACRDJ - AIR CONDITIONING  
RELAY DISABLE JUMPER  
LHT  
OFF  
DLY  
24-V THERMOSTAT  
TERMINALS  
HUMIDIFIER TERMINAL  
(24 VAC 0.5 AMPS MAX)  
TEST / TWIN  
HUM  
TRANSFORMER  
24 VAC CONNECTIONS  
PL1-LOW VOLTAGE  
FUSE 3-AMP  
MAIN HARNESS CONNECTOR  
3-AMP FUSE  
SEC-2  
COM  
SEC-1  
24VAC  
LED OPERATION  
& DIAGNOSTIC LIGHT  
COM  
HI HT  
COOL  
LO HT  
BLOWER SPEED  
TERMINALS  
SPARE 2 SPARE 1  
EAC-2  
EAC-1  
115-VAC (L2)  
NEUTRAL  
CONNECTIONS  
HSI HI LO  
L1 BL-1 PR-1  
115 VAC LINE (L1)  
CONNECTION  
PL2 - HOT SURFACE  
IGNITER/INDUCER  
MOTOR CONNECTION  
115 VAC  
BLOWER POWER (BL1)  
CONNECTION  
A08344  
Fig. 17 -- Two-Stage Control  
5. Insert funnel in tube and pour up to 1 quart of antifreeze,  
propylene glycol (RV, swimming pool antifreeze, or equi-  
valent) into funnel until it is visible at point where condens-  
ate enters open drain. (See Fig. 20.)  
To retrieve previous codes, remove one of the red main limit or  
flame rollout switch wires 1 to 4 sec until the LED light goes out,  
the reconnect it. (Do not leave red wire disconnected for longer  
periods of time as the control will assume an overtemperature  
condition exists and will respond with blower operation.) This  
places the control in the status recall mode and displays the first  
code stored in memory.  
6. Reconnect drain cap to inducer housing.  
7. Replace main furnace door.  
8. Propylene glycol need not be removed before restarting fur-  
nace.  
WIRING DIAGRAM  
See Fig. 22 for Wiring Diagram.  
TROUBLESHOOTING  
Use the Troubleshooting Guide, the status code LED on the  
control and the Component Test to isolate furnace operation  
problems.  
Step 1 — Status Codes  
For an explanation of status codes, refer to service label located on  
back of main furnace door or Fig. 21. The stored status codes will  
NOT be erased from the control memory, if 115-or 24-v power is  
interrupted. The control will store up to 7 Status Codes.  
NOTE: Removing the blower access door will open the blower  
access door switch and terminate 115--v power to the control. To  
read current status code, remove main furnace door. The status  
code LED can be viewed through the sight glass on the blower  
access door.  
NOTE: NO thermostat signals may be present at control and all  
blower off delays must be completed to view previous codes.  
A07911  
Fig. 18 -- Winterizing the Furnace  
13  
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A99118  
A99119  
Fig. 19 -- Inducer Housing Drain Tube Cap  
Fig. 20 -- Funnel in Drain Tube and Antifreeze  
Running Through Trap  
Record the code and repeat the disconnect and reconnect of the red  
wire, recording each code until code 11 is displayed indicating no  
additional codes. After the last code is displayed or after 2 minutes  
in the code recall mode the control will return to normal standby  
mode.  
1. Remove blower access door.  
2. Disconnect thermostat R lead from furnace control.  
3. Manually close blower door switch.  
4. For approximately 2 sec, short (jumper) the COM-24 v ter-  
minal on control to the TEST/TWIN 3/16-in. quick-connect  
terminal on control until LED turns off. Remove jumper  
from terminals. (See Fig.17.)  
Step 2 — Component Test  
NOTE:  
The furnace control component test allows all  
components to run for a short time; except the gas valve and  
humidifier terminal HUM are not energized for safety reasons. The  
EAC--1 terminal is energized when blower is energized. This  
feature helps diagnose a system problem in case of a component  
failure. The component test feature will not operate if any  
thermostat signal is present at control and not until all time delays  
are completed.  
NOTE: If TEST/TWIN and COM--24v terminals are jumpered  
longer than 2 sec, LED will flash rapidly and ignore status code  
retrieval request.  
Component test sequence for 2-stage furnace is as follows:  
a. LED will display previous status code 4 times.  
b. Inducer motor starts on high--speed and continues to run  
until Step g of component test sequence.  
To Begin Component Self-Test:  
c. Hot surface igniter is energized for 15 sec, then off.  
d. Blower motor operates on LO--HEAT speed for 10 sec.  
e. Blower motor operates on HI--HEAT speed for 10 sec.  
f. Blower motor operates on COOL speed for 10 sec.  
g. Inducer motor goes to low--speed for 10 sec, then stops.  
!
WARNING  
ELECTRICAL SHOCK AND UNIT OPERATION  
HAZARD  
5. Reconnect R lead to furnace control, remove tape from  
Failure to follow this warning could result in personal injury,  
or death.  
blower door switch, and re-install blower door.  
6. Operate furnace per instruction on outer door.  
Blower access panel door switch opens 115-v power to control  
board. No component operation can occur. Caution must be  
taken when manually closing this switch for service purposes.  
7. Verify furnace shut down by lowering thermostat setting  
below room temperature.  
8. Verify that furnace restarts by raising thermostat setting  
above room temperature.  
14  
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SERVICE  
If status code recall is needed, briefly remove then reconnect one main limit wire  
to display last stored status code. Repeat remove-and-reconnect four more times  
for previous four status codes, after which the five codes repeat. Status code 11  
will display when less than four previous status codes exist. On RED LED controls  
do not remove power or blower door before initiating status code recall.  
LED CODE  
STATUS  
CONTINUOUS OFF - Check for 115VAC at L1 & L2, & 24VAC at SEC-1 & SEC-2.  
CONTINUOUS ON - Control has 24VAC power.  
RAPID FLASHING - Line voltage (115VAC) polarity reversed. If twinned,  
refer to twinning kit instructions.  
EACH OF THE FOLLOWING STATUS CODES IS A TWO DIGIT NUMBER WITH THE FIRST  
DIGIT DETERMINED BY THE NUMBER OF SHORT FLASHES AND THE SECOND DIGIT BY  
THE NUMBER OF LONG FLASHES.  
11 NO PREVIOUS CODE - Stored status codes are erased automatically after 72  
hours. On RED LED boards stored status codes can also be erased when  
power (115 VAC or 24 VAC) to control is interrupted.  
12 BLOWER ON AFTER POWER UP (115 VAC or 24 VAC) -Blower runs for the  
selected blower off-delay time, if unit is powered up during a call for heat  
(R-W/W1 closed) or (R-W/W1) opens during blower on-delay.  
13 LIMIT CIRCUIT LOCKOUT - Lockout occurs if a limit or flame rollout switch is  
open longer than 3 minutes. - Control will auto reset after three hours.  
- Refer to #33.  
14 IGNITION LOCKOUT - Control will auto-reset after three hours. Refer to #34.  
21 GAS HEATING LOCKOUT - Control will NOT auto reset.  
Check for: - Mis-wired gas valve  
- Defective control (valve relay)  
22 ABNORMAL FLAME-PROVING SIGNAL - Flame is proved while gas valve  
is de-energized. Inducer will run until fault is cleared. Check for:  
- Leaky gas valve  
- Stuck-open gas valve  
23 PRESSURE SWITCH DID NOT OPEN Check for:  
- Obstructed pressure tubing  
- Pressure switch stuck closed  
24 SECONDARY VOLTAGE FUSE IS OPEN Check for:  
- Short circuit in secondary voltage (24VAC) wiring.  
31 HIGH-HEAT PRESSURE SWITCH OR RELAY DID NOT CLOSE OR  
REOPENED  
Control relay may be defective, refer to status code #32  
32 LOW-HEAT PRESSURE SWITCH DID NOT CLOSE OR REOPENED - If  
open longer than five minutes, inducer shuts off for 15 minutes before retry. If  
opens during blower on-delay period, blower will come on for the selected  
blower off-delay. Check for: - Excessive wind  
- Restricted vent  
- Defective inducer motor  
- Low inlet gas pressure (if LGPS used)  
- Low inducer voltage (115 VAC)  
- Proper vent sizing  
- Defective pressure switch  
- Inadequate combustion air supply  
- Disconnected or obstructed pressure tubing  
33 LIMIT CIRCUIT FAULT - Indicates a limit or flame rollout, switch is open.  
Blower will run for 4 minutes or until open switch remakes whichever is longer.  
If open longer than 3 minutes, code changes to lockout #13. If open less than  
3 minutes status code #33 continues to flash until blower shuts off. Flame rollout  
switch requires manual reset. Check for: - Dirty filter or restricted duct system  
- Proper vent sizing - Restricted vent - Loose blower wheel - Excessive wind  
- Defective blower motor or capacitor  
- Defective switch or connections  
- Inadequate combustion air supply (Flame Roll-out Switch open).  
34 IGNITION PROVING FAILURE - Control will try three more times before lock  
out #14 occurs. If flame signal lost during blower on-delay period, blower will  
come on for the selected blower off-delay. Check for:  
- Oxide buildup on flame sensor (clean with fine steel wool)  
- Proper flame sense microamps (.5 microamps D.C. min., 4.0 - 6.0 nominal)  
- Manual valve shut-off  
- Control ground continuity  
- Low inlet gas pressure  
- Gas valve defective or gas valve turned off  
- Inadequate flame carryover or rough ignition  
- Flame sensor must not be grounded  
- Defective Hot Surface Ignitor  
- Green/Yellow wire MUST be connected to furnace sheet metal  
43 LOW-HEAT PRESSURE SWITCH OPEN WHILE HIGH-HEAT PRESSURE  
SWITCH IS CLOSED - Check for: - Disconnected or obstructed pressure tubing  
- Mis-wired pressure switches  
- Low-heat pressure switch stuck open  
- Low inlet gas pressure (if LGPS used)  
45 CONTROL CIRCUITRY LOCKOUT Auto-reset after one hour lockout due to;  
- Gas valve relay stuck open  
- Software check error  
- Flame sense circuit failure  
Reset power to clear lockout. Replace control if status code repeats.  
COMPONENT TEST  
To initiate the component test sequence, shut OFF the room thermostat or  
disconnect the "R" thermostat lead. Briefly short the TEST/TWIN terminal to the  
"Com 24V" terminal. Status LED will flash last status code and then turn ON the  
inducer motor. The inducer motor will start in HIGH speed and remain on HIGH  
speed until the end of the test then shift to LOW speed for 7 to 15 seconds. The hot  
surface ignitor, blower motor LO HEAT speed, blower motor HI HEAT speed, and  
blower motor COOL speed will be turned ON for 10-15 seconds each. Gas Valve  
and Humidifier will not be turned on. When the blower is turned OFF the inducer will  
be switched to low-speed for 10 seconds.  
327885-101 REV. B  
A02258  
Fig. 21 -- Service Label  
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A08343  
Fig. 22 -- Wiring Diagram  
16  
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A05095  
17  
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A05095  
Catalog No: 58MEC---01SM  
Copyright 2009 Carrier Corp. S 7310 W. Morris St. S Indianapolis, IN 46231  
Printed in U.S.A.  
Edition Date: 09/09  
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.  
Replaces: NEW  
18  
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