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Service and Maintenance Instructions
For Sizes 070-155, Series 110 and 120
NOTE: Read the entire instruction manual before starting the
installation.
TABLE OF CONTENTS
SAFETY CONSIDERATIONS.....................................................1
INTRODUCTION..........................................................................1
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS PRO-
CEDURE........................................................................................2
CARE AND MAINTENANCE.....................................................2
Cleaning and/or Replacing Air Filter.......................................2
Blower Motor and Wheel.........................................................3
Cleaning Heat Exchanger.........................................................4
Electrical Controls and Wiring.................................................5
Wiring Diagrams............................................................................9
Troubleshooting..............................................................................9
SAFETY CONSIDERATIONS
58YAV
Induced-Combustion Furnaces
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Installing and servicing heating equipment can be hazardous due to
gas and electrical components. Only trained and qualified personnel 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, tags, and
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 No.
54-1999/ANSI Z223.1-1999. In Canada, refer to the current
edition of the National Standard of Canada CAN/CGA-B149.1and .2-M95 Natural Gas and Propane Gas Installation Codes
(NSCNGPIC). Wear safety glasses and work gloves. Have 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 furnace and in instructions or
manuals, be alert to the potential for personal injury.
A94085
Fig. 1—Model 58YAV Upflow Furnace
Understand these 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 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
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. A FAILURE
TO FOLLOW THIS WARNING COULD RESULT IN
POSSIBLE DAMAGE TO THIS EQUIPMENT, SERIOUS
PERSONAL INJURY, OR DEATH.
Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous
operation.
.
These procedures are written for size 66,000 through 154,000 Btuh
input units of the 58YAV Gas-Fired Induced Combustion Furnace.
INTRODUCTION
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. 535-771 Printed in U.S.A. Form 58YAV–3SM Pg 1 10-00 Replaces: 58YAV–2SM
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURE
Electrostatic discharge can affect electronic components.
Take precautions during furnace installation and servicing to
protect the furnace electronic control. Precautions will prevent electrostatic discharges from personnel and hand tools
which are held during the procedure. These precautions will
help to avoid exposing the control to electrostatic discharge
by putting the furnace, the control, and the person at the same
electrostatic potential.
1. Disconnect all power to the furnace. DO NOT TOUCH THE
CONTROL OR ANY WIRE CONNECTED TO THE CONTROL PRIOR TO DISCHARGING YOUR BODY’S ELECTROSTATIC CHARGE TO GROUND.
2. Firmly touch a clean, unpainted, metal surface of the 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.
CARE AND MAINTENANCE
For continuing high performance and to minimize possible equipment failure, it is essential that periodic maintenance be performed
on this equipment. Consult your local dealer as to proper frequency
of maintenance and availability of a maintenance contract.
Never store anything on, near, or in contact with 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. A failure to follow this warning could
result in corrosion of the heat exchanger, fire, personal injury,
or death.
Turn off gas and electrical supplies to unit before performing
any maintenance or service on it. Follow operating instructions on label attached to furnace. A failure to follow this
warning could result in personal injury.
The minimum maintenance that should be performed on this
equipment is as follows:
1. Check and clean air filter each month or more frequently if
required. Replace if torn.
2. Check blower motor and wheel for cleanliness each heating
and cooling season. Clean as necessary.
3. Check electrical connections for tightness and controls for
proper operation each heating season. Service as necessary.
As with any mechanical equipment, personal injury can result
from sharp metal edges, etc.; therefore, be careful when
removing parts.
Step 1—Cleaning and/or Replacing Air Filter
The air filter arrangement may vary depending on application.
NOTE: If the filter has an airflow direction arrow, the arrow must
point toward the blower.
Never operate unit without a filter or with filter access door
removed. A failure to follow this warning could result in fire,
personal injury, or death.
To clean or replace filters, proceed as follows:
1. Filters installed in media cabinet adjacent to furnace (see Fig.
2)
FLUE
COLLAR
MOUNTING
SCREWS
RELIEF
BOX
GAS
VALVE
CONTROL
HUM
C
24V
OM
GRYW
BLOCKED
VENT
SAFEGUARD
PRESSURE
SWITCH
FLUE
COLLECTOR
BOX
FILTER
RETAINER
WASHABLE
FILTER
A99284
Fig. 2—Model 58YAV Upflow Furnace
a. Turn off electrical supply to furnace
b. Remove filter cabinet door.
c. Slide filter out of cabinet.
2
d. 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.
e. If equipped with factory-specified disposable media filter,
replace only with media filter having the same part number
and size.
f. Slide filter into cabinet.
g. Replace filter cabinet door.
h. Turn on electrical supply to furnace.
2. Filters installed in side(s) and/or bottom of blower compartment (See Fig. 2)
a. Disconnect electrical power before removing access doors.
b. Remove blower and control access doors.
c. Release filter retainer from clip at front of furnace casing.
(See Fig. 2.) For side return, clips may be used on either or
both sides of the furnace.
d. Slide filter(s) out.
e. Furnaces are equipped with permanent, washable filters.
Clean filters with tap water. Spray water through filter in
opposite direction of airflow.
f. Rinse and let dry. Oiling or coating of filter is NOT
recommended or required.
g. Reinstall filter(s)
h. Replace blower and control access doors
i. Restore electrical power to furnace.
Step 2—Blower Motor and Wheel
The following items should be performed by a qualified service
technician:
To ensure long life, economy, and high efficiency, clean accumulated dirt and grease from blower wheel and motor annually.
The inducer and blower motors are prelubricated and require no
additional lubrication. These motors can be identified by the
absence of oil ports on each end of the motor.
Clean blower motor and wheel as follows:
1. Turn off electrical supply to furnace.
2. Remove control and blower access doors.
3. Disconnect blower leads from furnace control. Notice wire
color and location for reassembly.
All other factory wires can be left connected, but field
thermostat connections may need to be disconnected depending on their length and routing.
4. Remove 2 screws securing control and transformer support to
furnace.
5. Hang control box and transformer support to front of furnace
casing.
6. Remove screws holding blower assembly to blower deck and
slide blower assembly out of furnace.
7. Clean blower wheel and motor using a vacuum with soft brush
attachment. Do not remove or disturb balance weights (clips)
on blower wheel blades. The blower wheel should not be
dropped or bent as balance will be affected.
8. If a 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, motor, and blower housing
so motor and each arm is positioned at the same location during
reassembly.
c. Mark blower wheel orientation and cutoff plate location to
ensure proper reassembly.
d. Remove screws securing cutoff plate and remove cutoff
plate from housing.
e. Remove bolts holding motor mounts to blower housing and
slide motor and mounts out of housing. Disconnect capacitor and ground wire attached to blower housing before
removing motor. Motor mount belly band need not be
removed unless motor is to be replaced.
f. Remove blower wheel from housing.
The blower wheel should not be dropped or bend as balance
will be affected.
9. Reassemble motor and blower by reversing items 9a through
9f. Be sure to reattach ground wire.
10. Reinstall blower assembly in furnace.
11. Reinstall control and transformer support assembly in furnace.
12. Reconnect blower leads to furnace control.
Refer to furnace wiring diagram (See Fig. 6), and connect
thermostat leads if previously disconnected.
NOTE: Refer to Table 1 for motor speed lead relocation if leads
were not identified before disconnection
TABLE 1—SPEED SELECTOR
COLOR SPEED
Black High Cool
Yellow (When
Present)
Blue Medium Low Heat
Red Low Spare
White Common L2/COM
Medium High Spare
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.
13. 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 between heating and
cooling by jumpering R to W and then R to Y on furnace
control thermostat terminals.
Blower access 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.
NOTE: If thermostat terminals are jumpered before blower
access door switch is closed, blower will run for 90 sec before
beginning a heating or cooling cycle.
FACTORY-
ATTACHED
TO
3
14. If furnace is operating properly, REMOVE TAPE TO RELEASE BLOWER ACCESS DOOR SWITCH, replace
blower access door.
Step 3—Cleaning Heat Exchanger
The following steps should be performed by a qualified service
technician:
NOTE: If the heat exchangers get a heavy accumulation of soot
and carbon, they 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, incorrect size, or
damaged manifold orifice(s), improper gas, or a restricted heat
exchanger. Action must be taken to correct the problem.
If it becomes necessary to clean heat exchanger because of light
dust or corrosion proceed as follows:
1. Turn gas and electrical power to furnace to OFF.
2. Remove control access door.
3. Disconnect vent connector from furnace flue collar.
4. Remove 2 screws that secure relief box. (See Fig. 2.)
5. Disconnect wires to the following components. Mark wires to
aid in reconnection of:
a. Blocked vent safeguard switch.
b. Inducer motor.
c. Pressure switch.
d. Limit overtemperature switch(es).
e. Gas valve.
f. Hot surface ignitor.
g. Flame-sensing electrode
h. Flame rollout switch(es), if applicable.
6. Remove complete inducer assembly and relief box from
furnace.
7. Remove 8 screws that secure flue collector box to center
panel. Be careful not to damage collector box.
8. Remove burner assembly and cell inlet plates. IMPORTANT:
Replace screws in center panel before cleaning.
NOTE: Be very careful when removing burner assembly to avoid
breaking ignitor. See Fig. 3 for correct ignitor location.
9. Using field-provided small wire brush, steel spring cable,
reversible electric drill, and vacuum cleaner, clean cells as
follows:
a. Assemble wire brush and steel spring cable.
(1.) Use 48 in. of 1/4-in. diameter high-grade steel spring
cable (commonly known as drain clean-out or RotoRootert cable).
(2.) Use 1/4-in. diameter wire brush (commonly known as
25-caliber rifle cleaning brush).
NOTE: The materials needed in items (1.) and (2.) can usually be
purchased at local hardware stores.
(3.) Insert twisted wire end of brush into end of spring
cable, and crimp tight with crimping tool or strike with
ball-peen hammer. TIGHTNESS IS VERY IMPORTANT.
(4.) Remove metal screw fitting from wire brush to allow
insertion into cable.
b. Clean each heat exchanger cell.
(1.) Attach variable-speed, reversible drill to end of spring
cable (end opposite brush).
11
CELL
PANEL
HOT
SURFACE
IGNITOR
ASSEMBLY
C
IGNITOR
L
7
8
"
C
BURNER
L
IGNITOR
ASSEMBLY
32
"
A93347
BURNER
13
32
"
Fig. 3—Position of Ignitor to Burner
(2.) Insert brush end of cable into upper opening of cell
and slowly rotate with drill. DO NOT force cable.
Gradually insert at least 36 in. of cable into 2 upper
passes of cell. (See Fig. 4.)
A91252
Fig. 4–Cleaning Heat Exchanger Cell
(3.) Work cable in and out of cell 3 or 4 times to obtain
sufficient cleaning. DO NOT pull cable with great
force. Reverse drill and gradually work cable out.
(4.) Insert brush end of cable in lower opening of cell, and
proceed to clean 2 lower passes of cell in same manner
as 2 upper passes.
(5.) Repeat foregoing procedures until each cell in furnace
has been cleaned.
(6.) Using vacuum cleaner, remove residue from each cell.
(7.) Using vacuum cleaner with soft brush attachment,
clean burner assembly.
(8.) Reinstall cell inlet plates and burner assembly. Care
must be exercised to center burners in cell openings.
4
10. Clean flame sensor with fine steel wool
11. Remove old sealant from center panel and collector box flange
and apply new sealant to collector box flange and reinstall on
center panel, making sure all 8 screws are secure.
NOTE: A 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) and RTV sealant
(G.E. 162, 6702, or Dow-Corning 738) are needed before starting
installation. DO NOT substitute any other type of RTV sealant.
G.E. 162 (P771-9003) is available through RCD in 3-oz tubes.
12. Reinstall relief box and inducer assembly.
NOTE: If inducer assembly gasket is damaged, use RTV sealant
to seal inducer assembly to collector box.
13. Reconnect wires to the following components:
a. Blocked vent safeguard switch.
b. Inducer motor.
c. Pressure switch.
d. Limit overtemperature switch(es).
e. Gas valve.
f. Hot surface ignitor.
g. Flame-sensing electrode
h. Flame rollout switch(es), if applicable.
14. Reinstall vent connector to furnace flue collar. After fully
assembling vent connector to furnace flue collar, securely
fasten vent connector to flue collar with 2 field-supplied,
corrosion-resistant, sheet metal screws located 180 degrees
apart and midway up the collar.
15. Turn electrical power and gas to ON.
16. Set thermostat and check furnace for proper operation.
17. Verify blower airflow and speed changes between heating and
cooling.
18. Check for gas leaks.
Never use a match or other open flame to check for gas leaks.
Use a soap-and-water solution. A failure to follow this
warning could result in fire, personal injury, or death.
19. Replace control door.
Step 4—Electrical Controls and Wiring
There may be more than 1 electrical supply to 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. 5 for field wiring information
and to Fig. 6 for furnace wiring information.
NOTE: If the polarity is not correct, the STATUS LED on the
control will flash rapidly and prevent the furnace from heating.
The control system also requires an earth ground for proper
operation of the control and flame-sensing electrode.
The 24-v circuit contains an automotive-type, 3-amp fuse located
on the control. (See Fig. 7.) Any 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.
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 power to the 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.
The control in this furnace is equipped with an LED status light to
aid in installation, servicing, and troubleshooting. It can be viewed
FIVE WIRE
THREE-WIRE
HEATING-ONLY
BLOWER DOOR SWITCH
BLK
WHT
115-V FIELD-
SUPPLIED
DISCONNECT
BLK
WHT
GND
AUXILIARY
J-BOX
FIELD 24-V WIRING
FIELD 115-, 208/230-, 460-V WIRING
FACTORY 24-V WIRING
FACTORY 115-V WIRING
GND
FURNACE
NOTE 2
W
C
R
O
N
T
G
R
O
C
L
Y
24-V
TERMINAL
BLOCK
WCR GY
NOTE 1
NOTES: Connect Y-terminal in furnace as shown for proper blower operation.
1.
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.
THERMOSTAT
TERMINALS
CONDENSING
UNIT
TWO
WIRE
FIELD-SUPPLIED
DISCONNECT
Fig. 5–Heating and Cooling Application Wiring Diagram
208/230- OR
460-V
THREE
PHASE
208/230-V
SINGLE
PHASE
GND
A98521
5
SW2
SW1
321
6
9
24 VAC-3A
FUSE
COOL
HEAT
EAC-1
EAC-2
4
5
87
SEC-2
SPAR E-1
SPA RE-2
GRN/YEL
G
R
Y
W
C
HUM
LED
IDM
ORN
OM
1.5 AMP
BLOWER
PCB
(NOT ON ALL MODELS)
BLOWER OFF DELAY
SELECTION CHART
90 SEC
NOTE #9
OFF
DELAY
TEST/TWIN
135 SEC
180 SEC
225 SEC
PL1
GVR
SEC-1
HI/LO
RELAY
FU1
PL5
BLOWER
SPEED
SELECT
L2
PL3
1
1
2
PR2
2
OM
C
3
WHT
WHT
BLK
HSIR IDR BLWR
PL2
VAC
120
PR1
L1
BLK
BLK
BLK
WHT
6
12
HSI
DSS
BLU
RED
WHT
RED
BLK (HI)
YEL (MED HI)
NOTE #7
BLU (MED LO)
RED (LO)
WHT (COM)
(WHEN USED)
NOTE #14
BVSS
ORN
NOTE #14
LS
FSE
FRS1
WHT
LEGEND
ALS A UXILIARY LIMIT SWITCH, OVERTEMP. -MANUAL RESET, SPST-(N.C.)
BLWR BLOWER MOT O R RELAY, SPST-(N.O.)
BLWM BLOWER MOTOR
BVSS BLOC KED VENT SHUT OFF SW ITCH, SPST - (N.C.)
CAP CAPACITOR
CPU MICROPROCESSOR AND CIRCUITRY
DSS DRAFT SAFEGUARD SWITCH
EAC-1 ELECTRO NIC AIR CLEANER CONNECTION (115 VA C 1.5 AMP MAX.)
EAC-2 ELECTRO NIC AIR CLEANER CONNECTION (COM MO N)
FL FUSIBLE LINK
FRS FLAM E R O LLOUT SW . -MANU AL R ESET, SPST-(N.C.)
FSE FLAME PROVING ELECTRODE
FU1 FUSE, 3 AMP, AUT O MOTIVE BLADE TYPE, FACTORY INSTALLED
FU2 FUSE OR CIRCUIT BREAKER CURRENT INTERRUPT DEVICE
(FIELD INSTALLED & SUPPLIED)
GV GAS VALVE-REDUNDANT OPERA T ORS
GVR GAS V ALVE RELA Y , DPST -(N.O.)
HI/LO BLOWER MOTOR SPEED CHAN GE RELAY, SPDT
HSI HOT SURFACE IGNITOR (115 VAC)
HSIR HOT SURFACE IGNITOR RELAY, SPST -(N.O.)
HUM 24VAC H UM IDIFIER CONNECTION (.5 AMP. MAX.)
IDM INDUCED DRAFT MOTOR
IDR INDUCED DRAFT RELAY, SPST -(N.O.)
ILK BLOWER ACCESS PANEL INTERLOCK SWITCH, SPST -(N.O.)
JB JUNCTION BOX
LED LIGHT-EMITTING DIODE FOR STATUS CODES
LGPS LOW GAS PR ESSURE SW ITCH, SPST-(N.O.)
LS LIMIT SWITCH, AUTO RESET, SPST(N.C.)
OL AUTO-RESET INTERNAL MOTOR OVERLOAD TEMP. SW .
(WHEN USED)
NOTE #11
ALS
ORN
ORN
(WHEN USED)NOTE #11
BLU
RED
OL
ILK
TRAN
STAR T
BLWM
BLK
JB
PCB PRINTED CIRCUIT BOARD
PL1 9-CIRCUIT CONNECTOR
PL2 2-CIRCUIT PCB CONNECTOR
PL3 3-CIR C U IT ID M C ONN E C T O R
PL5 2-CIRCUIT HSI/PCB CONNECTOR
PRS PRESSURE SWITCH, SPST-(N.O.)
TEST/TWIN COMPONENT TEST & TWIN TERMINAL
TRAN TRANSFORMER-115VAC/24VAC
PRS
ORN
FL
FRS2
GRN/YEL
BLK
WHT
WHT (COM)
GRN/YEL
BRN
CAP
BRN
FUSED DISCONNECT
SWITCH (WHEN REQ’D)
NOTE #4
BLK
FU2
WHT
GND
JUNCTION
UNMARKED TERMINAL
PCB TERMINAL
FACTORY WIRING (115VAC)
FACTORY WIRING (24VAC)
FIELD WIRING (115V A C)
FIELD WIRING (24VAC)
CONDUCTOR ON PCB
FIELD WIRING TERMINAL
FIELD GROUND
EQUIPMENT GROUND
FIELD SPLICE
PLUG RECEPTACLE
(WHEN USED)
LGPS
NOTE #13
NOTE #15
GV
GRN/YEL
NOTE #5
L1
NEUTRAL
TO 115VAC FIELD DISCONNECT
L2
L1
YEL
ILK
L1
TEST/TWIN
NOTE #12
HUM
C
NOTE #4
BLWR
HSIR
IDR
FU1
R
W
Y
G
OM
NOTE #6
HSIR
EAC-1
IDR
EQUIPMENT GROUND
SPARE-2
HEA T
SPARE-1
HI/LO
COOL
COM
EAC-2
PL2
PR1
115VAC
TRAN
24VAC
SEC-2
SEC-1
GVR-2
BLWR
HI/LO
CPU
1
PL52
PR2
GVR
GVR-1
NOTES:
1. If an y of the original equipment wire is replaced use wire rated for 105°C.
2. Inducer (IDM) and blower (BLWM) motors contain internal auto-reset thermal overload s witches (OL).
3. Blower motor speed selections are for average conditions, see installation instructions for details on
optimum speed selection.
4. Use only copper wire betwe en the disconn e ct switch and the furnace junction box (JB).
5. This wire must be connec ted to furnace s he etm e tal for control to detect flame.
6. Replace only with a 3 am p fuse .
7. Yellow lead not on all motors.
8. Blower-on delay , gas heating 45 seconds, cooling or hea t pump 2 seconds.
9. Blower-off delay , gas he ating 90 , 135, 1 80 or 225 sec on ds , co oling or heat pu m p 90 se co nds .
(135 seconds only on some models)
10. Ignition-locko u t will occ u r a fte r f o u r c onsec u t ive unsucces s fu l t ria ls -f o r -ignition. Control will auto-reset
after thr e e hours .
11. When use d , a uxiliary limit switc h (ALS) is on so me do wnflow models only. When used , FL is o n
upflow models only.
12. Some mo de ls m ay have spade quick co nn e ct terminals.
13. Factory connected when LGPS is not used.
14. Factory connected when BVSS is not used. BVSS used when Chimney Adapter Accessory Kit is
installed.
15. Gas valve leads are intercha nge ab le on single stage valves.
SCHEMATIC DIAGRAM
(NAT URAL GAS & PROP ANE)
LO
MED LO
MED HI
HI
COM
1
3
2
3
2
8
5
6
9
PL3
NOTE #13
PL1
NOT USED
NOT USED
OL
HSI
NOT USED
FRS1
(WHEN USED)
NOTE #11
DSS
NOTE #15
NOTE #7
1
2
7
1
4
START
BLWM
IDM
FRS2
LS
LGPS
(WHEN USED)
(WHEN USED)
NOTE #14
BVSS
NOTE #14
(WHEN USED)
GV
NOTE #5
FSE
322869-101 REV. H
CAP
NOTE #13
PRS
ALS
L2
FL
Fig. 6—Unit Wiring Diagram
A00304
BLOWER OFF DELAY
ADJUSTMENT SWITCH
TEST/TWIN
3-AMP FUSE
115-VAC (L1)
POWER SUPPLY
HOT SURFACE
IGNITOR CONNECTOR
SEC-1
COOL
HEAT
G
R
Y
W
Com
24V
HUM
115-VAC (L2) NEUTRAL
CONNECTION
INDUCER MOTOR
CONNECTOR
24-V THERMOST AT
TERMINALS
HUMIDIFIER TERMINAL
(24-VAC 0.5 AMP MAX)
LED OPERATION &
DIAGNOSTIC LIGHT
HARNESS CONNECTOR
24-V TRANSFORMER SEC-2
SP ARE-1
BLOWER SPEED
SELECTION TERMINALS
SP ARE-2
EAC-1 (BLACK)
EAC-ELECTRONIC AIR CLEANER
TERMINALS (115-VAC 1 AMP MAX)
EAC-2 (WHITE)
Fig. 7—Furnace Control
A00292
through the sight glass or window on the blower access door. The
control indicates status with the LED on continuously, rapid
flashing, or a code composed of 2 digits. (The first digit is the
number of short flashes, the second is the number of longs flashes.)
For an explanation of status codes, refer to service label (See Fig.
8) located on blower access door or the Troubleshooting Guide.
The control stores 1 status code (the last status code to occur) for
a period of 48 hr or until the 115- or 24-v power is interrupted.
NOTE: Look into blower access door sight glass for current LED
status BEFORE removing the blower access door. Removing
blower access door will open blower access door switch and
terminate 115-v power to control, and status code will be erased.
1. To retrieve status code, proceed with the following:
NOTE: NO thermostat signal shall be present at control, and all
blower off delays must be completed.
a. Leave 115-v power to furnace turned on.
b. Look into blower access door sight glass for current LED
status.
NOTE: Leave blower access panel installed to maintain power to
control to view current LED status.
c. Remove control access door.
d. BRIEFLY remove either wire from the main limit switch
until LED goes out, then reconnect it.
NOTE: If wire to main limit is disconnected longer than 4 sec,
main blower starts, and retrieval request is ignored.
2. When above items have been completed, the following will
occur:
a. LED flashes a status code 4 times. Record this status code
for further troubleshooting.
b. Inducer motor starts and continues to run the entire
component test.
c. Hot surface ignitor is energized for 15 sec, then de-
energized.
d. Main blower operates at heating speed for 10 sec, then
turns off.
e. Main blower operates at cooling speed for 10 sec, then
turns off.
f. Inducer motor stops.
Items a through e above will assist in furnace troubleshooting since
all components are functionally operated except the gas valve. This
procedure is also referred to as ″Component Test.″
3. Operate furnace through 1 heat cycle to test for proper
operation and check LED status.
4. If furnace is operating properly and LED indicates proper
operation, replace control access door.
5. Component Test can also be initiated by performing the
following:
a. Remove control access door.
b. Remove blower access door.
c. Manually close blower access door switch.
7
SERVICE
If status code recall is needed, do not remove power or b lo w er door. Briefly remove and then
reconnect one main limit wire to display stored status code.
LED CODE
CONTINUOUS OFF - Check for 115VAC at L1 and L2, and 24VAC at SEC-1 and
CONTINUOUS ON - Control has 24VAC power.
RAPID FLASHING - Line voltage (115VAC) polarity reversed. If twinned, refer
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.
NO PREVIOUS CODE - Stored status codes are erased when power
11
(115VAC or 24VAC) to control is interrupted or 48 hours after each fault is cleared.
BLOWER ON AFTER POWER UP (115V AC or 24 VAC) - Blower runs for 90
12
seconds, if unit is powered up during a call for heat (R-W closed).
LIMIT OR FLAME ROLL-OUT SWITCH LOCKOUT - Control will auto reset after
13
three hours. Reset switch or replace fuse link. Refer to #33.
IGNITION LOCKOUT - Control will auto-reset after three hours. Refer to #34.
14
GAS HEA TING LOCKOUT - Control will NOT auto reset.
21
Check for: - Mis-wired gas valve -Defective control (Valve relay)
ABNORMAL FLAME-PROVING SIGNAL - Flame is pro ved while gas valve is
22
de-energized. Inducer will run until f ault is cleared.
Check for: - Leaky gas valve - Stuck-open gas valve
PRESSURE SWITCH DID NOT OPEN - Check f or:
23
- Obstructed pressure tubing. - Pressure switch stuck closed.
SECONDAR Y VOLTAGE FUSE IS OPEN
24
Check for: - Short circuit in secondary voltage (24VAC) wiring.
PRESSURE, DRAFT SAFEGU ARD, AUX-LIMIT SWITCH (when used*) OR BLOCKED
31
VENT SWITCH (when used) DID NOT CLOSE OR REOPENED
(DOWNFLOW ONLY*) If open longer than five minutes, inducer shuts off for 15
minutes before retry. Check for: - Proper vent sizing
- Low inducer voltage (115VAC) - Defective inducer motor
- Defective Blower motor or capacitor - Restricted vent
*
- Defective pressure s witch - Excessive wind
- Inadequate combustion air supply
- Disconnected or obstructed pressure tubing
If it opens after trial for ignition period, blower will come on for 90 second
recycle delay.
LIMIT OR FLAME ROLL-OUT SWITCH IS OPEN - If open longer than three
33
minutes, code changes to #13. Flame roll-out switch requires manual reset.
Check for: - Defective blower motor or capacitor .
- Dirty filter or restricted duct system.
- Loose blower wheel.
- Defective s witch or connections .
- Inadequate combustion air supply (Flame Roll-out Switch or fuse link open).
- Open Flame Roll-out Switch, or fuse link. Manual reset or replace .
IGNITION PROVING FAILURE - Control will try three more times before
34
lockout #14 occurs. If flame signal lost after trial for ignition period, blower
will come on for 90 second recycle 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).
- Gas valve defective or gas valve turned off.
- Defective Hot Surf ace Ignitor - Manual valve shut-off .
- Low inlet gas pressure. - Control ground continuity
- Green wire MUST be connected to furnace sheet metal.
- Inadequate flame carryover or rough ignition.
- Flame sensor must be ungrounded.
SEC-2.
to twinning kit instructions.
COMPONENT TEST
To initiate the component test sequence, shut OFF the room thermostat or
disconnect the "R" thermostat lead. Briefly short the TEST terminal to the "Com
24V" terminal. Status LED will flash code and then turn ON the inducer motor.
The inducer motor will run for the entire component test. The hot surface ignitor,
blower motor-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.
6
32
9
8
7
5
4
1
LED
TEST
HUM
STATUS
Com
W
24V
Y
320615-102 REV. K (LIT)
G
R
Fig. 8—Service Label
8
A99233
Blower access door switch opens 115-v power to control. 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 personal injury or death.
d. BRIEFLY short (jumper) TEST, 3/16 in. quick connect
terminal on control (adjacent to LED status light), and
C
OM-24V terminal on furnace control thermostat terminal
block. (See Fig. 7.)
NOTE: If TEST to C
OM-24V terminals are jumpered longer than
2 sec, LED will flash rapidly, and test request will be ignored.
e. Component Test will function as described in item 2 above.
f. Check LED status.
g. If LED status indicates proper operation, RELEASE
BLOWER ACCESS DOOR SWITCH, replace blower
access door, and replace control access door.
WIRING DIAGRAMS
Refer to Fig. 5, 6, and 7 for the 58YAV furnace wiring diagrams.
TROUBLESHOOTING
Refer to service label. (See Fig. 8.) The Troubleshooting Guide can
be a useful tool in isolating furnace operation problems. Beginning
with the word ″Start,″ answer each question and follow the
appropriate arrow to the next item.
The Guide will help you identify the problem or failed component.
After replacing any component, verify correct operation sequence.
9
Troubleshooting Guide
10
START
YES
Is red LED status light blinking
rapidly without a pause?
NO
Is red LED status light blinking
ON/OFF slowly with a
combination of short and long
flashes?
YES
Determine status code. The
status code is a 2 digit number
with the first digit determined by
the number of short flashes and
the second digit by the number of
long flashes.
Go to section with status code
determined.
NO
YES
NO
Is there 115v at L1 and L2?
YES
Is there 24v at SEC-1 and SEC-2?
YES
Check for correct line voltage
polarity. If units are twinned,
check for proper low-voltage
(24v) transformer phasing.
Check for previous fault by
momentarily shorting the TEST
terminal and the C terminal until
the LED goes out. LED will flash
the status code of any previous
fault or the code No. 11 (1 short
and 1 long flash) if no previous
fault. After the control repeats the
code 3 times, the control will go
through a brief component test
sequence. The inducer will start
and run for the entire component
test. The HSI, blower motor heat
speed, and blower motor cool
speed will run for 10-15 sec each.
Was there a previous fault code
other than No. 11?
YES
NO
NO
NO
YES
Is there 115v going to switch?
YES
Replace door switch.Replace control center.
Replace transformer.
Does control respond to W, Y,
or G 24-vac thermostat signals?
YES
Run system through a heating or
cooling cycle to check operation.
Status codes are erased after 48
hrs or whenever power (115v
or 24v) is interrupted.
NO
NO
NO
Close door switch and go to start.Is red LED status light on? Is door switch closed?
Is circuit breaker closed?
YES
Close circuit breaker and
go back to start.
Check for continuity in wire from circuit
breaker to furnace.
Check room thermostat or
interconnecting cable.
NO
Is 24 vac present at W, Y, or G
terminals on the control?
YES
Replace control if it does not
respond to 24-vac signal at W, Y,
or G screw terminals.
NO
A99123a
A99123b
Replace control center.
NO
YES
Unplug ignitor harness from control
center and inititate another
component test sequence. Check
for 115v between pins 1 and 2 on
the control center. Was 115v present
for the 17-sec period?
Check for continuity in the harness
and ignitor. Replace defective
component.
Check connections. If OK, replace
control center.
NO
Reconnect the R thermostat lead
and set thermostat to call for heat.
Connect voltmeter across gas valve
connections. Does gas valve
Check that all gas valves are turned
on. Replace valve.
NO
YES
receive 24v?
YES
Does gas valve open and allow gas
to flow?
NO
rough ignition.
• Low inlet gas pressure.
• Inadequate flame carryover on
Check for:
NO
YES
Do main burners ignite?
Repeat call for heat and check flame
sensor current during trial for ignition
NO
YES
Do main burners stay on?
Allow blower to come on and repeat
test to check for intermittent
Check connections and retry. If
current is near typical value and
control will not stay on, replace
control center.
YES
period. Is the DC microamps
below 0.5?
operation.
Replace electrode.
NO
Clean flame sensor with fine
sandpaper and recheck current.
Current is nominally 4.0 to 6.0 microamps.
Is current near typical value?
Replace control center.
NO
YES
YES
Will main burner ignite and stay on?
Fixed.
NOT CLOSE OR REOPEN - If
open longer than 5 minutes,
31 PRESSURE SWITCH WILL
11 NO PREVIOUS FAULT - Faults
sag.
inducer shuts off for 15 minutes
before retry.
Check for:
• Proper vent sizing or pitch or
are erased after 48 hrs or
whenever power (115v or 24v) is
interrupted. Run system through
a heating or cooling cycle to
check system.
connections. If it opens after
trial for ignition period, blower
will come on for 90 sec
• Vent restrictions or high winds.
• Defective inducer motor.
• Low line voltage (115v).
• Motor start capacitor.
• Low inlet gas pressure.
• Defective pressure switch or
UP (115V OR 24V) - Normal
operation. Blower will run for 90
sec when furnace power is
12 BLOWER ON AFTER POWER
recycle delay.
interrupted during a call for heat,
R-W closed.
13 LIMIT OR FLAME ROLLOUT
• Inadequate combustion air.
SWITCH IS OPEN - If
limit switch is open longer than 3
minutes, code changes to No. 13.
Check for:
• Blower motor failure.
33 LIMIT OR FLAME ROLLOUT
SWITCH LOCKOUT -
Limit switch was open longer
than 3 minutes. Auto-reset will
occur after 3 hrs. Flame rollout
switch requires manual reset.
See No. 33
failed to ignite gas and prove
14 IGNITION LOCKOUT - System
manual reset.
Inadequate combustion air
supply (flame rollout switch
• Motor start capacitor.
• Open flame rollout switch,
•
flame in 4 attempts. Control will
auto-reset in 3 hrs.
See No. 34
connections.
only).
• Dirty filter.
• Defective limit switch or
• Loose blower wheel.
• Stuck closed gas valve relay
Turn off power and wait 5
minutes to retry.
Check for:
21 GAS HEATING LOCKOUT -
If flame is not sensed during the
trial for ignition period, the control
will repeat the ignition sequence
3 more times before going into
lockout, No. 14.
If flame signal is lost after trial for
34 IGNITION PROVING FAILURE -
wire.
on control.
• Miswire or short to gas valve
SIGNAL - Flame was sensed
while gas valve was
de-energized. Inducer will run
22 ABNORMAL FLAME PROVING
NO
ignition period, blower will come
on for 90-sec recycle delay.
Check for the following items first
until fault is cleared.
Check for:
• Stuck open gas valve solenoid
to furnace sheet metal.
before proceding to the next step.
• Gas valve turned off.
• Manual shut-off valve.
• Green wire must be connected
To determine whether the
problem is in the gas valve,
ignitor, or flame sensor, the
or leak.
• Defective control center.
pressure tubing.
NOT OPEN - Check for:
• Disconnected or obstructed
23 PRESSURE SWITCH WILL
system can be operated in the
component test mode to check
the ignitor. First, remove the
R thermostat connection from the
control center and initiate the
component test sequence. Does
the ignitor glow orange/white hot
by the end of the 17-sec warm-up
period?
including thermostat leads
shorting to ductwork or
furnace cabinet. Disconnect
• Defective pressure switch.
OPEN - Check for:
24 LOW-VOLTAGE FUSE IS
thermostat leads to isolate
• Short in low-voltage wiring
YES
short circuit.
11
Copyright 2000 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231 58yav3sm
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. 535-771 Printed in U.S.A. Form 58YAV–3SM Pg 12 10-00 Replaces: 58YAV–2SM
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