Carrier Furnace 58YAV User Manual

58YAV  
Induced-Combustion Furnaces  
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  
EFFICIENCY  
RATING  
CERTIFIED  
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  
CERTIFIED  
R
E
M
®
I
E
REGISTERED QUALITY SYSTEM  
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.  
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. A FAILURE  
TO FOLLOW THIS WARNING COULD RESULT IN  
POSSIBLE DAMAGE TO THIS EQUIPMENT, SERIOUS  
PERSONAL INJURY, OR DEATH.  
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-B149.1-  
and .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.  
Label all wires prior to disconnection when servicing con-  
trols. Wiring errors can cause improper and dangerous  
operation.  
INTRODUCTION  
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.  
These procedures are written for size 66,000 through 154,000 Btuh  
input units of the 58YAV Gas-Fired Induced Combustion Furnace.  
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.  
Book  
Tab 6a 8a  
1
4
PC 101  
Catalog No. 535-771  
Printed in U.S.A.  
Form 58YAV–3SM  
Pg 1  
10-00  
Replaces: 58YAV–2SM  
 
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.  
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.  
e. If equipped with factory-specified disposable media filter,  
replace only with media filter having the same part number  
and size.  
d. Remove screws securing cutoff plate and remove cutoff  
plate from housing.  
f. Slide filter into cabinet.  
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. Motor mount belly band need not be  
removed unless motor is to be replaced.  
g. Replace filter cabinet door.  
h. Turn on electrical supply to furnace.  
2. Filters installed in side(s) and/or bottom of blower compart-  
ment (See Fig. 2)  
f. Remove blower wheel from housing.  
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.  
The blower wheel should not be dropped or bend as balance  
will be affected.  
d. Slide filter(s) out.  
9. Reassemble motor and blower by reversing items 9a through  
9f. Be sure to reattach ground wire.  
e. Furnaces are equipped with permanent, washable filters.  
Clean filters with tap water. Spray water through filter in  
opposite direction of airflow.  
10. Reinstall blower assembly in furnace.  
11. Reinstall control and transformer support assembly in furnace.  
f. Rinse and let dry. Oiling or coating of filter is NOT  
recommended or required.  
12. Reconnect blower leads to furnace control.  
Refer to furnace wiring diagram (See Fig. 6), and connect  
thermostat leads if previously disconnected.  
g. Reinstall filter(s)  
h. Replace blower and control access doors  
i. Restore electrical power to furnace.  
Step 2—Blower Motor and Wheel  
NOTE: Refer to Table 1 for motor speed lead relocation if leads  
were not identified before disconnection  
The following items should be performed by a qualified service  
technician:  
TABLE 1—SPEED SELECTOR  
FACTORY-  
To ensure long life, economy, and high efficiency, clean accumu-  
lated dirt and grease from blower wheel and motor annually.  
COLOR  
Black  
SPEED  
ATTACHED  
TO  
High  
Cool  
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.  
Yellow (When  
Present)  
Medium High  
Spare  
Blue  
Red  
Medium Low  
Low  
Heat  
Spare  
Clean blower motor and wheel as follows:  
1. Turn off electrical supply to furnace.  
2. Remove control and blower access doors.  
White  
Common  
L2/COM  
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 depend-  
ing on their length and routing.  
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.  
4. Remove 2 screws securing control and transformer support to  
furnace.  
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.  
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.  
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.  
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.  
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.  
b. Loosen setscrew holding blower wheel on motor shaft.  
3
 
14. If furnace is operating properly, REMOVE TAPE TO RE-  
LEASE BLOWER ACCESS DOOR SWITCH, replace  
blower access door.  
11  
13  
32"  
32"  
BURNER  
Step 3—Cleaning Heat Exchanger  
The following steps should be performed by a qualified service  
technician:  
CELL  
PANEL  
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:  
HOT  
SURFACE  
IGNITOR  
ASSEMBLY  
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.)  
C
IGNITOR  
BURNER  
L
7
8"  
C
L
5. Disconnect wires to the following components. Mark wires to  
aid in reconnection of:  
a. Blocked vent safeguard switch.  
b. Inducer motor.  
IGNITOR  
ASSEMBLY  
c. Pressure switch.  
A93347  
d. Limit overtemperature switch(es).  
e. Gas valve.  
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.)  
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 Roto-  
Rootert cable).  
A91252  
Fig. 4–Cleaning Heat Exchanger Cell  
(2.) Use 1/4-in. diameter wire brush (commonly known as  
25-caliber rifle cleaning brush).  
(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.  
NOTE: The materials needed in items (1.) and (2.) can usually be  
purchased at local hardware stores.  
(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.  
(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 IMPOR-  
TANT.  
(5.) Repeat foregoing procedures until each cell in furnace  
has been cleaned.  
(4.) Remove metal screw fitting from wire brush to allow  
insertion into cable.  
(6.) Using vacuum cleaner, remove residue from each cell.  
(7.) Using vacuum cleaner with soft brush attachment,  
clean burner assembly.  
b. Clean each heat exchanger cell.  
(1.) Attach variable-speed, reversible drill to end of spring  
cable (end opposite brush).  
(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.  
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.  
NOTE: A releasing agent such as PAM cooking spray or equiva-  
lent (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.  
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.  
12. Reinstall relief box and inducer assembly.  
NOTE: If inducer assembly gasket is damaged, use RTV sealant  
to seal inducer assembly to collector box.  
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.  
13. Reconnect wires to the following components:  
a. Blocked vent safeguard switch.  
b. Inducer motor.  
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.  
c. Pressure switch.  
d. Limit overtemperature switch(es).  
e. Gas valve.  
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.  
f. Hot surface ignitor.  
g. Flame-sensing electrode  
h. Flame rollout switch(es), if applicable.  
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.  
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.  
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.  
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.  
The control in this furnace is equipped with an LED status light to  
aid in installation, servicing, and troubleshooting. It can be viewed  
18. Check for gas leaks.  
FIELD 24-V WIRING  
FIELD 115-, 208/230-, 460-V WIRING  
FACTORY 24-V WIRING  
FACTORY 115-V WIRING  
NOTE 2  
THERMOSTAT  
TERMINALS  
W
C
R
G
Y
FIVE WIRE  
FIELD-SUPPLIED  
DISCONNECT  
THREE-WIRE  
HEATING-ONLY  
208/230- OR  
460-V  
BLOWER DOOR SWITCH  
THREE  
PHASE  
W
R
BLK  
BLK  
WHT  
C
O
N
T
R
O
L
WHT  
208/230-V  
SINGLE  
PHASE  
GND  
GND  
G
AUXILIARY  
J-BOX  
115-V FIELD-  
SUPPLIED  
DISCONNECT  
C
Y
GND  
NOTE 1  
CONDENSING  
UNIT  
TWO  
WIRE  
24-V  
TERMINAL  
BLOCK  
NOTES: 1. Connect Y-terminal in furnace as shown for proper blower operation.  
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.  
FURNACE  
A98521  
Fig. 5–Heating and Cooling Application Wiring Diagram  
5
 
(WHEN USED)  
NOTE #14  
BVSS  
SCHEMATIC DIAGRAM  
(WHEN USED)  
NOTE #11  
ALS  
TO 115VAC FIELD DISCONNECT  
L2  
SW2  
SW1  
G
R
Y
W
COM  
(WHEN USED)  
LGPS  
BLOWER  
OFF  
(NATURAL GAS & PROPANE)  
L1  
PRS  
DSS  
PCB  
NOTE #9  
NOTE #4  
EQUIPMENT GROUND  
DELAY  
ORN  
ORN  
ORN  
ORN  
ORN  
(NOT ON ALL MODELS)  
L2  
ILK  
LO  
MED LO  
MED HI  
BLOWER OFF DELAY  
SELECTION CHART  
SPARE-2  
HEAT  
YEL  
HUM  
NOTE #13  
NOTE #14  
HI  
TEST/TWIN  
90 SEC  
135 SEC  
180 SEC  
225 SEC  
START  
SPARE-1  
HI/LO  
OL  
L1  
NOTE #7  
LED  
BLWR  
HSIR  
COOL  
BLU  
LS  
CAP  
NOTE #15  
GV  
COM  
COM  
RED  
BLWM  
EAC-1  
EAC-2  
PL1  
3
2
1
(WHEN USED) NOTE #11  
WHT  
RED  
FL  
4
7
6
9
5
8
FSE  
1
2
1
HSI  
GVR  
FRS2  
GRN/YEL  
BLK  
FRS1  
GRN/YEL  
2
PL5  
PL2  
IDM  
NOTE #5  
SEC-1  
SEC-2  
IDR  
HI/LO  
RELAY  
BLU  
RED  
1
PR2  
PR1  
115VAC  
24VAC  
WHT  
3
2
PL3  
24 VAC-3A  
FUSE  
TRAN  
WHT (COM)  
FU1  
BLOWER  
GRN/YEL  
BLK (HI)  
NOT USED  
FRS1  
BRN  
HSIR IDR BLWR  
COOL  
SPEED  
SELECT  
SPARE-1  
TEST/TWIN  
FU1  
NOTE #6  
OL  
YEL (MED HI)  
NOTE #7  
SEC-2  
FRS2  
LS  
SEC-1  
GVR-2  
START  
BLWM  
CAP  
L2  
NOTE #12  
HEAT SPARE-2  
EAC-1  
7
PL3  
HUM  
PL2  
(WHEN USED)  
NOTE #11  
1
2
3
PR2  
COM  
BLU (MED LO)  
RED (LO)  
VAC  
PR1  
FL  
120  
L1  
BRN  
1
2
1
R
EAC-2  
NOTE #13  
PRS  
LGPS  
NOTE #13  
PL1  
WHT (COM)  
W
(WHEN USED)  
WHT  
4
BLK  
(WHEN USED)  
NOTE #14  
BVSS  
HSIR  
IDR  
BLWR  
CPU  
HI/LO  
FUSED DISCONNECT  
GVR  
PL5  
DSS  
SWITCH (WHEN REQ’D)  
WHT  
BLK  
ILK  
JB  
NOTE #4  
1
2
IDM  
L1  
3
BLK  
FU2  
ALS  
(WHEN USED)  
NOTE #14  
NOTE #15  
GRN/YEL  
HSI  
WHT  
GND  
NEUTRAL  
GVR-1  
2
GV  
Y
LEGEND  
8
NOTE #5  
ALS  
AUXILIARY LIMIT SWITCH, OVERTEMP. -MANUAL RESET, SPST-(N.C.)  
G
PCB  
PRINTED CIRCUIT BOARD  
BLWR BLOWER MOTOR RELAY, SPST-(N.O.)  
BLWM BLOWER MOTOR  
BVSS BLOCKED VENT SHUTOFF SWITCH, SPST - (N.C.)  
PL1  
PL2  
PL3  
PL5  
PRS  
9-CIRCUIT CONNECTOR  
5
6
FSE  
2-CIRCUIT PCB CONNECTOR  
3-CIRCUIT IDMCONNECTOR  
2-CIRCUIT HSI/PCB CONNECTOR  
PRESSURE SWITCH, SPST-(N.O.)  
CAP  
CPU  
DSS  
CAPACITOR  
MICROPROCESSOR AND CIRCUITRY  
DRAFT SAFEGUARD SWITCH  
NOT USED  
NOT USED  
COM  
9
EAC-1 ELECTRONIC AIR CLEANER CONNECTION (115 VAC 1.5 AMP MAX.)  
EAC-2 ELECTRONIC AIR CLEANER CONNECTION (COMMON)  
NOTES:  
TEST/TWIN COMPONENT TEST & TWIN TERMINAL  
1. If any of the original equipment wire is replaced use wire rated for 105°C.  
FL  
FUSIBLE LINK  
TRAN  
TRANSFORMER-115VAC/24VAC  
2. Inducer (IDM) and blower (BLWM) motors contain internal auto-reset thermal overload switches (OL).  
3. Blower motor speed selections are for average conditions, see installation instructions for details on  
optimum speed selection.  
FRS  
FSE  
FU1  
FU2  
FLAME ROLLOUT SW. -MANUAL RESET, SPST-(N.C.)  
FLAME PROVING ELECTRODE  
FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE, FACTORY INSTALLED  
FUSE OR CIRCUIT BREAKER CURRENT INTERRUPT DEVICE  
(FIELD INSTALLED & SUPPLIED)  
JUNCTION  
UNMARKED TERMINAL  
PCB TERMINAL  
4. Use only copper wire between the disconnect switch and the furnace junction box (JB).  
5. This wire must be connected to furnace sheetmetal for control to detect flame.  
6. Replace only with a 3 amp fuse.  
GV  
GVR  
GAS VALVE-REDUNDANT OPERATORS  
GAS VALVE RELAY, DPST-(N.O.)  
FACTORY WIRING (115VAC)  
FACTORY WIRING (24VAC)  
FIELD WIRING (115VAC)  
FIELD WIRING (24VAC)  
CONDUCTOR ON PCB  
FIELD WIRING TERMINAL  
FIELD GROUND  
7. Yellow lead not on all motors.  
8. Blower-on delay, gas heating 45 seconds, cooling or heat pump 2 seconds.  
9. Blower-off delay, gas heating 90, 135, 180 or 225 seconds, cooling or heat pump 90 seconds.  
(135 seconds only on some models)  
HI/LO BLOWER MOTOR SPEED CHANGE RELAY, SPDT  
HSI HOT SURFACE IGNITOR (115 VAC)  
HSIR HOT SURFACE IGNITOR RELAY, SPST-(N.O.)  
10. Ignition-lockout will occur after four consecutive unsuccessful trials-for-ignition. Control will auto-reset  
after three hours.  
HUM 24VAC HUMIDIFIER CONNECTION (.5 AMP. MAX.)  
IDM  
IDR  
ILK  
JB  
INDUCED DRAFT MOTOR  
11. When used, auxiliary limit switch (ALS) is on some downflow models only. When used, FL is on  
upflow models only.  
INDUCED DRAFT RELAY, SPST-(N.O.)  
BLOWER ACCESS PANEL INTERLOCK SWITCH, SPST-(N.O.)  
JUNCTION BOX  
12. Some models may have spade quick connect terminals.  
13. Factory connected when LGPS is not used.  
EQUIPMENT GROUND  
FIELD SPLICE  
LED  
LIGHT-EMITTING DIODE FOR STATUS CODES  
14. Factory connected when BVSS is not used. BVSS used when Chimney Adapter Accessory Kit is  
installed.  
LGPS LOW GAS PRESSURE SWITCH, SPST-(N.O.)  
LS  
OL  
LIMIT SWITCH, AUTO RESET, SPST(N.C.)  
AUTO-RESET INTERNAL MOTOR OVERLOAD TEMP. SW.  
PLUG RECEPTACLE  
15. Gas valve leads are interchangeable on single stage valves.  
322869-101 REV. H  
A00304  
Fig. 6—Unit Wiring Diagram  
 
BLOWER OFF DELAY  
ADJUSTMENT SWITCH  
24-V THERMOSTAT  
TERMINALS  
G
R
Y
W
Com  
24V  
TEST/TWIN  
HUMIDIFIER TERMINAL  
(24-VAC 0.5 AMP MAX)  
HUM  
LED OPERATION &  
DIAGNOSTIC LIGHT  
HARNESS CONNECTOR  
SEC-1  
24-V TRANSFORMER SEC-2  
SPARE-1  
3-AMP FUSE  
COOL  
HEAT  
BLOWER SPEED  
SELECTION TERMINALS  
SPARE-2  
EAC-1 (BLACK)  
EAC-ELECTRONIC AIR CLEANER  
TERMINALS (115-VAC 1 AMP MAX)  
115-VAC (L1)  
POWER SUPPLY  
EAC-2 (WHITE)  
115-VAC (L2) NEUTRAL  
CONNECTION  
HOT SURFACE  
IGNITOR CONNECTOR  
INDUCER MOTOR  
CONNECTOR  
A00292  
Fig. 7—Furnace Control  
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.)  
b. Inducer motor starts and continues to run the entire  
component test.  
c. Hot surface ignitor is energized for 15 sec, then de-  
energized.  
For an explanation of status codes, refer to service label (See Fig.  
8) located on blower access door or the Troubleshooting Guide.  
d. Main blower operates at heating speed for 10 sec, then  
turns off.  
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.  
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.  
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.  
4. If furnace is operating properly and LED indicates proper  
operation, replace control access door.  
a. Leave 115-v power to furnace turned on.  
b. Look into blower access door sight glass for current LED  
status.  
5. Component Test can also be initiated by performing the  
following:  
NOTE: Leave blower access panel installed to maintain power to  
control to view current LED status.  
a. Remove control access door.  
b. Remove blower access door.  
c. Remove control access door.  
c. Manually close blower access door switch.  
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.  
7
 
SERVICE  
If status code recall is needed, do not remove power or blower door. Briefly remove and then  
reconnect one main limit wire to display stored status code.  
LED CODE  
STATUS  
CONTINUOUS OFF - Check for 115VAC at L1 and L2, and 24VAC at SEC-1 and  
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.  
NO PREVIOUS CODE - Stored status codes are erased when power  
(115VAC or 24VAC) to control is interrupted or 48 hours after each fault is cleared.  
BLOWER ON AFTER POWER UP (115VAC or 24 VAC) - Blower runs for 90  
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  
three hours. Reset switch or replace fuse link. Refer to #33.  
11  
12  
13  
IGNITION LOCKOUT - Control will auto-reset after three hours. Refer to #34.  
GAS HEATING LOCKOUT - Control will NOT auto reset.  
14  
21  
Check for: - Mis-wired gas valve  
-Defective control (Valve relay)  
ABNORMAL FLAME-PROVING SIGNAL - Flame is proved while gas valve is  
22  
de-energized. Inducer will run until fault is cleared.  
Check for: - Leaky gas valve  
- Stuck-open gas valve  
PRESSURE SWITCH DID NOT OPEN - Check for:  
23  
24  
31  
- Obstructed pressure tubing.  
- Pressure switch stuck closed.  
SECONDARY VOLTAGE FUSE IS OPEN  
Check for:  
- Short circuit in secondary voltage (24VAC) wiring.  
PRESSURE, DRAFT SAFEGUARD, AUX-LIMIT SWITCH (when used*) OR BLOCKED  
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  
- Defective inducer motor  
- Restricted vent  
- Low inducer voltage (115VAC)  
*
- Defective Blower motor or capacitor  
- Defective pressure switch  
- 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  
minutes, code changes to #13. Flame roll-out switch requires manual reset.  
33  
34  
Check for:  
- Defective blower motor or capacitor.  
- Dirty filter or restricted duct system.  
- Loose blower wheel.  
- Defective switch 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  
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 Surface Ignitor  
- Low inlet gas pressure.  
- Manual valve shut-off.  
- Control ground continuity  
- Green wire MUST be connected to furnace sheet metal.  
- Inadequate flame carryover or rough ignition.  
- Flame sensor must be ungrounded.  
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.  
G
Com  
24V  
Y
W
R
HUM  
320615-102 REV. K (LIT)  
A99233  
Fig. 8—Service Label  
8
 
g. If LED status indicates proper operation, RELEASE  
BLOWER ACCESS DOOR SWITCH, replace blower  
access door, and replace control access door.  
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.  
WIRING DIAGRAMS  
Refer to Fig. 5, 6, and 7 for the 58YAV furnace wiring diagrams.  
d. BRIEFLY short (jumper) TEST, 3/16 in. quick connect  
terminal on control (adjacent to LED status light), and  
COM-24V terminal on furnace control thermostat terminal  
block. (See Fig. 7.)  
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.  
NOTE: If TEST to COM-24V terminals are jumpered longer than  
2 sec, LED will flash rapidly, and test request will be ignored.  
The Guide will help you identify the problem or failed component.  
After replacing any component, verify correct operation sequence.  
e. Component Test will function as described in item 2 above.  
f. Check LED status.  
9
 
Troubleshooting Guide  
START  
NO  
NO  
NO  
NO  
Is red LED status light on?  
Is there 115v at L1 and L2?  
Is door switch closed?  
Close door switch and go to start.  
YES  
YES  
YES  
NO  
NO  
Is there 24v at SEC-1 and SEC-2?  
Is there 115v going to switch?  
Is circuit breaker closed?  
YES  
YES  
YES  
Replace control center.  
Replace door switch.  
Close circuit breaker and  
go back to start.  
Replace transformer.  
Check for continuity in wire from circuit  
breaker to furnace.  
Is red LED status light blinking  
rapidly without a pause?  
Check for correct line voltage  
polarity. If units are twinned,  
check for proper low-voltage  
(24v) transformer phasing.  
YES  
NO  
NO  
Is red LED status light blinking  
ON/OFF slowly with a  
combination of short and long  
flashes?  
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.  
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.  
Check room thermostat or  
interconnecting cable.  
NO  
Does control respond to W, Y,  
or G 24-vac thermostat signals?  
Is 24 vac present at W, Y, or G  
terminals on the control?  
Was there a previous fault code  
other than No. 11?  
NO  
NO  
YES  
YES  
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.  
Replace control if it does not  
respond to 24-vac signal at W, Y,  
or G screw terminals.  
Go to section with status code  
determined.  
A99123a  
 
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  
Tab 6a 8a  
1
4
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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