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
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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
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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
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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
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(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
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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
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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
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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
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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
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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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