58PAV, 58RAV
Induced-Combustion Furnaces
Service and Maintenance Instructions
For Sizes 045-155, Series 131
NOTE: Read the entire instruction manual before performing any
service or maintenance.
This symbol → indicates a change since the last issue.
Index
Page
SAFETY CONSIDERATIONS..................................................1-2
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURES.........................................................................2
CARE AND MAINTENANCE................................................2-11
Air Filter Arrangement..........................................................2-3
Blower Motor and Wheel......................................................3-4
Cleaning Heat Exchanger......................................................4-5
Electrical Controls and Wiring.................................................6
Troubleshooting...................................................................6-11
Unit Wiring Diagram................................................................8
Service Label ............................................................................9
Troubleshooting Guide......................................................10-11
A94087
Fig. 1—Model 58RAV Horizontal
®
SAFETY CONSIDERATIONS
Installing and servicing heating equipment can be hazardous due to
gas and electrical components. Only trained and qualified person-
nel should install, repair, or service heating equipment.
Untrained personnel can perform basic maintenance functions
such as cleaning and replacing air filters. All other operations must
be performed by trained service personnel. When working on
heating equipment, observe precautions in the literature, on tags,
and on labels attached to or shipped with the unit and other safety
precautions that may apply.
ama
CANADIAN GAS ASSOCIATION
Follow all safety codes. In the United States, follow all safety
codes including the National Fuel Gas Code (NFGC) NFPA No.
54-1992/ANSI Z223.1-1992. In Canada, refer to the current
edition of the National Standard of Canada CAN/CGA-B149.1-
and .2-M91 Natural Gas and Propane Installation Codes (NSC-
NGPIC). Wear safety glasses and work gloves. Have fire extin-
guisher available during start-up and adjustment procedures and
service calls.
A PPROVED
R
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.
.
A94086
Fig. 2—Model 58RAV
Downflow
Understand the signal words DANGER, WARNING, and CAU-
TION. These words are used with the safety-alert symbol. DAN-
GER identifies the most serious hazards which will result in severe
personal injury or death. WARNING signifies a hazard 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.
A94085
Fig. 3—Model 58PAV
Upflow
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. 535-835
Printed in U.S.A.
Form 58P,R-9SM
Pg 1
9-94
Replaces: 58P,R-8SM
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d. Furnaces are equipped with permanent, washable filters.
Clean filters with tap water. Spray water through filter in
opposite direction of airflow.
e. Rinse and let dry. Oiling or coating of filters is not
recommended or required.
f. Reinstall filters.
g. Replace blower access door.
h. Restore electrical power to furnace.
AIRFLOW
2. Upflow
Each furnace requires 1 or 2 filters which are installed in the
blower compartment. (See Fig. 6.) To remove filters for
cleaning or replacement, proceed as follows:
A94307
a. Disconnect electrical power before removing access doors.
b. Remove blower and control access doors.
Fig. 4—Horizontal Filter Arrangement
c. Release filter retainer from clip at front of furnace casing.
(See Fig. 6.) For side return, clips may be used on either or
both sides of the furnace.
AIRFLOW
INSTALLATION
POSITION
d. Slide filter(s) out.
OF FILTERS
e. Furnaces are equipped with permanent, washable filters.
Clean filters with tap water. Spray water through filter in
opposite direction of airflow.
RETURN-AIR
PLENUM
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.
BLOWER MOTOR AND WHEEL
For long life, economy, and high efficiency, clean accumulated dirt
and grease from the blower wheel and motor annually.
The following steps should be performed by a qualified service
technician.
Some motors have prelubricated sealed bearings and require no
lubrication. These motors can be identified by the absence of oil
ports on each end of the motor. For those motors with oil ports,
lubricate motor every 5 years if motor is used on intermittent
operation (thermostat FAN switch in AUTO position), or every 2
years if motor is in continuous operation (thermostat FAN switch
in ON position).
ACCESS DOOR
NOTE: Remember to disconnect the electrical supply before
removing access doors.
A88486
Clean and lubricate as follows:
Fig. 5—Downflow Filter Arrangement
1. Remove
2
screws
from
blower
access
door
(downflow/horizontal furnace only) and remove blower access
door.
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.
2. Remove vent pipe enclosure (downflow/horizontal furnace
only) and disconnect short piece of vent pipe from relief box.
3. Disconnect wires from auxiliary limit on blower housing
(downflow/horizontal furnace only).
1. Downflow/Horizontal
4. Remove control.
Each furnace requires 2 filters which are installed in the
return-air duct. (See Fig. 4 and 5.) To remove filters for
cleaning or replacement, proceed as follows:
5. Disconnect electrical leads from control. (See Fig. 6 or 7.)
Note location of wires for reassembly.
a. Disconnect electrical power before removing blower access
door.
6. Remove screws holding blower assembly to blower deck and
slide blower assembly out of furnace.
b. Remove 2 screws from front of door and remove blower
access door.
7. Loosen screw in strap holding motor capacitor to blower
housing and slide capacitor out from under strap.
c. Reach up behind top plate, tilt filters toward center of
return-air plenum, remove filters, and clean as needed.
Replace if torn.
8. Mark blower wheel, motor, and motor support in relation to
blower housing before disassembly to ensure proper reassem-
bly.
3
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VENT PIPE
DRAFT
ENCLOSURE
MOUNTING
SCREWS
SAFEGUARD
SWITCH
AUXILIARY
LIMIT
SWITCH
RELIEF
BOX
(WHEN USED)
FLUE
COLLECTOR
BOX
CONTROL
BOARD
MOUNTING
SCREWS
CONTROL
BOARD
DRAFT
SAFEGUARD
SWITCH
MANUAL
RESET LIMIT
SWITCH
RELIEF
BOX
FILTER
RETAINER
MANUAL
RESET LIMIT
SWITCHES
WASHABLE
FILTER
A92063
A92064
Fig. 6—Model 58PAV Upflow
9. Loosen setscrew holding blower wheel on motor shaft.
Fig. 7—Model 58RAV Downflow
18. Reconnect wires to auxiliary limit switch on blower housing
(downflow/horizontal furnace only).
10. Remove bolts holding motor mount to blower housing and
slide motor and mount out of housing. Disconnect ground wire
attached to blower housing before removing motor.
19. Reinstall vent pipe and enclosure (downflow/horizontal fur-
nace only).
11. Lubricate motor (when oil ports are provided).
20. Turn on electrical power and check for proper rotation and
speed changes between heating and cooling.
a. Remove dust caps or plugs from oil ports located at each
end of motor.
21. Replace blower access door. Secure with
(downflow/horizontal furnace only).
2
screws
b. Use a good grade of SAE 20 nondetergent motor oil and
put 1 teaspoon, 5 cc, 3/16 oz, or 16 to 25 drops in each oil
port. Do not over-oil.
CLEANING HEAT EXCHANGER
The following steps should be performed by a qualified service
technician.
c. Allow time for total quantity of oil to be absorbed by each
bearing.
NOTE: Deposits of soot and carbon indicate the existence of a
problem which needs to be corrected. Take action to correct the
problem.
d. Wipe excess oil from motor housing.
e. Replace dust caps or plugs on oil ports.
12. Remove blower wheel from housing.
a. Mark cutoff location to ensure proper reassembly.
If it becomes necessary to clean the heat exchanger because of
carbon deposits, soot, etc., proceed as follows:
b. Remove screws holding cutoff plate and remove cutoff
plate from housing.
1. Turn off gas and electrical power to furnace.
2. Remove
2
screws from front of blower access door
c. Lift blower wheel from housing through opening.
(downflow/horizontal furnace only) and remove control and
blower access doors.
13. Clean blower wheel and motor using a vacuum cleaner 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.
3. Remove vent pipe enclosure (downflow/horizontal furnace
only) and disconnect vent pipe from relief box.
4. Remove 2 screws that secure relief box. (See Fig. 6 or 7.)
5. Disconnect wires to the following components.
a. Draft safeguard switch
14. Reinstall blower wheel by reversing items 12 a through c. Be
sure wheel is positioned for proper rotation.
15. Reassemble motor and blower by reversing items 5 through
10. If motor has ground wire, be sure it is connected as before.
b. Inducer motor
c. Pressure switch
d. Limit overtemperature switch(es)
e. Gas valve
Be sure the motor is properly positioned in the blower
housing. The motor oil ports must be at a minimum of 45°
above the horizontal centerline of the motor after the blower
assembly has been reinstalled in the furnace.
f. Hot surface ignitor
g. Flame-sensing electrode
h. Two wiring connectors leading to control
16. Reinstall blower assembly in furnace.
6. Remove 8 screws that secure flue collector box to center
panel. Be careful not to damage sealant.
17. Reinstall control. Connect blower electrical leads to control.
Please note that the common wire connection is 3/16 in. and
all other wire connections are 1/4 in. for assembly. DO NOT
FORCE.
7. Remove complete inducer assembly from furnace, exposing
flue openings.
4
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11
8. Clean cells using field-provided small wire brush, steel spring
cable, reversible electric drill, and vacuum cleaner.
13
32"
32"
BURNER
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-
Rooter cable).
CELL
PANEL
(2.) Use 1/4-in. diameter wire brush (commonly known as
25-caliber rifle cleaning brush).
HOT
SURFACE
IGNITOR
ASSEMBLY
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 steel 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.
C
IGNITOR
BURNER
L
(1.) Attach variable-speed, reversible drill to end of steel
spring cable (end opposite brush).
7
8"
C
L
(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. 8.)
IGNITOR
ASSEMBLY
A93347
Fig. 9—Position of Ignitor to Burner
9. After cleaning flue openings, check sealant on flue collector to
ensure that it has not been damaged. If new sealant is needed,
contact your dealer or distributor.
10. Clean and replace flue collector assembly, making sure all 8
screws are secure.
11. Reinstall relief box.
12. Reconnect wires to the following components.
a. Draft safeguard switch
b. Inducer motor
A91252
c. Pressure switch
Fig. 8—Cleaning Heat Exchanger Cell
d. Limit overtemperature switch(es)
e. Gas valve
(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.
f. Hot surface ignitor
g. Flame-sensing electrode
h. Two wiring connectors leading to control
(4.) Remove burner assembly and cell inlet plates.
13. Reconnect vent pipe to relief box. Replace vent pipe enclosure
(downflow/horizontal furnace only).
Be very careful when removing the burner assembly to avoid
breaking the ignitor. See Fig. 9 for the correct ignitor location.
14. Replace blower access door only.
15. Turn on electrical power and gas.
(5.) Replace screws in center panel and cells before
cleaning.
16. Set thermostat and check furnace for proper operation.
(6.) 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.
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.
(7.) Repeat foregoing procedures until each cell in furnace
has been cleaned.
(8.) Remove residue from each cell using vacuum cleaner.
17. Check for gas leaks.
(9.) Clean burner assembly using vacuum cleaner with soft
brush attachment.
18. Replace control access door on upflow furnace.
(10.) Reinstall cell inlet plates and burner assembly. Care
must be exercised to center the burners in the cell
openings.
19. On downflow/horizontal furnaces, remove blower access
door, replace control access door first, then replace blower
access door and secure with 2 screws in front of door.
5
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→ ELECTRICAL CONTROLS AND WIRING
a. LED flashes a fault code 4 times. Record this fault code for
further troubleshooting.
b. Inducer motor operates for 10 sec, then turns off.
There may be more than 1 electrical supply to the unit. Check
accessories and cooling unit for additional electrical supplies.
c. Hot surface ignitor is energized for 15 sec, then de-
energized.
d. Main blower operates at cooling speed for 10 sec, then
turns off.
The electrical ground and polarity for 115-v wiring must be
maintained properly. Refer to Fig. 10 for field wiring information
and to Fig. 12 for unit wiring information.
e. Main blower operates at heating speed for 10 sec, then
turns off.
NOTE: If the polarity is not correct, the STATUS LED on the
control center will flash rapidly and prevent the furnace from
operating. The control system also requires an earth ground for
proper operation of the control board and flame-sensing electrode.
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."
The 24-v circuit contains an automotive-type, 3-amp fuse located
on the control board. (See Fig. 11.) Any direct shorts of the 24-v
wiring during installation, service, or maintenance will cause this
fuse to blow. If fuse replacement is required, use ONLY a fuse of
identical size.
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:
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.
a. Remove control access door.
b. Remove blower access door.
c. Manually close blower access door switch.
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.
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 personal injury
or death.
For an explanation of fault codes, refer to service label located on
blower access door or Fig. 13, and the troubleshooting guide.
The control center stores 1 fault code (the last fault to occur) for a
period of 48 hrs or until the 115- or 24-v power is interrupted.
d. BRIEFLY short (jumper) TEST, 1/4-in. quick-connect
terminal on control center (adjacent to LED diagnostic
light) and Com terminal on thermostat connection block.
(See Fig. 11.)
NOTE: Removing blower access door will open blower access
door switch and terminate 115-v power to control center, and fault
code will be erased. Look into blower access door sight glass for
current LED status.
NOTE: If TEST to Com terminals are jumpered longer than 2 sec,
LED will flash rapidly, and retrieval request will be ignored.
1. To retrieve fault code, proceed with the following:
NOTE: NO thermostat signal may be present at control center,
and all blower time delay off periods must be completed.
e. Component Test will function as described in item 2 above.
f. Check LED status.
a. Leave 115-v power to furnace turned on.
g. If LED status indicates proper operation, release blower
access door switch, replace blower access door, and replace
control access door.
b. Look into blower access door sight glass for current LED
status.
NOTE: Leave blower access panel installed to maintain power to
control center to view current LED status.
TROUBLESHOOTING
Refer to the service label. (See Fig. 13.) Pages 10 and 11 contain
a troubleshooting guide. This 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.
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.
The guide will help to identify the problem or failed component.
After replacing any component, verify correct operation sequence.
2. When above items have been completed, the following will
occur:
6
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FIELD 24-VOLT WIRING
FIELD 115-, 208/230-, 460-VOLT WIRING
FACTORY 24-VOLT WIRING
FACTORY 115-VOLT WIRING
THERMOSTAT
TERMINALS
W
R
G
Y
FOUR
WIRE
FIELD-SUPPLIED
FUSED DISCONNECT
TWO-WIRE
HEATING-
ONLY
208/230- OR
460-VOLT
THREE
PHASE
W
R
BLK
BLK
WHT
WHT
208/230-
VOLT
SINGLE
PHASE
GND
GND
G
AUXILIARY
J-BOX
115-VOLT FIELD-
SUPPLIED
FUSED
DISCONNECT
C
Y
GND
CONTROL
CONDENSING
UNIT
BOX
TWO
24-VOLT
NOTE: If any of the original wire,
as supplied, must be replaced, use
same type or equivalent wire.
WIRE
TERMINAL
BLOCK
NOTE: Connect Y-terminal as
shown for proper
FURNACE
operation.
A78461
Fig. 10—Heating and Cooling Application Wiring Diagram
BLOWER OFF DELAY
ADJUSTMENT SWITCH
24V 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
24V 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)
EAC 2 (WHITE)
POWER
SUPPLY
115-VAC (L2) NEUTRAL
CONNECTION
HOT SURFACE
IGNITOR
CONNECTOR
INDUCER MOTOR
CONNECTOR
A93052
Fig. 11—Control Board
7
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N A R T
P M A 5 . 1
T H W
T H W
K L B
K L B
K L B
8
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SERVICE LABEL
SERVICE
LED CODE
STATUS
CONTINUOUS OFF - Check for 115VAC at L1 and L2, and 24VAC at SEC-1 and SEC-2.
CONTINUOUS ON - Control has 24V power.
RAPID FLASHING - Line voltage (115V) polarity reversed. If twinned, 24V power to
one furnace may be out of phase with 24V power to other furnace.
EACH OF THE FOLLOWING STATUS CODES IS A TWO DIGIT NUMBER WITH THE FIRST
DIGIT DETERMINED BY THE NUMBER OF SHORT FLASHES AND THE SECOND DIGIT
BY THE NUMBER OF LONG FLASHES.
11
12
13
NO PREVIOUS CODE - Stored status codes are erased when power (115V or 24V) to
control is interrupted or 48 hours after each fault is cleared.
BLOWER ON AFTER POWER UP (115V OR 24V) - Blower runs for 90 seconds, if unit
is powered up during a call for heat (R-W closed).
LIMIT OR FLAME ROLLOUT SWITCH LOCKOUT - Auto reset after three hours. Flame
rollout switch requires manual reset. Refer to #33.
14
21
IGNITION LOCKOUT - Control will auto-reset after three hours. Refer to #34.
GAS HEATING LOCKOUT - Control will NOT auto reset.
Check for: - Stuck gas valve relay on control or miswire to gas valve circuit.
ABNORMAL FLAME-PROVING SIGNAL - Flame is proved while gas valve is
de-energized. Inducer will run until fault is cleared.
22
Check for: - Stuck-open gas valve or leaky gas valve.
23
24
31
PRESSURE SWITCH DID NOT OPEN Check for:
- Obstructed pressure tubing.
- Defective pressure switch (stuck closed).
SECONDARY VOLTAGE FUSE IS OPEN
Check for: - Short circuit in secondary voltage (24V) wiring.
PRESSURE, DRAFT SAFEGUARD, OR AUXILIARY LIMIT (when used) SWITCH DID
NOT CLOSE OR REOPENED - If open longer than five minutes, inducer shuts off for
15 minutes before retry. Check for:
- Proper vent sizing and condensate pitch. - Inadequate combustion air supply.
- Vent restriction or high winds.
- Low inducer voltage.
- Defective inducer motor or start capacitor.
- Defective pressure switch or connections. If it opens after trial for ignition
period, blower will come on for 90 second recycle delay.
- Disconnected or obstructed pressure tubing.
LIMIT OR FLAME ROLLOUT SWITCH IS OPEN - If open longer than three minutes, code
changes to #13. Check for:
33
34
- Defective blower motor or start capacitor. - Dirty filter or restricted duct system.
- Loose blower wheel.
- Defective switch or connections.
- Inadequate combustion air supply (flame rollout switch only).
- Open flame rollout switch, manual reset.
IGNITION PROVING FAILURE - Control will try three more times before a 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 sandpaper).
- Proper flame sense microamps (.5 microamps D.C. minimum).
- Gas valve turned off.
- Manual shut-off valve.
- Green wire MUST be connected to furnace sheet metal.
- Inadequate flame carryover or rough ignition.
- Low inlet gas pressure.
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 "C" terminal. Status LED will flash code
and then turn on the inducer motor, hot surface igniter, blower motor-heat speed, and blower
motor-cool speed for 10-15 seconds each.
BLOWER OFF
DELAY SELECT
HUM
C
W
Y
R
G
320615-102 REV. A
A93297
Fig. 13—Service Label
9
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Copyright 1994 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231
58pr9sm
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. 535-835
Printed in U.S.A.
Form 58P,R-9SM
Pg 12
9-94
Replaces: 58P,R-8SM
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