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carrier 58mvp furnace installation manualThis is only intended as a guide and should not be used blindly. Your experience and expertise are of high value when troubleshooting this unit. Do not disregard all of your instincts. The microprocessor furnace control was designed with diagnostic capabilities built in. LEDs are used to flash a fault code which will lead you to 1 of the subsections as listed in the Index. You should ALWAYS begin in the START HERE subsection (see Index for page number) which will guide you to the appropriate subsection where a minimal number of steps will be used to correct the problem. If you are very experienced at how this furnace operates and you suspect the problem is either the blower motor, inducer motor, or furnace control board, you can use the quick motor test procedure at the end of the troubleshooting guide to isolate the problem or direct you to appropriate section in main troubleshooting guide. Once in a subsection, read the statement or question. Let’s try our guide out using the EXAMPLE section below, and see how it works. Suppose that the problem is a defective low-pressure switch (for example will not make). This is an internal problem and cannot simply be seen. We go to the START HERE section to Step 1. Additional Service Tools are available for current variable speed condensing furnaces. The Advanced Product Monitor Kit KGAFP0101APM includes a harness and diskette that allows communication with the control board through a personal com- puter (RS-485 adapter required). The ICM Motor Simulator Kit KGASD0101FMS is a plug-in device to help trooubleshoot ICM inducer and blower motors and control boards. Reference price pages for current kit numbers. SEQUENCE OF OPERATION Furnace control must be grounded for proper operation, or control will lock out. Control is grounded through green wire routed to gas valve and burner box screw. Using schematic diagram (see Appendix A), follow sequence of operation through different modes. This furnace has a new control system.http://www.rcot.org/userfiles/environment-safety-and-health-manual.xml
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Read and follow wiring diagram carefully. NOTE: If 115-v power supply to furnace or blower access panel switch is interrupted during a call for heat, blower operates at low-heat speed for 60 sec when power is restored before heating cycle is resumed. Visit www.carrier.com 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. 535-754 Printed in U.S.A. Form 58MVP-8SM Pg 1 9-99 Replaces: 58MVP-6SM Next Visit www.carrier.comNOTE: Read the entire instruction manual before starting the. Page 2: Emergency Heat Mode EXAMPLEPage 3: Heat Pump Mode In emergency heat mode, the normal heat mode outlined in 4. Cooling unit—The cooling unit stops when thermostat R-Y. Heating. Page 4: Component Test HUMRED LED2 ON The microprocessor has.Page 12: RED LED2 Flashing 28. Put setup switch SW-1 back in OFF position. — — 29. Page 13: Fault Code 12—Blower Calibration Lockout Fault Code 11. NO FAULT IN RECENT HISTORY DISPLAY—This indicates 1 of the following. Page 14 You have an open wire or bad terminal on either the ORANGE or VIOLET wire between connectorsIGNITION LOCKOUT—This fault indicates the system failed to ignite gas and prove flame in 4 attempts. Control. Page 18: Fault Code 23—Invalid Blower Airflow Selection Fault Code 22. SETUP ERROR—This fault indicates that setup switches SW-1 or SW-6 are ON when they should be OFF.HIGH-PRESSURE SWITCH FAULT—This fault can occur under the scenarios shown below, keep in mind thatConnect other sideKeep in mind thatIs inducer blower wheel okay? 31 30 —Otherwise, replace inducer. Page 25 9. Go to page number indicated in Index for CLEANUP AND START-UP INSTRUCTIONS. — — INDEXPage 26: Fault Code 34—Ignition Proving Fault Fault Code 34. IGNITION PROVING FAULT—This fault can indicate 1 of the following. Page 27: Fault Code 41—Blower Outside Valid Speed Range 41. Make sure perforated disks are in combustion-air vent inlet.http://www.tercovci.cz/files/environment-of-care-manual.xml — — 42Page 29: Fault Code 42—Inducer Outside Valid Speed Range Fault Code 42. INDUCER OUTSIDE VALID SPEED RANGE—This fault indicates that inducer motor is not operating atIf possible, replace inducer wheel. Otherwise, replace inducer motor assembly. — — 8BLOWER CALIBRATION FAULT-This fault indicates that calculated blower motor speed is below 250 or aboveIn an effort to provide a method of troubleshooting inducer and blower motor. Page 38 30. Does blower wheel rub against blower housing? 16 31 —This variable-speed furnace has an Integrated Control and Motor. Page 41 Air Delivery CurvesFurnace: Indoor Coil. Model Number Model Number. Serial Number Serial NumberPage 48 SERVICE TRAINING. WARNING: Carbon Monoxide is invisible, odorless, and toxic. Carrier Corporation recommends a carbon mon- oxide alarm in your home, even if you do not own a gas appliance. Locate the carbon monoxide alarm in the living area of your home and away from gas appliances and doorways to attached garages. Follow the alarm manufacturer’s instruc- tion included with the alarm. ! Do not use this furnace if any part has been under water. A flood-damaged furnace is extremely dangerous. Attempts to use the furnace can result in fire or explosion. A qualified service agency should be contacted to inspect the furnace and to replace all gas controls, control system parts, electrical parts that have been wet or the furnace if deemed necessary. USER’S INFORMATION MANUAL FOR OPERATION AND MAINTENANCE OF YOUR GAS-FIRED FURNACE Next Recognize safety information. Page 5 STARTING AND SHUTTING DOWN CLPage 7 Only trained and qualified personnel should install, repair, orUntrained personnel can performPage 9 When dirt, soot, scale, or rust is allowed to build up, your fur-Page 10 HEADING SOUTH FOR THE WINTER? 8. 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See Continu- ous Fan Setup Switches section in Installation, Start-Up, and Operating Instructions for details. Step 8—Component Test All components are functionally operated except gas valve with component test feature. This feature helps diagnose a system problem in case of a component failure. NOTE: Setup switch SW-1 MUST be in OFF position or Fault Code 22 (setup error) will occur. NOTE: NO thermostat signal may be present at control center, and all blower time delay off periods must be completed. To initiate component test feature, proceed with the following: 1. Leave 115-v power to furnace turned on. 2. Remove main furnace door. 3. Remove blower access panel. 4. Turn setup switch SW-6 to ON position. 5. Manually close blower access panel door switch. On some models, blower access panel door switch opens only 24-v power to control center. No component operation can occur. The 115-v power is still present at control center, transformer, inducer motor, and main blower motor. Caution must be taken when manually closing this switch for service purposes.NOTE: Torque belly band screw to 80 in.lb (6.7 ft. lb). WARNING: DO NOT OVERTIGHTEN! 17 Fault Code 14 Fault Code 21 INVALID MODEL SELECTIONPersonality connector PL5 is either not connected or jumpered wrong. 18 Fault Code 22 Thermostat call with SW-1 ON. Thermostat call with SW-6 ON. SW-1 and SW-6 both ON together. Fault Code 23 19 Fault Code 24 SECONDARY VOLTAGE FUSE IS OPENIndicates fuse is open and there is a short in low-voltage wiring. Factory connected when LGPS not used. 9. Blower-off delay, gas heating 90, 135, 180 or 225 seconds, cooling or heat pump 90 sec onds. 7. Inductor used on all 060 or -20 airflow units. 6. Replace only with a 3 AMP fuse. 4. Symbols are electrical representation only. 3. This wire must be connected to furnace sheet metal for control to prove flame. 2. Use only copper wire between the disconnect switch and the furnace junction box (JB). 1. If any of the original equipment wire is replaced use wire rated for 105C. Do not disregard all of your instincts. LEDs are used to flash a fault code which will lead you to 1 of the subsections as listed in the Index. If you are very experienced at how this furnace operates and you suspect the problem is either the blower motor, inducer motor, or furnace control board, you can use the quick motor test procedure at the end of the troubleshooting guide to isolate the problem or direct you to appropriate section in main troubleshooting guide. Suppose that the problem is a defective low-pressure switch (for example will not make). Reference price pages for current kit numbers. Control is grounded through green wire routed to gas valve and burner box screw. This furnace has a new control system. Electronic Condensing Furnace. Visit www.carrier.com. Troubleshooting Guide. NOTE: Read the entire instruction manual before starting theExample.2. Sequence of Operation.1-5. Self-Test Mode.2. Heating Mode.2. Heating Mode-Two Stage.2. Emergency Heat Mode.2-3. Cooling Mode.3. Heat Pump Mode.3-4. Continuous Fan Mode.4. Component Test.4-5. Bypass Humidifier Mode.5. Dehumidification Mode.5. Zone Mode.5. Start Here.6. Improper Operation With No Flashing Fault Code.9. Not Enough Cooling Airflow.10. High-Fire Temperature Rise Too Low (Cold Blow).11. LEDs 1, 2, 3, or 4 On Solid.11-12. RED LED2 Flashing.12. Fault Code 11—No Fault in Recent History Display.13. Fault Code 12—Blower Calibration Lockout.13-15. Fault Code 13—Limit Switch Lockout.15-16. Fault Code 14—Ignition Lockout.17. Fault Code 21—Invalid Model Selection.17. Fault Code 22—Set Up Error.18. Fault Code 23—Invalid Blower Airflow Selection.18. Fault Code 24—Secondary Voltage Fuse Is Open.19-20. Fault Code 31—High-Pressure Switch Fault.21-22. Fault Code 32—Low-Pressure Switch Fault.23-24. Fault Code 33—Limit Switch Fault.24-25. Fault Code 34—Ignition Proving Fault.26-27. Fault Code 41—Blower Outside Valid Speed Range.27-28. Fault Code 42—Inducer Outside Valid Speed Range.29-30. Fault Code 43—Pressure Switch Calibration Fault.30-31. Fault Code 44—Blower Calibration Fault.32. Cleanup and Start-Up Instructions.33. APPENDIX B—Isolation Circuits.36. APPENDIX C—Pressure Check Diagram.36. APPENDIX D—Quick Motor Test Procedure.37-39. APPENDIX E—Variable-Speed Condensing Furnace Duct StaticAPPENDIX F—Quick Reference Information.45. APPENDIX G—Thermostat Staging Algorithm.46-47This is only intended as aYour experience andThe microprocessor furnace control was designed with diagnosticLEDs are used to flash a fault code which willYou should ALWAYS begin in the START HERE subsectionIf you are very experienced at howOnce in a subsection, read the statement or question. A statement. Do whatever theIf the step is a question (a question will have a number in the. If the answer is. Let’s try our guide out using the EXAMPLE section below, andWe go to the START. HERE section to Step 1. Additional Service Tools are available for current variable speedKGAFP0101APM includes a harness and diskette that allowsThe ICM Motor Simulator Kit. KGASD0101FMS is a plug-in device to help trooubleshoot ICMReference priceControl is grounded through green wireUsing schematic diagram (see Appendix A), follow sequence ofThis furnace has a new controlNOTE: If 115-v power supply to furnace or blower access panelManufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Book 1 4Printed in U.S.A. Form 58MVP-8SM. Pg 1Tab 6a 8aWe go to Step 7. Step 7 tells us to go to low-pressure switch fault subsection. Step 1—Self-Test ModeThe control center goes through a brief self test whenever 115-v orThe self test takes approximately 2 secDuring this time,NOTE: The blower starts at approximately 400-500 RPM. AfterStep 2—Heating ModeRPM necessary to operate inducer in low-heat mode.The blower reduces its speed to low-heat RPM. The blowerThe furnace is factory set forNOTE: The heat cycle can start in either high or low heat. If aWhen high-pressure switchThe RPM is used to evaluate ventStep 3—Heating Mode—Two Stage. The control center provides 2-stage heating using a single-stageIf thermostat control over furnace staging is desired, a 2-stageWhen control center receives a thermostat. This methodNOTE: The initial heat mode after 115-v or 24-v power interruption will be LOW HEAT. Low heat remains energized for 16The heat cycle operates as stated in Heating Mode section. To allow for greater comfort, a 2-stage thermostat control isAfter the initial cycle, the microprocessor evaluates the length ofThis accommodates theSee Appendix G for details on thermostat staging algorithm. Step 4—Emergency Heat Mode. NOTE: The furnace should not be operated in emergency heatOperation is only recommended to provide heat until replacement components can beIn this mode, the microprocessor is bypassed and the motorsThe heat exchangers, motors, and electronics can be overstressed and may reduceNOTE: Ignition sequence repeats 3 additional times before aNOTE: No safeties are bypassed when using emergency heatIf cycle starts inThe reduction in speed in low heat is to optimize combustionEmergency heat mode can be selected using setup switch SW-4. SW-4 should be used when a fault condition exists or difficult toThis allows heating until the fault can beIn emergency heat mode, the normal heat mode outlined in. Heating Mode section is not followed. The following sequenceThe DE jumper isPrepurge begins 25 sec after highpressure switch closes.Step 6—Heat Pump ModeWhen heat pump defrost is required,RPM necessary to operate inducer in low-heat mode.After 5 sec, the HSI is de-energizedNOTE: Emergency heat mode only operates in high heat. NOTE: The heat cycle can start in either high or low heat. If aWhen high-pressure switchThe RPM is used to evaluate ventRPM necessary to operate inducer in high-heat mode.If burner flame is not sensed, controlNOTE: Ignition sequence repeats 3 additional times before lockout occurs. Lockout automatically resets after 3 hr, or can beFault codesThe inducer stopsStep 5—Cooling Mode. If burner flame is not sensed, control center de-energizes gasThe blower startsAfter 20 sec, the blower isThe microprocessor then determines blower RPM required toNOTE: In cooling mode, the microprocessor adjusts blower RPMInstallation, Start-Up and Operating Instructions for details. ThereNOTE: The blower starts at approximately 400-500 RPM. AfterIf cycle starts inThe reduction in speed in low heat is to optimize combustionThe blower continues to operate completing a normalStep 8—Component Test. Step 7—Continuous Fan Mode. All components are functionally operated except gas valve withThis feature helps diagnose a system problem in case of aNOTE: Setup switch SW-1 MUST be in OFF position or Fault. Code 22 (setup error) will occur.NOTE: The blower starts at approximately 400-500 RPM. AfterNOTE: NO thermostat signal may be present at control center,To initiate component test feature, proceed with the following:NOTE: The continuous fan speed is the same as low-heat speedSee Continuous Fan Setup Switches section in Installation, Start-Up, and. Operating Instructions for details. There is also a chart onOn some models, blower access panel door switch opens onlyNo component operation canOn the older style variable speed furnace controls, a field suppliedOn newer style variable speed furnace controls, a field suppliedThe DEHUM output on the thermidistatDEHUM terminal on the furnace control. In addition, the DEWhen items 1-5 have been completed, the following will occur:This self testAfter door switch isDuring this time, the microprocessor is checking itself.See service label on backNOTE: To repeat component test, turn setup switch SW-6 to OFFAfter component test, perform the following:SW-6 to OFF position.NOTE 1 - Remove DE Connection. To Enable DEHUM InputThis blower speed reduction compensates for high humidityStep 11—Zone Mode. When setup switch SW-5 MZ is in ON position, blower motorNOTE: Boards with date codes of 9506 or later will not performThis prevents nuisance faults fromRPM is within 10 percent of calculated blower RPM for 5 sec.The DEHUM input acts differently depending on which style of variable speed furnace control you have. The older style variable speed furnace control (shown in Fig. 1). DOES NOT have a DE connection while the newer style variableBoth of these variable speed furnaceThis logic reversal has come about from historical use of aAre any LEDs flashing? Are any LEDs on solid? (Solid means ON continuously.). Go to page number indicated in Index for LEDs 1, 2, 3, or 4 ON SOLID. Is RED LED2 flashing? Go to page number indicated in Index for RED LED2 FLASHING. Go to page number indicated in Index for subsection covering fault code being flashed. Is power on? (DO NOT cycle power to unit). Turn power on. Remove blower access panel and depress door switch. Use a piece of tape to hold switch closed. Wait a few sec for self test before proceeding to next step. Does problem appear to be low cooling airflow? Go to page number indicated in Index for subsection covering NOT ENOUGH COOLING AIRFLOW. Make sure thermostat is calling for heat. Make sure thermostat fan control is in AUTO position if equipped. Observe operation of furnace for 20 minutes or until fault occurs. Does a fault occur? Is temperature rise below range specified on rating plate when unit is running in high fire? Go to page number indicated in Index for subsectionDoes furnace operate properly? Disconnect R thermostat lead, then wait until blower motor stops. Are any LEDs flashing? Put setup switch SW-1 in ON position. Record fault codes listed in fault history. NOTE: Read fault codes until they repeat. The last fault code that occurred will flash first followed by the lowest number fault code. (EXAMPLE: 13, 13, 44). Are LEDs 3 and 4 flashing a Fault Code 11? Go to page number indicated in Index for subsection covering NO OPERATION WITH NO FLASHING FAULT CODE. Go to page number indicated in Index for CLEANUP AND START-UP INSTRUCTIONS. Go to page number indicated in Index for subsection covering first fault code flashed. Disconnect the R thermostat lead, then wait until blower motor stops. Go to page number indicated in Index for the CLEANUP AND START-UP INSTRUCTIONS. If thisIf problem still persists onThe microprocessor has malfunctioned. Disconnect jumper and place. If LED2 reappears replace main control board. Furnace is operating in high heat. Furnace is operating in low heat. Line voltage polarity is reversed.To clear recent faultAuto reset after three hours. ResetAuto reset after three hours. Check for:See wiring diagramThe followingCheck for:Check for:A99243aCheck wiring toCheck for:If this fault occurs in conjunction. If this faultWhen component test is completed one or more of the following codes will flash. Gas Valve and. Humidifier will not be turned on.Visual check of hot surface ignitor required.Check blower, wiring,Check inducer,After component test isRemove blower access panel and depress door switch. Check fuses, breakers, or manual disconnects to be sure they are correctly set. Does 120-v wiring match unit wiring schematic? Fix problem. Do you have 120 vac at primary leads P1 and P2 on furnace control board? Do you have 120 vac to furnace control board? Check all 120-vac connections at furnace control board. If necessary, replace furnace control board. Turn power off. Check continuity of power supply leads and door switch if wired with 120 vac. Do you have 24v between SEC-1 and SEC-2 on furnace control board? Do you have continuity across door switch? Replace transformer. If transformer fails again, replace transformer and furnace control board. Replace door switch. Do you have 24v between R and Com on furnace control board? Replace furnace control board. Check to see that thermostat is calling for heat. You have a defective thermostat or a break in the wiring between thermostat and furnace. Does furnace respond to the call for heat? Press down on microprocessor chip and make sure it is properly seated to furnace control board. IfDoes furnace keep repeating the following cycle. Inducer motor MTR1 runs, inducer motor MTR1Disconnect BROWN wire to gas valve GV. Does furnace still alternately cycle inducer motor, go through a self test, and then run blower motorDisconnect humidifier lead from HUM terminal on furnace control board.