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Carrier 58MVP 170 Series Troubleshooting Manual

Variable speed, two-stage electronic condensing four-way multipoise gas furnace
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(This document is to be used for Series 170 58MVP furnaces. Use
NOTE: Read the entire instruction manual before starting the
installation.

TABLE OF CONTENTS

Safety Considerations.....................................................................1
Instructions .....................................................................................1
General............................................................................................3
Sequence of Operation...................................................................3
(Adaptive Mode).......................................................................3
Cooling Mode ...........................................................................5
Thermidistat Mode....................................................................6
Super-Dehumidify Mode ..........................................................6
Continuous Blower Mode.........................................................6
Heat Pump Defrost ...................................................................7
Component Test ........................................................................7
Service/Status Code Instructions ...................................................8
Component Test .............................................................................9
Start Here......................................................................................10
Rapid Flashing Amber LED ........................................................11
Improper Cooling Airflow ...........................................................12
High-Heat Temperature Rise Too Low.......................................13
Status Code 11-No Previous Code ...........................................14
Status Code 12-Blower On After Power Up............................14
Status Code 13-Limit Circuit Lockout .....................................15
Status Code 14-Ignition Lockout ..............................................16
Status Code 15-Blower Motor Lockout....................................16
Status Code 21-Gas Heating Lockout ......................................16
Not Close or Reopened................................................................21
or Reopened..................................................................................23
Status Code 33-Limit Circuit Fault ..........................................24
Status Code 34-Ignition Proving Fault .....................................27
Status Code 41-Blower Motor Fault.........................................29
Status Code 42-Inducer Motor Fault ........................................31
High-Heat Pressure Switch is Closed..........................................33
Status Code 45-Control Circuitry Lockout...............................34
Cleanup and Start-Up Instructions ..............................................34
Appendix A
Board Layout and Wiring Schematics ........................................35
Appendix B
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4
PC 101
Catalog No. 535-80083
Tab 6a 8a
Troubleshooting Guide
58MVP-8SM for all previous Series.)
Printed in U.S.A.
Variable Speed, Two-Stage
Electronic Condensing
Four-Way Multipoise Gas Furnace
Pressure Check Diagram..............................................................38
Appendix D
Static Pressure Reading Location Diagrams ...............................38
Appendix E
Quick Reference Information ......................................................40
Flame Sensor Microamperage...........................................40
Hot Surface Igniter Reading .............................................40
Gas Valve Ohm Readings.................................................40
Power choke (Inductor).....................................................40
Appendix F
Furnace Staging Algorithm..........................................................40

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.
Follow all safety codes. In the United States, follow all safety
codes including the National Fuel Gas Code (NFGC) NFPA 54
2002/ANSI Z223.1-2002 and the Installation Standards, Warm Air
Heating and Air Conditioning Systems (NFPA 90B) ANSI/NFPA
90B. In Canada, refer to the CAN/CGA-B/49.1- and .2-M00
National Standard of Canada, Natural Gas and Propane Installation
Codes (NSCNGPIC). Wear safety glasses and work gloves. Have
a fire extinguisher available during start-up and adjustment proce-
dures and service calls.
Recognize safety information. This is the safety-alert symbol
.When you see this symbol on the unit and in instructions or
manuals, be alert to the potential for personal injury.
Understand the signal words DANGER, WARNING, CAUTION,
and NOTE. 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.

INSTRUCTIONS

This guide uses your expertise and observations to lead you to the
trouble spot as efficiently as possible. This 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.
Form 58MVP-10SM
Pg 1
6-03
Replaces: New

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  • Page 1: Table Of Contents

    Variable Speed, Two-Stage Electronic Condensing Four-Way Multipoise Gas Furnace Visit www.carrier.com Troubleshooting Guide (This document is to be used for Series 170 58MVP furnaces. Use 58MVP-8SM for all previous Series.) NOTE: Read the entire instruction manual before starting the Appendix C installation.
  • Page 2 The variable speed furnace control was designed with diagnostic capabilities built in. An AMBER LED is used to flash a status code, which will lead you to one of the sections as listed in the Index. You should ALWAYS begin in the START HERE section (see Index for page number), which will guide you to the appropriate section where a minimal number of steps will be used to correct the problem.

  • Page 3: General

    If the ACTION is a question (a question will have a number in the SEQUENCE OF OPERATION YES or NO column), answer it YES or NO. If the answer is YES, Using the schematic diagram in Appendix A, follow the sequence go to the step indicated in the YES column.

  • Page 4: Two-Stage Thermostat And Two-Stage Heating

    switch to high-heat, as long as the thermostat continues to call for Simultaneously, the humidifier terminal HUM and electronic heat. Subsequent selection is based on stored history of the air cleaner terminal EAC-1 are energized and remain ener- thermostat cycle times. gized throughout the heating cycle.

  • Page 5: Cooling Mode

    Table 1—Cooling Tonnage vs. Airflow (CFM) AIR CONDITIONING TONS AIRFLOW 040, 060, AND 3T-080 MODEL 5T-080 AND 100 MODEL 120 MODEL (12,000 BTU/HR) (CFM) 1-1/2 2-1/2 1050 3-1/2 1225 1400 1750 2100 high-heat gas valve solenoid GV-HI is de-energized. When NOTE: The air conditioning relay disable jumper ACRDJ must the inducer motor IDM reduces pressure sufficiently, the be connected to enable the adaptive cooling mode in response to a...

  • Page 6: Thermidistat Mode

    Step 5—Super-Dehumidify Mode BLWM to high-cooling airflow. High-cooling airflow is based on the A/C selection shown in Table 1 and 1a. Super-Dehumidify mode can only be entered if the furnace control NOTE: When transitioning from low-cooling to high-cooling the is in the Thermidistat mode and there is a demand for dehumidi- outdoor unit compressor will shut down for 1 minute while the fication.

  • Page 7: Heat Pump Defrost

    the continuous-blower airflow from the factory setting to the next highest CF selection airflow as shown in Table 1 and 1a. Momentarily turning off the FAN switch again at the thermo- stat will shift the continuous-blower airflow up one more increment.

  • Page 8: Service/Status Code Instructions

    SERVICE/STATUS CODE INSTRUCTIONS If status code recall is needed disconnect the ″R″ thermostat lead, reset power, and put setup switch ″SW1-1″ in the ON position. To clear the status code history put setup switch ″SW1-1″ in the ON position and jumper thermostat terminals ″R″, ″W/W1″, and ″Y/Y2″ simultaneously until status code #11 is flashed.

  • Page 9: Component Test

    • Loose blower wheel. • Defective switch or connections. • Improper low-heat gas input adjustment. • Stuck high-heat solenoid in gas valve. • Improper or misaligned limit and/or limit shield. 34 IGNITION PROVING FAILURE – Control will try three more times before lockout #14 occurs. If flame signal is lost during blower on-delay period, blower will come on for the selected blower off-delay.

  • Page 10: Start Here

    START HERE-IF A PROBLEM EXISTS, THE SERVICE TECHNICIAN SHOULD ALWAYS BEGIN TROUBLSHOOTING HERE Special Note: All voltmeters are not the same - your readings will vary. This applies to the entire content of this troubleshooting manual. They are not absolute values. Correct 115-VAC VOLTAGE, CURRENT, and power MEASUREMENTS CANNOT BE TAKEN ON VARIABLE SPEED FURNACES UNLESS USING A TRUE rms METER.

  • Page 11: Rapid Flashing Amber Led

    STEP ACTION GO TO Is 115-vac across the transformer leads? Replace the transformer. Is 24-vac across W/W1 and C -24V on the variable speed furnace control? You have a defective thermostat, or a break in wiring be- tween thermostat and furnace. Fix problem. Disconnect all thermostat leads from the thermostat termi- nal block and jumper R to W/W1.Does the furnace respond to the call for heat?

  • Page 12: Improper Cooling Airflow

    IMPROPER COOLING AIRFLOW — Generally, this indicates the Y/Y2 thermostat lead is not properly connected. STEP ACTION GO TO Remove blower access panel and depress door switch. Use a piece of tape to hold switch closed. Set thermostat to call for cooling. If thermostat does not have G connection jumper across thermostat terminals R and G.

  • Page 13: High-Heat Temperature Rise Too Low

    Table 2—Cooling Tonnage vs. Airflow (CFM) AIR CONDITIONING TONS AIRFLOW 040, 060, AND 3T-080 MODEL 5T-080 AND 100 MODEL 120 MODEL (12,000 BTU/HR) (CFM) 1-1/2 2-1/2 1050 3-1/2 1225 1400 1750 2100 A/C OR CF AIRFLOW SELECTION CHART BASED ON 350 CFM/TON MODEL SIZE 040,060, 3T-080...

  • Page 14: Status Code 11-No Previous Code

    STEP ACTION GO TO Is outdoor condensing unit operating during heating cycle? Check temperature rise and external static pressure with blower access panel in place. Temperature rise should be mid range or higher than midpoint of range stated on fur- nace rating plate.

  • Page 15: Status Code 13-Limit Circuit Lockout

    STEP ACTION GO TO The thermostat and/or thermostat wires are loading down the transformer. Replace the thermostat or repair thermo- stat wires. Does the hot surface ignitor HSI come on during the cycle? Disconnect the humidifier lead from HUM terminal on vari- able speed furnace control.

  • Page 16: Status Code 14-Ignition Lockout

    STEP ACTION GO TO Does a different status code flash? You have inadequate combustion-air supply. This may be caused by: - Reversed vent and combustion-air pipes. - Poor burner, manifold, or orifice alignment. - Blocked heat exchanger. - Leak somewhere between primary and secondary heat exchangers.

  • Page 17: Status Code 22-Abnormal Flame-Proving Signal

    STEP ACTION GO TO Does a different status code flash? Disconnect the jumper wire across R and W/W1 thermostat terminals and wait until the blower stops. Jumper R, W/W1, and W2 thermostat terminals on the vari- able speed furnace control. Does status code 21 start flashing when the high heat pres- sure switch HPS makes? The BLUE and GREEN wires to gas valve GV are re-...

  • Page 18: Status Code 24-Secondary Voltage Fuse Is Open

    STEP ACTION GO TO Replace the pressure switch assembly. Is the high heat pressure switch HPS wired correctly? Rewire high heat pressure switch HPS per wiring diagram. Replace the pressure switch assembly and replace the vari- able speed furnace control. Check the inducer PWM line.
  • Page 19 STEP ACTION GO TO Do you have continuity between the ORANGE wire con- nected to the low heat pressure switch LPS and chassis ground? The ORANGE wire from low heat pressure switch LPS is shorting to ground. Replace or repair it. Does status code 24 begin flashing when the gas valve GV is energized? Disconnect jumper wire across R and W/W1 thermostat ter-...

  • Page 20: Status Code 25-Model Selection Or Setup Error

    STEP ACTION GO TO Continue to observe the furnace operation for 10 minutes. Does status code 24 flash after the blower comes on? The insulation is loose and has shorted against the limit switch(es). Check for loose or torn insulation because it can cause in- termittent occurrences of status code 24.

  • Page 21: Status Code 31-High-Heat Pressure Switch Or Relay Did Not Close Or Reopened

    Status Code 31 HIGH-HEAT PRESSURE SWITCH OR RELAY DID NOT CLOSE OR REOPENED - This status code can occur under the scenarios shown below. Keep in mind that whenever the variable speed furnace control shuts unit down, gas remains off or shuts off immediately, inducer continues running for 15 seconds, and if the blower is running, it remains running at low heat airflow or reduces to low heat airflow for the selected off-delay.
  • Page 22 STEP ACTION GO TO You have an open wire or bad terminal on the BROWN wire from the high heat pressure switch HPS to the variable speed furnace control. Turn power off and disconnect jumper wire across R, W/W1, and W2 thermostat terminals. Connect 1 side of slope manometer with a tee to collector box pressure tap.

  • Page 23: Status Code 32-Low-Heat Pressure Switch Did Not Close Or Reopened

    Status Code 32 LOW-HEAT PRESSURE SWITCH DID NOT CLOSE OR REOPENED - This status code can occur as a result of the low heat pressure switch LPS not making or the low gas pressure switch LGPS opening. Regardless of which switch is open, the variable speed furnace control will operate under the scenarios shown below.

  • Page 24: Status Code 33-Limit Circuit Fault

    STEP ACTION GO TO Connect 1 side of slope manometer with a tee to collector box pressure tap. Connect other side with a tee to gas valve pressure fitting. Refer to pressure check diagram in Appendix C. Turn power on and jumper R and W/W1 thermostat termi- nals.
  • Page 25 STEP ACTION GO TO Return setup switch SW1-2 to its original setting and go to page number indicated in the Index for the section covering INDEX the status code. Jumper R and W/W1 thermostat terminals. Observe the furnace operation for 25 minutes or until status code starts flashing.
  • Page 26 STEP ACTION GO TO Turn power on and depress door switch. Use a piece of tape to hold switch closed. Jumper R and W/W1 thermostat terminals. Does status code 33 occur during low heat? Clean or replace filter if necessary, then recycle furnace after limit resets.

  • Page 27: Status Code 34-Ignition Proving Fault

    Status Code 34 IGNITION-PROVING FAULT - This status code indicates flame was not sensed during trial for ignition period. The control will repeat ignition sequence 3 more times before going to status code 14 - IGNITION LOCKOUT. This status code can also indicate flame signal was lost during steady-state operation.
  • Page 28 STEP ACTION GO TO Check connections and retry. If current is near typical value (4.0 to 6.0 microamps) and main burners will not stay on longer than a few seconds, check the following: - Air leakage around igniter bracket. - Inadequate flame carryover on rough ignition. - Low inlet gas pressure.

  • Page 29: Status Code 41-Blower Motor Fault

    Status Code 41 BLOWER MOTOR FAULT - This status code indicates the blower failed to reach 250 RPM or the blower failed to communicate to the variable speed furnace control within 30 seconds after being turned ON or within 10 seconds during steady-state operation. STEP ACTION GO TO...
  • Page 30 STEP ACTION GO TO Reconnect PL3 to the variable speed furnace control and connect a DC voltmeter across terminals PL3-3 YELLOW (+) and PL3-2 GREEN (-). Does the voltage appear to fluc- tuate more than it did in step 26? Note: Typical voltmeters will show a fluctuation of .2-vdc to 1-vdc.

  • Page 31: Status Code 42-Inducer Motor Fault

    STEP ACTION GO TO Remove tape from door switch and turn power off at main disconnect. Disconnect both multi-pin connectors from blower control module attached to the blower motor. Be sure to depress release latches on connectors or they may get damaged. Remove control box assembly from blower shelf and posi- tion out of the way.
  • Page 32 STEP ACTION GO TO Turn power back on. Check the inducer PWM line. To do this disconnect PL11 from the inducer motor and connect a DC voltmeter across terminals PL11-2 BROWN (+) and PL11-10 YELLOW (-) then run COMPONENT TEST by turning setup switch SW1-6 ON.

  • Page 33: Status Code 43-Low-Heat Pressure Switch Open While High-Heat Pressure Switch Is Closed

    STEP ACTION GO TO Is inducer blower wheel okay? If possible, replace inducer wheel. Otherwise replace in- ducer motor assembly. Is there any frost build-up on combustion-air inlet? The problem is caused by reversed vent and combustion-air pipes or some other moist air entering combustion-air pipe. You have excessive restriction in combustion-air or vent pipe.

  • Page 34: Status Code 45-Control Circuitry Lockout

    STEP ACTION GO TO Is 24-vac across YELLOW wire to the low heat pressure switch LPS and COM-24V on variable speed furnace con- trol? Is 24-vac across connector terminal PL1-2 and C -24V on variable speed furnace control? You have an open wire or bad terminal on the YELLOW wire from the variable speed furnace control to the low heat pressure switch LPS.

  • Page 35: Board Layout And Wiring Schematics

    APPENDIX A BOARD LAYOUT AND WIRING SCHEMATICS COMMUNICATION CONTINUOUS FAN FUTURE CONNECTOR (CF) AIRFLOW APPLICATIONS MODEL PLUG SETUP SWITCHES CONNECTOR SW1 SETUP SWITCHES AND BLOWER OFF- DELAY AIR CONDITIONING (A/C) AIRFLOW SETUP SWITCHES HUMIDIFIER TERMINAL (24-VAC 0.5 AMP MAX. ACRDJ – AIR CONDITIONING RELAY DISABLE JUMPER...
  • Page 36 ACRDJ PRINTED CIRCIUT BOARD TRAN PL12 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 SW 4 7 8 7 8 7 8 7 8 OFF OFF OFF OFF PRINTED CIRCIUT BOARD...

  • Page 37: Ecm Blower Motor Description And Operation

    9 10 11 12 13 14 15 16 CONTROL POWER CONTROL CONNECTOR PL13 POWER CONNECTOR PL14 A02277 Fig. 4—ECM Blower Motor APPENDIX B ECM BLOWER MOTOR DESCRIPTION AND OPERATION The G.E. Electronically Commutated Motor (ECM) shown in figure 3 is different than previous generations of variable speed blower motors. This motor has all of the capabilities of previous ECM blower motors but it does not have to be pre-programmed at the factory.

  • Page 38: Appendix Cpressure Check Diagram

    APPENDIX C PRESSURE CHECK DIAGRAM Pressure Switch Make/Break Points HIGH-HEAT PRESSURE SWITCH LOW-HEAT PRESSURE SWITCH UNIT SIZE (BTUH) Make Point Break Point Make Point Break Point 40,000 1.81 in. wc max 1.63 in. wc +/- 0.05 0.75 in. wc max 0.60 in.
  • Page 39 ELECTRONIC AIR CLEANER RETURN STATIC VENT INCLINE MANOMETER COMBUSTION HUMIDIFIER OUTDOOR UNIT SUPPLY STATIC INCLINE MANOMETER A/C COIL AIRFLOW A03092 Fig. 7—Downflow Total Static Pressure RETURN STATIC COMBUSTION-AIR PIPE VENT PIPE INCLINE MANOMETER ELECTRONIC AIR CLEANER SUPPLY STATIC FURNACE CONDENSATE DRAIN AIR CONDITIONING COIL...

  • Page 40: Quick Reference Information

    Example 2: Return ESP before Filter 0.10 in.w.c. Filter Static Pressure Drop 2000 cfm 0.10 in.w.c. Supply ESP after Coil 0.20 in.w.c. Coil Static Pressure Drop Wet 0.20 in.w.c. ------------------------------------------------------ Total ESP 0.60 in.w.c. Both Examples 1 and 2 are correct. Example 1 ESP readings were taken as laid out in static pressure reading location diagrams (Figure 6 - 8). Example 2 readings are taken as described.
  • Page 41 EXAMPLE 1: Furnace ran for 16 minutes in low heat and 5 minutes in high heat during previous call for heat. LH = 16 HH = 5 Calculate: (228 x 16) + (350 x 5) = 5398 3648 < 5398 < 5600 ⇒ Calculate low heat run time for next cycle. = (5600 - 5398) / 122 = 1.6 ⇒Next cycle, furnace will run for 2 minutes in low heat and then switch to high heat, if heat run time call is still present.
  • Page 43 SERVICE TRAINING Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual, including: • Unit Familiarization • Maintenance • Installation Overview • Operating Sequence A large selection of product, theory, and skills programs is available, using popular video-based formats and materials.
  • Page 44 Copyright 2003 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231 58mvp10sm Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Book 1 4 PC 101 Catalog No. 535–80083 Printed in U.S.A.

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