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Carrier 58SU0A Troubleshooting Manual

Comfort 80% afue, ultra low nox, 4-way multipoise gas furnace
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58SU0A (Series 2 & 3)
Comfort™ 80% AFUE, Ultra Low NOx,
4-Way Multipoise Gas Furnace

Table of Contents:

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Start Here Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE/STATUS CODE INSTRUCTIONS . . . . . . . . . . . . . . . . . 6
Rapid Flashing LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Status Code 11 - No Previous Code . . . . . . . . . . . . . . . . . . . . . . . . . 10
Status Code 12 - Blower on After Power Up . . . . . . . . . . . . . . . . . . 10
Status Code 13 - Limit Circuit Lockout . . . . . . . . . . . . . . . . . . . . . . 11
Status Code 14 - Ignition Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Status Code 21 - Gas Heating Lockout. . . . . . . . . . . . . . . . . . . . . . . 13
Status Code 23 - Transducer Greater than 0.15" . . . . . . . . . . . . . . . 14
Status Code 24 - Secondary Voltage Fuse Open . . . . . . . . . . . . . . . 15
Status Code 25 - Setup Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Status Code 26 - Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Status Code 34 - Ignition-Proving Failure . . . . . . . . . . . . . . . . . . . . 18
Status Code 42 - Inducer Motor Fault . . . . . . . . . . . . . . . . . . . . . . . 20
Status Code 45 - Control Circuitry Lockout. . . . . . . . . . . . . . . . . . . 21
CLEAN UP AND STARTUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
COMBUSTION TONE MITIGATION . . . . . . . . . . . . . . . . . . . . . . 22
APPENDIX A - Furnace Control Board Layout . . . . . . . . . . . . . . . 23
APPENDIX B - Wiring and Connection Diagram . . . . . . . . . . . . . . 24
APPENDIX C - Transducer Pressure Check . . . . . . . . . . . . . . . . . . 25
APPENDIX D - Transducer Target Pressures . . . . . . . . . . . . . . . . . 26
QUICK REFERENCE INFORMATION . . . . . . . . . . . . . . . . . . . . . 29
Flame Sensor Microamperage . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Hot Surface Igniter Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SERVICE TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Troubleshooting Guide

SAFETY CONSIDERATIONS

WARNING
!
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury and/or
death.
Carbon Monoxide (CO) is a colorless, odorless, and tasteless poisonous
gas that can be fatal when inhaled. Follow all installation, maintenance,
and service instructions. See additional information below regarding
the installation of a CO Alarm.
WARNING
!
FIRE, EXPLOSION, ELECTRICAL SHOCK, AND
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in dangerous operation,
personal injury, death, or property damage.
Improper installation, adjustment, alteration, service, maintenance, or
use can cause carbon monoxide poisoning, explosion, fire, electrical
shock, or other conditions which may cause personal injury or property
damage. Consult a qualified service agency, local gas supplier, or your
distributor or branch for information or assistance. The qualified
service agency must use only factory-authorized accessories and
replacement parts when installing and servicing this product.
Improper installation, adjustment, alteration, service, maintenance, or
use can cause explosion, fire, electrical shock, or other conditions which
may cause death, personal injury, or property damage. Consult a
qualified installer, service agency, or your distributor or branch for
information or assistance. The qualified installer or agency must use
factory-authorized kits or accessories when modifying this product.
Refer to the individual instructions packaged with the kits or accessories
when installing.
Installing and servicing heating equipment can be hazardous due to gas
and electrical components. Only trained and qualified personnel 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
literature, on tags, and on labels attached to or shipped with furnace and
other safety precautions that may apply.
These instructions cover minimum requirements and conform to existing
national standards and safety codes. In some instances, these instructions
exceed certain local codes and ordinances, especially those that may not
have kept up with changing residential construction practices. We
require these instructions as a minimum for a safe installation.
This is the safety-alert symbol
furnace and in instructions or manuals, be alert to the potential for
personal injury.
. When you see this symbol on the

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Summary of Contents for Carrier 58SU0A

  • Page 1: Table Of Contents

    58SU0A (Series 2 & 3) Comfort™ 80% AFUE, Ultra Low NOx, 4-Way Multipoise Gas Furnace Troubleshooting Guide SAFETY CONSIDERATIONS Table of Contents: SAFETY CONSIDERATIONS ......1 WARNING INSTRUCTIONS .
  • Page 2 58SU0A (Series 2 & 3): Troubleshooting Guide Follow all safety codes. Wear safety glasses, protective clothing, and WARNING work gloves. Have a fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions included in literature and ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD attached to the unit.

  • Page 3: Instructions

    58SU0A (Series 2 & 3): Troubleshooting Guide MODEL NUMBER NOMENCLATURE 1, 2 Major 7, 8, 9 11, 12 Voltage 15, 16 Gas Furnace Heating Stages Tier Min. AFUE/NOx Series Heating Input Motor Type Width (1-phase) Minor Series Airflow 08 = 800 CFM...

  • Page 4: General

    58SU0A (Series 2 & 3): Troubleshooting Guide GENERAL present, the furnace control CPU will lock out of Heating mode and operate the inducer motor IDM until flame is no longer The furnace must have a 115-VAC power supply properly connected and proved.
  • Page 5 58SU0A (Series 2 & 3): Troubleshooting Guide Wiring Diagrams 5. Component Test: The furnace features a component test feature to help diagnose a system problem in the case of a component failure. Refer to Fig. 3 for wiring diagram. To initiate the component test sequence, shut OFF the room Troubleshooting thermostat or disconnect the R thermostat lead.

  • Page 6: Service/Status Code Instructions

    58SU0A (Series 2 & 3): Troubleshooting Guide 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 7 58SU0A (Series 2 & 3): Troubleshooting Guide 42 INDUCER MOTOR FAULT the RPM pulses are not detected from the inducer motor within 20 seconds after a heat request the inducer is outside of its valid range of operation, or the inducer RPM signal was lost for 5 seconds during operation.
  • Page 8 58SU0A (Series 2 & 3): Troubleshooting Guide START HERE If a problem exists, the service technician should always begin troubleshooting here. NOTICE SPECIAL NOTE: All voltmeters are not the same - Your voltage readings may vary. This applies to the entire content of this troubleshooting manual.

  • Page 9: Rapid Flashing Led

    58SU0A (Series 2 & 3): Troubleshooting Guide Rapid Flashing LED Indicates that line voltage polarity is reversed. STEP ACTION GO TO Is this furnace twinned with another furnace? Remove blower access panel and depress door switch. Use a piece of tape to hold switch closed.

  • Page 10: Status Code 11 - No Previous Code

    58SU0A (Series 2 & 3): Troubleshooting Guide Status Code 11 - No Previous Code Stored status codes are erased after 72 hours Run system through a heating or cooling cycle to check system. STEP ACTION GO TO No Previous Fault Codes – Stored status codes are erased automatically after 72 hours...

  • Page 11: Status Code 13 - Limit Circuit Lockout

    58SU0A (Series 2 & 3): Troubleshooting Guide Status Code 13 - Limit Circuit Lockout Lockout occurs if a limit, draft safeguard, burner thermal switch or blocked vent switch (if used) or blower auxiliary limit switch is open. Control will auto-reset after three hours. Blower will run for 4 minutes or until limit switch closes, whichever is longer.
  • Page 12 58SU0A (Series 2 & 3): Troubleshooting Guide STEP ACTION GO TO Turn power off and adjust blower speed to achieve higher airflow Do you have continuity across the draft safeguard switch (DSS)? Allow draft safeguard switch (DSS) to cool for 10 minutes. Do you have continuity across the draft safeguard switch (DSS)? Replace draft safeguard switch.

  • Page 13: Status Code 14 - Ignition Lockout

    58SU0A (Series 2 & 3): Troubleshooting Guide STEP ACTION GO TO Remove Inducer assembly Inspect inducer gasket and replace if damaged Inspect inducer wheel for debris and clean as needed Inspect Inducer choke plate to cell panel connection and reseal as needed Reinstall inducer assembly Turn power on and jumper the R and W thermostat terminals.

  • Page 14: Status Code 22 - Abnormal Flame-Proving Signal

    58SU0A (Series 2 & 3): Troubleshooting Guide Status Code 22 - Abnormal Flame-proving Signal This status code indicates the flame signal was sensed while gas valve GV was de- energized. The inducer will run until the fault is cleared. STEP...

  • Page 15: Status Code 24 - Secondary Voltage Fuse Open

    58SU0A (Series 2 & 3): Troubleshooting Guide Status Code 24 - Secondary Voltage Fuse Open Indicates fuse is open and/or there is a short in low-voltage wiring. STEP ACTION GO TO Turn power off and remove the blower access panel.

  • Page 16: Status Code 25 - Setup Error

    58SU0A (Series 2 & 3): Troubleshooting Guide Status Code 25 - Setup Error Indicates model plug PL4 is missing or incorrect. STEP ACTION GO TO Turn power off, remove blower the blower access panel, and disconnect the R thermostat lead from the furnace control board.

  • Page 17: Status Code 31 - Transducer Does Not Sense Target Pressure

    58SU0A (Series 2 & 3): Troubleshooting Guide Status Code 31 - Transducer Does Not Sense Target Pressure indicates that transducer does not sense the target pressure, pressure is out of range, or there was a sudden change of pressure greater than 0.15-in. w.c.

  • Page 18: Status Code 34 - Ignition-Proving Failure

    58SU0A (Series 2 & 3): Troubleshooting Guide STEP ACTION GO TO Observe the furnace operation for at least 20 minutes or until status code starts flashing, monitoring for any sudden changes in inducer speed, pressure or in voltage Did status code 31 flash? Does a different status code flash? Turn power off and disconnect jumper wire across R and W thermostat terminals.
  • Page 19 58SU0A (Series 2 & 3): Troubleshooting Guide STEP ACTION GO TO Turn off power and disconnect the jumper across the R and W thermostat terminals. Connect a water column manometer or similar device to the gas valve outlet pressure port.

  • Page 20: Status Code 42 - Inducer Motor Fault

    58SU0A (Series 2 & 3): Troubleshooting Guide Status Code 42 - Inducer Motor Fault Indicates RPM pulses from inducer are not detected within 20 seconds after a heat request, that inducer RPM was lost for greater than 5 seconds during...

  • Page 21: Status Code 45 - Control Circuitry Lockout

    58SU0A (Series 2 & 3): Troubleshooting Guide STEP ACTION GO TO Referencing the Voltage/Pressure graph located in APPENDIX D, compare the pressure from the slope manometer to the output signal voltage from the transducer. EXAMPLE: The graph illustrates that at 1" of negative pressure, the transducer output should be approximately 1.5 VDC.

  • Page 22: Combustion Tone Mitigation

    58SU0A (Series 2 & 3): Troubleshooting Guide COMBUSTION TONE MITIGATION STEP ACTION GO TO Remove outer furnace door. Record status of AMBER LED. See Service/Status Code Instructions. Is the AMBER LED status light blinking ON/OFF slowly with a combination of short and long flashes? Determine status code.

  • Page 23: Appendix A - Furnace Control Board Layout

    58SU0A (Series 2 & 3): Troubleshooting Guide APPENDIX A - Furnace Control Board Layout MODEL PLUG J1 HEAT OFF-DELAY J2 DEFEAT CONNECTOR JUMPER SELECT JUMPER HEAT OFF-DELAY PROGRAMMING FLASH PORTS (FACTORY ONLY) 24-V THERMOSTAT TERMINALS FACTORY RUN TEST PORT (FACTORY ONLY)

  • Page 24: Appendix B - Wiring And Connection Diagram

    58SU0A (Series 2 & 3): Troubleshooting Guide APPENDIX B - Wiring and Connection Diagram A190414 Fig. 3 – Wiring and Connection Diagram Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

  • Page 25: Appendix C - Transducer Pressure Check

    58SU0A (Series 2 & 3): Troubleshooting Guide APPENDIX C - Transducer Pressure Check STEP ACTION GO TO Shut the power off, remove the blower access panel and disconnect the R thermostat lead from the furnace control board Turn the power on and depress the door switch. Use a piece of tape to hold it closed.

  • Page 26: Appendix D - Transducer Target Pressures

    58SU0A (Series 2 & 3): Troubleshooting Guide APPENDIX D - Transducer Target Pressures Heating Call Sequence UNIT SIZE (KBTU/h) Model Plug HK70EZ024 HK70EZ026 HK70EZ028 HK70EZ029 Startup (Heat call initiation) Inducer Pressure (in. w.c.) must be less than 0.15 0.15 0.15 0.15...

  • Page 27: Appendix E - Static Pressure Reading Locations

    58SU0A (Series 2 & 3): Troubleshooting Guide APPENDIX E - Static Pressure Reading Locations A122333 Fig. 6 – Upflow Total Static Pressure Reading Locations A122334 Fig. 7 – Downflow Total Static Pressure Reading Locations Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
  • Page 28 58SU0A (Series 2 & 3): Troubleshooting Guide A122335 Fig. 8 – Horizontal Total Static Pressure Reading Locations Tools Needed: Example 2: 1. Pilot Tube Return ESP before Filter 0.10-in. w.c. 2. Incline Manometer/Magnahelic Example 1: Filter Static Pressure Drop @ 2000 CFM 0.10-in.

  • Page 29: Quick Reference Information

    58SU0A (Series 2 & 3): Troubleshooting Guide QUICK REFERENCE INFORMATION Flame Sensor Microamperage Microamp Range: 0.5 to 6.0 microamps Typical Reading: 4 to 6 microamps Hot Surface Igniter Reading The Silicon Nitride igniter in this furnace is not voltage sensitive and will work within the voltage range of 102 to 132-VAC. Hence, there is no voltage regulation circuits on the furnace control board.

  • Page 30: Service Training

    58SU0A (Series 2 & 3): Troubleshooting Guide SERVICE TRAINING Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual, including: • Unit Familiarization • Installation Overview • Maintenance • Operating Sequence A large selection of product, theory, and skills programs is available, using popular video-based formats and materials.

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