Goodman ACVC96,AMVC96, GCVC96,GMVC96 Service Manual

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Page 1

Service Instructions

34.5" Chassis

ACVC96/AMVC96

GCVC96/GMVC96

Gas

Furnaces

This manual is to be used by qualified, professionally trained HVAC technicians only. Goodman does not assume any responsibility for property damage or personal injury due to improper service procedures or services performed by an unqualified person.

The material in this manual does not supercede manufacturer's installation and operation instructions

RS6612010r6

November 2017

Page 2

TABLE OF CONTENTS

IMPORTANT INFORMATION..................................... 2 - 6

PRODUCT IDENITIFICATION .................................. 7 - 11

ACCESSORIES .................................................... 12 - 15

INSTALLATION CONSIDERATIONS...................... 16 - 41

SYSTEM OPERATION.......................................... 42 - 46

SYSTEM OPERATION COMFORTNET™ ............ 53 - 59

SERVICING .......................................................... 60 - 77

MAINTENANCE ................................................... 79 - 80

ACCESSORY WIRING DIAGRAMS ...................... 81, 83

WIRING DIAGRAMS...................................................84

TROUBLESHOOTING ........................................... 47 - 52

IMPORTANT INFORMATION

Pride and workmanship go into every product to provide our customers with quality products. It is possible, however, that during its lifetime a product may require service. Products should be serviced only by a qualified service technician who is familiar with the safety procedures required in the repair and who is equipped with the proper tools, parts, testing instruments and the appropriate service manual. REVIEW ALL SERVICE INFORMATION IN THE APPROPRIATE

SERVICE MANUAL BEFORE BEGINNING REPAIRS.

IMPORTANT NOTICES FOR CONSUMERS AND SERVICERS

RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS

NLY PERSONNEL THAT HAVE BEEN TRAINED TO INSTALL, ADJUST, SERVICE OR REPAIR (HEREINAFTER MANUAL SHOULD SERVICE THE EQUIPMENT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES ASSUME RESPONSIBILITY FOR ANY INJURY OR PROPERTY DAMAGE WHICH MAY RESULT

. IN

LICENSES TO SERVICE THE EQUIPMENT SPECIFIED IN THIS MANUAL, ONLY LICENSED PERSONNEL SHOULD SERVICE THE EQUIPMENT INSTALLATION, ADJUSTMENT, SERVICING OR REPAIR OF THE EQUIPMENT SPECIFIED IN THIS MANUAL, OR ATTEMPTING TO INSTALL, ADJUST, SERVICE OR REPAIR THE EQUIPMENT SPECIFIED IN THIS MANUAL WITHOUT PROPER TRAINING MAY RESULT IN PRODUCT DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH

, “

SERVICE

”)

THE EQUIPMENT SPECIFIED IN THIS

. THE

MANUFACTURER WILL NOT

. IF

YOU SERVICE THIS UNIT, YOU

ADDITION, IN JURISDICTIONS THAT REQUIRE ONE OR MORE

. I

MPROPER

WARNING

O PREVENT THE RISK OF PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH, DO NOT STORE COMBUSTIBLE MATER IALS OR USE GASOLINE OR OTHER FLAMMABLE LIQUIDS OR VAPORS IN THE VICINITY OF THIS APPL IANCE.

WARNING

HIGH VOLTAGE D

ISCONNECT ALL POWER BEFOR E SERVICING OR

INSTALLI NG THIS UNIT . BE PRESENT. DAMAGE, PE RSONAL INJURY O R DEATH.

MULTIPLE POWER SOURCES MAY

FAILURE TO DO SO MAY CAU SE PROPERTY

Page 3

IMPORTANT INFORMATION

To locate an authorized servicer, please consult your telephone book or the dealer from whom you purchased this product. For further assistance, please contact:

CONSUMER INFORMATION LINE GOODMAN® BRAND PRODUCTS

TOLL FREE

1-877-254-4729 (U.S. only)

email us at:

customerservice@goodmanmfg.com

fax us at: (731) 856-1821

(Not a technical assistance line for dealers.)

Outside the U.S., call 1-713-861-2500.

(Not a technical assistance line for dealers.) Your telephone company will bill you for the call.

CONSUMER INFORMATION LINE

AMANA® BRAND PRODUCTS

TOLL FREE

1-877-254-4729 (U.S. only)

email us at:

hac.consumer.affairs@amanahvac.com

fax us at: (731) 856-1821

(Not a technical assistance line for dealers.)

Page 4

IMPORTANT INFORMATION

CO can cause s erious illness including permanent brain damage or death.

B10259-216

Advertencia especial para la instalación de calentadores ó manejadoras de aire en áreas cerradas como estacionamientos ó cuartos de servicio.

Las emisiones de monóxido de carbono pueden circular a través del aparato cu ando se opera en cualquie r modo.

El monóx ido de ca rb ono puede causar enfe rm edades severas como daño cerebral permanente ó muerte.

RISQUE D'EM PO IS ON NEMENT AU

Cette ventilation est nécessaire pour éviter le danger d'intoxication au CO pouv ant sur v enir si u n appareil produisant du monoxyde de carbone continue de fonctionner au sein de la zone confinée.

MONOXYDE DE CARBONE

B10259-216

Page 5

IMPORTANT INFORMATION

FOR Y OUR S AFETY READ BEFORE OPERATING

If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burners. Do not try to light the burners by hand.

B. BEFORE OPERATING smell around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

Do not try to light any appliance. Do not touch any electric switch; do not use any telephone in your building. Immediately call your supplier from a neighbor's phone. Follow the gas suppliers instructions.

If you cannot reach your gas supplier, call the fire department.

C. Use only your hand to move the gas control switch or knob. Never use tools. If the gas control switch or knob will not operate, don't try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

D. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the appliance.

4. This appliance is equipped with an automatic ignition system which automatically lights the burners. Do not try to light the burners by hand.

5. Remove control access panel.

6. Move the gas control switch or knob to "OFF ".

GAS CONTROL SWITCH SHOWN IN "ON" POSITION

7. Wait five (5) minutes to clear out any gas. If you then smell gas, STOP!above on this label. Follow "B" in the safety information above on this label. If you don't smell gas, go to the next step.

8. Move the gas control switch or knob to "ON".

9. Replace control access panel.

10. Turn on all electric power to the appliance.

11. Set the thermostat to the desired setting.

12. If the appliance will not operate, follow the instructions "To Turn Off Gas To Appliance" and call your service technician or gas supplier.

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to its lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

3. Remove control access panel.

4. Move the gas control switch or knob to "OFF". Do not force .

5. Replace control access panel.

WARNING: Improper alteration, service or

maintenance can cause injury or property damage.

Refer to the user's information manual provided with this

consult a qualified or the gas supplier.

This furnace must be

instructions and local codes. In the absence of local codes, follow the National Fuel Gas

Code, ANSI Z223.1.

For indoor installation.

PGB & PGJ For outdoor installation only .

If notWARNING:

installed, operated and maintained in accordance with the manufacturer's instru ctions, this product could expose you to substances in fuel combust ion which can cause death or serious illness and which are known to the State of California to cause cancer, birth defects or other reproductive harm. This product contains fiberglass insulation. Fiberglass insu la tion contains a chemic al

California to cause cancer.

FOR YOUR SAFETY

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other app liance.

0140F00001P

Page 6

IMPORTANT INFORMATION

CONSIGNES DE SECURITE - LIRE

AVANT D'ALLUMER L'APPAREIL

AVERTISSEMENT: Le non-respect des in structions qui suivent peut

entrainer un r i sque d'incendie ou d'explosion causant des dommages, des blessures ou la mort.

A. Cet appareil comporte pas de veilleuse. Il est muni d'un mecanis m e qui allume automatiquement le bruleur. N

B. Sentir tout autour de l'appariel AVANT D'ALLUMER afin de deceler toute fuite de gaz. Assurez-vous de sentir tout pres du plancher car certains gaz sont plus lourds que l'air et se deposeront sur le plancher.

SI VOUS SENTEZ UNE ODEUR DE GAZ: Ne tentez d'allumer aucun appariel.

Ne touchez pas aux interrupteurs electriques; n'utiliser aucun telephone dans l'edifice ou vous vous trouvez. Appelez immediatement votre fournisseur de gaz en utilisant le telephone d'un voisin et suivez les instructions du fournisseur. Appelez les pompiers si vous ne parvenez pas a rejoindre votre fournisseur de gaz.

C. N'utiliser que votre main pour pousser ou tourner le commande du gaz. N'utilisez jamais d'outils. Si vous ne parvenez pas a pousser ou a t ourner la commande, ne tentez pas de la reparer; appelez un reparateur qualifie. Forcer la commande ou essayer de la reparer peut entrainer un risque d'incendie ou d'explosion.

D. N'utilisez pas cet appareil si l'une de ses parties a ete dans l'eau. Si cela se produit, demandez immediatement a un reparateur qualifie d'insp ecter l'appareil et de remplacer toute piece du systeme de controle et toute commande de gaz ayant ete dans l'eau.

'allumez paz le bruleur manuellement.

0140F00002P

1. UN INSTANT! Lisez d'abord les consignes

INSTRUCTIONS DE SERVICE

d e securi te ci-dessus.

2. Reglez le thermostat a son point le plus bas.

3. Coupez l'alimentation electrique de l'appareil.

4. Cet appareil est muni d'un mecanisme qui allume automatiquement le bruleur. Ne tentez pa s d'allum er le bruleur manuellement.

5. Retirez le panneau d'acces de la commande.

6. Mettez la commande de gaz a la position

ARRET ("OFF").

7. Attendez cinq (5) minutes afin de permettre a t ou t gaz present d'etre evacue. Si vous sentez une odeur de gaz a ce moment, ARRETEZ! et suivez les consignes de securite donnees au paragraphe B ci-dessus. Si vous ne sentez pas de gaz, passez a l'etape suivante.

8. Mettez la commande de gaz a la position MARCHE ("ON").

9. Remettez la panneau d'acces de la commande en plac e.

10. Retablissez l'alimenation electrique de l'appareil.

11. Reglez le thermostat a le temperature desiree.

12. Si l'appareil ne fonctionne pas, suivez les instructions intitulees "Arret du gaz" et appelez un reparateur qualifie ou votre fournisseur de gaz.

1. Reglez le thermostat a son point le plus bas.

2. Coupez l'alimentation electrique de l'appareil si vous devez effectuer un entretien.

3. Retirez le panneau d'acces de la commande.

4. Mettez la commande de gaz a la position ARRET ("OFF").

5. Remettez le panneau d'acces de la commande en p lace.

ARRET DU GAZ

Commande de gaz en position

"MARCHE"

Page 7

PRODUCT IDENTIFICATION

The model and manufacturing number are used for positive identification of component parts used in manufacturing. Please use these numbers when requesting service or parts information.

G M V C 96 080 4 C N A A

PRODUCT

TYPE :

G: Go od m a n A: Amana®

Brand

D: A m ana®

Distinctions™ Brand

M: Upflo w/Horizon tal D: De cidated Downflow C: Downfl ow/Horiz on tal H: High Air Flow

FURNACE

TYPE

E: T wo-Stage/ S: Single-Stage / V: T wo Stage/ Spee d

H: Two Sta ge Gas Valve -

SUPPLY TYPE

COMMUNICATION FEATURE

C: 4-Wire Communicatio n Ready

X-13 Mot or Multi-Speed Varia ble-

Multi-Speed

NOMI NAL I NPUT

040: 40,000 Bt uh 060: 60,000 Bt uh 080: 80,000 Bt uh 100: 100,000 Bt uh 120: 120, 000 B tu h

AFUE

8: 80% 9: 90%

95: 95 %

AIRFLOW

CA PABILITY

@ 0.5" E SP

3: 12 00 4: 16 00 5: 20 00

CABINET

WIDTH

A: 14" B: 17- 1 /2" C: 21 " D: 24 - 1 /2"

MAJOR REVIS ION

A: In itial R e le ase

MI NOR REVI S ION

A: In itial R e le ase

ADDITIONAL

FEA TURE S

N: Natural Gas X: L o w N O x

Page 8

PRODUCT IDENTIFICATION

MODEL: GMVC96 REV AA

Equipment Type Goodman Brand Residential Gas Furnace Hea tin g Sta ges Two Cooling Stages Two Cont rol Ty pe ClimateTalk

™ or Conventional 24 Volt

Blowe r Motor Type 4 Wire Variable Speed ECM

GMV C96

Installation Positions BTUH Input Low F ire (X 1000) BTUH Input High Fire (X 1000) A/C Capable Tons Cabi net Hight " Cabinet Width " Heating CFM @ 100% Firing Rate Draft Inducer Gas Valve 24 VAC Heating Inputs 24 VAC Cooling Inputs Primary Heat Exchanger

Accessory Terminals

Gas Line Entry

Revision Attribu tes

0403BN 0603BN 0803BN 0804CN 1005CN 1005DN 1205DN

UF, Hor L/RUF, Hor L/RUF, Hor L/RUF, Hor L/RUF, Hor L/RUF, Hor L/RUF, Hor L/R

30 45 60 60 75 75 90 40 60 80 80 100 100 120

1.5 - 31.5 - 31.5 - 32 - 41.5 - 52 - 5 2 - 5

34.5 34.5 34.5 34.5 34.5 34.5 34.5

17.5 17.5 17.5 21 21 24.5 24.5 553 1059 1316 1337 1870 1940 1940

Two Sp eed Two Stage W1 / W2 Y1 / Y2 Aluminized S teel EAC terminal, Field Powered HUM IN / HUM OUT terminals, Single Hum term i nal powered

simultaneously with draft inducer, A UX circuit

Left or Right

First revision of 34.5" two stage comm u nicating capable up flow furnace

MODEL: AMVC96 REV AA

Equipment Type Amana Brand Residential Gas Furnace Hea ting Stages Two Cooling St ages Two Control Type ClimateTalk Blowe r Mo tor Type 4 Wire Variable Speed ECM

AMVC96

Installation Positions BTUH Input Low F ire (X 1000) BTUH Input High Fi re (X 1000) A/C Capable Tons Cabi net Hight " Cabine t Width " Heating CFM @ 100% Firing Rate Draft Inducer Gas Valve 24 VAC Heating Inputs 24 VAC Cooling Inputs Primary Heat Exchanger

Accessory Terminals

Gas Line Entry

Revision Attributes

™ or Conventional 24 Volt

0403BN 0603BN 0803BN 0804CN 1005CN 1005DN 1205DN

UF, Hor L/R UF , Hor L/R UF, Hor L/R UF, Hor L/R UF, Hor L/R UF, Hor L/R UF, Hor L/R

30 45 60 60 75 75 90 40 60 80 80 100 100 120

1.5 - 3 1.5 - 3 1.5 - 3 2 - 4 1.5 - 5 2 - 5 2 - 5

34.5 34.5 34.5 34. 5 34.5 34.5 34.5

17.5 17.5 17.5 21 21 24. 5 24.5 553 1059 1316 1337 1870 1940 1940

Two Sp eed Two Sta ge W1 / W2 Y1 / Y2 Stainless Steel EAC terminal, Field Power ed HUM IN / HUM OUT t erminals, Single Hum term inal powered

simulta neously with draft inducer, AUX circuit

Left or R ight

First revision of 34.5" two stage communicating capable up flow furnace

MODEL: GCVC96 REV AA

Equipment Ty pe Goodman Brand Residential Gas Furnace Heating Stages Two Cooling Stages Two Control Ty p e ClimateTalk

™ or Conventional 24 Volt

Blowe r Motor Type 4 Wire Variable Sp eed ECM

GCV C96

Installation Positions CF, Hor L/R CF, H or L /R CF, Hor L/R CF, Hor L/R CF, Hor L/R CF, Hor L/R BTUH Input Low Fire (X 1000) 30 45 60 60 75 90 BTUH I nput High Fire (X 1000) 40 60 80 80 100 120 A/C Capable Tons 1.5 - 3 1.5 - 3 2 - 4 2 - 4 2 - 5 2 - 5 Cabinet Hight " 34.5 34.5 34.5 34.5 34.5 Cabinet Width " 17.5 17.5 21 21 24.5 Heating CFM @ 100% Firing Rate 1059 950 1146 1325 1797 1827 Draft Inducer Gas Valve 24 VAC Heating Inputs 24 VAC Cooling Inputs Primary Heat Exchange r

Accessory Terminals

Gas Line Entry

Revision Attributes

0403BN 0603BN 0803BN 0804CN 1005CN 1205DN

Two Speed Two Stage W1 / W2 Y1 / Y2 Aluminized Steel EAC terminal, Field Powered HUM IN / HUM OUT term i n als, Singl e Hum terminal

powered simultaneously with draft inducer, AUX circuit

Left or Right

First revision of 34.5" modulating cou nter flow furnace

MODEL: ACVC96 REV AA

Equipment Ty pe Amana Bra nd Residential Gas Furnac e Heating Stages Two Coo lin g Stages Two Cont ro l Ty pe ClimateTalk Blowe r M o tor Type 4 Wire Variable Speed ECM

ACVC96

Inst allatio n Positi o n s CF, Hor L/R CF, Hor L/R CF, Hor L/R CF, Hor L/R CF, Hor L/R CF, Hor L/R BTUH Input Low Fire (X 1000) 30 45 60 60 75 90 BTUH Input High Fire (X 1000) 40 60 80 80 100 120 A/C Capable Tons 1.5 - 3 1.5 - 3 2 - 4 2 - 4 2 - 5 2 - 5 Cabinet Hight " 34.5 34.5 34.5 34.5 34.5 Cabinet Width " 17.5 17.5 21 21 24.5 Heating CFM @ 100% Firing Rate 1059 950 1146 1325 1797 1827 Draft Inducer Gas Valve 24 VAC Heating Inputs 24 VAC Cooling Inputs Primary Heat Ex changer

Accessory Terminals

Gas Line Entry

Revision Attributes

Two Speed Two Stage W1 / W2 Y1 / Y2 Stainless Steel EAC terminal, Field Powered HUM IN / HUM OUT term in als, Singl e Hum terminal

powered simul taneously with draft inducer, AUX circuit

Left or Right

First revision of 34.5" m od ulating counter flow furnace

™ or Conventional 24 Volt

0403BN 0603BN 0803BN 0804CN 1005CN 1205DN

Page 9

PRODUCT IDENTIFICATION

MODEL # MFG # DESCRI PTION

AFE18-60A

AMU1620 AMU1625 AMU2020 AMU2025

GMU1620 GMU1625 GMU2020 GMU2025

ASAS-10 ASAS-11 ASAS-12 ASAS-18

CFSB17 CFSB21 CFSB24

N/A

P1251305F P1251306F P1251307F P1251308F

N/A

P1251301F P1251302F P1251303F P1251304F

N/A

Fossil Fue l Kit.

above/d ownst r eam of a gas or fossil fuel furnace when used wit h a heat pump. I t will opera te with single and two stage heat pumps and single and two stage furnac es. The AFE 1 8- 60 A cont rol will t ur n the heat pu mp unit off whe n the f ur nac e is t ur ned on. An ant i- short cycle feature initiates a 3 minute timed off d elay when the c o mpressor goes off.

Med ia Air Cleaner.

furnace models. The Amana ( AM U*) and Goodman (GMU*) Media Ai r C leaner is a high efficienc y air fi ltrat ion device designed to r emove dirt, dust , pollen and other microscopic particles from th e a ir passing thro ugh it. Flexible performance range up to 2,0 00 CFM capac ity. The a ir cleaner should be installed in the sy stem so that a ll the syste m air is circulated through the a ir c lea ner . Th e air cleaner wi ll only remov e the airbor ne contaminant s delivered to it. Maximum performance is obtain ed wh en the sy stem blower is set f or c on tinuous operation. Car b on filt er s (optional) ar e available.

E lectron i c Air C l e an er.

furnace models. The High - Eff i c iency E lectro nic Air Cleaner is designed to r emove air cont a minant s down t o .01 microns. Car bo n filte r s (optional) remove odors. Dual indica tor lights show unit operation a t a glance. Electronic pr o ving sw itch cycles the air cleaner On/O ff with the system f an . Durable powder-coat paint finish resist s cor rosion.

Counterflow Subbase Kit.

models ACV C9 an d GCVC9. These kits are available for the fol lowing furnace widt hs: 17.5" wide (CFSB17) , 21" w ide (CFS B 21) and 24" wide (CFSB24) . The k its must be used t o pr e vent excessive temperatur e from reachin g c ombustible mater i als, if the furnace is installed on a combustible f loor . T his subbase effec tively separate d the furnace base and plenum from combustible materials. To ensure safe installation, do not install the counterflow floor base direc tly on carpe ting, tile, or other combustible mater i al o ther t h an wood flooring.

The AFE18 - 60A control is designed for use where the indoor c oil is located

For use with c ur r ent ar c hitect ur al gr ey Goodman® and A mana® Br a nd

For use with cur r en t architect ural grey Goodman® and Amana® Brand

For use with select Goodman® and Amana® Brand 34.5" furnace

CTK01AA

CTK01BA

CTK01AA

CTK01BA

Communicating Thermostat Kit-

for use with compatib le Amana® B rand or Goodman® Brand Air Handlers or F u r naces and outdoor split AC or Heat Pump units. This thermostat supports up to three stages of heat, two stages of c ooling, dual f uel app lic ations, dehumidification, filter maintenance reminders, outdo or temperature display an d advanced menus including diagnostics. The CTK01AA kit includes a communicating touchscree n thermostat and sub base, 230V-24V 40va tr ansf ormer, terminal blocks(2) , wir e jumpers, mounting scr ews, installation manual and homeowner guide.

Communicating Thermostat Kit-

for use with compatib le Amana® B rand or Goodman® Brand Air Handlers or F u r naces and outdoor split AC or Heat Pump units. This thermostat supports up to three stages of heat, two stages of c ooling, dual f uel app lic ations, dehumidification, filter maintenance reminders, outdo or temperature display an d advanced menus including diagnostics. The CTK01BA kit includes a communicating touchscree n thermostat and sub base, terminal block s(2), installat ion manual and homeowner guid e.

Digitall y communicat i ng t ouc hscr een t her mostat . Designed

Page 10

PRODUCT IDENTIFICATION

MODEL # MFG # DESCRIPTION

Communicating Thermostat Kit- D igita lly communicating thermo stat. Designed for u se

with compatible Amana® Brand or Goodman® Brand Air Handlers or Furnaces and outdoor spli t AC or Heat Pump units . The CTK02** thermostat features a ful l color high

CTK02**

CTK03AA

CTK03AB

CTK02**

CTK03AA

CTK03AB

definition display, advanced programming options including humidification control & heat and cool maximum temperature settings, a USB plug allowing dealers the ability to in sert p re-prog ram med ope ratin g para m eters a nd de ale r info rmat ion b y us e o f a n online data entry system.

Communicating Thermostat Kit- D igita lly communicating touchscreen thermos tat fro m Honeywell . Designed for use with compatible Amana® Brand or Goodman® Brand Air Handlers or Furnaces and outdoor split AC or Heat Pump units. The CTK03AA thermostat features full color high definition display and can be us ed wi th RedLINK wireless accessories.

Communicating Thermostat Kit- D igita lly communicating touchscreen thermos tat fro m Honeywell . Designed for use with compatible Amana® Brand or Goodman® Brand Air Handlers or Furnaces and outdoor split AC or Heat Pump units. The CTK03AB thermostat features full color high definition display and can be us ed wi th RedLINK wireless accesso rie s an d added cap abi lty to control the HUM I N - HUM OUT rel ay.

CTK04

DCVK-20

(CVENT-2)

DCVK-30

(CVENT-3)

0170K00000S

0170K00001S

DEHUM1

CTK04AA CTK04AB

N/A

P1227801F

Communicating Thermostat Kit- D igita lly communicating touchscreen thermos tat fro m Honeywell . Designed for use with compatible Amana® Brand or Goodman® Brand Air Handlers or Furnaces and outdoor split AC or Heat Pump units. The CTK04 thermostat features full color high definition display and can be us ed wi th RedLINK wireless accessories and added capabilty to control the HUM IN - HUM OUT relay. Split system inverter capable .

Concentri c Vent Kit. For use with Amana® Brand 90% furnace models. This kit is designed to allow terminations of a direct vent furnace to be "concentrically" vented through a wall or roof. This kit allows a single penetration to support terminations for both the vent/flue a nd the com bustion air inta ke p ip e. The DCVK-20 (2") an d DCVK-30 (3") k its a re certified for models listed above. See specification sheets on future models for use of the vent kit.

Side Wall Only Concentric Vent Kit. For use with 90% furnace mod els. This kit is to be used with 2" - 3" vent systems. The vent kit must te rm in ate outsi de the structure. This kit is NOT intended for use with single pipe (indirect vent) installations.

Side Wall Only Concentric Vent Kit. For use with 90% furnace mod els. This kit is to be used only with 2" vent systems. The vent kit must terminate outside the structure. This kit is NOT intended for use with single pipe (indirect vent) installations.

Dehumidistat. For use with Goodman® and Amana® Brand two-stage variable speed furnace models. Wall mounted, 24 volt humidity control available as a Dehumidistat used to redu ce the a irflow in the air con ditio ni n g mode w hen necessary to lower th e humid ity in an occupied home to prevent dew build-up associate d wi th hi gh humidity levels. This control features a moisture-sensitive nylon element and also provides positive ON-OFF settings for manual operation. The control is a normally closed switch that opens on humidity rise causing the blower to switch to a lower speed to control the humidity wi thin the s tructure .

Page 11

PRODUCT IDENTIFICATION

MODEL # MFG # DESCRIPTION

Ex ternal F i l ter R ac k Kit. For use with Goodman® and Ama na ® Brand 90% upflow variabl e speed gas

fu rn ace models. This kit i s intend ed to provide a lo cation , exte rn al to th e fu rnace casin g , f or

EFR02

HASFK-1 HASFK-2 HASFK-3

LPLP03

LPM-08

N/A

install ation of a permanent filter. The rack is mounted over the indoor a ir blower compartment area of either side panel, and provide filter retention as well as a location for attaching return ai r ductwork.

High Alti tude Natural G a s Kit & LP Kit. Used on se l e cted Goodman® Brand a nd Amana® Brand 90% two stage furnace models. These kits are required when installing the furnaces above their maxi m um rated alti tude. The orifices in th e kit have been selecte d as a resu lt of testi ng with the American Gas Association. They will provide appropriate derating at the altitude listed in the High A ltitud e Charts as s how n i n the instal lati ons of the k it.

LP Gas Low Pressure Kit. Designed for application on Goodman® and Amana® Brand's gas furnace products installed on LP gas listed in this manual. This kit includes harness adaptors to work with White-Rodgers single & two stage gas valves,Honeywell single and two-s tage gas valves, as well as modulating gas valves.

LP Conve rsi on Kit. For use with Goodman® and Amana® Brand 34.5" 2-s tage va riable spee d models using a White-Rodgers 36J54,, 2-stage gas valve kit. Includes regulator springs, 1.25mm orifices, ins tructions and a label to show the furnace ha s been converted to L.P.

Page 12

ACCESSORIES

96% Com Furnace Accessories

Model

Number

Desc ription

*MVC960403 BN** X X X X X

*MVC960603 BN** X X X X X

*MVC960803 BN** X X X X X

*MVC960804 CN** X X X X X

*MVC961005CN** X X X X X

*MVC961005DN X X X X X

*MVC961205DN** X X X X X

*CVC960403BN** X X X X X

*CVC960603BN** X X X X X

*CVC960804CN** X X X X X

*CVC961005CN** X X X X X

*CVC961205DN** X X X X X

AFE180-60A AMU / GMU EFR02 ASAS / G S AS CFSB17 CFSB21 CFS B24 RF000142

Fossil

Fuel

Kit

Media Air

Cleaners

Exte rna l

Filte r Rack

Electronic

Air

Cleane r

Downflow

Subbase

17.5"

Downflow

Subbase

21"

Downflow

Subba se

24.5"

Drain

Coupling

Kit

Model

Number

Desc ription

*MVC960403BN**XXXXXXXX *MVC960603BN**XXXXXXXX *MVC960803BN**XXXXXXXX *MVC960804CN**XXXXXXXX *MVC961005CN** X X X X X X *MVC961005DN X X X X X X *MVC961205DN** X X X X X X *CVC960403BN**XXXXXXXX *CVC960603BN**XXXXXXXX *CVC960804CN**XXXXXXXX *CVC961005CN** X X X X X X *CVC961205DN** X X X X X X

CTK01* CTK02* CTK03* CTK04* 0170K00000S 0170K00001S

Com.

Thermosta t

Kit

Com

Thermostat

Kit

Modulating,

High Def

Com

Thermosta

Kit

Modulating,

High Def

Com

Thermostat

Kit

Modulating,

High Def

Conc e ntric

Side Wall

Vent Kit (3 ")

Conce ntric

Side Wall

Vent Kit (2")

DCVK- 20

(CVENT- 2 )

Conc e ntric

Vent Kit (2 ")

DCVK- 3 0

(CVENT- 3 )

Conce ntric

Vent Kit (3")

Page 13

ACCESSORIES

96% Com Furnace Accessories

Model

Number

Description Dehumidistat L.P . Kit

*MVC960403BN**XXXXX

*MVC960603BN**XXXXX

*MVC960803BN**XXXXX

*MVC960804CN**XXX XX

*MVC961005CN**XXX XX

*MVC961005DNXXX XX

*MVC961205DN**XXX XX

*CVC960403BN** XXXXX

*CVC960603BN** XXXXX

*CVC960804CN** X X X X X

*CVC961005CN**XXX XX

*CVC961205DN**XXX XX

DEHUM1 LPM- 08 LPLP 03 HASFK- 1 HASFK- 1 HASFK- 2 HASFK- 2 HASFK- 3 HASFK- 3

Low LP

Tank

Protection

High Altitude

Natural Gas Kit

Kit

High Altitude

LP Gas Kit

Kit

High Altitude

Natural Gas Kit

Kit

High Altitude

LP G as Kit

Kit

High Altitude

Natural Gas Kit

Kit

High Altitude

LP Gas Kit

Kit

Page 14

ACCESSORIES

EXTERNAL FILTER RACK (EFR02)

96% Upflow Model Furnaces

FRONT

OF UNIT

BASE

OF UNIT

UNIT SIDE

PANEL

RETURN AIR

CUTOUT AREA

SLOTS IN FILTER CLEAR SCREWS

ON UNIT

BLOWER DECK

SCREWS

LOWER EDGE

SCREW

FILTER RACK ASSEMBLY

(FACE FILTER OPENING

TOWARDS FRONT

OF UNIT)

SIDE WALL VENT KITS (0170K00000S) (0170K00001S)

Description 0170K00000S

This side wall only vent kit #0170K00000S is to be used with 2” - 3” vent systems. This kit is NOT intended for use with single pipe (indirect vent) installations.

The vent kit must terminate outside the structure and may be installed with the intake and exhaust pipes located side-byside or with one pipe above the other.

See the section in this manual under "Vent Flue and Combustion Air Pipe Terminations" for more information or consult the Installation Instructions (IO-635).

0170K00001S

This vent kit is to be used with 2” vent systems. The vent kit must terminate outside the structure and may be installed with the intake and exhaust pipes located side-by side or with one pipe above the other. This kit is NOT intended for use with single pipe (indirect vent) installations.

See the section in this manual under "Vent Flue and Combustion Air Pipe Terminations" for more information or consult the Installation Instructions (IO-805).

Horizontal Installation

Vertica l I n s tallatio n

Page 15

ACCESSORIES

CONCENTRIC VENT CONVERSION KIT

The CVENT-2 (DCVK20) (2") or the CVENT-3 (DCVK-30) (3") is a concentric vent kit approved with furnaces listed in this manual.

This concentric vent kit allows for vertical or horizontal vent termination. The illustrations give a brief view of the kit and its application.

See the section in this manual under "Vent Flue and Combustion Air Pipe Terminations" for more information or consult the Installation and Operating Instructions (IO-619*).

Vent

Maintain 12" (18" for Canada) minimum clearance above highest anticipated snow level. Maximum of

Combustion Air

24" above roof.

Roof Boot/Flashing (Field Supplied)

Support (Field Supplied)

45 Elbow (Field Supplied)

Vent

Combustion Air

DCVK (Vertical Installation)

AFE18-60A Dual Fuel Accessory

When installing the communicating capable furnace with a heat pump, the preferred installation would include a communicating thermostat. A communicating thermostat provides control of gas heat and heat pump operation and eliminates the need for a separate dual fuel control. A legacy dual fuel thermostat could also be used with 24 volt wiring to control the gas furnace and heat pump. If a communicating thermostat or legacy dual fuel thermostat are not used, the AFE18-60A kit must be added to provide control of the equipment. This control is mounted indoors near the furnace and provides terminals for thermostat, furnace, and heat pump wiring. The AFE18-60A may be used with or without a separate outdoor thermostat.

CFSB17, 21, 24 Counter Flow Base

The CFSB base must be used when installing a *CVC96 furnace in the vertical position on a combustible floor without a coil under the furnace.

Vent

Combustion Air

Strap (Field Supplied)

45 Elbow (Field Supplied)

Combustion Air

Flush to

1" maximum

DCVK (Horizontal Installation)

LPLP03 Low LP Gas Pressure Shut-off Kit

Installation of the LPLP03 kit is recommended on every L.P. converted furnace to protect the furnace against low L.P. gas supply pressure. Low L.P. supply pressure can cause poor combustion and carbon in the heat exchanger. The LPLP03 kit will open the electrical circuit to the gas valve in the event of low supply pressure. The kit contains a pressure switch, gas fittings and electrical harness to connect the switch in series with the gas valve.

LPM-08 LP Conversion Kit

This furnace is factory equipped to operate on Natural Gas but may be field converted to operate on L.P. gas. To convert a *MVC96 or *CVC96 furnace to operate on L.P. gas, the LPM-08 conversion kit must be used. The LPM-08 kit contains a set of 1.25 mm orifices to replace the factory installed natural gas orifices and a set of springs to convert the gas valve to L.P. gas.

OT18-60A Outdoor Thermostat

For use in a legacy dual fuel installation to lock-out the heat pump at a selected temperature.

Vent

Page 16

INST ALLATION CONSIDERA TIONS

Safety

Please adhere to the following warnings and cautions when installing, adjusting, altering, servicing, or operating the furnace.

WARNING

O PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION, ADJUSTMENT, ALTERATI ON, SERV ICE OR MAINTENANCE, R EFER TO THI S MANUAL. QUALIFIED INSTALLE R, SERVICE AGENCY OR THE GAS SUPPLIER.

OR ADDITIONAL ASSISTANCE OR INFORMATION, CONSULT A

WARNING

HIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS WHICH

MAY CAUSE SERI OUS ILLNESS OR DEATH AN D WHICH ARE KNOWN TO THE

TATE OF CALIFORNIA TO CAUSE CANCER, BI RTH DEFECTS OR OTHER

REPRODUCTIVE HARM.

WARNING

TO PREVENT POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH

DUE TO ELECTRICAL SHOCK, THE FURNACE MUST BE LOCATED TO PROTECT THE ELEC TRICA L COMPON ENTS FROM WAT ER.

Charge (ESD) Precautions NOTE: Discharge body’s static electricity before touching

unit. An electrostatic discharge can adversely affect electrical components.

Use the following precautions during furnace installation and servicing to protect the integrated control module from damage. By putting the furnace, the control, and the person at the same electrostatic potential, these steps will help avoid exposing the integrated control module to electrostatic discharge. This procedure is applicable to both installed and uninstalled (ungrounded) furnaces.

1. Disconnect all power to the furnace. Do not touch the integrated control module or any wire connected to the control prior to discharging your body’s electrostatic charge to ground.

2. Firmly touch a clean, unpainted, metal surface of the furnace near the control. Any tools held in a person’s hand during grounding will be discharged.

3. Service integrated control module or connecting wiring following the discharge process in Step 2. Use caution not to recharge your body with static electricity; (i.e., do not move or shuffle your feet, do not touch ungrounded objects, etc.). If you come in contact with an ungrounded object, repeat Step 2 before touching control or wires.

4. Discharge any static electricity from your body to ground before removing a new control from its container. Follow Steps 1 through 3 if installing the control on a furnace. Return any old or new controls to their containers before touching any ungrounded object.

Product Application

This product is designed for use as a residential home gas furnace. It is not designed or certified for use in mobile home, trailer, or recreational vehicle applications.

This furnace can be used in the following non-industrial commercial applications: Schools, Office buildings, Churches,

Retail stores, Nursing homes, Hotels/motels, Common or office areas. In such applications, the furnace must be installed

with the

Goodman® Brand and Amana® Brand 90% furnaces are ETL certified appliances and are appropriate for use with natural or propane gas. (NOTE: If using propane gas, a propane conversion kit is required).

Dual certification means that the combustion air inlet pipe is optional and the furnace can be vented as a:

To ensure proper installation, operation and servicing, thoroughly read the installation and service manuals for specifics pertaining to the installation, servicing and application of this product.

OSSIBLE PROPERTY D AMAGE, PERSONAL INJ URY OR DEATH DUE TO FIRE,

EXPLOSION, SMOKE, S OOT, CONDENSTAION, E LECTRICAL SHOCK OR C ARBON MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION, RE PAIR, OPERATI ON, OR MAINTENANCE OF THI S PRODUCT.

O PREVENT PROPERTY DAMAGE, PERSONAL INJ URY OR DEATH D UE TO FIRE, DO NOT INSTALL T HIS FURNACE IN A MOBILE HOME, TRAILER, OR RECREATIONAL VEHICLE.

To ensure proper furnace operation, install, operate, maintain and service the furnace in accordance with the installation, operation and service instructions, all local building codes and ordinances. In their absence, follow the latest edition of the National Fuel Gas Code (NFPA 54/ANSI Z223.1), and/or CAN/CGA B149 Installation Codes, local plumbing or waste water codes, and other applicable codes.

A copy of the National Fuel Gas Code (NFPA 54/ANSI Z223.1) can be obtained from any of the following:

installation instructions.

Non-direct vent (single pipe) central forced air furnace in which combustion air is taken from the installation area or from air ducted from the outside or,

Direct vent (dual pipe) central forced air furnace in which all combustion air supplied directly to the furnace burners through a special air intake system outlined in this manual and the installation instructions.

WARNING

American National Standards Institute 25 West 43rd Street, 4th Floor New York, NY 10036

Page 17

INST ALLATION CONSIDERA TIONS

• Set the 90% furnace on a level floor to enable proper National Fire Protection Association 1 Batterymarch Park Quincy, MA 02169-7471

The rated heating capacity of the furnace should be greater than or equal to the total heat loss of the area to be heated. The total heat loss should be calculated by an approved method or in accordance with “ASHRAE Guide” or “Manual J-Load Calculations” published by the Air Conditioning Contractors of America.

Location Requirements and Considerations

WARNING

O PREVENT POSSIBLE EQUI PMENT DAMAGE, PROPERTY DAMAGE, PERSONAL

INJURY OR DEATH, THE FO LLOWING BULLET P OINTS MUST BE OBSERVED WHEN INSTALLING THE UNIT.

Follow the instructions listed below when selecting a furnace location. Refer also to the guidelines provided in the Combustion and Ventilation Air Requirements section in this manual or the installation instructions for details.

• Centrally locate the furnace with respect to the proposed or existing air distribution system.

• Ensure the temperature of the return air entering the furnace is between 55°F and 100°F when the furnace is heating.

• If the furnace is installed in an application where the typical operating sound level of a furnace is deemed objectionable, an optional sound reduction kit is available. Consult your local distributor for more details.

• Provide provisions for venting combustion products outdoors through a proper venting system. Special consideration should be given to vent/flue pipe routing and combustion air intake pipe when applicable.

90% Furnaces: Refer to the Vent/Flue Pipe and Com- bustion Air Pipe -Termination Locations section in this

manual or the installation instructions for appropriate termination locations. Also for 90% furnaces, refer to the Vent/Flue Pipe and Combustion Air Pipe -Termi- nation Locations section in this manual or the installation instructions to determine if the piping system from furnace to termination can be accomplished within the guidelines given. NOTE: The length of flue and/or combustion air piping can be a limiting factor in the location of the furnace.

• Locate the 90% furnace so that the condensate can be piped at a downward slope away from the furnace to the drain. Do not locate the furnace or its condensate drainage system in any area subject to below freezing temperatures without proper freeze protection. Refer to the Condensate Drain Lines and Trap section in this manual or the installation instructions for further details.

• Ensure upflow or horizontal furnaces are not installed

• A special accessory subbase must be used for up-

• Exposure to contaminated combustion air will result

• Isolate a non-direct furnace from an area contaminated

• If the furnace is used in connection with a cooling

condensate drainage. If the floor becomes wet or damp at times, place the furnace above the floor on a concrete base sized approximately 1-1/2" larger than the base of the furnace. Refer to the Horizontal Applica- tions and Considerations section in this manual or the installation instructions for leveling of horizontal furnaces.

directly on carpeting, or any other combustible material. The only combustible material allowed is wood.

right counterflow unit installations over any combustible material (including wood). Refer to subbase instructions for installation details. (NOTE: A subbase will not be required if an air conditioning coil is located beneath the furnace between the supply air opening and the combustible floor.

in safety and performance-related problems. Do not install the furnace where the combustion air is exposed to the following substances:

chlorinated waxes or cleaners chlorine-based swimming pool chemicals water softening chemicals deicing salts or chemicals carbon tetrachloride halogen type refrigerants cleaning solutions (such as perchloroethylene) printing inks paint removers varnishes hydrochloric acid cements and glues antistatic fabric softeners for clothes dryers and masonry acid washing materials

by any of the above substances. This protects the non-direct vent furnace from airborne contaminants. To ensure that the enclosed non-direct vent furnace has an adequate supply of combustion air, vent from a nearby uncontaminated room or from outdoors. Refer to the Combustion and Ventilation Air Require- ments section in this manual or the installation instructions for details.

unit, install the furnace upstream or in parallel with the cooling unit coil. Premature heat exchanger failure will result if the cooling unit coil is placed in the return air of the furnace.

Page 18

INST ALLATION CONSIDERA TIONS

• If the furnace is installed in a residential garage, position the furnace so that the burners and ignition source are located not less than 18 inches (457 mm) above the floor. Protect the furnace from physical damage by vehicles.

• If the furnace is installed horizontally, the furnace access doors must be vertical so that the burners fire horizontally into the heat exchanger. Do not install the unit with the access doors on the “up/top” or “down/ bottom” side of the furnace.

Clearances and Accessibility

Installations must adhere to the clearances to combustible materials to which this furnace has been design certified. The minimum clearance information for this furnace is provided on the unit’s clearance label. These clearances must be permanently maintained. Refer to Specification Sheet for minimum clearances to combustible materials. Clearances must also accommodate an installation’s gas, electrical, and drain trap and drain line connections. If the alternate combustion air intake or vent/flue connections are used on a 90% furnace, additional clearances must be provided to accommodate these connections. Refer to Vent Flue Pipe and Combustion Air Pipe section in this manual or the installation instructions for details. NOTE: In addition to the required clearances to combustible materials, a minimum of 24 inches service clearance must be available in front of the unit.

A furnace installed in a confined space (i.e., a closet or utility room) must have two ventilation openings with a total minimum free area of 0.25 square inches per 1,000 BTU/hr of furnace input rating. One of the ventilation openings must be within 12 inches of the top; the other opening must be within 12 inches of the bottom of the confined space. In a typical construction, the clearance between the door and door frame is usually adequate to satisfy this ventilation requirement.

Furnace Suspension

If suspending the furnace from rafters or joist, use 3/8" threaded rod and 2”x2”x1/8” angle iron as shown in the following figure. If the furnace is installed in a crawl space it must also be suspended from the floor joist or supported by a concrete pad. Never install the furnace on the ground or allow it to be exposed to water. The length of rod will depend on the application and the clearances necessary.

3/8" DIAMETER

THREADED ROD

HOLD DOWN

NUTS

SUPPORT

NUTS

GAS PIPING

2"X2"X1/8" ANGLE IRON

(3 PLACES)

EXISTING FURNACE REMOVAL

NOTE: When an existing furnace is removed from a venting

system serving other appliances, the venting system may be too large to properly vent the remaining attached appliances.

The following vent testing procedure is reproduced from the

American National Standard/National Standard of Canada for Gas-Fired Central Furnaces ANSI Z21.47, latest edition, CSA-2.3b, latest edition Section 1.23.1.

The following steps shall be followed with each appliance connected to the venting system placed in operation, while any other appliances connected to the venting system are not in operation:

a. Seal any unused openings in the venting system; b. Inspect the venting system for proper size and horizontal pitch,

c. In so far as practical, close all building doors and windows and all

d. Follow the lighting instructions. Place the appliance being in-

e. Test for draft hood equipped spillage at the draft hood relief

f. After it has been determined that each appliance connected to the

g . If improper venting is observed during any of the above tests, the

Corrections must be in accordance with the latest edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1 and/or CSA B149 Installation Codes.

PROVIDE 8" MINIMUM CLEARANCE BETWEEN

CENTER ROD AND FURNACE CABINET

TO ALLOW FOR CIRCULATOR BLOWER REMOVAL.

ASSURE FURNACE IS LEVEL FROM

END TO END.

90% FURNACES MAKE SURE

THE UNIT HAS A SLIGHT

FORWARD TILT WITH THE FRONT

OF THE FURNACE 0"-3/4"

BELOW THE BACK OF THE FURNACE.

CONDENSATE

DRAIN

TILT OUTWARD TO ALLOW FOR

DOOR AND CIRCULATOR BLOWER

REMOVAL.

(6 PLACES)

ALTERNATE GAS PIPING

POSITION AS CLOSE AS POSSIBLE TO BLOWER DECK TO ALLOW FOR

CIRCULATOR BLOWER REMOVAL.

90% Suspended Furnace Shown

as required by the National Fuel Gas Code, ANSI Z223.1 or the CSA B149 Installation Codes and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition;

doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers;

spected in operation. Adjust thermostat so appliance shall operate continuously;

opening after 5 minutes of main burner operation. Use the flame of a match or candle;

venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous conditions of use;

common venting system must be corrected.

Page 19

INST ALLATION CONSIDERA TIONS

If resizing is required on any portion of the venting system, use the appropriate table in Appendix G in the latest edition of the National Fuel Gas Code ANSI Z223.1 and/or CSA B149

Installation Codes.

Thermostat Requirements

The optional CTK0*** thermostat kit may be used with ComfortNet™ compatable furnaces (ACVC, AMVC, GCVC, GMVC models). Refer to System Operation - ComfortNet™ System for details.

NOTE: A single-stage thermostat with only one heating stage can be used to control a two-stage furnace. The application of a single-stage thermostat does not offer "true" thermostat driven two-stage operation, but provides a timed transition from low to high fire. The furnace will run on low stage for a fixed period of time before stepping up to high stage to satisfy the thermostat's call for heat. The delay period prior to stepping up can be set at either 5 or 10 minutes through the DIP switch adjacent to the Heat Off delay DIP switches on the integrated control module. To use a single-stage thermostat, turn off power to the furnace, move the thermostat selection jumper on the integrated contro module from the "two-stage" position to the "single-stage" position, turn power back on. Refer to DIP switch charts on pages 41 & 42.

NOTE: A single-stage thermostat with only one heating stage may be used to control ComfortNet™ compatible furnaces (ACVC, AMVC, GCVC, GMVC models). The application of a single-stage thermostat does not offer “true” thermostatdriven two-stage operation, but provides a timed transition from low to high fire. The furnace will run on low stage for a fixed period of time before stepping up to high stage to satisfy the thermostat’s call for heat. The delay period prior to stepping up can be set at either a fixed 5 minute time delay or a load based variable time between 1 and 12 minutes (AUTO mode). If the AUTOmode is selected, the control averages the cycle times of the previous three cycles and uses the average to determine the time to transition from low stage to high stage.

To use a single-stage thermostat, turn off power to the furnace, move the thermostat selection DIP switch to the OFF position. Set the desired transition time by setting the transition delay DIP switch to the desired ON/OFF position. Turn power back on. Refer to DIP switch charts on pages 41 &

42.

Dehumidistat Requirements

A dehumidistat can be used in conjunction with the twostage variable speed furnace to lower the humidity in the conditioned space. The dehumidistat will improve dehumidification of the conditioned air by prompting the furnace to reduce the speed of the circulator blower during operation in the cooling mode. To be compatible with these furnaces, a dehumidistat must operate on 24 VAC and utilize a switch

which opens on humidity rise. Refer to Electrical Connec- tions - 24 Volt Dehumidistat Wiring section in this manual or the installation instructions for correct installation procedure.

Thermostat and Dehumidistat Location

In an area having good air circulation, locate the thermostat and dehumidistat (if applicable) about five feet high on a vibration-free inside wall. Do not install the thermostat or dehumidistat where it may be influenced by any of the following:

• Drafts, or dead spots behind doors, in corners, or un-

• Hot or cold air from registers.

• Radiant heat from the sun.

• Light fixtures or other appliances.

• Radiant heat from a fireplace.

• Concealed hot or cold water pipes, or chimneys.

• Unconditioned areas behind the thermostat and de-

Consult the instructions packaged with the thermostat and dehumidistat for mounting instructions and further precautions.

COMBUSTION AND VENTILATION AIR REQUIREMENTS

OSSIBLE PROPERTY DAMAGE, PERSONAL I NJURY OR DEATH MAY OCCUR

IF THE FURNACE I S NOT PR OVIDED WITH ENOUGH FRESH AIR FOR PROPER COMBUSTION AND VENTIL ATION OF F LUE GASES. MOST HOMES REQUI RE OUTSIDE AIR BE SUPPLIED TO THE FURNACE AREA.

Improved construction and additional insulation in buildings have reduced heat loss by reducing air infiltration and escape around doors and windows. These changes have helped in reducing heating/cooling costs but have created a problem supplying combustion and ventilation air for gas fired and other fuel burning appliances. Appliances that pull air out of the house (clothes dryers, exhaust fans, fireplaces, etc.) increase the problem by starving appliances for air.

When the furnace is installed as a direct vent (2-pipe) furnace, no special provisions for air for combustion are required. However, if this furnace is to be installed in the same space with other gas appliances, such as a water heater, ensure there is an adequate supply of combustion and ventilation air for the other appliances. Refer to the latest edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1 (Section 9.3), or CAN/CGA B149 Installation Codes (Sections 7.2, 7.3, or 7.4), or applicable provisions of the local building codes for determining the combustion air requirements for the appliances.

der cabinets.

humidistat, such as an outside wall.

WARNING

Page 20

INST ALLATION CONSIDERA TIONS

Most homes will require outside air be supplied to the furnace area by means of ventilation grilles or ducts connecting directly to the outdoors or spaces open to the outdoors such as attics or crawl spaces.

The following information on air for combustion and ventilation is reproduced from the National Fuel Gas Code NFPA 54/ANSI

Z223.1 Section 9.3.

9.3* Air for Combustion and Ventilation.

9.3.1 General.

9.3.1.1 Air for combustion, ventilation, and dilution of flue gases for

appliances installed in buildings shall be obtained by application of one of the methods covered in 9.3.2 through 9.3.6. Where the requirements of 9.3.2 are not met, outdoor air shall be introduced in accordance with methods covered in 9.3.3 through 9.3.6.

Exception No. 1: This provision shall not apply to direct vent appliances.

9.3.1.2 Appliances of other than natural draft design and other than Category 1 vented appliances shall be provided with combustion, ventilation, and dilution air in accordance with the appliance manufacturer’s instructions.

9.3.1.3 Appliances shall be located so as not to interfere with proper circulation of combustion, ventilation, and dilution air.

9.3.1.4 Where used, a draft hood or a barometric draft regulator shall be installed in the same room or enclosure as the appliance served so as to prevent any difference in pressure between the hood or regulator and the combustion air supply.

(2) For fan-assisted appliances, calculate using the following equation:

Required Volume

where:

other

fan

ACH = air change per hour (percent of volume of space exchanged

(3) For purposes of this calculation, an infiltration rate greater than

0.60 ACH shall not be used in the equations in 9.3.2.2(1) and

9.3.2.2(2).

9.3.2.3 Indoor Opening Size and Location. Openings used to connect indoor spaces shall be sized and located in accordance with the following:

(1)*Combining spaces on the same story. Each opening shall have a

minimum free area of 1 in. input rating of all appliances in the space but not less than 100 in. (0.60m2). One opening shall commence within 12 in. (300 mm) of the top, and one opening shall commence within 12 in. (300 mm) of the bottom, of the enclosure [see Figure A.9.3.2.3(1)]. The mini- mum dimension of air openings shall be not less than 3 in. (80 mm).

NOTE: Each opening must have a free area of not less than one square inch per 1000 BTU of the total input rating of all equipment in the enclosure, but not less than 100 square inches.

> ________ _________

fan

15 ft

ACH 1000 Btu/hr

fan

(

)

= all appliances other than fan-assisted input in Btu per

hour

= fan-assisted appliances input in Btu per hour

per hour, expressed as a decimal)

/1000Btu/hr (2200 mm2/kW) of the total

Chimney or Gas Vent

9.3.1.5 Makeup air requirements for the operation of exhaust fans, kitchen ventilation systems, clothes dryers, and fireplaces shall be considered in determining the adequacy of a space to provide combustion air requirements.

9.3.2 Indoor Combustion Air . The required volume of indoor air shall be determined in accordance with the method in 9.3.2.1 or 9.3.2.2 except that where the air infiltration rate is known to be less than 0.40 ACH, the method in 9.3.2.2 shall be used. The total required volume shall be the sum of the required volume calculated for all appliances located within the space. Rooms communicating directly with the space in which the appliances are installed through openings not furnished with doors, and through combustion air openings sized and located in accordance with 9.3.2.3, are considered a part of the required volume.

9.3.2.1* Standard Method. The minimum required volume shall be 50 ft 3 per 1,000/Btu/hour (4.8m3/kW).

9.3.2.2* Known Air Infiltration Rate Method. Where the air infiltration rate of a structure is known, the minimum required volume shall be determined as follows:

(1) For appliances other than fan-assisted, calculate using the following

equation: Required Volume

> ________ _________

other

21 ft

ACH 1000 Btu/hr

other

(

)

Opening

Water Heater

Furnace

Opening

Figure A.9.2.3.3.(1) All Combustion Air from Adjacent

Indoor Spaces through Indoor Combustion Air Openings.

(2) Combining spaces in different stories. The volumes of spaces in

different stories shall be considered as communicating spaces where such spaces are connected by one or more openings in doors or floors having a total minimum free area of 2 in.2/1000 Btu/hr (4400 mm2/kW) of total input rating of all appliances.

9.3.3 Outdoor Combustion Air. Outdoor combustion air shall be provided through opening(s) to the outdoors in accordance with the methods in 9.3.3.1 or 9.3.3.2. The minimum dimension of air openings shall not be less than 3 in. (80 mm).

9.3.3.1 Two Permanent Openings Method. Two permanent openings, one commencing within 12 in. (300 mm) of the top and one commencing within 12 in. (300 mm) of the bottom, of the enclosure shall be provided. The openings shall communicate directly, or by ducts, with the outdoors or spaces that freely communicate with the outdoors, as follows:

Page 21

INST ALLATION CONSIDERA TIONS

(1)*Where directly communicating with the outdoors or where commu-

nicating to the outdoors through vertical ducts, each opening shall have a minimum free area of 1 in.2/4000 Btu/hr (550 min2/kW) of total input rating of all appliances in the enclosure. [See Figure

A.9.3.3.1(1)(a) and Figure A.9.3.3.1(1)(b).]

Chimney or Gas Vent

Ventilation louvers (each end of attic)

NOTE: The inlet and outlet a ir openings must each have a free area of not less than one square inch per 4000 BTU of the total input rating of all equipment in the enclosure.

Outlet Air

Water Heater

lternate

air inlet

Furnace

Ventilation louvers for unheated crawl space

Inlet Air

Figure A.9.3.3.1(1)(a) All Combustion Air Fr om Outdoors -

Inlet Air from Ventilated Crawl Space and Outlet Air

to Ventilated Attic.

9.3.3.2* One Permanent Opening Method. One permanent open-

ings, commencing within 12 in. (300 mm) of the top of the enclosure, shall be provided. The appliance shall have clearances of at least 1 in. (25 mm) from the sides and back and 6 in. (150 mm) from the front of the appliance. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors (see Figure A.9.3.3.2) and shall have a minimum free area of the following: (1) 1 in.

appliances located in the enclosure, and

(2) Not less than the sum of the areas of all vent connectors in the

space.

Chimney or Gas Vent

NOTE: The air duct openings must have a free a r ea o f not less than one square inch per 2000 BTU of the total input rating of all equipment in the enclosure*.

Furnace

Water Heater

Outlet air duct

Inlet air duct

Figure A.9.3.3.1(2) All Combustion Air From Outdoors

through Horizontal Ducts.

/3000 Btu/hr (700 mm2 per kW) of the total input rating of all

Chimney or Gas Vent

Ventilation louvers (each end of attic)

NOTE: The inlet and outlet air openings must each have a free area of not less than one square inch per 4000 BTU of the total input rating of all equipmen t in the enclosure.

Outlet Air

Water Heater

Furnace

Inlet air duct [ends 1 ft (300 mm) above floor]

Figure A.9.3.3.1(1)(b) All Combustion Air

From Outdoors through Ventilated Attic.

(2)*Where communicating with the outdoors through horizontal ducts,

each opening shall have a minimum free area of 1 in.2/2000 Btu/hr (1100 min2/kW) of total input rating of all appliances in the enclosure. [See Figure A.9.3.3.1(2).]

NOTE: The single opening must have a free area of not less than one square inch per 30 00 BT U o f the total in p ut rat i ng of all equipment in th e enclosure, but not less than the sum of the areas of all vent connecto rs in the confined space.

Chimney or Gas Vent

Furnace

Water Heater

Opening

Alternate Opening Location

Figure A.9.3.3.2 All Combustion Air

From Outdoors through Single Combustion Air Opening.

9.3.4 Combination Indoor and Outdoor Combustion Air. The use of

a combination of indoor and outdoor combustion air shall be in accordance with (1) through (3) (see example calculation in Annex J]:

(1) Indoor Openings: Where used, openings connecting the interior

spaces shall comply with 9.3.2.3.

(2) Outdoor Opening(s) Location. Outdoor opening(s) shall be located

in accordance with 9.3.3.

(3) Outdoor Opening(s) Size. The outdoor opening(s) size shall be

calculated in accordance with the following:

(a) The ratio of the interior spaces shall be the available volume of

all communicating spaces divided by the required volume.

(b) The outdoor size reduction factor shall be 1 minus the ratio of

interior spaces.

Page 22

INST ALLATION CONSIDERA TIONS

of outdoor opening(s) calculated in accordance with 9.3.3, multiplied by the reduction factor. The minimum dimension of air openings shall not be less than 3 in. (80 mm).

9.3.8.4 Ducts shall not serve both upper and lower combustion air openings where both such openings are used. The separation between ducts servicing upper and lower combustion air openings shall be maintained to the source of combustion air.

9.3.5 Engineered Installations. Engineered combustion air installations shall provide an adequate supply of combustion, ventilation, and dilution air and shall be approved by the authority having jurisdiction.

9.3.6 Mechanical Combustion Air Supply. Where all combustion air is provided by a mechanical air supply system, the combustion air shall be supplied form outdoors at the minimum rate of 0.35 ft3/min per 1000 Btu/hr (0.034 m space.

9.3.6.1 Where exhaust fans are installed, additional air shall be provided to replace the exhausted air.

9.3.6.2 Each of the appliances served shall be interlocked to the mechanical air supply system to prevent main burner operation where the mechanical air supply system is not in operation.

9.3.6.3 Where combustion air is provided by the building’ s mechanical ventilation system, the system shall provide the specified combustion air rate in addition to the required ventilation air.

9.3.7 Louvers, Grilles, and Screens.

9.3.7.1 Louvers and Grilles. The required size of openings for com-

bustion, ventilation, and dilution air shall be based on the net free area of each opening. Where the free area through a design of louver or grille or screen is known, it shall be used in calculating the size opening required to provide the free area specified. Where the louver and grille design and free area are not known, it shall be assumed that wood louvers will have 25 percent free area, and metal louvers and grilles will have 75 percent free area. Nonmotorized louvers and grilles shall be fixed in the open position.

/min per kW) for all appliances located within the

9.3.8.5 Ducts shall not be screened where terminating in an attic space.

9.3.8.6 Horizontal upper combustion air ducts shall not slope down-

ward toward the source of combustion air.

9.3.8.7 The remaining space surrounding a chimney liner, gas vent, special gas vent, or plastic piping installed within a masonry, metal, or factory built chimney shall not be used to supply combustion air.

Exception: Direct vent appliances designed for installation in a solid fuel-burning fireplace where installed in accordance with the manufacture’s installation instructions.

9.3.8.8 Combustion air intake openings located on the exterior of the building shall have the lowest side of the combustion air intake openings located at least 12 in. (300 mm) vertically from the adjoining grade level.

Horizontal Applications and Considerations

Horizontal applications, in particular, may dictate many of the installation’s specifics such as airflow direction, ductwork connections, flue and/or combustion air pipe connections, etc. The basic application of this furnace as a horizontal furnace differs only slightly from an upright installation. When installing a furnace horizontally, additional consideration must be given to the following:

9.3.7.2 Minimum Scree Mesh Size. Screens shall not be smaller than 1/4 in. mesh.

9.3.7.3 Motorized Louvers. Motorized louvers shall be interlocked with the appliance so they are proven in the full open position prior to main burner ignition and during main burner operation. Means shall be provided to prevent the main burner form igniting should the louver fail to open during burner startup and to shut down the main burner if the louvers close during burner operation.

9.3.8 Combustion Air Ducts. Combustion air ducts shall comply with

9.3.8.1 through 9.3.8.8.

9.3.8.1 Ducts shall be constructed of galvanized steel or a material having equivalent corrosion resistance, strength, and rigidity.

Exception: Within dwellings units, unobstructed stud and joist spaces shall not be prohibited from conveying combustion air, provided that not more than one fireblock is removed.

9.3.8.2 Ducts shall terminate in an unobstructed space, allowing free movement of combustion air to the appliances.

9.3.8.3 Ducts shall serve a single space.

90% Horizontal Furnace Shown

Page 23

INST ALLATION CONSIDERA TIONS

Installation Positions

*MVC96 models may be installed up flow or horizontally with left or right side down. *CVC96 models may be installed down flow or horizontally with left or right side down. Do not install any furnace on its back.

Horizontal Installations

1. Horizontal installations require 5.5" under the furnace to accommodate the drain trap.

2. Horizontal furnaces must be installed with ¾” slope from back to front to permit condensate flow towards the front of the furnace.

When installing a *MVC96 horizontally with the left side down, there are two options for connecting the vent pipe to the furnace.

1. Venting may be connected to the furnace vent pipe fitting on the original top (now the end) of the furnace

2. The internal vent pipe and elbow may be removed from the furnace to permit the vent to exit the top (original side) of the furnace. If this option is used, an RF000142 Vent-Drain coupling must be used to keep condensate from collecting in the inducer assembly.

Refer to the following instructions and illustration.

1. Remove screws from vent flange.

2. Remove internal elbow and vent pipe.

3. Cut pipe 2 1/2” from flange.

4. Remove cabinet plug adjacent to inducer outlet and install an original cabinet vent hole.

5. Install RF000142 coupling on inducer outlet.

6. Install flanged vent section removed in step 2 & secure with clamps.

7. Secure flange to cabinet using screws removed in step

E R E

H T

U C

Vent/Flue Pipe Cuts

R 000142F

Insert flange. Cut 2 ½” long.

90% Furnace Recommended Installation Positions

NOTE: Alternate "vertical" piping connections can not be

used when an upflow 90% furnace is installed with supply air discharging to the right or when a counterflow furnace is installed with supply discharging to the left. In this case, use the standard flue and combustion air piping connections

Page 24

INST ALLATION CONSIDERA TIONS

Alternate Electrical and Gas Line Connections

The furnaces have provisions allowing for electrical and gas line connections through either side panel. In horizontal applications the connections can be made either through the “top” or “bottom” of the furnace.

Drain Pan

A drain pan must be provided if the furnace is installed above a conditioned area. The drain pan must cover the entire area under the furnace (and air conditioning coil if applicable).

Freeze Protection

If the drain trap and drain line will be exposed to temperatures near or below freezing, adequate measures must be taken to prevent condensate from freezing. NOTE: The use of insulation and/or heat tape is recommended. Failure to provide proper condensate drainage can result in property damage.

Propane Gas and/or High Altitude Installations

WARNING

OSSIBLE PRO PERTY DA MAGE, PERSO NAL IN JURY OR DEATH MAY OCCUR IF THE CORRECT CONV ERSI ON KITS ARE NOT IN STALLE D. MUST BE APPLIE D TO I NSURE SAFE AN D PROPER FURNAC E OPERAT ION. CONVERSIONS MUS T BE PERFORMED BY A QUALIF IE D INSTA LLER OR SERV ICE AGENCY.

THE APPROPRIATE KI TS

ALL

WARNING

UPON COMPLETION OF THE FURNA CE INSTALLATIO N, CAREFULLY I NSPECT THE

ENTIRE FLUE SYSTEM BO TH INSIDE AND OUTSIDE THE FURNACE TO ASS URE IT IS PROPERLY SEALED. PERSONAL INJURY OR DE ATH DUE TO EXPOS URE TO FLUE PRODUCTS, INCLUDING CARBON MONOXIDE.

LEAKS IN THE FLUE SYSTEM CAN RESULT IN SERIOUS

A condensing gas furnace achieves its high level of efficiency by extracting almost all of the heat from the products of combustion and cooling them to the point where condensation takes place. Because of the relatively low flue gas temperature and water condensation requirements, PVC pipe is used as venting material.

This furnace must not be connected to Type B, BW, or L vent or vent connector, and must not be vented into any portion of a factory built or masonry chimney except when used as a pathway for PVC as described later in this section. Never common vent this appliance with another appliance or use a vent which is used by a solid fuel appliance.

It is the responsibility of the installer to follow the manufacturers’ recommendations and to verify that all vent/flue piping and connectors are compatible with furnace flue products. Additionally, it is the responsibility of the installer to ensure that all piping and connections possess adequate structural integrity and support to prevent flue pipe separation, shifting, or sagging during furnace operation.

This furnace is shipped from the factory configured for natural gas at standard altitude. Propane gas installations require an orifice change to compensate for the energy content difference between natural and propane gas.

High altitude installations may require both a pressure switch and an orifice change. These changes are necessary to compensate for the natural reduction in the density of both the gas fuel and the combustion air at higher altitude.

Refer to the Accessories Charts in this manual or product Specification Sheet for a tabular listing of appropriate manufacturer’s kits for propane gas and/or high altitude installations. The indicated kits must be used to insure safe and proper furnace operation. All conversions must be performed by a qualified installer, or service agency.

VENT/FLUE PIPE AND COMBUSTION AIR PIPE

WARNING

AILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN BODILY INJURY OR

DEATH.

CAREFULLY READ AND FOLLOW ALL INSTRUCTIONS GIVEN IN THIS

SECTION.

Materials and Joining Methods

WARNING

O AVOID BODILY INJURY, FIRE OR EXPLOSION, SOLVENT CEMENTS MUST BE KEPT AWAY FROM ALL IGNITION SOURCES (I.E., SPARKS, OPEN FLAMES, AND EXCESSIVE HEAT) AS THEY ARE COMBUSTIBLE LIQUIDS. CEMENT VAPORS OR CONTACT WITH SKIN AND/ OR EYES.

VOID BREATHING

Precautions should be taken to prevent condensate from freezing inside the vent/flue pipe and/or at the vent/flue pipe termination. It is our recommendation that all vent/flue piping exposed to temperatures below 35°F for extended periods of time should be insulated with 1/2” thick closed cell foam. Also all vent/flue piping exposed outdoors in excess of the terminations shown in this manual (or in unheated areas) should be insulated with 1/2” thick closed cell foam. Inspect piping for leaks prior to installing insulation.

The following bullets and diagram describe the restrictions concerning the appropriate location of vent/flue pipe and combustion air intake pipe (when applicable) terminations. Refer to the installation instructions for specific details on termination construction.

• All terminations must be located at least 12 inches above ground level or the anticipated snow level.

• Vent terminations must terminate at least 3 feet above any forced air inlet located within 10 feet.

Page 25

INST ALLATION CONSIDERA TIONS

NOTE: This provision does not apply to the combus-

tion air intake termination of a direct vent application.

• The vent termination of a non-direct vent application must terminate at least 4 feet below, 4 feet horizontally from, or 1 foot above any door, window, or gravity air inlet into any building.

• The vent termination of a direct vent application must terminate at least 12 inches from any opening through which flue gases may enter a building (door, window, or gravity air inlet).

• The vent termination of vent pipe run vertically through a roof must terminate at least 12 inches above the roof line (or the anticipated snow level) and be at least 12 inches from any vertical wall (including any anticipated snow build up).

• A vent termination shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves, or other equipment.

• The combustion air intake termination of a direct vent application should not terminate in an area which is frequently dusty or dirty.

NOTE: In Canada, CAN B149.1 Fuel Gas Code takes precedence over the preceding termination restrictions.

OTHER THAN

COMBUSTION AIR

TERMINATION INTAKE

NON-DIRECT VENT

VENT/FLUE TERMINATION

NO TERMINATIONS

ABOVE WALKWAY

GRADE OR HIGHEST

ANTICIPATED

SNOW LEVEL

FORCED AIR

INLET

10'

12"

DIRECT VENT

VENT/FLUE TERMINATION

12"

VENT/FLUE TERMINATION

12"

NON-DIRECT VENT

90% Furnace Vent Termination Clearances

Direct Vent Installations

On upflow units secure the combustion air intake pipe directly to the air intake coupling. On counterflow units secure the combustion air intake pipe to the air intake coupling using the rubber coupling and worm gear hose clamps provided with the unit. The counterflow rubber coupling allows service removal of air intake piping internal to the furnace blower compartment. The combustion air intake pipe can also be secured directly to the counterflow unit air intake pipe coupling.

Non-Direct Vent Installations

A minimum of one 90° elbow must be installed on the combustion air intake “coupling” to guard against inadvertent blockage.

HE RUBBER ELBOW IS NOT DESIGNED TO SUPPORAT A LOAD. WHEN THE

RUBBER ELBOW IS MOUNTED EXTERNALLY TO THE FURNACE CABINET, EXTREME CARE MUST BE TAKEN TO ADEQUATELY SUPPORT FIELD-SUPPLI ED VENT/FLUE PIPING, AS DAMAGE CAN RESULT IN LEAKS CAUSING BODILY INJURY OR DEATH DUE TO EXPOSURE TO FLUE GASES, INCLUDING CARBON MONOXIDE.

Vent/Flue Pipe Lengths (Non-Direct Vent) and Diameters

Refer to the following table for applicable length, elbows, and pipe diameter for construction of the vent/flue pipe system of a non-direct vent installation. In addition to the vent/ flue pipe, a single 90° elbow must be secured to the combustion air intake to prevent inadvertent blockage. The tee or elbows used in the vent/flue termination must be included when determining the number of elbows in the piping system.

Vent/Flue and Combustion Air Pipe Lengths and Diameters

Refer to the following table for applicable length, elbows, and pipe diameter for construction of the vent/flue and combustion air intake pipe systems of a non-direct vent (single pipe) installation. The number of elbows tabulated represents the number of elbows and/or tees in each (Vent/Flue & Combustion Air Intake) pipe. Elbows and/or tees used in the terminations must be included when determining the number of elbows in the piping systems.

If the combustion air intake pipe is to be installed above a finished ceiling or other area where dripping of condensate will be objectionable, insulation of the combustion air pipe may be required. Use 1/2” thick closed cell foam insulation such as Armaflex or Insultube where required.

Vent/Flue Pipe Terminations

The vent/flue pipe may terminate vertically, as through a roof, or horizontally, as through an outside wall.

Vertical vent/flue pipe termination should be as shown in the following figures. Refer to Vent/Flue Pipe and Combustion Air Pipe - Termination Locations section in this manual or the installation instructions for details concerning location restrictions. The penetration of the vent through the roof must be sealed tight with proper flashing such as is used with a plastic plumbing vent.

WARNING

Page 26

INST ALLATION CONSIDERA TIONS

Horizontal vent/flue pipe terminations should be as shown in the following figure. Refer to Vent/Flue Pipe and Combus- tion Air Pipe - Termination Locations section in this manual or the installation instructions for details concerning location restrictions. A 2 3/8" diameter wall penetration is required for 2" diameter pipe while a 3 1/2" diameter hole is required for 3" diameter pipe. To secure the pipe passing through the wall and prohibit damage to piping connections, a coupling should be installed on either side of the wall and solvent cemented to a length of pipe connecting the two couplings. The length of pipe should be the wall thickness plus the depth of the socket fittings to be installed on the inside and outside of the wall. The wall penetration should be sealed with silicone caulking material.

In a basement installation, the vent/flue pipe can be run between joist spaces. If the vent pipe must go below a joist and then up into the last joist space to penetrate the header, two 45° elbows should be used to reach the header rather than two 90° elbows.

NOTE: Terminate both pipes in the same pressure zone (same side of roof, no major obstacle between pipes, etc).

TEE (OPTIONAL)

COMBUSTION AIR INTAKE

(OPTIONAL)

*Not required for

single pipe installation

12” MIN TO ROOF OR HIGHEST ANTICIPATED SNOW LEVEL

ELBOWS

12” MIN HEIGHT DIFFERENCE BETWEEN INT AKE AND VENT

”

STRAIGHT

90% Furnace Horizontal Termination (Single Pipe)

Direct Vent (Dual Pipe) Piping

Direct vent installations require both a combustion air intake and a vent/flue pipe. The pipes may be run horizontally and exit through the side of the building or run vertically and exit through the roof of the building. The pipes may be run through an existing unused chimney; however, they must extend a minimum of 12 inches above the top of the chimney. The space between the pipes and the chimney must be closed with a weather tight, corrosion resistant flashing. Both the combustion air intake and a vent/flue pipe terminations must be in the same atmospheric pressure zone. Refer to Vent/Flue and Combustion Air Pipe - Termination Lo- cations or Concentric Vent Termination section in this manual or the installation instructions for specific details on termination construction.

Vent/Flue and Combustion Air Pipe Terminations

VENT/FLUE AND COMBUSTION AIR PIPE TERMINATIONS

The vent/flue and combustion air pipes may terminate vertically, as through a roof, or horizontally, as through an outside wall.

Vertical pipe terminations should be as shown in the following figure. Refer to Section IX, Vent/Flue Pipe and Com- bustion Pipe - Termination Locations for details concerning location restrictions. The penetrations through the roof must be sealed tight with proper flashing such as is used with a plastic plumbing vent.

Horizontal terminations should be as shown in the following figure. Refer to Vent/Flue Pipe and Combustion Pipe - Ter- mination Location section in this manual or the installation instructions for location restrictions. A 2 3/8" diameter wall penetration is required for 2" diameter pipe while a 3 1/2" diameter hole is required for 3" diameter pipe. To secure the pipe passing through the wall and prohibit damage to piping connections, a coupling should be installed on either side of the wall and solvent cemented to a pipe connecting the two couplings. The pipe length should be the wall thickness plus the depth of the socket fittings to be installed on theinside

12" MINIMUM

VENT/FLUE TEE

90° ELBOW TURNED

DOWN

12" MINIMUM ABOVE

HIGHEST ANTICIPATED

SNOW LEVEL

Above Highest Anticipated Snow Level

Page 27

INST ALLATION CONSIDERA TIONS

and outside of the wall. The wall penetration should be sealed with silicone caulking material.

(6)

(3) (5)

MODEL

*MV96C 0403BN

*MVC96 0603BN

*MVC96 0803BN

*MVC96 0804CN

*MVC96 1005CN

*MVC96 1005D N

*MVC96 1205D N

*CVC960403BN

*CVC960603BN

*CVC960804CN

*CVC961005CN

*CVC961205DN

*MVC96/*CVC96 Direct Vent (2 - Pipe) and Non-Direct Vent (1- Pipe)

Pipe Size

(4)

(in.)

2 120 115 110 105 100 95 90 85 3 134 127 120 113 106 99 92 85 2 100 95 90 85 80 75 70 65 3 151 144 137 130 123 116 109 102 2 4540353025201510 3 113 106 99 92 85 78 71 64 2 706560555045N/AN/A 3 8982756861544740 2 N/A N/A N/A N/A N/A N/A N/A N/A 31201131069992857871 2 N/A N/A N/A N/A N/A N/A N/A N/A 3 151 144 137 130 123 116 109 102 2 N/A N/A N/A N/A N/A N/A N/A N/A 3 151 144 137 130 123 116 109 102 2 120 115 110 105 100 95 N/A N/A 3 185 178 171 164 157 150 143 136 2 8580757065605550 3 168 161 154 147 140 133 126 119 2 40353025201510 5 31201131069992857871 2 N/A N/A N/A N/A N/A N/A N/A N/A 3 113 106 99 92 85 78 71 64 2 N/A N/A N/A N/A N/A N/A N/A N/A 3 151 144 137 130 123 116 109 102

Maxi mum Allowable Lengt h o f Vent/Flue Pipe

Number of Elbow s

12345678

1) Maximum allowable limits listed on individual lengths for inlet and flue and NOT a combination.

2) Minimum requirement for each vent pipe is five (5) feet in length and one elbow/tee.

3) Tee used in the vent/flue termination must be included when determining the number of elbows in the piping system.

4) 2 1/2” or 3” diameter pipe can be used in place of 2” diameter pipe.

5) Increased Clearance Configurations using (2) 45 deg. Long Sweep elbows should be considered equivalent to one 90 deg. elbow.

6) One 90° elbow should be secured to the combustion air intake connection.

90° ELBOWS

3” - 24”

AIR INTAKE

12" MIN. ABOVE

HIGHEST ANTICIPATED

SNOW LEVEL

90% Alternate Horizontal Vent Termination (Dual Pipe)

10”- 24”

6” MAX

4” MIN

90º OR 45°

ELBOW

12" MIN. TO GRADE OR HIGHEST ANTIC IP ATED

SNOW LEVEL

Standard Horizontal Terminiations (Dual Pipe)

Vent & Combustion Air Intake Measurements for Standard Horizontal Terminations (Dual Pipe)

Center to center = 10” min / 24” max. Vertical separation: 0” - 24” Vent termination from wall = 8” min / 12” max. Combustion air intake from wall = 6” max. Vent and intake clearance to ground

or anticipated snow level = 12” min.

Page 28

INST ALLATION CONSIDERA TIONS

90° ELBOWS

3”-24” BETWEEN PIPES

AIR INTAKE

12" MIN . AB OVE

HIGHEST ANTICIPA TED

SNOW LEVEL

Combustion Air Intake may also be snorkeled to obtain 12” min ground clearance.

90% Furnace Alternate Vent Termination

Above Anticipated Snow Level (Dual Pipe)

In a basement installation, the pipes may be run between the joist spaces. If the pipes must go below the joist and then up into the last joist space to penetrate the header, two 45° elbows should be used to reach the header rather than two 90° elbows.

VENT/INTAKE TERMINATIONS FOR INSTALLATION OF MULTIPLE DIRECT VENT FURNACES

If more than one direct vent furnace is to be installed vertically through a common roof top, maintain the same minimum clearances between the exhaust vent and air intake terminations of adjacent units as with the exhaust vent and air intake terminations of a single unit.

If more than one direct vent furnace is to be installed horizontally through a common side wall, maintain the clearances as in the following figure. Always terminate all exhaust vent outlets at the same elevation and always terminate all air intakes at the same elevation.

Condensate Drain Lines and Drain Trap

A condensing gas furnace achieves its high level of efficiency by extracting heat from the products of combustion to the point where condensation takes place. The condensate must be collected in the furnace drain trap and routed to an appropriate drain location in compliance with local and national codes.

Follow the bullets listed below when installing the drain system. Refer to the following sections for specific details concerning furnace drain trap installation and drain hose hook ups.

• The drain trap supplied with the furnace must be used.

• The drain trap must be primed at time of installation.

• The drain line between furnace and drain location must meet local and nation codes.

• The drain line between furnace and drain location must maintain a 1/4 inch per foot downward slope toward the drain.

• Do not trap the drain line in any other location than at the drain trap supplied with the furnace.

• If the drain line is routed through an area which may see temperatures near or below freezing, precautions must be taken to prevent condensate from freezing within the drain line.

• If an air conditioning coil is installed with the furnace, a common drain may be used. An open tee must be installed in the drain line, near the cooling coil, to relieve positive air pressure from the coil’s plenum. This is necessary to prohibit any interference with the function of the furnace’s drain trap.

WARNING

N UPRIGHT UPFLOW INS TALLATIONS, THE DRA IN TRAP MUST BE MOUNTED ON

THE OPPOSITE S IDE OF THE UNIT FROM THE JUNC TION BOX . REDUCE THE RIS K OF WATER REACH ING THE JUNCTION BOX I N THE EVENT OF

trap.

A BLOCKED DRAIN CONDITION. CAN RESULT I N POSSIBLE PRO PERTY DAMAGE, PERS ONAL INJURY, OR DEATH DUE TO EL ECT RI CAL S HOC K.

AILURE TO FOLLOW THESE I NSTRUCTIONS

HIS WILL

3” - 24”

12” MIN SEPARATION

3” MIN

12” MIN TO GRADE OR HIGHEST ANTICIPATED SNOW LEVEL

90% Furance Horizontal Venting of Multiple Units

(Dual Pipe)

GAS SUPPLY AND PIPING

The furnace rating plate includes the approved furnace gas input rating and gas types. The furnace must be equipped to operate on the type of gas applied. This includes any conversion kits required for alternate fuels and/or high altitude.

CAUTION

O PREVENT UNRELI ABLE OPE RATION OR EQUIP MENT DAMAGE, THE INLE T

GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE WITH ALL OTHE R HOUSEHOL D GAS FIRED APPLIANCES O PERATING.

Page 29

INST ALLATION CONSIDERA TIONS

Inlet gas supply pressures must be maintained within the ranges specified below. The supply pressure must be constant and available with all other household gas fired appliances operating. The minimum gas supply pressure must be maintained to prevent unreliable ignition. The maximum must not be exceeded to prevent unit overfiring.

INLET GAS SUPPLY PRESSURE

Natural Gas Minimum: 4.5" w.c. Maximum: 10.0" w.c.

Propane Gas Minimum: 11.0" w.c. Maximum: 13.0" w.c.

HIGH ALTITUDE DERATE

When this furnace is installed at high altitude, the appropriate High Altitude orifice kit must be applied. This is required due to the natural reduction in the density of both the gas fuel and combustion air as altitude increases. The kit will provide the proper design certified input rate within the specified altitude range.

High altitude kits are purchased according to the installation altitude and usage of either natural or propane gas. Refer to the product Specification Sheet or Technical Manual for a tabular listing of appropriate altitude ranges and corresponding manufacturer’s high altitude (Natural, Propane gas, and/or Pressure Switch) kits.

Do not derate the furnace by adjusting the manifold pressure to a lower pressure than specified on the furnace rating plate. The combination of the lower air density and a lower manifold pressure will prohibit the burner orifice from drawing the proper amount of air into the burner. This may cause incomplete combustion, flashback, and possible yellow tipping.

In some areas the gas supplier may artificially derate the gas in an effort to compensate for the effects of altitude. If the gas is artificially derated, the appropriate orifice size must be determined based upon the BTU/ft3 content of the derated gas and the altitude. Refer to the National Fuel Gas Code, NFPA 54/ANSI Z223.1, and information provided by the gas supplier to determine the proper orifice size.

A different pressure switch may be required at high altitude regardless of the BTU/ft3 content of the fuel used. Refer to the product Specification Sheet or Technical Manual for a tabular listing of appropriate altitude ranges and corresponding manufacturer’s pressure switch kits.

PROPANE GAS CONVERSION

WARNING

OSSIBLE PROPERTY DAMAGE, PERS ONAL INJURY OR DEATH MAY OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INST ALLED. MUST BE APPLIED TO I NSURE SAFE AND P ROPER FURNACE OPERATION. CONVERSIONS MUST BE PERFORMED BY A QUALIFIED INSTALL ER OR SERVICE AGENCY.

HE APPROPRIATE KITS

MANIFOLD

DESCRIPTION: This kit is designed for gas-fired units con-

verted to propane gas use. The Propane Low Pressure (LPLP03) Kit monitors the gas line pressure with a pressure switch and disables the unit's gas valve if the line pressure drops below acceptable levels.

GAS VALVE

This unit is equipped with a 24 volt gas valve controlled during furnace operation by the integrated control module. As shipped, the valve is configured for natural gas. The valve is field convertible for use with propane gas by using the appropriate propane gas conversion kit. Taps for measuring the gas supply pressure and manifold pressure are provided on the valve.

Low (Main) Common High

White-Rodgers 2-Stage Valve

NOTE: The gas supply pressure on White-Rodger "J" model gas valve, used on single and two stage furnaces, can be checked with a gas pressure test kit (Part #0151K00000S) available through our authorized distributors.

Page 30

INST ALLATION CONSIDERA TIONS

GAS PIPING CONNECTIONS

CAUTION

O AVOID POSSI BLE UNSATISFACTO RY OPERATION OR EQU IPMENT DAMAGE DUE TO UNDERFIRING O F EQUIPMENT, US E THE PROPER SIZ E OF NATURAL/PROPANE GAS PIP ING NEEDED WHEN RUNNING PIPE FR OM THE METER/TANK TO THE FURN ACE.

The gas piping supplying the furnace must be properly sized based on the gas flow required, specific gravity of the gas, and length of the run. The gas line installation must comply with local codes, or in their absence, with the latest edition of the National Fuel Gas Code, NFPA 54/ANSI Z223.1.

Natural Ga s Capacity of Pip e

In Cubic Feet of Gas Per Hour (CFH)

Length of Nominal Black Pipe Size

Pipe in Feet 1/2" 3/4" 1" 1 1/4" 1 1/2"

10 132 278 520 1050 1600 20 92 190 350 730 1100 30 73 152 285 590 980 40 63 130 245 500 760 50 56 115 215 440 670 60 50 105 195 400 610 70 46 96 180 370 560 80 43 90 170 350 530 90 40 84 160 320 490

100 38 79 150 305 460

(Pressure 0.5 psig or less and pressure drop of 0. 3" W.C.; Based on 0.60 Specific Gravity Gas)

CFH =

BTUH Furnace Input Heating Value of Gas (BTU/Cubic Foot)

4. Install a drip leg to trap dirt and moisture before it can enter the gas valve. The drip leg must be a minimum of three inches long.

5. Install a 1/8" NPT pipe plug fitting, accessible for test gage connection, immediately upstream of the gas supply connection to the furnace.

6. Use two pipe wrenches when making connection to the gas valve to keep it from turning. The orientation of the gas valve on the manifold must be maintained as shipped from the factory .

7. Install a manual shutoff valve between the gas meter and unit within six feet of the unit. If a union is installed, the union must be downstream of the manual shutoff valve, between the shutoff valve and the furnace.

8. Tighten all joints securely.

To connect the furnace to the building’s gas piping, the installer must supply a ground joint union, drip leg, manual shutoff valve, and line and fittings to connect to gas valve. In some cases, the installer may also need to supply a transition piece from 1/2" pipe to a larger pipe size.

The following stipulations apply when connecting gas piping. Refer to the following figures for typical gas line connections to the furnace.

1. Use black iron or steel pipe and fittings for the building piping.

2. Use pipe joint compound on male threads only . Pipe joint compound must be resistant to the action of the fuel used.

3. Use ground joint unions.

Page 31

INST ALLATION CONSIDERA TIONS

GAS PIPING CHECKS

Before placing unit in operation, leak test the unit and gas connections.

WARNING

TO AVOID THE POSSIBLITY OF EXPLOSION OR FIRE, NEVER USE A MATCH

OR OPEN FLAME TO TEST FOR LEAKS.

Check for leaks using an approved chloride-free soap and water solution, an electronic combustible gas detector, or other approved testing methods.

NOTE: Never exceed specified pressures for testing. Higher pressure may damage the gas valve and cause subsequent overfiring, resulting in heat exchanger failure. Disconnect this unit and shutoff valve from the gas supply piping system before pressure testing the supply piping system with pressures in excess of 1/2 psig (3.48 kPa). Isolate this unit from the gas supply piping system by closing its external manual gas shutoff valve before pressure testing supply piping system with test pressures equal to or less than 1/2 psig (3.48 kPa).

PROPANE GAS TANKS AND PIPING

All propane gas equipment must conform to the safety standards of the National Board of Fire Underwriters, NBFU Manual 58.

For satisfactory operation, propane gas pressure must be 10 inch WC at the furnace manifold with all gas appliances in operation. Maintaining proper gas pressure depends on three main factors:

1. Vaporization rate, depending on temperature of the liquid, and “wetted surface” area of the container or containers.

2. Proper pressure regulation. (Two-stage regulation is recommended for both cost and efficiency).

3. Pressure drop in lines between regulators, and between second stage regulator and the appliance. Pipe size will depend on length of pipe run and total load of all appliances.

Complete information regarding tank sizing for vaporization, recommended regulator settings, and pipe sizing is available from most regulator manufacturers and propane gas suppliers.

Use pipe dope approved for use with L.P. gas. Refer to the following illustration for typical propane gas in-

stallations and piping.

WARNING

ROPANE GAS IS HEAVIER THAN AIR AND ANY LEAKING GAS CAN SETTLE IN

ANY LOW AR EAS OR CO NFIN ED SPACE S. PERSONAL INJURY, OR DEATH DU E TO FIRE OR EXPLOSI ON CAUSED BY A PROPANE GAS LEAK, INSTALL A GAS DETE CTION WARNING DEVICE.

TO PREVENT PROPERTY DAMAGE,

A gas detecting warning system is the only reliable way to detect a propane gas leak. Iron oxide (rust) can reduce the level of odorant in propane gas. Do not rely on your sense of smell. Contact a local propane gas supplier about installing a gas detecting warning system. If the presence of gas is suspected, adhere to the instructions in the following warning.

WARNING

F THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A

FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOS S OF LIF E.

–

O NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND

LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE. –

WHAT TO DO IF YOU SMELL GAS

•

• PHONE IN YOUR BUILDING.

• PHONE.

• DEPARTMENT.

–

NSTALLATI ON AN D SER VICE MUST BE PERF ORMED BY A QU ALIFI ED I NSTAL LER,

SERVICE AGENCY OR THE GAS SUPPLIER.

O NOT TRY TO LIGHT ANY APPLIANCE.

O NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY

MMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR’S

OLLOW THE GAS SUPPLIER’S INSTRUCTIONS.

F YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE

First Stage Regulator

200 PSIG Maximum

5 to 15 PSIG (20 PSIG Max.)

Continuous

Second Stage Regulator

11" W.C.

Typical Propane Gas Installation

WARNING

F THE GAS FURNA CE IS INS TALLED IN A BASEMENT, A N EXCAVATED AREA OR A CONFINED SPACE, IT IS ST RONGLY RECOMMENDED TO CONTACT A PROPANE SUPPLIER TO INSTALL A GAS DETECTING WARNING DEVICE IN CASE OF A GAS LEAK.

•

SINCE PROPANE GAS I S HEAVIER THAN AIR, ANY LEAKING G AS CAN

SETTLE IN ANY LOW AREAS OR CONFINED SPACES.

•

PROPANE GAS ODORANT MAY FADE, MAKING THE GAS UNDETECTABLE

EXCEPT WITH A WARNING DEV ICE.

WARNING

AN UNDETECTED GAS LEAK WILL CREATE A DANGER OF EXPLOSI ON

OR FIR E.

IF THE PRESENCE OF GAS IS SUSPECTED, FOLLOW THE

INSTRUCTIONS ON THE COVER OF THIS MANUAL. COULD RESULT IN

SERIOUS PERSONAL INJURY OR DEATH.

FAILURE TO DO SO

Page 32

INST ALLATION CONSIDERA TIONS

WARNING

F THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A

FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOS S OF LIF E.

O NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND

–

LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE. –

WHAT TO DO IF YOU SMELL GAS

•

• PHONE IN YOUR BUILDING.

• PHONE.

• DEPARTMENT.

–

NSTALLATI ON AN D SER VICE MUST BE PERF ORMED BY A QU ALIFI ED I NSTAL LER,

SERVICE AGENCY OR THE GAS SUPPLIER.

Sizing Between First and Second S ta ge R eg ul at or *

Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting. Capacities in 1,000 BTU/hour.

Pipe or Tubing Length

Feet

10 730 1,700 3,200 5,300 8 ,300 3,200 7,500 20 500 1,100 220 3,700 5,800 2,200 4,200 30 400 920 2,000 2,900 4 ,700 1,800 4,000 40 370 850 1,700 2,700 4 ,100 1,600 3,700 50 330 770 1,500 2,400 3 ,700 1,500 3,400 60 300 700 1,300 2,200 3 ,300 1,300 3,100

80 260 610 1,200 1,900 2 ,900 1,200 2,600 100 220 540 1,000 1,700 2,600 1,000 2,300 125 200 490 900 1,400 2,300 900 2,100 150 190 430 830 1,300 2,100 830 1,900 175 170 400 780 1,200 1,900 770 1,700 200 160 380 730 1,100 1,800 720 1,500

To convert to capacities at 15 psig settings - multiply by 1.130 To convert to capacities at 5 psig settings - multiply by 0.879

O NOT TRY TO LIGHT ANY APPLIANCE.

O NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY

MMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR’S

OLLOW THE GAS SUPPLIER’S INSTRUCTIONS.

F YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE

Tubing Size, O.D . Type L

3/8" 1/2" 5/8" 3/4" 7/8" 1/2" 3/4"

Nominal Pipe Size

Schedule 40

When installing a propane storage tank, the contractor must consider proper tank sizing, safety, efficiency, ground characteristics and aesthetics. For a residential customer, the size may range from 100-1,000 gallons, depending on household use. Typically, a 500 gallon tank is ample for an average four-bedroom home. However, it is best to consult your local propane supplier to ensure the proper sizing for propane storage requirements. Determining the correct tank size for each household is a function of demand, economy, efficiency and convenience. It is a process that requires cooperation between the propane supplier and customer.

ELECTRICAL CONNECTIONS

WARNING

TO AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO THE UNIT MUST BE

PROPERLY POLARIZED AND GROUNDED.

WARNING

HIGH VOLTAGE D

ISCO NN E CT ALL POWER BEFORE SERVI CING OR

INSTALLING THIS UNIT. BE PRESENT. DAMAGE, PERSONAL INJ URY OR DEATH.

ABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS.

WIRING ERRORS CAN COUSE IMPR OPER AND DAN GEROUS OPERAT ION. VERIFY PROPER OPERATION AFTER SERVICING.

MULTIPLE POWER SOURCES MAY

FAILURE TO DO SO MAY CAUSE PROPERTY

CAUTION

Sizing Between Second or Second St ag e Regula tor & App l iance*

Maximum Propane Capacities lis ted are based on 1/2" W.C. pressure drop at 11" W.C. setting. Capacities in 1,000 BTU/hour.

Pipe or Tubing Length

Feet

10 39 92 199 329 501 275 5 67 1,071 2,205 3,307 20 26 62 131 216 346 189 3 93 73 2 1,496 2,299 30 21 50 107 181 277 152 3 15 59 0 1,212 1,858 40 19 41 90 145 233 129 2 67 50 4 1,039 1,559 50 18 37 79 131 198 114 2 37 44 8 913 1,417 60 16 35 72 1,211 187 103 217 409 834 1,275

80 13 29 62 104 155 89 185 34 6 724 1,066 100 11 26 55 90 138 7 8 162 307 630 976 125 10 24 48 81 122 6 9 146 275 567 866 150 9 21 43 72 109 63 132 25 2 511 787 200 8 19 39 66 100 54 112 20 9 439 665 250 8 17 36 60 93 48 100 185 390 590

*Data in accordance with NFPA pa m phlet No. 54

Tubing Size, O.D. Type L

3/8" 1/2" 5/8" 3/4" 7/8" 1/2" 3/4" 1" 1-1/4" 1-1/2"

Nominal Pipe Size

Schedule 40

Propane Gas Piping Charts

WIRING HARNESS

The wiring harness is an integral part of this furnace. Field alteration to comply with electrical codes should not be required. Wires are color coded for identification purposes. Refer to the wiring diagram for wire routings. If any of the original wire as supplied with the furnace must be replaced, it must be replaced with wiring material having a temperature rating of at least 105° C. Any replacement wiring must be copper conductor.

115 VOLT LINE CONNECTIONS

Before proceeding with electrical connections, ensure that the supply voltage, frequency, and phase correspond to that specified on the unit rating plate. Power supply to the furnace must be N.E.C. Class 1, and must comply with all applicable codes. The furnace must be electrically grounded in accordance with local codes or, in their absence, with the latest edition of The National Electric Code, ANSI NFPA 70 and/or The Canadian Electric Code CSA C22.1.

Page 33

INST ALLATION CONSIDERA TIONS

Use a separate fused branch electrical circuit containing properly sized wire, and fuse or circuit breaker. The fuse or circuit breaker must be sized in accordance with the maximum overcurrent protection specified on the unit rating plate. An electrical disconnect must be provided at the furnace location.

NOTE: Line polarity must be observed when making field connections.

Humidifier 1.0 Amp maximum a t 120 VAC Electro nic Air Cleaner 1.0 Amp maximum at 120 VAC

Turn OFF power to the furnace before installing any accessories. Follow the humidifier or air cleaner manufacturers’ instructions for locating, mounting, grounding, and controlling these accessories.

Accesso ry Loa d Specifications

IN 90% FURNACE UPRIGHT UP FLOW INSTALLATIONS, THE DRA IN TRAP MUST

BE MOUNTED ON THE OPPOSITE SIDE OF THE UNIT FROM THE JUNCTION BOX.

THIS WILL REDUCE THE RISK OF WATER REACHING THE JUNCTION

BOX IN THE EVENT O F A BLOCKED DRAIN CONDITION.

Connect hot, neutral, and ground wires as shown in the wiring diagram located on the unit’s blower door. Line polarity must be observed when making field connections. Line voltage connections can be made through either the right or left side panel.

NOTE: Wire routing must not interfere with circulator blower operation, filter removal, or routine maintenance.

WARNING

TO AVOID THE RISK OF ELECTRICAL SHOCK, INJ URY, OR DEATH, T HE

FURNACE MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH LOCAL CODES OR, IN THEIR ABSENCE, WITH THE LATEST EDITION OF THE

ATIONAL ELECTRIC CODE.

115 VOLT LINE CONNECTION OF ACCESSORIES (HUMIDIFIER AND ELECTRONIC AIR CLEANER)

WARNING

HIGH VOLTAGE

ISCONNECT

CHANGING A NY ELECT RICAL WIRIN G. SOURCES MAY BE PRESENT. PROPERTY DAMA GE, PERSONA L INJURY OR DEATH.

POWER BEF ORE SERVI CING OR

ALL

MULTIPLE POWER

FAILURE TO DO S O MAY CAUSE

All communicating furnaces have an integrated ignition control that is equipped with line voltage accessory terminals for controlling power to an optional fieldsupplied humidifier and/or electronic air cleaner.

HUMIDIFIER CONNECTION OPTIONS

24 volt thermostat

Option 1: Use the single HUM terminal to supply 115 VAC

to a humidifier transformer. This terminal is powered anytime there is a call for heat.

Option 2: Use the brown wire coming off the common side

of the pressure switch to supply 24 VAC to humidifier

Option 3: The HUM IN / HUM OUT terminals are dry con-

tacts that will close during a call for heat. To power a humidifier with these contacts The HUM IN contact can be fed with 24vac from the R terminal or line voltage from the L1 terminal.

Communicating Thermostat

CTK01: The CTK01 is not capable of supplying a call for humidity; therefore if a humidifier is used it must be controlled by a separate humidistat. The recommended wiring is one of the methods shown with a 24 volt thermostat.

CTK02 is capable of generating a call for humidity. See diagram for wiring. The user is now provided with 3 modes of operations which can be selected within the thermostat user menu.

1. ON: Humidifier is turned on with a heat demand.

2. OFF: Humidifier remains off (relay never closes).

3. IND: Humidifier will cycle with humidification demand, independent of heat demand. This mode allows the user to select one of 4 fan speeds (25, 50, 75, and 100%).

CTK03AA, does notprovide a call for humidity when used with the 2 stage communicating furnaces. The single HUM terminal on the PCBKF103, PCBKF104, or PCBKF105 control board will provide a line voltage output when the inducer is running.

CTK03AB and CTK04, can provide a humidity call to the PCBKF103, PCBKF104, or PCBKF105 control board relay and operate the HUM IN - HUM OUT dry contacts.

HUMIDIFIER WIRING

Accessory wiring connections are to be made through the 1/4" quick connect terminals provided on the furnace integrated control module. The Humidifier and Electronic Air Cleaner hot and neutral terminals are identified as HUM and EAC. All field wiring must conform to applicable codes. Connections should be made as shown in OPTIONAL ACCESSORIES, Accessories Wiring figure.

Page 34

INST ALLATION CONSIDERA TIONS

Accessories Wiring

If it is necessary for the installer to supply additional line voltage wiring to the inside of the furnace, the wiring must conform to all local codes, and have a minimum temperature rating of 105°C. All line voltage wire splices must be made inside the furnace junction box.

The integrated control module humidifier terminal (HUM) is energized with 115 volts whenever the induced draft blower is energized. The integrated control module electronic air cleaner terminals (EAC) are energized with 115 volts whenever the circulator blower is energized.

In addition, the control is equipped with a dedicated humidification relay which is available through ¼ inch terminals HUM-IN and HUM-OUT. Similar to the HUM terminal, when utilizing legacy connections, this relay will be closed during normal heating operation (115VAC must be present on the HUM-IN terminal to take advantage of HUM-OUT). However, the control can provide additional humidification features when wired to a communicating thermostat (1, 2, R, C connections). If the communicating thermostat is not capable of providing a humidification call, this dedicated relay will function exactly as mentioned above with a legacy setup. If the communicating thermostat is capable of providing a humidification call the user is now provided with 3 modes of operations which can be selected within the thermostat user menu.

1. ON: Humidifier is turned on during a call for heat along with a call for humidity

2. OFF: Humidifier remains off (relay never closes).

3. IND: Humidifier will cycle with humidification demand, independent of heat demand. This mode allows the user to select one of 4 fan speeds (25, 50, 75, and 100%).

NEUTRAL

HUM-IN

HUM-OUT

24 VOLT HUMIDIFIER

A 24 volt hum circuit may be powered off of the n/c side of the low fire pressure. If added in the field, the wiring must conform to all local and national codes. Connect the COM side of the humidifier to the C terminal on the furnace control board (or to the COM side of the 24 VAC transformer). Do not connect 115V humidifier to these terminals.

AUXILIARY ALARM SWITCH:

The control is equipped with a 24VAC Auxiliary Alarm Input (12 inch purple / white wire attached to pin 6 of 15 pin connector) which can be utilized with communicating mode setups (typically used for condensate switch wiring but could be used with compatible C02 sensors or Fire Alarms).

Legacy mode use

In a legacy system (Non-communicating), this auxiliary alarm input is not operational. Any auxiliary alarm switch must be used to interrupt Y1 signal either to IFC or to UC.

Communication mode use

This feature can be activated or deactivated through the thermostat user menus. By default, an AUX switch is normally closed and opens when the water level in the evaporator coil base pan reaches a particular level. The control will respond by turning off the outdoor compressor and display the proper fault codes. If the AUX switch is detected closed for 30 seconds, normal operation resumes and error messages are no longer displayed. Installer must wire control voltage (24VAC) to AUX switch to ensure the Auxiliary Alarm Input has 24VAC during normal operation.

24 VOLT THERMOSTAT WIRING NOTE: Low voltage connections can be made through ei-

ther the right or left side panel. Wire routing must not interfere with circulator blower operation, filter removal, or routine maintenance.

A 40 V.A. transformer and an integrated electronic control are built into the furnace to allow use with most cooling equipment. Consult the wiring diagram, located in the Technical Manual or on the blower door for further details of 115 Volt and 24 Volt wiring.

Page 35

INST ALLATION CONSIDERA TIONS

Thermostat Wiring - Two-Stage Variable Speed ComfortNet™ Furnaces

As a two-stage non-communicating furnace, the furnace integrated control module provides terminals for both “W1” and “W2”, and “Y1” and “Y2” thermostat connections. This allows the furnace to support the following system applications: ‘Two-Stage Heating Only’, ‘Two-Stage Heating with Single Stage Cooling’, and ‘Two-Stage Heating with TwoStage Cooling’. Refer to the following figures for proper connections to the integrated control module.

Low voltage connections can be made through either the right or left side panel. Thermostat wiring entrance holes are located in the blower compartment. The following figure shows connections for a “heat/cool system”.

This furnace is equipped with a 40 VA transformer to facilitate use with most cooling equipment. Consult the wiring diagram, located on the blower compartment door, for further details of 115 Volt and 24 Volt wiring.

NOTE: For single stage cooling applications, a jumper may be required between Y1 and Y2 at the furnace control in order to achieve the desired single stage cooling airflow. Consult the blower performance tables to determine if the required single stage cooling airflow can be delivered at low stage (Y1 input) or high stage (Y2 input). Additionally, use of ramping profile features require a jumper between Y1 and O when used with a straight cooling unit.

NOTE: Thermostat “R” required if outdoor unit is equipped with a Comfort Alert™ module or if the out door unit is a part of the ComfortNet family of equipment AND is wired as a legacy system.

In a Non-Dual Fuel

Application, Place Jumper

Between Y1 and O For

Proper Dehumidification

Operation and Proper

Ramping Profile Operation

(Single-Stage Coolin g)

Two-Stage Heating with Single-Stage Cooling

In a Non-Dual Fuel

Application, Place Jumper

Between Y1 and O For

Proper Dehumidification

Operation and Proper

Ramping Profile Operation

Thermostat

Two-Stage Heating

Y C

Remote

Condensing Unit

Remote

Condensin g Unit

(Two-Stage Cooling)

Two-Stage Heating with Two-Stage Cooling

Single-Stage Cooling

Furnace Integrated

NEU

Dehumidistat

[Optional]

Thermostat

Two-Stage Heating

()

NEU

Two-Stage Cooling

Dehumidistat

[Optional]

W1 W2

with

Control Module

with

Furnace Integrated

Control Module

In a Non-Dual Fuel

Application, Place Jumper

Between Y1 and O For

Proper Dehumidification

Operation and Proper

Ramping Profile Operation

Condensing Unit

(Single-Stage Cooling)

Single Stage Heating with Single Stage Cooling

NOTE:

Thermostat

Single Stage Heating with

Y C

Remote

To apply a single-stage Heati ng Thermostat, the thermostat selector switch on the Integrated Control Module be set on

Single Stage Cooling

NEU

Dehumidistat

must

Furnace Integrated

Control Module

[Optional]

single-stage.

Thermostat Wiring Diagrams

Page 36

INST ALLATION CONSIDERA TIONS

CFM CHART

Model Tap

*MVC960403BN*

*MVC960603BN*

*MVC960803BN*

*MVC960804CN*

*MVC961005CN*

*MVC961005DN*

*MVC961205DN*

*CVC960403BN*

*CVC960603BN

*CVC960803BN

*CVC960804CN *

*CVC961005CN *

*CVC961205DN *

A B C D

A 405 624 758 1057 B 549 808 815 1146 C 678 994 882 1256 D 784 1177 946 1349

A B C D

A B C D 1185 1766 1300 1881

A B C D

Low

Stage

Cool

403 596 422 494 527 796 471 553 675 974 521 601 803 1192 574 676 398 599 667 953 557 817 740 1059 696 1007 808 1158 810 1212 881 1260 403 629 855 1202 540 806 923 1316 705 1023 1033 1389 819 1230 1063 1396 513 789 867 1228 660 967 939 1337 791 1182 1016 1430 913 1375 1077 1516 564 820 1256 1818 784 1133 1292 1870 982 1464 1316 1910

1259 1736 1358 1957

597 895 1205 1683

852 1156 1230 1727 1031 1459 1256 1763 1282 1864 1281 1796

547 867 1329 1891

831 1160 1362 1940 1020 1467 1390 1968 1278 1910 1440 2028

449 655 682 957

569 807 750 1059

716 998 820 1155

854 1207 888 1251

433 656 687

541 790 751

686 972 814 986

806 1195 874 992

556 837 889 1234

714 1022 944 1325

838 1206 1019 1442

991 1475 1068 1528

524 784 1209 1759

744 1078 1249 1797

927 1388 1277 1840

540 854 1284 1744

870 1123 1310 1827 1000 1399 1350 1860 1235 1804 1388 1918

High

Stage

Cool

Low Stage

Heat

High

Stage

Heat

938 950

AIRFLOW TABLE

Page 37

INST ALLATION CONSIDERA TIONS

DIP SWITCHES - FURNACES EQUIPPED WITH PCBKF103, PCBKF104, or PCBKF105

Switch Bank Purpose Function

90 Off Off

120 150 Off On

180 On On 2 Stage S tat 2 Stage S tat On Off

AOffOff BOnOff COffOn D

Add 5%

Minus 5% On Off

Add 10% Off On

Minus 10% On On

A BOnOff COffOn DOnOn AOffOff B COffOn DOnOn

Disabled

Enabled On

Disabled

Enabled On

25% Off Off 50% 75% Off On

100% On On

Heati n g Off Delay

Thermostat

Setup

Cooling Airflow

Trim

Rampi ng Profile

Heating A i rflow

Dehum

Trim

Continuous F an

1 St g Stat 5 m i n del ay Off Off

1 Stg St at auto del ay Off On

Dip Swit ch

1234

On Off

On On

Off Off

On Off

Off

On Off

* = Factory Setting

Page 38

INST ALLATION CONSIDERA TIONS

Single-Stage Thermostat Application

A single-stage thermostat with only one heating stage may be used to control this furnace. The application of a singlestage thermostat does not offer “true” thermostat-driven twostage operation, but provides a timed transition from low to high fire. The furnace will run on low stage for a fixed period of time before stepping up to high stage to satisfy the thermostat’s call for heat. The delay period prior to stepping up can be set at either a fixed 5 minute time delay or a load based variable time between 1 and 12 minutes (AUTO mode). If the AUTOmode is selected, the control averages the cycle times of the previous three cycles and uses the average to determine the time to transition from low stage to high stage.

24 Volt Dehumidistat Wiring (Not needed if a communicating thermostat is used)

The optional usage of a dehumidistat allows the furnace’s circulator blower to operate at a slightly lower speed (85% of desired speed) during a combined thermostat call for cooling and dehumidistat call for dehumidification. This can be done through an independent dehumidistat or through a thermostat’s DEHUM terminal (if available). This lower blower speed enhances dehumidification of the conditioned air as it passes through the AC coil. For proper function, a dehumidistat applied to this furnace must operate on 24 VAC and utilize a switch which opens on humidity rise.

To install/connect a dehumidistat:

1. Turn OFF power to furnace.

2. Secure the dehumidistat neutral wire (typically the white lead) to the terminal marked “DEHUM” on the furnace integrated control module.

3. Secure the dehumidistat hot wire (typically the black lead) to the terminal marked “R” on the furnace integrated control module.

4. Secure the dehumidistat ground wire (typically the green lead) to the ground screw on the furnace junction box. NOTE: Ground wire may not be present on all dehumidistats.

5. Turn ON power to furnace.

To enable the dehumidify function on the integrated control module, set the dehumidification ENABLE dipswitch from OFF to ON.

Once the switch is set, the dehumidify function is enabled during a combination call for cooling (T-Stat) and dehumidification (DEHUM-Stat).

For a furnace equpped with aPCBKF101 or PCBKF102 control board, select preferences on S5 #9 DIP switch.

For a furnace equipped with a PCBKF103, PCBKF104, or PCBKF105 control board, select preferences on S5 #1 DIP switch.

Fossil Fuel Applications

Furnaces can be used in conjunction with a heat pump in a fossil fuel application. A fossil fuel application is where an outdoor temperature sensor determines the most cost efficient means of heating (heat pump, gas furnace, or both).

A heat pump thermostat with two stages of heat is required to properly use the single-stage furnace with a heat pump. A heat pump thermostat with three stages of heat is required to properly use the two-stage furnace with a heat pump. Refer to dual fuel, AFE-18-60A installation manual (IO-627) for additional wiring instructions.

CONTINUOUS FAN OPERATION

Continuous fan speed is selectable from a communicating thermostat or by DIP switches when using a conventional thermostat. ----------------------------

CIRCULATOR BLOWER SPEED ADJUSTMENT

HIGH VOLTAGE

ISCONNECT ALL POWER BEFOR CHANGING SPEED TAPS.

ULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO

SO MAY CAUSE PROPERTY D AMAGE, PERSO NAL INJURY OR DEATH .

Adjustments can also be made at the communicating thermostat. Set up blower speeds with DIP switches when using a conventional thermostat.

This furnace is equipped with a multi-speed circulator blower. This blower provides ease in adjusting blower speeds. The heating blower speed is shipped set at “B”, and the cooling blower speed is set at “D”. These blower speeds should be adjusted by the installer to match the installation requirements so as to provide the correct heating temperature rise and correct cooling CFM.

Use the dual 7-segment LED display adjacent to the dipswitches to obtain the approximate airflow quantity. The airflow quantity is displayed as a number on the display, rounded to the nearest 100 CFM. The display alternates airflow delivery indication and the operating mode indication.

COOLING CFM Example: The airflow being delivered is 1225 CFM. The

display indicates 12. If the airflow being delivered is 1275, the display indicates 13.

1. Determine the tonnage of the cooling system installed with the furnace. If the cooling capacity is in BTU/hr divide it by 12,000 to convert capacity to TONs.

Example: Cooling Capacity of 30,000 BTU/hr.

WARNING

30,000/12,000 = 2.5 Tons

Page 39

INST ALLATION CONSIDERA TIONS

2. Determine the proper air flow for the cooling system. Most cooling systems are designed to work with air flows between 350 and 450 CFM per ton. Most manufacturers recommend an air flow of about 400 CFM per ton.

Example: 2.5 tons X 400 CFM per ton = 1000 CFM

The cooling system manufacturer’s instructions must be checked for required air flow. Any electronic air cleaners or other devices may require specific air flows, consult installation instructions of those devices for requirements.

3. Knowing the furnace model, locate the high stage cooling air flow charts in the Specification Sheet applicable to your model. Look up the cooling air flow determined in step 2 and find the required cooling speed and adjustment setting. -----------------------------------

4. Locate the blower speed selection DIP switches on the integrated control module. Select the desired “cooling” speed tap by positioning switches S3 1 and 2 appropriately. ------------------------------------------

NOTE: Trim function must also be inabled on S5 #2 DIP

switch.

RAMPING PROFILE

5.The multi-speed circulator blower also offers several custom ON/OFF ramping profiles. These profiles may be used to enhance cooling performance and increase comfort level. ------------------------------------

Refer to the bullet points below for a description of each ramping profile. Verify CFM by noting the number displayed on the dual 7-segment LED display.

• Profile A provides only an OFF delay of one (1) minute at 100% of the cooling demand airflow.

OFF

100% CFM 100% CFM

1 min

OFF

• Profile B ramps up to full cooling demand airflow by first stepping up to 50% of the full demand for 30 seconds. The motor then ramps to 100% of the required airflow. A one (1) minute OFF delay at 100% of the cooling airflow is provided.

OFF

50% CFM

1/2 min

100% CFM

OFF

1 min

OFF

• Profile D ramps up to 50% of the demand for 1/2 minute, then ramps to 85% of the full cooling demand airflow and operates there for approximately 7 1/2 minutes. The motor then steps up to the full demand airflow. Profile D has a 1/2 minute at 50% airflow OFF delay.

OFF

HEATING SPEED

1.Select the heating speed for your model from the heating speed chart in the Specification Sheet. The adjust setting (already established by the cooling speed selection) determines which set of speeds are available.

The selected speed must provide a temperature rise within the rise range listed with the particular model.

Select Heating Speed preferences on S4 #7 & #8 DIP Switches. Verify CFM by noting the number displayed on the dual 7-segment LED display.

In general lower heating speeds will: reduce electrical consumption, lower operating sound levels of the blower, and increase the outlet air temperature delivered to the home. The speeds available allow the blower performance to be optimized for the particular homeowner’s needs.

CIRCULATING AIR AND FILTERS DUCTWORK - AIR FLOW

Duct systems and register sizes must be properly designed for the C.F.M. and external static pressure rating of the furnace. Ductwork should be designed in accordance with the recommended methods of "Air Conditioning Contractors of America" manual D.

A duct system should be installed in accordance with Standards of the National Board of Fire Underwriters for the Installation of Air Conditioning, Warm Air Heating and Ventilating Systems, Pamphlets No. 90A and 90B.

A return air filter is not supplied with the furnace. The installer must supply a means of filtering all of the return air. Filter(s) shall comply with UL900 or CAN/ULC-S111 Standards.

100% CFM

OFF

• Profile C ramps up to 85% of the full cooling demand airflow and operates there for approximately 7 1/2 minutes. The motor then steps up to the full demand airflow. Profile C also has a one (1) minute 100% OFF delay.

Page 40

INST ALLATION CONSIDERA TIONS

vent operation of either unit unless the damper is in the full heat or cool position.

M o d el Minimum Reco m m ended F ilt er Siz e^

*MVC960403BN* 1 - 16 X 25 Side or Bottom *MVC960603BN* 1 - 16 X 25 Side or Bottom *MVC960803BN* 1 - 16 X 25 Side or Bottom *MVC960804CN* 1 - 16 X 25 Side or Bottom *MVC961005CN* 1 - 20 X 25 Bottom / 2 - 16 X 25 Side Return *MVC961005DN* 1 - 20 X 25 Bottom / 2 - 16 X 25 Side Return *MVC961205DN* 1 - 20 X 25 Bottom / 2 - 16 X 25 Side Return

*CVC960403BN* 2 - 10 X 20 or 1 - 16 X 25 Top Return *CVC960603BN* 2 - 10 X 20 or 1 - 16 X 25 Top Return *CVC960804CN* 2 - 10 X 20 or 1 - 16 X 25 Top Return *CVC961005CN* 2 - 14 X 20 or 1 - 20 X 25 Top Return *CVC961205DN* 2 - 14 X 20 or 1 - 20 X 25 Top Return

Larger filters may be used, filters may also be centrally located

Upflow furnaces with air delivery of less than 1800 CFM:

Use one side return or one bottom return ductwork connection.

Upflow furnaces with air delivery of 1800 CFM or higher:

Use two side returns or one side return and one bottom return connection.

Guide dimples locate the side and bottom return cutout locations. Use a straight edge to scribe lines connecting the dimples. Cut out the opening on these lines. An undersized opening will cause reduced airflow. For bottom return connection, remove the bottom of the cabinet before setting the furnace on the raised platform or return air duct.

A closed return duct system must be used, with the return duct connected to the furnace. NOTE: Ductwork must never be attached to the back of the furnace. Supply and return connections to the furnace may be made with flexible joints to reduce noise transmission, if desired. If a central return is used, a connecting duct must be installed between the unit and the utility room wall so the blower will not interfere with combustion air or draft. The room, closet, or alcove must not be used as a return air chamber.

When the furnace is used in connection with a cooling unit, the furnace should be installed in parallel with or on the upstream side of the cooling unit to avoid condensation in the heating element. With a parallel flow arrangement, the dampers or other means used to control the flow of air must be adequate to prevent chilled air from entering the furnace and, if manually operated, must be equipped with means to pre-

When the furnace is heating, the temperature of the return air entering the furnace must be between 55°F and 100°F.

Consider installing an air cleaner with deep-pleated media filter at the time of furnace installation. A deep-pleated filter with a MERV rating of 8 (minimum) will often provide better filtration to protect equipment and the air distribution system than a standard 1" filter and often has lower static pressure loss than a 1" filter. Also a deep-pleated filter will typically require less frequent replacement intervals. Avoid using highly restrictive 1" filters which produce static pressure loss greater than .25" W.C. In some installations the minimum filter size required (consult filter sizing chart ) will not lend itself to a filter installation on the side of the furnace. The installation of a centrally installed air cleaner cabinet or a return duct filter installation may offer more practicality.

Clean Comfort™ brand MERV 11 air cleaners have 5¼” media filters and are available in the following configurations. Consult your distributor for information on our complete line of IAQ Clean Comfort™ products.

UPRIGHT FILTER INSTALLATIONS

Depending on the installation and/or customer preference, differing filter arrangements can be applied. Filters can beinstalled in the central return register and a side panel extern filter rack kit (upflow filter kit # EFR01). As an alternative a media air filter or electronic air cleaner can be used as the requested filter. Refer to the following minimum filter requirement charts for determination of the minimum filter area to ensure proper unit performance. The following figures show possible filter locations. NOTE: A ductwork access door must be used in counterflow applications to allow filter removal.

COUNTERFLOW FILTER INSTALLATION

This furnace has provisions for the installation of return air filters at the counterflow top return. The furnace will accommodate the following filter sizes depending on cabinet size:

Page 41

INST ALLATION CONSIDERA TIONS

Horizontal Installations

Filter(s) must be installed external to the furnace casing for horizotal installations. For most installations it is preferable to use a central return with filters installed in the duct behind the return air grill. In this way filter replacement is relatively simple by merely removing the grille, rather than going into the attic or crawl space.

ADDITIONAL FILTERING ACCESSORIES External Filter Rack Kit (EFR01)

The external filter rack kit is intended to provide a location external to the furnace casing, for installation of a permanent filter on upflow model furnaces. The rack is designed to mount over the indoor blower compartment area of either side panel, and provide filter retention as well as a location for attaching return air ductwork.

Electronic Air Cleaner (ASAS and GSAS) or Media Air Cleaner (AMU and GMU)

The electronic air cleaner and media air cleaner are multipositional high efficiency air filtration devices that can be installed in any position, except with the access door facing down. The best location for the air cleaner is in the return air

Optional

Access

Door

Return Air

"A" Min

Air Cleaner Installation

Location

Sid e or bottom re t urn 1200 CFM 16 in X 20 in x 5¼ " AM11 -1620-5 Sid e or bottom re t urn 1600 CFM 16 in X 25 in x 5¼ " AM11 -1625-5 Sid e or bottom re t urn 1600 CFM 20 in X 20 in x 5¼ " AM11 -2020-5 Sid e or bottom re t urn 2000 CFM 20 in X 25 in x 5¼ " AM11 -2025-5

Side return

(for 2 separate returns)

Side re t u r n (Right an g le) 2000 CFM 20 in X 25 in x 5¼ " AM11-2025-5RA AM 11-5RA Bott om ret urn (p latfor m) 2000 CFM 20 in X 25 in x 5¼" AM 11-2832-5PP Bott om ret urn (p latfor m) 2000 CFM 20 in X 25 in x 5¼" AM 11-2843-5PP

AM11-5 AM11-5RA AM11-5PP

Family Family Family

Maximum Heating

Airflow

2 X 1600 CFM 2, 16 in X 25 in x 5¼" AM 11-3225-5 AM11-3225

Filter (Media)

Dimensions

Part Number

Air Cleaner

Family

AM11-5PP

duct next to the blower compartment. Before installing the air cleaner, consider the application. The electronic air cleaner must be readily accessible for periodic inspection and clean-

AM11-5

ing of the pre-filters and electronic cells while the media air cleaner must be readily accessible for periodic inspection and replacement of the Media Air Cleaner (AMU and GMU) filter cartridge (3 per carton) M0-1056, M1-1056, M2-1056, M8-1056, to maintain maximum efficiency and trouble-free operation. Carbon Filters 1156-3 and 1856-3 (set of 3) are also available. See Product Catalog for exact filter for your model.

Page 42

SYSTEM OPERATION

NORMAL SEQUENCE OF OPERATION POWER UP

The normal power up sequence is as follows:

• 115 VAC power applied to furnace.

• Integrated control module performs internal checks.

• Integrated control module displays 8 8 on dual 7-segment display LED’s.

• Integrated control module monitors safety circuits continuously.

• Furnace awaits call from thermostat. Dual 7-segment LED’s display ON while awaiting call from thermo- stat.

HEATING MODE

The normal operational sequence in heating mode is as follows:

• R and W1 (or R and W1/W2) thermostat contacts close, initiating a call for heat.

• Integrated control module performs safety circuit checks.

• Induced draft blower is energized on high speed for a 15-second prepurge. Humidifier terminal is energized with induced draft blower.

• Induced draft blower steps to low speed following prepurge. Low stage pressure switch contacts are closed.

• Igniter warm up begins upon step to low speed and presence of closed low stage pressure switch contacts.

• Gas valve opens at end of igniter warm up period, delivering gas to burners and establishing flame.

• Integrated control module monitors flame presence. Gas valve will remain open only if flame is detected.

• If the thermostat call is for low heat, gas valve and induced draft blower will continue on low stage. If the call is for high heat, the gas valve and induced draft blower will change to high stage.

• Circulator blower is energized on heat speed following a thirty (30) second blower on delay. The circulator blower requires thirty seconds to ramp up to full speed. Electronic air cleaner terminal is energized with circulator blower.

• Furnace is now operating on the specified stage called for by the two-stage thermostat.

• Furnace runs, integrated control module monitors safety circuits continuously.

• If the two-stage thermostat changes the call from low heat to high heat, the integrated control module will immediately switch the induced draft blower, gas valve, and circulator blower to their high stage settings.

• If the two-stage thermostat changes the call from high heat to low heat, the control will immediately switch the induced draft blower and gas valve to their low

stage settings. The circulator blower will remain on high heating speed for thirty (30) seconds before switching to the low heat circulating speed.

• R and W1 (or R and W1/W2) thermostat contacts open, completing the call for heat.

• Gas valve closes, extinguishing flame.

• Induced draft blower is de-energized following a fifteen second post purge. Humidifier terminals are deenergized.

• Circulator blower continues running for the selected heat off delay period (90, 120, 150 or 180 seconds). The speed run during this period depends on the last heat call provided by the thermostat.

If the last call for heat was a call for low heat, the air circulator motor will run on low heat speed for the duration of the heat off delay period (90, 120, 150 or 180 seconds).

If the last call for heat was a call for high heat, the air circulating motor will run on the high heating speed for thirty (30) seconds and then switch to the low heating speed for the balance of the heat off delay period (60, 90, 120 or 150 seconds).

• Circulator blower and electronic air cleaner terminal is de-energized.

• Circulator blower ramps down to OFF during the 30 seconds following the heat off delay period.

• Furnace awaits next call from thermostat.

COOLING MODE

The normal operational sequence in cooling mode is as follows:

• R and Y1/G or Y2/G thermostat contacts close, initiating a call for cool.

• Integrated control module performs safety circuit checks.

• Outdoor fan and compressor are energized to their appropriate speed.

• Circulator blower is energized on the appropriate cool speed at the level and time determined by the selected ramping profile. Electronic air cleaner terminal is energized with circulator blower.

• Furnace circulator blower and outdoor cooling unit run their appropriate speeds, integrated control module monitors safety circuits continuously.

• R and Y1/G or Y2/G thermostat contacts open, completing the call for cool.

• Outdoor fan and compressor are de-energized.

• Circulator blower continues running during a cool off delay period. The OFF delay time and airflow level are determined by the selected ramping profile.

• Electronic air cleaner terminal and circulator blower are de-energized.

• Furnace awaits next call from thermostat.

Page 43

SYSTEM OPERATION

FAN ONLY MODE

The normal operational sequence in fan only mode is as follows:

• R and G thermostat contacts close, initiating a call for fan.

• Integrated control module performs safety circuit checks.

• Circulator blower is energized on continuous fan speed following a five (5) second delay. Electronic air cleaner terminal is energized.

• Circulator blower runs, integrated control module monitors safety circuits continuously.

• R and G thermostat contacts open, completing the call for fan.

• Circulator blower is de-energized. Electronic air cleaner terminal is de-energized.

DEHUMIDIFICATION MODE

The normal operational sequence in dehumidification mode is as follows:

1. R and Y1/G or Y1+Y2/G thermostat contacts close, initiaing a call for cool.

2. Integrated control module performs safety circuit checks.

3. Outdoor fan and compressor are energized to their appropriate speed.

4. Circulator blower is energized on the appropriate cool speed at the level and time determined by the selected ramping profile. Electronic air cleaner terminals are energized with circulator blower.

5. Furnace circulator blower and outdoor cooling unit run their appropriate speed, integrated control module monitors safety circuits continuously.

6. Dehumidistat opens on humidity rise allowing the furnace circulator blower to operate at 85% of the cooling speed during combined thermostat call for cooling and dehumidistat call for dehumidification.

7. Humidistat opens on humidity fall allowing furnace circulator blower to switch back to normal cooling speed.

8. R and Y1/G or Y1+Y2/G thermostat contacts open, completing the call for cool.

9. Outdoor fan and compressor are de-energized.

10. Circulator blower continues running during a cool off delay period. The OFF delay time and airflow level are determined by the selected ramping profile.

11. Electronic air cleaner terminals and circulator blower are de-energized.

12. Furnace awaits next call from thermostat.

HEATING - ABNORMAL OPERATION

The following presents the probable causes of questionable furnace operation and how to fix them. Look through the observation window in the blower access door and make a note of the error code displayed on the dual 7-segment dis-

play. Next, refer to the Troubleshooting Chart - ComfortNet™ on the following pages for an interpretation of the code displayed on the LED's for a description of the problem.

NOTE: Use caution when reading the diagnostic codes from the furnace control's dual, 7-segment LED's. The position of the control within the furnace can lead to a misinterpretation of the error codes. With the control in an orienation as shown below, codes on the dual, 7-segment LED's are read left to right.

2 Y2

Memory Card Connector

Dual 7-Segment LED’s

OG Y1CW1R

HUM

1. Internal Control Failure with Integrated Ignition Control. Check for voltage to the furnace and low voltage at the control board. Check for blown fuse on the control board. If the control determines it has an internal fault, it enters a locked-out state. Any of the situations mentioned will cause the dual, 7-segment LED's to be off. The control board should only be replaced only after all other checks from the Troubleshooting Chart - ComfortNet™ have been verified.

2. System Lockout. If a flame is not sensed during the first seven (4) seconds after the gas valve is energized, the control turns off the gas. There will then be a 30 second delay while the induced draft blower is energized to purge the heat exchanger. The ignitor will again be energized and preheated for an additional (1) second. The gas valve will then be energized. If flame is not sensed

Page 44

SYSTEM OPERATION

the gas valve will be de-energized and another purge will occur and a third ignitor warm up for an additional (2) seconds will occur. The control will cycle the gas valve a total of three (3) times before it determines it cannot establish measurable combustion and enters a locked out state. The diagnostic error code for this problem is E0. The control can be reset and brought out of lockout mode by turning the thermostat off for more than (5) seconds and less then (20) seconds and then back on. It can also be reset by turning off the electrical disconnect switch to the furnace for a minimum of 5 seconds.

NOTE: The control board will automatically reset one hour after lockout occurs. If the furnace frequently has to be reset, it means that a problem exists that should be corrected. Refer to Troubleshooting Chart - ComfortNet™ on the fol- lowing pages for aid in determining the cause.

3. Low Stage Pressure Switch Stuck Closed. If the con- trol senses the low stage pressure switch is closed when the induced draft blower is off, it waits until the fault is corrected. The diagnostic error code for this problem is E1. The probable cause is either a faulty pressure switch or wiring.

4. Low Stage Pressure Switch Stuck Open. If, after the induced draft blower is energized, the low stage pressure switch does not close within 5 minutes, the control will go into a 1-hour lockout. The control will automatically reset fro lockout and restart the ignition sequance. The diagnostic error code for this problem is E2. The probable causes are either disconnected hose to the pressure switch, faulty pressure switch or wiring, restricted air intake or flue piping.

5. Open Primary, Auxiliary, or Rollout Limit. If the limit control opens, the air circulator blower and induced draft blower will be turned on until the limit closes. The diagnostic error code for this problem is E3. The probable cause is either low conditioned air flow due to dirty filter or resistance in duct work, faulty limit, faulty blower, blower speed set to low, misaligned burners, faulty induced draft blower, or blocked flue.

6. Flame Sensed with No Call for Heat. If the control senses a flame when the gas valve is de-energized, it will run the air circulation blower and the induced draft blower continuously with no further furnace operation. The diagnostic error code for this condition is E4. The probable causes are either a short to ground in flame sense circuit, miswiring, lingering burner flame or a slow closing gas valve.

7. Open Fuse. If the control detects an open fuse, it will inhibit all furnace operation, except the display of the error code. The diagnostic error code for this condition is E5. The probable cause is a short in the low voltage wiring, either internal to the furnace or external to the furnace.

8. Low Flame Sense Signal. If the furnace continues to operate and the micro-amp signal from the flame sensor falls below specified level. The diagnostic error code for this problem is E6. The probable cause is either a coated/ oxidized sensor, incorrectly positioned senser in burner flame or lazy burner flame due to improper gas pressure or combustion air.

9. Check Igniter or No Ground Condition. Check for broken or improperly connected igniter. Check for proper ground and correct. The diagnostic error code for this problem is E7.

10. High Stage Pressure Switch Stuck Closed. If the control fails to operate at high stage heat when commanded to do so, the high stage pressure switch is stuck closed. For this condition, the furnace will operate at low stage only, regardless of the thermostat demand. The diagnostic error code for this condition is E8. The probable cause is sticking high stage pressure switch contacts or a short in the high stage pressure switch wiring.

11. High Stage Pressure Switch Stuck Open. This con- dition can occur if the pressure switch hose is blocked or pinched. Check for blocked flue and/or inlet air pipe. Blocked drain, weak induced draft blower and malfunctioning pressure switch are possible. The diagnostic error code for this problem is E9 followed by a pause.

12. Reversed Polarity. If the 115V or 24V AC power leads are reversed, the furnace will fail to operate. The diagnostic error code for this problem is EA. The probable cause is either the 115V AC power to furnace or integrated control module is reversed, the 24V AC wires to transformer are reversed, or poor unit ground.

13. No Shared Data. The control does not contain any shared data. Shared data sets contain all the information required to drive the variable speed motor as well as calculate airflow demands. The furnace cannot function without the approriate shared data set. The diagnostic error code for the this condition is d0. A memory card must be used to populate shared data to the control. Contact your distributor to obtain the appropriate memory card for your particular furnace model.

NOTE: Turn off power to the furnace prior to inserting memory card onto the control. With memory card inserted onto control, turn power to furnace on. Control has accepted memory card data once control displays ON on the dual, 7-segment display. Memory card may be left on control or removed and used on another furnace of the same model. Turn power off to furnace prior to removing memory card.

14. Invalid Memory Card Data. This condition occurs if the control rejects the shared data set on a memory card. Memory cards are model specific. If a memory card for a different model is used to populate data to a specific furnace, if will be rejected by the control. If using a memory card to populate shared data to a control, ensure the memory card is specific to the furnace. The diagnostic error code for this condition is d4

Page 45

SYSTEM OPERATION

NOTE: Turn off power to the furnace prior to inserting memory

card onto the control. With memory card inserted onto control, turn power to furnace on. Control has accepted memory card data once control displays ON on the dual, 7-segment display. Memory card may be left on control or removed and used on another furnace of the same model. Turn power off to furnace prior to removing memory card.

15. ECM Blower Motor Not Running. This condition occurs if the control fails to detect the ECM blower motor running when it should be running. The furnace will not operate if the control detects the blower motor is not running when it should be running. The diagnostic error code for this condition is b0. The probable cause loose or disconnected wiring between the motor and control, an open inductor (3/4 Hp and 1 Hp motors only), or a failed ECM blower motor (see section S-16C in Servic- ing).

16. ECM Motor Communciations Lost. This condition oc- curs if the furnace control cannot communicate with the ECM blower motor. The furnace will not operate if the control cannot communicate with the blower motor. The diagnostic error code for this condition is b1. The probable cause loose or disconnected wiring between the motor and control, a failed ECM blower motor (see section S-16C in Servicing), or a failed control.

17. Motor Horsepower Mismatch. This condition occurs if the horsepower of the motor connected to the control does not match the motor horsepower specified in the shared data set. The furnace will not operate is there is a motor horsepower mismatch. The diagnostic error code for this condition is b2.

Verify that the installed motor is the correct motor for the furnace model. Obtain the correct motor for the furnace model. Verify the shared data set is correct for the furnace. The shared data set may be corrected using the appropriate memory card. Contact your distributor for the correct memory card. See 13 and 14 above for additional memory card information.

18. ECM Motor Operating in a Limiting Condition. This condition will occur if the ECM operates in a power, speed, or temperature limiting condition. The furnace will continue operating at reduced performance. The diagnostic error code for the this condition is b3.

Power Limit. In attempting to deliver the airflow demand, the motor may exceed its rated output power. The motor will reduce its output to prevent exceeding its power limit. This will result in lower than demanded airflow. This will occur under high loading conditions. High loading conditions could be due to blocked/clogged filters, blocked or restrictive ductwork, or undersized ductwork.

Speed Limit. In attempting to deliver the airflow demand, the motor may exceed its maximum speed of 1500 RPM. The motor will reduce its speed to prevent exceeding its maximum. This will result in lower than demanded airflow. A blocked inlet, lightly loaded or no load conditions could cause high motor speeds.

Temperature Limit. In attempting to deliver the airflow demand, the motor may exceed its temperature limit. The motor will reduce its output in an attempt to reduce its temperature. This will result in lower than demanded airflow. A high ambient temperatue at a high loading condition is the most probable cause. Reduce the ambient temperature and/or motor loading/demand.

19. Motor Trips. This condition occurs if the ECM motor senses a loss of control or becomes overloaded. The furnace may halt operation if the motor shuts down for a trip condition. The diagnostic error code for this condition is b4.

Loss of Control (Lost Rotor Trip). This occurs if a sudden change in speed or torque is detected. The motor will shut down and restart if this condition is encountered. Possible causes are abnormal loading conditions due to sudden blockages of the duct system or sudden high increases in the loading on the motor.

Overload (Current Trip). This occurs if the motor becomes overloaded due to high loading conditions. The motor will shut down and restart if this condition is encountered. High loading conditions could be due to blocked/clogged filters, blocked or restrictive ductwork, or undersized ductwork.

20. Motor Locked Rotor. This condition occurs if the motor fails to start after (10) consecutive attempts. The furnace will not operate if the ECM blower motor fails to start. The diagnostic error code for this condition is b5. The probable cause is an obstruction in the blower housing or wheel, siezed motor bearings, or a failed blower motor.

21. Motor Volts. This condition occurs if the line voltage is too low or too high, or if the motors power module gets too hot. The ECM motor will shut down while the abnormal condition is present. If the abnormal condition is cleared, the motor will restart. The furnace will be inoperable while the motor is off.

Over Voltage. If the line voltage exceeds 140VAC, the motor will shut down due to an over voltage condition. Verify the line voltage to the furnace is within the range specified on the rating plate.

Under Voltage. If the line voltage is less than 70VAC, the motor will shut down due to an under voltage condition. Verify the line voltage to the furnace is within the range specified on the rating plate.

Over Temperature. A high ambient temperatue or a high loading condition is the most probable cause. Reduce the ambient temperature and/or motor loading/demand.

Page 46

SYSTEM OPERATION

22. Motor Parameters. This condition occurs if the motor does not receive all the information is requires to operate or an event occurs that prevents the motor from running, or the motor fails to start for (40) consecutive attempts. The diagnostic error code for the this condition is b7. Probable causes are intermittent wiring connection between the control and motor, an error with the furnace control, or any of the conditions described in 19, 20, or 21 above.

23. Low Indoor Airflow. This condition occurs if the indoor airflow falls below a calculated minimum value. The minimum airflow value is calculated from factors defined in the shared data set. If the airflow falls below the calculated minimum, the furnace will continue to operate with the reduce airflow. If the furnace was operating at high stage, it will stage back to low in an effort to remedy the condition. The furnace will halt operation if the airflow falls to 0 CFM.

The diagnostic error code for the this condition is b9. Probable causes are blocked/clogged filters, blocked or restrictive ductwork, or undersized ductwork.

Page 47

TROUBLESHOOTING

Symptoms of Abnormal

Operation (Legacy &

ComfortNet™ Thermostat)

• Furnace fails to operate

• Integrated control module LED display provides no signal.

• ComfortNet™ thermostat “Call for Service” icon illuminated

• ComfortNet™ thermostat scrolls “Check Furnace” message

• LED display indicates On On • Nor mal operation None None • Normal operation • None • Normal operation

• Furnace fails to operate

• Integrated control module LED display provides E0 error code.

• ComfortNet™ thermostat “Call for Service” icon illuminated.

• ComfortNet™ thermostat scrolls “Check Furnace” message.

• Furnace fails to operate.

• Integrated control module LED display provides E1 error code.

• ComfortNet™ thermostat “Call for Service” icon illuminated.

• ComfortNet™ thermostat scrolls “Check Furnace” message.

Diagnostic/ Status LE D

Codes

None • No 115 power to

E0 • Furnace lockout

E1 • Low stage pressure

Fault Description

furnace or no 24 volt power to integrated control module

•Blown fuse or circuit breaker

• Integrated control module has an internal fault

due to an excessive number of ignition “retries” (3 total)

switch circuit is closed at start of heating cycle.

ComfortNet™

Thermostat Only

Message Code

INTERNAL

FAULT

LOCKOUT E0 • Failure to establish flame.

PS1

CLOSED

EE • Manual disconnect switch

E1 • Low stage pressure switch

Possible Causes Corrective Actions Notes & Cautions

OFF, door switch open or 24 volt wir e improperly connected or loose

• Blown fuse or circuit breaker

• Integrated control module has an internal fault

Cause may be no gas to burners, front cover pressure swi t ch st uck open, bad igniter or igniter alignment, improper orifces, or coated/oxidized or improperly connected fame sensor.

• Loss of flame after establishment. Cause may be in te rrupted gas supply, lazy burner flames (improper gas pressure or restriction in flue and/ or combustion air piping), front cover pressure switch opening, or improper induced draft blower performance.

contacts sticking.

• Shorts in pressure switch circuit wiring.

• Assure 115 and 24 volt power to furnace and integrated control module.

• Check integrated control module fuse (3A). Replace if necessary.

• Check for possible shorts in 115 and 24 volt circuits. Repair as necessary.

• Replace bad integrated control module.

• Locate and correct gas interruption.

• Check f r o nt cover pressure switch operation (hose, wiring, contact operation). Correct if necessary.

• Replace or realign igniter.

• Check f l ame sense signal. Clean sensor if coated and/or oxidized.

• Check flue piping for blockage, proper length, elbows, and termination.

• Verify proper induced draft blower performance.

• Replace low stage pressure switch.

• Repair short in wiring.

• Turn power OFF prior to repair.

• Replace integrated control module fuse with 3A automotive fuse.

• Read precautions in “Electrostatic Discharge” section of manual.

•Replace control with correct replacement part

• Turn power OFF prior to repair.

• Igniter is fragil e, handle with care.

• Clean flame sensor. See “Vent/Flue Pipe”

• section for piping details.

• Turn power OFF prior to repair.

• Replace pressure switch with proper replacement part.

Page 48

TROUBLESHOOTING

Symptoms of Abnormal

Operation (Legacy

& Comfo rt Ne t™

Thermostat)

• In duce d dr aft blower runs continuously with no further furnace operation.

• Integrated control module LED display provides E2 error code.

• ComfortNet™ thermostat “Call for Service” icon illuminated.

• ComfortNet™ thermostat scrolls “Check Furnace” message.

• Circulato r blower runs continuously. No furnace operation.

• Integrated control module LED display provides E3 error code.

•ComfortNet™ thermostat “Call for Service” icon illuminated.

•ComfortNet™ thermostat scrolls “Check Furnace” message.

• In duce d dr aft blowe r and circulator blower runs continuously. No furnace operation.

• Integrated control module LED display provides E4 error code.

•ComfortNet™ thermostat “Call for Service” icon illuminated.

•ComfortNet™ thermostat scrolls “Check Furnace” message.

• No furnace o peration.

• Integrated control module LED display provides E5 error code.

•ComfortNet™ thermostat displays “Battery Power”

• Normal furnace operation.

• Integrated control module LED display provides E6 error code.

Diagnostic/

Status LED

Codes

E2 • Low stage

E3 • Primary limit or

E4 • Fl ame sensed

E5 • Open Fuse Not

E6 • Fl ame sense

Fault Description

pressure switch circuit is not closed.

auxiliary limit circuit is open.

• Rollout limit circuit is open.

with no call for heat.

micro amp signal is low

ComfortNet™

Thermostat Only

Message Code

PS1 OPEN E2 • Pressure switch hose

HIGH LIM IT

OPEN

IMPROPER

FLAME

Displayed

WEAK

FLAME

E3 • Insuffcient conditioned

E4 • Short to ground in

Not

Displayed

E6 • F lame sensor is

Possible Causes Corrective Actions Notes & Cautions

blocked pinched, or connected improperly.

• Blocked fue and/or inlet air pipe, blocked drain system or weak induced draft blower.

• Incorrect pressure switch s e t p o in t o r malfunctioning switch contacts.

• Loose or improperly connected wiring.

air over the heat exchanger. Blocked flters, res t rictive ductwork, improper circulator blower speed, or failed circulator blower motor.

• Flame rollout .

• Misaligned burners, blocked fue and/or air inlet pipe, or failed induced draft blow er.

• Loose or improperly connected wiring.

Flame sen se cir c ui t.

• Lingering burner fame.

• Slow closing gas valve.

• Short in low voltag e wiring

coated/oxidized.

•Flame sensor incorrectly positioned in burner fame.

• Lazy burner flame due to improper gas pressure or combustion air.

• Inspect pressure switch hose. Repair/replace if necessary.

• Inspect fue and/or inlet air piping for blockage, proper length, elbows, and ter mination. Check drain syst em. Corr e ct as necessary.

• Check induced draft blower performance. Correct as necessary.

• Correc t pressure switch set point or cont act motion.

• Tighten or correct wiring connection.

• Check filters and ductwork for blockage. Clean flters or remove obstruction.

• Che ck circ ul ator blower speed and performance. Correct speed or replace blower motor if necessary.

•Check burners for proper ali gnment.

• Check fue and air inlet piping for blockage, proper length, elbows, and termination. Correct as necessary.

• Che ck indu c ed draf t blower for proper performance. Replace if necessary.

• Tighten or correct Wiring connection.

• Correct short at flame sensor or in flame sensor wiring.

• Check for lingering flame.

• V erify proper operation of gas valve.

• Locate and correct short in low voltage wiring

• Clean flame sensor if coated/oxidized.

• Inspect for proper sensor alignment.

• Check inlet air piping for blockage, proper length, elbows, and termination.

• Comp a r e current gas pressure to rating plate. Adjust as needed.

• T urn power OFF prior to repair.

• Rep la ce pr es sur e switch with proper replacement part.

• Rep la ce in duced draft blower with proper replacement part.

• Turn power OFF

prior to repair .

• See Specifcation

Sheet applicable to your model* for allowable rise range and proper circulator speed.

• See "Vent/Flu e Pipe "

section for piping details.

• Turn power OFF

prior to repair .

• Turn power OFF

prior to repair .

• Replace fuse with

3-amp automotive type

• Turn power OFF

prior to repair .

• Clean fame sensor

• See "Vent/Flu e Pipe "

section for piping details.

• See rating plate for

proper gas pressure.

Page 49

TROUBLESHOOTING

Symptoms of Abnormal

Operation (Legacy

& Com f ortNet ™

Thermostat)

• Furnace fails to operate.

• Integrated control module LED display provides E7 error code.

•ComfortNet™ thermostat “Call for Service” icon illuminated.

•ComfortNet™ therm o stat scr o l ls “Check Furnace” message.

• Furnace fails to operate on high stage; furnace operates normally on low stage.

• Integrated control module LED display provides E8 error code.

• Furnace fails to operate on high stage; furnace operates normally on low stage.

• Integrated control module LED display provides E9 error code.

• Furnace fails to operate.

• Integrated control module LED display provides EA error code.

• ComfortNet™ therm ostat “Call for Service” icon illuminated.

• ComfortNet™ therm ostat scrol ls “Ch eck Furna ce” message.

• Integrated control module LED display EF error code.

• ComfortNet™ therm ostat “Call for Serv ic e ” .

Diagnostic/ Status LE D

Codes

E7 • Problem with

E8 • High stage

E9 • High stage

EA • Polarity of 115 volt

EF • Aux switch open Aux Alarm

Fault Description

igniter circuit.

pressur e swi tch circu i t is clo se d at start of heating cycle.

• Induced draft blower is operating.

• Furnace is operating on low stage only

pressur e swi tch circuit is not closed.

• Induced draft blower is operating.

• Furnace is operating on low stage only

AC is reversed

PS2 CLOSED E8 • High stage pressure

REVERSED

ComfortNet™

Thermostat Only

Message Code

IGNITER

FAULT

PS2 OPEN E9 • Pressure switch hose

PLTY

Fault

E7 • Improperly connected

EA • Polarity of 115 volt AC

EF • High water level in the

Possible Causes Corrective Actions Notes & Cautions

igniter .

• Shorted igniter.

• Poor unit ground.

• Igniter relay fault on integrated control module.

switch contacts sticking.

• Shorts in pressure switch circuit wiring.

blocked pinched, or connected improperly.

• Blocked fue and/or inlet air pipe, blocked drain system or weak induced draft blower.

• Incorrect pressure switch set point or malfunctioning switch contacts.

• Loose or i mproperly connected wiring.

power to furnace or integrated module is revered.

• Poor unit ground

evaporation coil.

• Check and correct wiring from integrated control module to igniter .

• Replace shorted igniter.

• Check and correct unit ground wiring.

• Check igniter output from control. Replace if necessary.

• Replace high stage pressure switch.

• Repair short in w iring

• Inspect pressure switch hose. Repair/replace if necessary.

• Inspect fue and/or inlet air piping for blockage, proper length, elbows, and termination. Check drain system. Correct as necessary.

• Check induced draft blower performance. Correct as necessary.

• Correct pressure switch set point or contact motion.

• Tighten or correct wiring connection.

• Review wiring diagram to correct polarity.

• Verify proper gr ound. Correct if necessary .

• Check and correct wiring.

• Check overfow pan and service.

• Turn power OFF prior to repair.

• Replace igniter with correct replacement part.

• Replace control with correct replacement part.

• Turn power OFF prior to repair.

• Replace pressure switch with proper replacement part.

• Turn power OFF prior to repair.

• Replace pressure switch with proper replacement part.

• Replace induced draft blower with proper replacement part.

• Turn power OFF prior to repair.

• Turn power OFF prior to service.

• Furnace fails to operate.

• Integrated control module LED display provides d0 error code.

• ComfortNet™ therm ostat “Call for Service” icon illuminated.

• ComfortNet™ therm ostat scrol ls “Ch eck Furna ce” message.

d0 • Data not yet on

network.

NO NET

DA TA

d0 • Furn ace does not

contain any shared data.

• Populate shared data set using memory card.

• Turn power OFF prior to repair

• Use m emory card for the specifc model.

• Insert memory card BEFORE turning power ON. Memory card may be removed after data is loaded and power is turned off.

• Error code will be cleared once data is

Page 50

TROUBLESHOOTING

Symptoms of Abnormal

Operation (Legacy

& ComfortNet™

Thermostat)

• Operation different than expected or no operation.

• Integrated control module LED display provides d4 error code.

• ComfortNet™ thermostat “Call for Se rvice” icon illuminated.

• ComfortNet™ thermostat scro ll s “ Check Furna ce” message.

• Furnace fails to operate.

• Integrated control module LED display provides b0 error code.

• ComfortNet™ thermostat “Call for Se rvice” icon illuminated.

• ComfortNet™ thermostat scro ll s “ Check Furna ce” message.

• Furnace fails to operate.

• Integrated control module LED display provides b1 error code.

• ComfortNet™ thermostat “Call for Se rvice” icon illuminated.

• ComfortNet™ thermostat scro ll s “ Check Furna ce” message.

• Furnace fails to operate.

• Integrated control module LED display provides b2 error code.

• ComfortNet™ thermostat “Call for Se rvice” icon illuminated.

• ComfortNet™ thermostat scro ll s “ Check Furna ce” message.

• Furnace operates at reduced performance.

• Airfow delivered is less than expected.

• Integrated control module LED display provides b3 error code.

Diagnostic/ Status LED

Fau lt Descrip tion

Codes

d4 • Invalid memory

b0 • Circulator blower

b1 • Integrated control

b2 • Circulator blower

b3 • Circulator blower

card data.

motor is not running when it should be running.

module has lost communic ations with circulator blower motor.

motor horse power in shared data set does not match circulator blower motor horse pow er.

motor is operating in a power, temperature, or speed limiting condition.

ComfortNet™

Thermostat Only

Message Code

INVALID MC

DA TA

MOTOR NOT

RUN

MOTOR

COMM

MOTOR

MISMATCH

MOTOR

LIMITS

Possible Causes Corrective Actions Notes & Cautions

d4 • Shared data set on

memory card has been rejected by integrated control module

b0 • Loose wiring connection

at circulator motor power leads or circulator motor power leads disconnected.

• Open circuit in inductor or loose wiring connection at inductor (3/4 Hp and 1 Hp models only).

• Failed ci r cul at or blower motor.

b1 • Loose wiring connection

at circulator motor control leads.

• Failed ci r cul at or blower motor.

• Failed integrated control module.

b2 • Incorrect circulator

blower motor in furnace.

• Incorrect shared data set in integrated control module.

b3 • Blocked flters.

• Restrictive ductwork.

• Undersized ductwork.

• High ambient temperatures.

• Verify sha r e d data set is correct for the specifc model. Re-popul ate data using correct memory card if required.

• Tighten or correct wiring connection.

• V erify continuous circuit through inductor. Replace if open or short circuit.

• C heck circulator blower motor. Replace if necessary.

• Tighten or correct wiring connection.

• C heck circulator blower motor. Replace if necessary.

• C heck in tegr at e d con t ro l module. Replac e if necessary.

• V erify circulator blower if motor horse power is the same specifed for the specifc furnace model. Replace if nec ess ary.

• Verify sha r e d data set is correct for the specifc model. Re-popul ate data using correct memory card if required.

• C h e ck fl t e r s for blockage. Clean flters or remove obstruction.

• C heck duct wo rk for blockage. Remove obstruction. Verify all registers are fully open.

•Verify ductwork is appropriately sized for system. Resize/ replace ductwork if necessary.

•See "III. Product Description" and "IV. Location R eq u ir ements & Considerations" furnace installation requirements.

• Turn power OFF prio r to repair

• U se memory card for the specifc model.

• Insert memory card BEFORE turning power ON. Memor y card may be remove d after data is load ed and power is tur ned off.

• Error code will be cleared once data is loaded and power is turned off.

• Turn power OFF prio r to repair

• Replace inductor with correct replacement part.

• Rep la ce ci r cul at or motor with correct replacement part.

• Turn power OFF prio r to repair

• Rep la ce ci r cul at or motor with correct replacement part.

• Replace integrated control module with correct replacement part.

• Turn power OFF prio r to repair

•Replace motor with correct replacement part.

• U se memory card for the specifc model

• Insert memory card BEFORE turning power ON. Memor y card may be remove d after data is load ed and power is tur ned off.

• Error code will be cleared once shared data and motor horse power matc h .

• Turn power OFF prio r to repair.

Page 51

TROUBLESHOOTING

Symptoms of Abnormal

Operation (L egacy

& ComfortNet™

Thermostat)

• Furnace fails to operate.

• Integrated control module LED display provides b4 error code.

• ComfortNet™ thermostat “Call for Service” icon illuminated.

• ComfortNet™ thermostat scrol ls “Che ck Furnac e” message.

Diagnostic/ Status LED

Codes

Faul t D es cription

•

Circulator blower motor senses a loss of rotor control.

• Circulator blo wer motor senses

high current.

ComfortNet™

Thermostat Only

Message Code

MOTOR

TRIPS

b4 • Turn power OFF prior

Possible Causes Corrective Actions Notes & Cautions

to repair

• Furnace fails to operate.

• Integrated control module LED display provides b5 error code .

• ComfortNet™ thermostat “Call for Service” icon illuminated.

• ComfortNet™ thermostat scrolls “Check Furnace” message.

• Furnace fails to operate.

• Integrated control module LED display provides b6 error c ode.

• ComfortNet™ thermostat “Call for Serv ice” icon illuminated.

• ComfortNet™ thermostat scrolls “Check Furnace” message.

• Furnace fails to operate.

• Integrated control module LED display provides b7 error c ode.

• ComfortNet™ thermostat “Call for Serv ice” icon illuminated.

• ComfortNet™ thermostat scrolls “Check Furnace” message.

• Circulator blo wer

b6 MOTOR

moto r fa i ls to start

10 consecutive

times.

•

Circulator blower motor shuts down

MOTOR LCKD

ROTOR

VOLTS

for over or under voltage condition.

•

Circulator blower motor shuts down due to over temperature condition on power module.

•

b7 MOTOR

Circulator blower motor does not have enough information to operate properly. Motor fails to start

PARAMS

40 consecutive times.

b5 • Turn power OFF prior

•

b6 • Turn power OFF prior

•

to repair.

• Replace motor with correct replacement part.

• Replace wheel with correct replacement part.

to repair

•

• Furnace operates at reduced performance or

operates on low stage when high stage is expected.

• Integrated control

module LED dis play provides b9 error code .

•

b9 LOW ID

Airflow is lower than demanded.

AIRFLOW

B9 • B locked filters.

• Restrictive ductwork.

• Undersized ductwork.

• Check filters for blockage. Clean filters or remove obstruction.

• Check ductwork for blockage. Remove obstruction. V erify all registers are fully open.

• V erify ductwork is appropriately sized for syste m. Resize/replace ductwork if necessary.

• Turn power OFF prior to repair.

Page 52

TROUBLESHOOTING

O E0

E2 E3

E E5 E6 E7 E8

E9 E A

INTERNAL CONTROL FAULT/NO NORMAL OPERATION LO CKOUT DUE TO EXCESSIVERE TRIES LOW STAGE PRESSURE SWITCH STUCK CLOSED AT START OF HEA TING CYCLE LOW STAGE PRESSURE SWITCH STUCK OPEN OPEN HIGH LIMIT FLAME DETECTED WHEN NO FLAME SHOULD BE PRESENT OPE N FU SE LOW FLAME SIGNAL IGNITER F AUL T OR IMP ROPER GROUN DI NG

HIGH STAGE PRESSURE SWITCH STUCK CLO SED AT START O F HEATING CYCLE

HIGH STAGE PRESSU RE SWITCH STUCK

REVERSED 115 VAC POLARITY

AUXILIARY SWITCH OPEN

DATA NOT YET ON NETWORK INVALID M E MORY CARD DATA

SWITCH

POWER

OPEN

BLOWER MO TOR NOT R UN NING

BLOW ER COMMUNICATION ERROR

BLOW ER HP MIS-M ATCH

BLOW ER MOTOR OPERATING IN PO W ER, TEMPERATURE, OR SPEED LIMIT

BLOWER MOTOR CURRENT TRIP O R LOST

BLOWER MOTOR LOCKED ROTOR

OVER/UNDER VOLTAGE TRIP OR OVER TEMPERATURE TRIP

INCOM PLET E PARAMETERS SENT T O

LOWINDOO RAIRFLOW

LOW STAGE COO L

C C2

P1 P2

HIGH ST AG ECO O L LOW STAGE H EAT PUMP H EAT

HIGH STAGE HEAT PUMP

LOW STAGE G AS

HIGH STAGE GAS HEAT

CONT INUO US FAN

HEAT

ROTOR

MOTOR

CFM/100; AL TERNA TES WITH

, , , ,

P1 P2

0140F011 69REV A

Page 53

SYSTEM OPERATION

ComfortNet™ System

OVERVIEW

The ComfortNet system is a system that includes a ComfortNet compatible furnace and air conditioner or heat pump with a CTK0*** thermostat. A valid ComfortNet system could also be a compatible furnace, CTK0*** thermostat and non-communicating, single stage air conditioner. Any other system configurations are considered invalid ComfortNet systems and must be connected as a traditional (or legacy) system (see Electrical Connections for wiring connections).

A ComfortNet heating/air conditioning system differs from a legacy/traditional system in the manner in which the indoor unit, outdoor unit and thermostat interact with one another. In a traditional system, the thermostat sends commands to the indoor and outdoor units via analog 24 VAC signals. It is a one-way communication path in that the indoor and outdoor units typically do not return information to the thermostat.

On the other hand, the indoor unit, outdoor unit, and thermostat comprising a ComfortNet system “communicate” digitally with one another. It is now a two-way communications path. The thermostat still sends commands to the indoor and outdoor units. However, the thermostat may also request and receive information from both the indoor and outdoor units. This information may be displayed on the ComfortNet thermostat. The indoor and outdoor units also interact with one another. The outdoor unit may send commands to or request information from the indoor unit. This two-way digital communications between the thermostat and subsystems (indoor/outdoor unit) and between subsystems is the key to unlocking the benefits and features of the ComfortNet system.

Two-way digital communications is accomplished using only two wires. The thermostat and subsystem controls are power with 24 VAC. Thus, a maximum of 4 wires between the equipment and thermostat is all that is required to operate the system.

OPERATIONS WITH CTK03AB AND CTK04

1. Humidification Options are ON / OFF with the CTK03AB. When “On” is selected, the humidification relay on the furnace control board will function during a heat call if a humidity demand exists. Selecting “Off” means the humidification relay will not function.

2. If the CTK03AB and CTK04 are set up so the compressor off delay is 0 min, it will display a cool / heat call immediately regardless of the delay built into the outdoor unit control board. This means the CTK03A* could show COOL ON when the outdoor unit is still in a delay period. The recommendation is to set up the compressor delay to at least 3 minutes

3. Dual Fuel – When the CTK03AB and CTK04 call for gas heat, the heat pump will shut off, after a delay of approximately 3 minutes it will then turn on gas heat.

4. Dehumidification (lowering of CFM to 85%) only hap-

ComfortNet™ System

pens during low stage cooling operation. The dehumidification feature is not active during high stage cool. The CTK03AB and CTK04 can be set up to overcool the home in order to reach the RH set point.

CTK0*** WIRING

NOTE: Refer to Electrical Connections for 115 volt line

connections to the furnace. NOTE: A removable plug connector is provided with the

control to make thermostat wire connections. This plug may be removed, wire connections made to the plug, and replaced. It is recommended that multiple wires be connected with a wire nut and only one wire be inserted under a screw. Failure to do so may result in intermittent operation.

Typical 18 AWG thermostat wire may be used to wire the system components. However, communications reliability may be improved by using a high quality, shielded, twisted pair cable for the data transmission lines. In either case, 100 feet is the maximum length of wire between indoor unit and outdoor unit, or between indoor unit and thermostat.

FOUR-WIRE INDOOR AND OUTDOOR WIRING

Typical wiring will consist of four wires between the indoor unit and outdoor unit and between the indoor unit and thermostat. The required wires are: (a) data lines, 1 and 2; (b) thermostat “R” (24 VAC hot) and “C” (24 VAC common).

12RC

TWO-WIRE OUTDOOR, FOUR-WIRE INDOOR WIRING

Two wires only may be utilized between the indoor and outdoor units. For this wiring scheme, only the data lines, 1 and 2, are required between the indoor and outdoor units. A 40VA, 208/230 VAC to 24VAC transformer must be installed in the outdoor unit to provide 24VAC power to the outdoor unit’s electronic control.

NOTE: Use of an accessory transformer is recommended if installing a dual fuel system. Failure to use the transformer in the outdoor unit could result in overloading of the furnace transformer.

When using a CTK03A*or CTK04 thermostat, the included transformer must be used.

CTK0*** Thermostat

ComfortNet Compatible Furnace Integrated Control Module

ComfortNet Compatible AC/HP Integrated Control Module

Page 54

SYSTEM OPERATION

If your communicating thermostat kit does not include a transformer, an accessory kit is available separately by ordering part TFK01.

ComfortNet™ System

CTK0*** Thermostat

40V A Transformer

208/230 VAC

12RC

24 VAC

CTK0***

Thermostat

ComfortN et Compatible Furnace Integrated Control Module

ComfortNet Compatible

AC/HP Integrated Control Module

SYSTEM WIRING USING TWO-WIRES BETWEEN FURNACE AND FOUR-WIRES BETWEEN FURNACE AND THERMOSTAT

COMFORTNET FURNACE WITH NON-COMFORTNET A/C S

INGLE STAGE AIR CONDITIONER

Four wires are required between the furnace and thermostat. Two wires are required between the furnace control and single stage air conditioner. For this system configuration, the “Y1” terminal on the integrated furnace control becomes an output rather than an input.

ComfortNet

12RC

C Y

W1 W2 Y1 Y2

Non-ComfortNet Compatible Single Stage AC

Compatible Furnace Inte grated Control Module

SYSTEM WIRING BETWEEN FURNACE AND NON-COMFORTNET COMPATIBLE SINGLE STAGE AIR CONDITIONER

COMFORTNET SYSTEM ADVANCED FEATURES

The ComfortNet system permits access to additional system information, advanced setup features, and advanced diagnostic/troubleshooting features. These advanced features are organized into a menu structure.

NOTE: PCBKF105 IFC has the added feature of 24 VAC input to G terminal when using a communicating thermostat. ERV/HRV and other assessories can send a signal to the G terminal and energize the continuous fan. The continuous fan speed can be adjusted on switch bank S5, dip switch 3 & 4. The 24 vac source must originate from the R terminal of furnace.

CTK0* Thermostat

112RC

4-Pin (X2), 7 Pin, or 9 Pin Connector

W1 W2 Y1 Y2 O DEHUM

24 vac "G " input to Furnace Integrat ed C o n t rol modu le F rom ER V / HRV or S imila r Devices

Furnace Integrated Control Module

Page 55

SYSTEM OPERATION

FURNACE ADVANCED FEATURES MENUS

Submenu Item Indication/User Modifiab le Options Comments

Fault 1 (FAULT #1) Most recent furnace fault For display only Fault 2 ( FAULT #2) Ne x t mos t re c ent fur nac e fault For dis play only Fault 3 ( FAULT #3) Ne x t mos t re c ent fur nac e fault For dis play only Fault 4 ( FAULT #4) Ne x t mos t re c ent fur nac e fault For dis play only Fault 5 ( FAULT #5) Ne x t mos t re c ent fur nac e fault For dis play only Fault 6 (FAULT #6) Least recent furnace fault For display only

Clear F ault History (CLEA R) NO or Y ES

NOTE:

Consecutively repeated faults are shown a maximum of 3 times.

ComfortNet™ System

DIAGNOSTICS

Selecti ng “YES” clears th e fault hist or y

IDENTIFICATION

Submenu Item Indication (for Display Only; not User Modifia ble)

Model Nu m ber ( M OD NU M ) Displays the furnace m odel n um ber Serial Number ( S E R NUM) Displays the furnace seria l number ( Op tiona l) Software (SOFTWARE) Displays the application software revision

SET-UP

Submenu Item User Modifiable Options Comme nts

Heat Airflow Trim (HT TRM) Heat ON Delay (HT ON 5, 10, 15, 20, 25, or 30 seconds,

Heat O FF Delay ( HT OFF) 30, 60, 90, 120, 150, or 180

Heat Airflow (HT ADJ ) 1, 2, 3, or 4 Selects the nominal heat ing air flow ( see

-10% to +10% in 2% increments, de fa ul t is 0%

d e f a ul t is 30 se c o nds

seconds, d efault is 150 secon ds

Tr im s the hea ting airflow by the se le cted amount. Selects th e i ndoor bl ower heat ON delay

Selects th e i ndoor bl ower heat OFF de lay

Startup Procedure and Adjustment – Circulator Blower Speeds for additional

information)

THERMOSTAT MENU

If this furnace is installed with a ComfortNet compatible heat pump, the system is recognized as a dual fuel system. The balance point temperature should be set via the thermostat advanced menu.

Page 56

SYSTEM OPERATION

NON- C O M M (A P P LI E S ONL Y TO A COM MUNICAT ING COMPATIBL E FURNACE MATCHED

WITH A NON - COM MUNICATING COMPATIBLE SINGL E STAGE AIR CONDITIONER)

Subm e nu Item U s er Mo difiab le Options Co m ments

Cool Air flow (C L CFM) 18, 24, 30, 36, 42, 48, or 60, default

is 18

ComfortNet™ System

Sele c ts the airflow for the non-CT comp atib le sing l e s tag e A C un it

Cool Airflow Trim (CL TRM) -10% to +10% in 2% increment s,

d efault is 0%

Cool A ir flow Profile (CL P RFL) A, B , C, or D, default is A Sele c ts the airflow profile for the non-

Cool ON Delay (CL ON) 5, 10, 20, or 30 seconds, default is

5 secon ds

Cool OFF Delay (CL OFF) 30, 60, 90, or 120 seconds, default

is 30 sec o nd s

STAT US

Submenu Item Indication (for Display Only; not User Modifiable)

Mode (MODE) Displays the current furnace operating mode CFM (CFM) Displays the airfl ow for the c urrent operating mode

Sele cts the airf low trim amount for the noncommunicating compatible s ingle stage AC unit

communicating compatible s ingle stage AC unit Sele c ts t he ind oor blower ON delay for the non - c om m unicat ing c om patible si ngle st age A C unit Sele c ts t he ind oor blower OFF dela y for t he non - c om m unicat ing c om patible si ngle st age A C unit

DIAGNOSTICS

Accessing the furnace’s diagnostics menu provides ready access to the last six faults detected by the furnace. Faults are stored most recent to least recent. Any consecutively repeated fault is stored a maximum of three times. Example: A clogged return air filter causes the furnace limit to trip repeatedly. The control will only store this fault the first three consecutive times the fault occurs. Navigate to the diagnostics menu as described above in Accessing and Navi- gating the Advanced Features Menus.

NOTE: It is highly recommended that the fault history be cleared when performing maintenance or servicing the furnace.

bank of two dipswitches that provide termination functions for the communications transmission lines. Communications errors will result if these switches are not correctly set. The table below indicates the switch position for the bias and termination dipswitches along with the expected voltages. Note that the ON position is the correct position for all bias and termination dipswitches.

The ComfortNet system is a fully communicating system, and thus, constitutes a network. Occasionally the need to troubleshoot the network may arise. The integrated furnace control has some on-board tools that may be used to troubleshoot the network. These tools are: red communications LED, green receive (Rx) LED, and learn button.

NETWORK TROUBLESHOOTING

Communications is achieved by taking the difference between two dc signals. The signals and transmission lines are referred to as “data 1” and “data 2”. Each transmission line is biased to approximately 2.5Vdc. During data reception/transmission, the data lines vary between +5V and ground. (When data 1 is increasing towards +5V, data 2 is decreasing towards ground and when data 1 is decreasing towards ground, data 2 is increasing towards +5V. Typically, the data 1 line is approximately 2.6Vdc and the data 2 transmission line is approximately 2.3Vdc. The voltage difference between data 1 and data 2 is typically 0.2 to 0.6 Vdc.

The indoor control is equipped with a bank of three dipswitches that provide biasing and termination functions for the communications transmission lines. The outdoor control in the ComfortNet compatible unit is equipped with a

• Red communications LED – Indicates the status of the network. The table below indicates the LED status and the corresponding potential problem.

• Green receive LED – Indicates network traffic. The table below indicates the LED status and the corresponding potential problem.

• Learn button – Used to reset the network. Depress the button for approximately 2 seconds to reset the network.

Page 57

SYSTEM OPERATION

ComfortNet™ System

SYSTEM TROUBLESHOOTING

NOTE: Refer to the instructions accompanying the ComfortNet compatible outdoor AC/HP unit for troubleshooting information.

Refer to the Troubleshooting Chart for a listing of possible furnace error codes, possible causes and corrective actions.

LED LED

Status

1 Flash

Red

Communications

LED

2 Flashes

1 Steady

Flash

Green Receive

LED

Rapid

Flashing On Solid

Off

Indication Possible Causes Corrective Action(s) Notes & Cautions

x Normal condition x None x None x None x Communications

Failure

x Out-of-box reset x Control power up

x No power x Communications

error

x No network found x Broken/ disconnected

x Normal network

traffic

x Data 1/ Data 2

miss-wire

x Communications

Failure

x Learn button

depressed

x No power to furnace x Open fuse x Communications error

data wire(s)

x Furnace is installed as

a legacy/ traditional system

x Control is “talking” on

network as expected

x Data 1 and data 2

wires reversed at furnace, thermostat, or CT™ compatible outdoor AC/HP

x Short between data 1

and data 2 wires

x Short between data 1

or data 2 wires and R (24VAC) or C (24VAC common)

x Depress Learn Button x Verify that bus BIAS

and TERM dipswitches are in the ON position.

x None x None

x Check fuses and

circuit breakers; replace/reset

x Replace blown fuse x Check for shorts in

low voltage wiring in furnace/system

x Reset network by

depressing learn button

x Check data 1/ data 2

voltages

x Check

communications wiring (data 1/ data 2 wires)

x Check wire

connections at terminal block

x Verify furnace

installation type (legacy/ traditional or communicating)

x Check data 1/ data 2

voltages

x None x None

x Check

communications wiring (data 1/ data 2 wires)

x Check wire

connections at terminal block

x Check data 1/ data 2

voltages

x Depress once

quickly for a powerup reset

x Depress and hold

for 2 seconds for an out-of-box reset

x Turn power OFF

prior to repair

x Turn power OFF

prior to repair

x Verify wires at

terminal blocks are securely twisted together prior to inserting into terminal block

x Verify data1 and

data voltages as described above

x Turn power OFF

prior to repair

x Verify wires at

terminal blocks are securely twisted together prior to inserting into terminal block

x Verify data1 and

data voltages as described above

Page 58

SYSTEM OPERATION

ComfortNet™ System

TROUBLESHOOTING

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

NOTE: Discharge body’s static electricity before touching

unit. An electrostatic discharge can adversely affect electrical components.

1. Disconnect all power to the furnace. Do not touch the integrated control module or any wire connected to the control prior to discharging your body’s electrostatic charge to ground.

2. Firmly touch a clean, unpainted, metal surface of the furnace away from the control. Any tools held in a person’s hand during grounding will be discharged.

3. Service integrated control module or connecting wiring following the discharge process in step 2. Use caution not to recharge your body with static electricity; (i.e., do not move or shuffle your feet, do not touch ungrounded objects, etc.). If you come in contact with an ungrounded object, repeat step 2 before touching control or wires.

4. Discharge your body to ground before removing a new control from its container . Follow steps 1 through 3 if installing the control on a furnace. Return any old or new controls to their containers before touching any ungrounded object.

FOUR WIRE MOTOR TROUBLESHOOTING

Any manual testing of the 4 wire seriallY communicating motor should only be done with the ULTRACHECK-EZ diagnostic tool (part # UTT-01). All other methods may not be reliable or cause damage to the 4 wire motor. See section S-16C for additional details.

COMFORTNET SYSTEM TROUBLESHOOTING

At system power-up, the CTK0*** thermostat will begin searching for any connected compatible equipment. The thermostat will scroll "SEARCHING". The thermostat will scroll <equipment> FOUND once it indentifies that piece of equipment. In a typical installation, an indoor unit and outdoor unit will be identified.

Wiring issues may be confirmed (or eliminated) by using the CTK0*** thermostat and sub base, a 4-position connector (included with the kit), and a short section (~ 2ft) of thermostat wire. Connect the wire between the connector and thermostat sub base. Connect the thermostat to the indoor unit and apply power. If the thermostat identifies the indoor unit, then a wiring problem exists between the indoor unit and the permanent thermostat location. Repair or replace wiring.

Connect the thermostat to the outdoor unit. If the thermostat identifies the outdoor unit, then a wiring problem exists between the indoor and outdoor units. Repair or replace wiring.

NOTE: A 24VAC source will be needed to power the thermostat and outdoor unit control.

DIAGNOSTIC CHART

W ARN ING

HIGH VOLTAGE !

AVOID PERSONAL INJURY OR DEATH DUE TO

ELECTRICAL SHOCK, DISCONNECT ELECTRICA L POWER

BEFORE

Refer to the Troubleshooting Chart in the Appendix for assistance in determining the source of unit operational problems. The dual 7-segment LED display will display an error code that may contain a letter and number. The error code may be used to assist in troubleshooting the unit.

RESETTING FROM LOCKOUT

Furnace lockout results when a furnace is unable to achieve ignition after three attempts during a single call for heat. It is characterized by a non-functioning furnace and a E code displayed on the dual 7-segment display. If the furnace is in “lockout”, it will (or can be) reset in any of the following ways.

1. Automatic reset. The integrated control module will

2. Manual power interruption. Interrupt 115 volt power to

3. Manual thermostat cycle. Lower the thermostat so

PERFORMING ANY SERVICE OR MAINTENANCE

automatically reset itself and attempt to resume normal operations following a one hour lockout period.

the furnace.

that there is no longer a call for heat for 1 -20 seconds then reset to previous setting.

If the thermostat scrolls "SEARCHING" for several minutes, then it has failed to identify any connected equipment. The thermostat may identify one piece of equipment, but not the other. Broken or improper wiring is the most likely cause for the thermostat to fail to identify any equipment. If an outdoor unit is not identified, the thermostat will scroll "CHECK SYSTEM", indicating that no indoor unit was found.

NOTE: If the condition which originally caused the lockout still exists, the control will return to lockout. Refer to the Diagnostic Chart for aid in determining the cause.

Combustion Quality Combustion quality can be affected by several factors. Major

factors are venting and draining.

Page 59

SYSTEM OPERATION

Venting The venting system should be planned and installed with

the following in mind;

• Should not be longer than necessary

• Use 45°elbows rather than 90° elbows when possible

• Must not sag or otherwise trap condensate

• Use longest radius fittings possible

• If using 3" venting, make the transition from 2" to 3" as close as practically possible

• Make sure there is no flue gas recirculation into the combustion air pipe

Condensate Drainage Furnace combustion can be affected if a furnace is holding

condensate. Check for proper connections of drain hoses, make sure furnace condensate trap is clean. Make sure furnace is not improperly sloped. Make sure air conditioning coil drain is not interfering with furnace drain.

Other Causes

1. Manifold Gas Pressure must be set for the gas being used, Natural or L.P., high and low firing rates. If converted to L.P. gas, check size of all orifices

2. Remove Draft Inducer, Check the integrity of the gasket between the inducer and the collector box cover, any air leak here will have a negative effect on combustion. Check the orifice hole in the collector box, it must be free of burrs on both sides

3. Make sure burners are clean, not out of position and line up correctly with exchanger tubes, including the heat exchanger orifice plate between the burners and the heat exchanger tubes, make sure it is not loose, missing a screw or hanging down between the burners and heat exchangers causing flame impingement.

4. Make sure the field installed gas line is not binding and causing distortion of burner assembly

5. If the furnace is installed as a one pipe system; make

sure the surrounding area and structure are adequate to provide combustion air

6. Make sure there are no cabinet air leaks allowing sup-

ply air to affect combustion

7. If heat exchanger integrity is uncertain, follow proce-

dures in Service Bulletin SF-041

ComfortNet™ System

Page 60

SYSTEM OPERATION

Some of the electronic boards being used today, with flame rectification, will not function properly and/or at all without polarization of incoming power. Some also require phasing between the primary and secondary sides of step-down transformers.

METER READS 120 VOLTS

INCOMING POWER

METER READS 0 VOLTS

THIS IS L1 OR THE HOT POWER LEG

VOLT / OHM METER

GND

VOLT / OHM METER

THIS IS THE COMMON OR NEUTRAL LEG

CHECKING FOR PHASING - PRIMARY TO SECONDARY OF UNMARKED TRANSFORMERS*

METER READS 24 VOLTS

VOLT / OHM METE R

TRANSFORMER

SECONDARY

LINE VOLTAGE (NEUTRAL)

PRIMARY

LINE VOLTAGE L1 (HOT)

METER READS 120 VOLTS

VOLT / OHM METE R

READS 96 VOL TS - IN PHASE

VOLT / OH M M E TER

READS 144 VOLTS - OUT OF PHASE

If meter reads approximately 96 volts - the primary to secondary are in phase - if reads approximately 144 volts out of phase

- reverse low voltage wires.

NEUTRAL

These then should be wired to the furnace accordingly. Some transformers will display phasing symbols as shown

in the illustration to the left to assist in determining proper

24 V

120 V

PHASING SYMBOL

transformer phasing.

Page 61

SYSTEM OPERATION

Seconds for

One

Revolutio n

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

One

G AS RA TE -- CUBIC FEET PER HO UR

Size of Test Dial

1/4

cu/ft

90 180 360 720 1800 82 164 327 655 1636 75 150 300 600 1500 69 138 277 555 1385 64 129 257 514 1286 60 120 240 480 1200 56 113 225 450 1125 53 106 212 424 1059 50 100 200 400 1000 47 95 189 379 947 45 90 180 360 900 43 86 171 343 857 41 82 164 327 818 39 78 157 313 783 37 75 150 300 750 36 72 144 288 720 34 69 138 277 692 33 67 133 265 667 32 64 129 257 643 31 62 124 248 621 30 60 120 240 600

28 56 113 225 563

26 53 106 212 529

1/2

cu/ft1cu/ft2cu/ft5cu/ft

-- -- 116 232 581

-- -- 109 218 545

-- -- 103 206 514

CUBIC FEET

Seconds for

One

Revolution

36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

Size of Test Dial

1/4

cu/ft

25 50 100 200 500

23 47 95 189 474

22 45 90 180 450

21 43 86 172 429

20 40 80 160 400

19 38 76 153 383

18 36 72 144 360

17 34 -- 136 340

16 32 64 129 321

15 30 60 120 300

1/2

cu/ft1cu/ft2cu/ft5cu/ft

-- -- 97 195 486

-- -- 92 185 462

-- -- -- 176 439

-- -- -- 167 419

-- 41 82 164 409

-- -- 78 157 391

-- -- 75 150 375

-- -- -- 147 367

-- -- -- 141 355

-- -- 69 138 346

-- -- 67 133 333

-- -- -- 131 327

-- -- -- 126 316

-- 31 62 124 310

-- -- -- 122 305

Page 62

SYSTEM OPERATION

Service Problem No Heat Unsatisfactory Heat

POSSIB LE CAUSE

DOT S IN ANAL YSIS

GUIDE INDICATE

"POSSIBLE CAUSE"

Power Failure Blown Fuse L o ose Con n ec t i on Shorted or Broken Wires No Low V oltag e Faulty Thermostat Faulty Transformer Poor or High Res istanc e Ground Improper Heat Anticipator Setting Improper Thermostat Location Fa ulty Limit or Roll Out Switch Faul ty Fl am e Senso r F au l ty Ig ni tion C o nt ro l Gas Valve or Gas Supply Shut Off Faul ty In du c e d D r af t Blow e r Faulty Blower Motor (ECM) Broken or Shorted Ignitor Dirty Flame Sensor, Low UA Stuck Gas Valve Faulty Gas Valve Open Auxili ary Li mit Improper Air Flow or Distribution Cycling on Limit Dela y e d I g ni t i o n Flashback Orifice Size Gas Pre ssu r e Cracked Hea t Exchanger Furn ace Undersized Furn ace Oversi z e d Faulty Pressure Switch Blocked or Restricted Flue Open Ro ll Out S witch Bouncin g On Press ur e Sw itc h

SYMPTOM

Burner Won't Ignite

S ys t em Wil l No t St ar t

Burner Ignites-Locks Out

B ur ner Shuts Off prio r to T'Stat being Satisf ied

•

•••••

•

••

•

•••

•

••

•

•••

••

•• •

••••

•••

••

•

Lo ng Cycles

Short Cycles

Too Much Heat

Not Enough Heat

So o t an d /o r Fu m es

•• ••

•

•••

•

••

•

Test Voltage S-1 Test Voltage S-4 Check Wiring S-2 Check Wiring S- 3A Check Transf ormer S- 4 Che ck Thermostat S-3A Check Transf ormer S-4 Measure Ground Resistance S-17B Adju st Heat An ticip at or Settin g S-3 B Relocate Thermosta t S-316 Test Control S-300 / S-302 Test Flame Sensor S-314 Test Control S-313 Turn Valves to On Position S-317 Te s t I n du c e d D r af t Mo tor S -3 0 3 Te s t Blo w e r Motor ( & EC M) S-16A,B ,C Test Ignitor S-308 Clean Fl am e Sensor S-314 Replace Gas Valve S-304 Replace Gas Valve S-304 Res et Control S-301 Check Duct S tat i c S- 200 Chec k Controls & Temperature Rise S-201 / S -300 Tes t f or D elay ed Igni tion S-312 Test for Flas hback S-309 / S -311 Check Orifices S-306 / S-311 Che ck Gas Pressure S-307 Check Burner Flames S-305 Replace w ith Proper S ize Furnace S-318 Replace w ith Proper S ize Furnace S-318 Test Pressure Switc h S-310 Check Flue /Dr awdown P r es sure S-310 Tes t Flame Roll Ou t C ontrol S-302 Test Negative Pressure S-310

Test Met hod

Remedy

See Service Procedure Reference

Page 63

SYSTEM OPERATION

sERVICE NUMBERS

S-1 CHECKING VOLTAGE ................................. 64

S-2 CHECKING WIRING ...................................64

CHECKING THERMOSTAT, WIRING

AND ANTICIPATOR ...................................64

S-3A THERMOSTAT AND WIRING ......................64

S-3B HEATING ANTICIPATOR ............................64

S-200 CHECKING DUCT STATIC ............................68

S-201 CHECKING TEMPERATURE RISE .................68

S-300 CHECKING PRIMARY

LIMIT CONTROL ........................................69

S-301 CHECKING AUXILIARY

LIMIT CONTROL ........................................70

S-302 CHECKING FLAME ROLLOUT

CONTROL..................................................70

S-303 INDUCED DRAFT BLOWER M S-304 CHECKING GAS VALVE

OTOR ..............71

S-305 CHECKING MAIN BURNERS.......................72

S-306 CHECKING ORIFICES ................................. 72

S-307 CHECKING GAS PRESSURE ........................72

S-308 CHECKING

HOT SURFACE IGNITOR.............................74

S-309 CHECKING FOR FLASHBACK .....................75

S-310 CHECKING PRESSURE CONTROL ...............75

S-311 HIGH ALTITUDE

APPLICATION (USA) ..................................75

S-312 CHECKING FOR

DELAYED IGNITION ...................................76

S-313 CHECKING INTEGRATED

IGNITION CONTROL BOARDS ..................76

S-313A MEMORY CHIPS ........................................77

S-314 CHECKING FLAME SENSOR .....................78

EDUNDANT).................................................71

Page 64

SYSTEM OPERATION

S-1 CHECKING VOLTAGE

WARNING

HIGH VOLTAGE

ISCONNECT ALL POWER BEFORE SERVICI NG OR

CHANGING ANY E LECTRI CAL WI RING. SOURCES MAY BE PRESENT. PROPERTY DAMAGE, PERS ONAL INJURY OR DEATH.

1. Remove the burner door.

2. Remove cover from the Junction Box and gain access to incoming power lines.

With Power ON:

LINE VOLTAGE NOW PRESENT

MULTIPLE POWER

FAILURE TO DO SO MAY CAUSE

WARNING

CHECKING THERMOSTAT, WIRING AND ANTICIPATOR

S-3A THERMOSTAT AND WIRING

WARNING

DISCONNECT ALL POWER BEFORE SERVICING.

1. Remove the blower compartment door to gain access to the thermostat low voltage wires located at the furnace integrated control module terminals.

2. Remove the thermostat low voltage wires at the furnace control panel terminal board.

3. Jumper terminals R to W (or W1 and W2 for two-stage models) on the integrated ignition control.

With Power On (and Door Interlock Switch closed):

3. Using a voltmeter, measure the voltage across the hot and neutral connections.

NOTE: To energize the furnace, the Door Interlock Switch must be engaged at this point.

4. No reading - indicates open wiring, open fuse, no

power, or faulty Door Interlock Switch from unit to fused disconnect service. Repair as needed.

5. With ample voltage at line voltage connectors, ener-

gize the furnace blower motor by jumpering terminals R to G on the integrated ignition control.

6. With the blower motor in operation, the voltage should

be 1 15 volts ± 10 percent.

7. If the reading falls below the minimum voltage, check

the line wire size. Long runs of undersized wire can cause low voltage. If wire size is adequate, notify the local power company of the condition.

8. After completing check and/or repair, replace Junction

Box cover and reinstall the service panel doors.

9. Turn on electrical power and verify proper unit opera-

tion.

S-2 CHECKING WIRING

WARNING

DISCONNECT ALL POWER BEFORE SERVICING.

1. Check wiring visually for signs of overheating, damaged insulation and loose connections.

2. Use an ohmmeter to check continuity of any suspected open wires.

3. If any wires must be replaced, replace with AWM, 105°C. 2/64 thick insulation of the same gauge or its equivalent.

WARNING

LINE VOLTAGE NOW PRESENT

4. Induced Draft Motor must run and pull in pressure switch.

5. If the hot surface ignitor heats and at the end of the ignitor warm-up period the gas valve opens and the burners ignite, the trouble is in the thermostat or wiring.

6. With power off, check the continuity of the thermostat and wiring. Repair or replace as necessary .

If checking the furnace in the air conditioning mode, pro-

ceed as follows.

7. With power off, Jumper terminals R to Y (or Y1 or Y2 for two-stage models) to G .

8. Turn on the power .

9. If the furnace blower motor starts and the condensing unit runs, then the trouble is in the thermostat or wiring. Repair or replace as necessary .

10. After completing check and/or repair of wiring and check and/or replacement of thermostat, reinstall blower compartment door.

1 1. Turn on electrical power and verify proper unit opera-

tion.

S-3B HEATING ANTICIPATOR

On older thermostats, the heating anticipator is a wire wound adjustable heater which is energized during the "ON" cycle to help prevent overheating of the conditioned space.

The anticipator is a part of the thermostat and if it should fail for any reason, the thermostat must be replaced.

The heating anticipator setting for furnaces covered in this manual is 0.70 Amps.

Modern thermostats do not have this type of heat anticipator. Many have a selector switch to adjust the number of cycles per hour

Page 65

SYSTEM OPERATION

S-4 CHECKING TRANSFORMER AND Control CIRCUIT

A step-down transformer 120 volt primary to 24 volt secondary, 40 VA (Heating and Cooling Models) supplies ample capacity of power for either operation.

WARNING

HIGH VOLTAGE D

ISCO NN E CT ALL POWER BEFORE SERV ICI NG OR

CHANGING ANY ELECTRICAL WIRING. SOURCES MAY BE PRESENT. PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

MULTI PLE POWER

FAILURE TO DO SO MAY CAUSE

1. Remove blower compartment door to gain access to the thermostat low voltage wires located at the furnace integrated control module.

2. Remove the thermostat low voltage wires at the furnace integrated control module terminals.

With Power On (and Door Interlock Switch closed):

WARNING

LINE VOLTAGE NOW PRESENT

ECM control connections are made through the integrated ignition control. No other control connections are needed.

NOTE: An inductor (Factor Power Choke Correction) is re- quired when powering the 3/4 and 1 horsepower motors with 115 volts (inductor pictured below). The operation of this inductor is to reduce the line current by storing the electrical energy in a magnetic field, such that the voltage AC waveform leads the current AC waveform. In other words, the inductor reduces line current which extends the life of the 3/4 and 1 horsepower motors.

IMPORTANT: If the inductor fails, there will be no motor operation since this is the "LINE" power supply, black wire, from the integrated ignition control to the motor. To determine if the inductor is at fault, you can bypass by the inductor by disconnecting the black wire from the inductor and connecting it directly to the motor. If the motor operates then the inductor will need to be replaced.

3. Use a voltmeter, check voltage across terminals R

and C. Must read 24 V AC.

4. No voltage indicates faulty transformer, open fuse, bad

wiring, bad splice, or open door interlock switch.

5. Check transformer primary voltage at incoming line

voltage connections, fuse, splices, and blower door interlock switch.

6. If line voltage is available to the primary side of trans-

former and not at secondary side, the transformer is inoperative. Replace.

7. After completing check and/or replacement of trans-

former and check and/or repair of control circuit, reinstall blower compartment door .

8. Turn on electrical power and verify proper unit opera-

tion.

4-Wire ECM Motors Description

These models utilize an Nidec US motors, 4-wire variable speed ECM blower motor. The ECM blower motor provides constant CFM.

The motor is a serially communicating variable speed motor. Only four wires are required to control the motor: +Vdc, Common, Receive, and Transmit.

The +Vdc and Common wires provide power to the motor's low voltage control circuits. Typical supply voltage is 9-15 volts DC.

ECM Control Connections

Checking ECM Motors ECMmotors connect directly to the AC Line Voltage. DO NOT insert contactors in series with the ECM Motor AC

Line. The control is powered continuously to insure reliable start-up. The connector plug is polarized, verify and reverify correct connector orientation before applying power. DO NOT force plug into motor and make sure power is off before inserting power connector. DO NOT apply voltage to terminals 1 or 2.

General Checks/Considerations

1. Check power supply to the furnace. Ensure power supply is within the range specified on rating plate. See section S-1.

2. Check motor power harness. Ensure wires are continuous and make good contact when seated in the connectors. Repair or replace as needed.

3. Check motor control harness. Ensure wires are continuous and make good contact when seated in the connectors. Repair or replace as needed.

4. Check thermostat and thermostat wiring. Ensure thermostat is providing proper cooling/heating/continuous fan demands. Repair or replace as needed.

5. Check blower wheel. Confirm wheel is properly seated on motor shaft. Set screw must be on shaft flat and torqued to 165 in-lbs minimum. Confirm wheel has no broken or loose blades. Repair or replace as needed.

Page 66

SYSTEM OPERATION

6. Ensure motor and wheel turn freely. Check for interference between wheel and housing or wheel and motor. Repair or replace as needed.

7. Check housing for cracks and/or corrosion. Repair or replace as needed.

8. Check motor mounting bracket. Ensure mouting bracket is tightly secured to the housing. Ensure bracket is not cracked or broken.

UltraCheck-EZTM Diagnostic Tool

The UltraCheck-EZTM diaganostic tool is the preferred method (part # UTT-01) to diagnose the ECM motor.

HIGH VOLT AGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.

To use the diagnostic tool, perform the following steps:

1. Disconnect power to the furnace.

2. Disconnect the 4-circuit control harness from the motor.

3. Plug the 4-circuit connector from the diagnostic tool into the motor control connector.

4. Connect one alligator clip from the diagnostic tool to a ground source.

5. Connect the other alligator clip to a 24VAC source.

NOTE: The alligator clips are NOT polarized.

NOTE: The UltraCheck-EZTM diagnostic tool is equipped

with a nonreplaceable fuse. Connecting the tool to a source other than 24VAC could damage the tool and cause the fuse to open. Doing so will render the diagnostic tool inoperable.

6. Turn on power to the furnace.

Power Button

OFF OFF

ON B linking Rotating

ON OFF Rotating

ON Blinking

ON OFF

Green

LED

Motor

Action

Not

Rotating

Not

Rotating

Not

Rotating

Indication(s)

Confirm 24VAC to UltraCheck-EZ

If 24VAC is c on firm ed, diagnost ic tool is inoperable. M otor and cont rol/end bell are func tioning properly. Replace motor cont rol/end bell. Ch eck mot o r (s e e Motor Chec ks below). Replace motor cont rol/end bell; ve rify motor (see Motor Check s below).

tool.

9. Depress the orange power button to turn off motor.

10. Disconnect power. Disconnect diagnostic tool.

11. Reconnect the 4-wire harness from control board to motor.

Electrical Checks - High Voltage Power Circuits

HIGH VOLT AGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.

1. Disconnect power to the furnace.

2. Disconnect the 5-circuit power connector to the ECM

motor.

3. Turn on power to the furnace.

WARNING

Line Voltage now present.

7. Depress the orange power button on the diagnostic tool to send a run signal to the motor. Allow up to 5 seconds for the motor to start.

NOTE: If the orange power button does not illuminate when depressed, the tool either has an open fuse or is not properly connected to a 24VAC source.

8. The green LED on the diagnostic tool will blink indicating communications between the tool and motor. See table below for indications of tool indicators and motor actions. Replace or repair as needed.

WARNING

Line V oltage now present.

4. Measure voltage between pins 4 and 5 on the 5-circuit connector. Measured voltage should be the same as the supply voltage to the furnace.

Page 67

SYSTEM OPERATION

AC Line Hot Connection

Motor Control/End Bell Checks

4 3 2 1

5 4 3 2 1

5. Measure voltage between pins 4 and 3. Voltage should be approximately zero.

6. Measure voltage between pins 5 and 3. Voltage should be the same as the supply voltage to the furnace.

7. If no voltage is present, check supply voltage to the furnace. See section S-1.

8. Disconnect power to the furnace. Reconnect the 5-circuit power harness disconnected in step 2.

AC Line Neutral Connection Gnd

Lines 1 and 2 will be connected for 120VAC Power Connector

}

applications only

POWER CONNECTOR

(1/2 HP MOTORS)

"Motor Half“

(Viewed from Plug End)

inductor

AC Line Hot Connection

AC Line Neutral Connection Gnd

Lines 1 and 2 will be connected for 120VAC Power Connector

}

applications only

POWER CONNECTOR

(3/4 & 1 HP MOTORS)

"Motor Half“

(Viewed from Plug End)

HIGH VOLTAGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.

1. Disconnect power to the furnace. NOTE: Motor contains capacitors that can hold a charge

for several minutes after disconnecting power. Wait 5 minutes after removing power to allow capacitors to discharge.

2. Disconnect the motor control harness and motor power

harness.

3. Remove the blower assembly from the furnace.

4. Remove the (3) screws securing the control/end bell to

the motor. Separate the control/end bell. Disconnect the 3-circuit harness from the control/end bell to remove the control/end bell from the motor.

5. Inspect the NTC thermistor inside the control/end bell

(see figure below). Replace control/end bell if thermistor is cracked or broken.

Electrical Checks - Low Voltage Control Circuits

1. Turn on power to the furnace.

WARNING

Line V oltage now present.

2. Check voltage between pins 1 and 4 on the 4-wire motor control harness between the motor and control board. Voltage should be between 3 and 15 VDC.

3. If no voltage is present, check control board. See section S-313.

6. Inspect the large capacitors inside the control/end bell (see figure below). Replace the control/end bell if any of the capacitors are bulging or swollen.

Page 68

SYSTEM OPERATION

7. Locate the 3-circuit connector in the control/end bell. Using an ohmmeter, check the resistance between each terminal in the connector. If the resistance is 100kΩ or greater, the control/end bell is functioning properly. Replace the control/end bell if the resistance is lower than 100kΩ.

8. Reassemble motor and control/end bell in reverse of disassembly. Replace blower assembly into the furnace.

Motor Checks

HIGH VOLTAGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.

Too great of an external static pressure will result in insufficient air that can cause excessive temperature rise, resulting in limit tripping, etc. Whereas not enough static may result in motor overloading.

To determine proper air movement, proceed as follows:

1. With clean filters in the furnace, use a draft gauge (inclined manometer) to measure the static pressure of the return duct at the inlet of the furnace. (Negative Pressure)

2. Measure the static pressure of the supply duct. (Positive Pressure)

3. Add the two (2) readings together for total external static pressure.

NOTE: Both readings may be taken simultaneously and read directly on the manometer if so desired. If an air conditioner coil or Electronic Air Cleaner is used in conjunction with the furnace, the readings must also include theses components, as shown in the following drawing.

4. Consult proper tables for the quantity of air.

If the total external static pressure exceeds the minimum or maximum allowable statics, check for closed dampers, registers, undersized and/or oversized poorly laid out duct work.

1. Disconnect power to the furnace. NOTE: Motor contains capacitors that can hold a charge

for several minutes after disconnecting power. Wait 5 minutes after removing power to allow capacitors to discharge.

2. Disassemble motor as described in steps 2 through 4

above.

3. Locate the 3-circuit harness from the motor. Using an

ohmmeter, measure the resistance between each motor phase winding. The resistance levels should be equal. Replace the motor if the resistance levels are unequal, open circuited or short circuited.

4. Measure the resistance between each motor phase wind-

ing and the motor shell. Replace the motor if any phase winding is short circuited to the motor shell.

5. Reassemble motor and control/end bell in reverse of dis-

assembly. Replace blower assembly into the furnace.

S-200 CHECKING DUCT STATIC

The maximum and minimum allowable external static pressures are found in the specification section. These tables also show the amount of air being delivered at a given static by a given motor speed or pulley adjustment.

The furnace motor cannot deliver proper air quantities (CFM) against statics other than those listed.

Checking Static Pressure

S-201 CHECKING TEMPERATURE RISE

The more air (CFM) being delivered through a given furnace, the less the rise will be; so the less air (CFM) being delivered, the greater the rise. The temperature rise should be adjusted in accordance to a given furnace specifications and its external static pressure. An incorrect temperature rise

Page 69

SYSTEM OPERATION

may result in condensing in or overheating of the heat exchanger. An airflow and temperature rise table is provided in the blower performance specification section. Determine and adjust temperature rise as follows:

1. Operate furnace with burners firing for approximately ten minutes. Check BTU input to furnace - do not exceed input rating stamped on rating plate. Ensure all registers are open and all duct dampers are in their final (fully or partially open) position.

2. Place thermometers in the return and supply ducts as close to the furnace as possible. Thermometers must not be influenced by radiant heat by being able to “see” the heat exchanger.

SUPPLY AIR

PRIMARY LIMIT CONTROL

Primary Limit Control Location

(90% Upflow Furnace Shown, Counterflow Similar)

The following drawing illustrates the style of limit switches used on the 90% furnaces.

ENCLOSED DISK

RETURN AIR

Temperature Rise Measurement

3. Subtract the return air temperature from the supply air temperature to determine the air temperature rise. Allow adequate time for thermometer readings to stabilize.

4. Adjust temperature rise by adjusting the circulator blower speed. Increase blower speed to reduce temperature rise. Decrease blower speed to increase temperature rise. Refer to Circulator Blower Speed section in the Product Design section of this manual for speed changing details. Temperature rise is related to the BTUH output of the furnace and the amount of air (CFM) circulated over the heat exchanger. Measure motor current draw to determine that the motor is not overloaded during adjustments.

S-300 CHECKING PRIMARY LIMIT CONTROL

Primary limit controls are nonadjustable, automatic reset, bi-metal type limit control. Refer to the following drawing for the location of the primary limit.

FRONT VIEW SIDE VIEW

Primary Limit Control Style

(90% Furnaces)

WARNING

HIGH VOLTAGE D

ISCONNECT ALL POWER BEFORE SERVI CING OR

CHANGING A NY ELE CTRI CAL WI RIN G. SOURCES MAY BE PRESENT. PROPERTY DAMAGE, PERSONAL I NJURY OR DEATH.

MULTIPLE POWER

FAILURE TO DO SO MAY CAUSE

1. Remove burner compartment door to gain access to the primary limit.

2. Remove low voltage wires at limit control terminals.

3. With an ohmmeter, test between these two terminals as shown in the following drawing. The ohmmeter should read continuous unless heat exchanger temperature is above limit control setting. If not as above, replace the control.

Page 70

SYSTEM OPERATION

VOLT / OHM METER

COLOR IDENTIFYING TAB

Testing Primary Limit Control

(90% Furnaces)

4. After completing check and/or replacement of primary limit control, reinstall burner compartment door.

5. Turn on electrical power and verify proper unit operation.

To aid in identifying these controls, refer to the Primary Limit Charts in furnace Technical Manual for part number, temperature setting and color(s) code.

S-301 CHECKING AUXILIARY LIMIT CONTROL

The auxiliary limit control is designed to prevent furnace operation in case of main blower failure in horizontal or counterflow installations. It may also open if the power supply is interrupted while the furnace is firing.

The auxiliary limit control is suitable for both horizontal right and horizontal left installations. Regardless of airflow direction, it does not need to be relocated. The (2) two auxiliary limits are located on the blower housing (one on each side), as shown in the following illustration.

Manual or Automatic Reset Auxiliary Limits Located in Blower Side

WARNING

HIGH VOLTAGE

ISCONNECT ALL POWER BEFORE SERVICING OR

INSTALLI NG THIS UNIT. BE PRESENT. DAMAGE, PERS ONAL I NJURY OR D EATH.

MULTIPLE POWER SOURCES MAY

FAILURE TO DO SO MAY CAUSE PROPERTY

1. Remove the wires from the auxiliary limit control terminals.

2. Using an ohmmeter, test for continuity across the two terminals (only test when the auxiliary limit is at room temperature).

VOLT / OHM METER

RED RESET BUTTON

COLOR IDENTIFYING TAB

Testing Auxiliary Limit Control

WARNING

AUXI L IARY LIMI T CONTROL

BLOWER HOUSING

AUXILIARY LIMIT CONTROL

Auxiliary Limit Control Location

(Select 90% / 95% Furnaces)

O AVOID POSSIBLE FIRE, ONLY RESET THE AUXILIARY LIMIT CONTROL

ONCE.

F IT SHOULD OPEN A SECOND TIME, A QUALIFIED SERVICER MUST DETERMINE WHY THE AUXILIARY LIMIT OPENED BEFORE RESETTING AGAIN.

S-302 CHECKING FLAME ROLLOUT CONTROL

A temperature activated manual reset control is mounted to the manifold assembly on 90% furnaces, as shown in the following illustration.

Page 71

SYSTEM OPERATION

FLAME ROLLOUT SWITCHES

Flame Rollout Switch Location

(90% Upflow Furnace Shown, Counterflow Similar)

The control is designed to open should a flame roll out occur. An over firing condition or flame impingement on the heat shield may also cause the control to open. If the rollout control opens, the air circulation blower will run continuously.

WARNING

INE VOLTAGE NOW PRESENT

1. Remove the burner compartment door to gain access to the rollout switch(es) mounted to burner bracket.

2. Reset the manual rollout switch.

3. Remove wires from rollout switch.

4. Using an ohmmeter, check for coninuity across the swtch.

5. if the switch will not close afer manually resetting, it must be replaced.

If a roll out switch has tripped, it is important to find out why. Possible causes could be flame impingement, orifice plate out of position, burners with excessive cross-over slot dimension, over-firing, improper orifices, improper gas pressure, air leaking from around the heat exchanger into the burner compartment, air leaking through the heat exchanger itself.

6. After check and/or replacement of rollout switch, reinstall burner compartment door and verify proper unit operation.

S-303 INDUCED DRAFT BLOWER Motor

1. Remove burner compartment door to gain access to the induced draft blower motor .

2. Disconnect the motor wire leads from its connection point at the induced draft motor .

3. Using a ohmmeter, test for continuity between each of the motor leads.

4. T ouch one probe of the ohmmeter to the motor frame (ground) and the other probe in turn to each lead.

If the windings do not test continuous or a reading is obtained to ground, replace the motor .

5. If the windings have a continuity reading, reconnect wires. Turn power on to the furnace and turn the thermostat on in the heating mode. Check voltage for 1 15V at the induced draft motor terminals during the trial for ignition. If you have 1 15V and the motor does not run, replace the induced draft motor .

6. After completing check and/or replacement of induced draft motor , reinstall burner compartment door .

7. Turn on electrical power and verify proper unit operation.

S-304 CHECKING GAS VALVE (Redundant)

A combination redundant operator type gas valve which provides all manual and automatic control functions required for gas fired heating equipment is used.

The valve provides control of main burner gas flow, pressure regulation, and 100 percent safety shut-off.

Two stage gas valves always require 24 volts between common and low fire (main coil) to open. The furnace front cover pressure switch is wired in series with the low (main) solenoid of the gas valve. In the event of a non-functioning gas valve, always check the front cover pressure switch. Also see section S-307 on Checking Gas Pressure and section S-310 on Checking Pressure Switches.

Low (Main) Common High

WARNING

HIGH VOLTAGE D

ISCONNECT ALL POWER BEFORE SERVICING OR

INSTALLI NG THIS UNIT. BE PRESENT. DAMAGE, PERSON AL INJURY OR DEATH.

MULTIPLE POWER SOURCES MAY

FAILURE TO DO SO MAY CAUSE PROPERTY

ISCONNECT

White-Rodgers 2-Stage Valve

WARNING

ALL

POWER BEFO RE SE RVICING

Page 72

SYSTEM OPERATION

S-305 CHECKING MAIN BURNERS

The main burners are used to provide complete combustion of various fuels in a limited space, and transfer this heat of the burning process to the heat exchanger.

Proper ignition, combustion, and extinction are primarily due to burner design, orifice sizing, gas pressure, primary and secondary air, vent and proper seating of burners.

BURNERS

Burners have been redesigned for 34.5" chassis furnaces. Overall length and width dimensions remain the same as 40" model burners. The burners used 34.5" models have burner head insert with larger diameter center hole and a larger number of surrounding holes.

Orifices should be treated with care in order to prevent damage. They should be removed and installed with a box-end wrench in order to prevent distortion. In no instance should an orifice be peened over and redrilled. This will change the angle or deflection of the vacuum effect or entraining of primary air, which will make it difficult to adjust the flame properly. This same problem can occur if an orifice spud of a different length is substituted.

WARNING

ISCONNECT

1. Check orifice visually for distortion and/or burrs.

2. Check orifice size by the number stamped on the orifice.

ALL G

AS AND ELECTRICAL POWER SUPPLY.

New 34.5 Burners

WARNING

ISCONNECT

In checking main burners, look for signs of rust, oversized and undersized carry over ports restricted with foreign material, etc., burner cross-over slots should not be altered in size.

ALL G

AS AND ELECTRICAL POWER SUPPLY.

S-306 CHECKING ORIFICES

A/GMVC, A/GCVC model furnaces have factory installed #45 natural gas orifices.

The only time resizing is required is when a reduction in firing rate is required for an increase in altitude or a funace is being converted for use with L.P. gas.

GAS STREAM

The length of Dimension "A" determines the angle of Gas Stream "B".

DENT OR BURR

GAS

STREAM

A dent or burr will cause a severe deflection of the gas stream.

S-307 CHECKING GAS PRESSURE

Gas Supply Pressure Measurement

CAUTION

O PREVENT UNRELIABL E OPERATI ON OR E QUIPMENT DAMAGE, T HE INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING.

Gas inlet and manifold pressures should be checked and adjusted in accordance to the type of fuel being consumed.

The line pressure supplied to the gas valve must be within the range specified below. The supply pressure can be measured at the gas valve inlet pressure tap or at a hose fitting installed in the gas piping drip leg. The supply pressure must be measured with the burners operating. To measure the gas supply pressure, use the following procedure.

Page 73

SYSTEM OPERATION

WARNING

ISCONNECT ELECTRICAL POWER AND SHUT OFF GAS SUPPLY.

1. After turning off gas to furnace at the manual gas shutoff valve external to the furnace, remove burner compartment door to gain access to the gas valve.

2. Connect a calibrated water manometer (or appropriate gas pressure gauge) at either the gas valve inlet pressure tap or the gas piping drip leg as shown in the following figures.

NOTE: At either location, a hose fitting must be installed prior to making the hose connection.

NOTE: Use adapter kit #0151K00000S to measure gas pressure on White-Rodgers 36J54 gas valves.

GAS LINE

GAS SHUTOFF VALVE

GAS LINE TO FURNACE

WARNING

HIGH V OLTAGE

ISCONNECT ALL ELECTRICAL POWER AND SHU T OFF GAS

SUPPLY BEFORE SERVICING OR INSTAL LING THIS UNIT.

MULTIP LE POW ER SOURC ES MAY B E PRES ENT. FAILURE TO

DO SO MAY CAUSE P ROPERTY DAMAG E, PERSONAL INJURY O R DEATH.

5. Disconnect manometer after turning off gas at manual shutoff valve. Reinstall plug before turning on gas to furnace.

6. Turn OFF any unnecessary gas appliances started in step 3.

7. Turn on gas to furnace and check for leaks. If leaks are found, repair and then reinstall burner compartment door.

8. Turn on electrical power and verify proper unit operation.

WARNING

HIGH V OLTAGE

ISCONNECT ALL ELECTRICAL POWER AND SHU T OFF GAS

SUPPLY BEFORE SERVICING OR INSTAL LING THIS UNIT.

MULTIP LE POW ER SOURC ES MAY B E PRES ENT. FAILURE TO

DO SO MAY CAUSE P ROPERTY DAMAG E, PERSONAL INJURY O R DEATH.

OPEN TO ATMOSPHERE

DRIP LEG CAP WITH FITTING

MANOMET E R HO S E

MANOMETER

Measuring Inlet Gas Pressure

(Alternate Method)

3. Turn ON the gas and electrical power supply and operate the furnace and all other gas consuming appliances on the same gas supply line.

4. Measure furnace gas supply pressure with burners firing. Supply pressure must be within the range specified in the following table.

INLET GAS SUPPLY PRESSURE

Natural Gas Minimum: 4.5" w.c. Maximum: 10.0" w.c.

Propane Gas Minimum: 11.0" w.c. Maximum: 13.0" w.c.

If supply pressure differs from above, make necessary adjustments to pressure regulator, gas piping size, etc., and/ or consult with local gas utility.

Gas Manifold Pressure Measurement and Adjustment

Natural Gas Adjustments

WARNING

HIGH VOLTAGE D

ISCONNECT

BEFORE SERVICING OR INSTALLING.

NOTE: Use apapter kit #0151K00000S to measure gas pres-

sure on White-Rodgers 36J54 gas valves. Only small variations in gas pressure should be made by

adjusting the gas valve pressure regulator. The manifold pressure must be measured with the burners operating. To measure and adjust the manifold pressure, use the following procedure.

1. After turning off gas to furnace at the manual gas shutoff valve external to the furnace, remove burner compartment door to gain access to the gas valve.

2. Connect a calibrated water manometer (or appropriate gas pressure gauge) at the gas valve outlet pressure tap. Refer to Measuring Gas Pressure: Two-Stage Valves figure for two-stage gas valve outlet pressure tap connections.

ALL

ELECTRICAL POWER AND SHUT OFF GAS SUPPLY

Page 74

SYSTEM OPERATION

WARNING

INE VOLTAGE NOW PRESENT

3. Turn ON the gas and electrical power supply and operate the furnace.

4. White-Rodgers 36J54 Valves: a. Back outlet pressure test screw (inlet/outlet pressure

boss) out one turn (counterclockwise, not more than one turn).

b. Attach a hose and manometer to the outlet pressure

outlet pressure boss. c. Turn ON the gas supply. d. Turn on power and close thermostat “R” and “W1” con-

tacts to provide a call for low stage heat. e. Measure the gas manifold pressure with burners fir-

ing. Adjust manifold pressure using the Manifold Gas

Pressure table shown on page 86. f. Remove regulator cover screw from the low (LO) out-

let pressure regulator adjust tower and turn screw

clockwise to increase pressure or counterclockwise

to decrease pressure. Replace regulator cover screw. g. Close thermostat “R” and “W2” contacts to provide a

call for high stage heat. h. Remove regulator cover screw from the high (HI) out-

let pressure regulator adjust tower and turn screw

clockwise to increase pressure or counterclockwise

to decrease pressure. Replace regulator cover screw. i. Turn off all electrical power and gas supply to the sys-

tem. j. Remove the manometer hose from the hose barb fit-

ting or outlet pressure boss. k. Turn outlet pressure test screw in to seal pressure

port (clockwise, 7 in-lb minimum).

High Fire Regulator

Adjust

Regulator

Vent

WARNING

HIGH VOLTAGE D

ISCONNECT

BEFORE SERVICING OR INSTALLING.

ALL

ELECTRICAL POWER AND SHUT OFF GAS SUPPLY

Manifold Gas Pressure

GasRateRangeNominal

Natural Gas

High Stage 3.2 to 3.8" w.c. 3.5" w.c.

Low Stage 1.6 to 2.2" w.c. 1.9" w.c.

WARNING

HIGH VOLTAGE

ISCONNECT

SUPPLY BEFORE SERVICING OR INSTAL LING THIS UNIT.

ELECTRICAL P OWER AND SHUT OFF GAS

ALL

MULTIP LE POW ER SOURC ES MAY B E PRES ENT. FAILURE TO

DO SO MAY CAUSE P ROPERTY DAMAG E, PERSONAL INJURY O R DEATH.

WARNING

HIGH VOLTAG E D

ISCO NNEC T

BEFORE SERVICING OR INSTALLING.

Propane Gas

S-308 CHECKING HOT SURFACE IGNITOR

120V Silicon Nitride Igniter - Amana® Brand and

Goodman® Brand A/GMVC96 and A/GCVC96 furnaces use a 120V silicon nitride igniter for ignition. The normal operating temperature is approximately 2156°F - 2678°F.

ALL

ELECTRICAL POWER AND SHUT OFF GAS SUPPLY

Manifold Gas Pressure

Gas Rate Range Nominal

High Stage 9.7 to 10.3" w.c. 10.0" w.c.

Low Stage 5.7 to 6.3" w.c. 6.0" w.c.

WARNING

DISCONNECT ALL POWER BE FORE SERVICING.

1. Remove burner compartment door to gain access to the ignitor.

2. Ignitor cool - approximately 70 - 77°F.

3. Disconnect the ignitor from the Ignition Control.

4. Using an ohmmeter measure the resistance of the ignitor:

Measuring Manifold Gas Pressure

(36J54 Valve)

120 Volt Silicon Nitride : 120V Nitride Igniter should read between 37 to 68 ohms.

5. Reconnect ignitor.

Page 75

SYSTEM OPERATION

WARNING

INE VOLTAGE NOW PRESENT

6. Place unit in heating cycle, measure current draw of ignitor during preheat cycle.

The steady state current at 120V is 0.37 to 0.68 amps.

7. After checking and/or replacing of hot surface ignitor, reinstall burner compartment door and verify proper unit operation.

S-309 CHECKING FOR FLASHBACK

Flashback will also cause burning in the burner venturi, but is caused by the burning speed being greater than the gasair flow velocity coming from a burner port.

Flashback may occur at the moment of ignition, after a burner heats up or when the burner turns off. The latter is known as extinction pop.

Since the end results of flashback and delayed ignition can be the same (burning in the burner venturi) a definite attempt should be made to determine which has occurred.

If flashback should occur, check for the following:

1. Improper gas pressure - adjust to proper pressure (See S-307 CHECKING GAS PRESSURE)..

2. Check burner for proper alignment and/or replace burner.

3. Improper orifice size - check orifice for obstruction.

S-310 CHECKING PRESSURE CONTROL

The pressure control is a safety device to prevent the combustion cycle from occurring with inadequate venting caused by a restricted or blocked vent pipe. In addition to the high fire and low fire pressure switches, A/GMVC96 and A/GCVC model furnaces have a "front cover pressure switch" wired in series with the gas valve. This pressure switch keeps the gas valve from opening in the event of condensate backing up in the secondary heat exchanger. This could occur from improperly connected drains or a plugged drain tube.

WARNING

HIGH VOLTAGE

ISCONNECT ALL POWER BEFORE SERVICING OR

INSTALLI NG THIS UNIT. BE PRESENT. DAMAGE, PERSON AL INJURY OR DEATH.

1. Remove burner compartment door to gain access to pressure switch(es).

2. Remove wires from the pressure switch(es) electrical terminals.

3. Remove the pressure control hose from the control and interconnect with an inclined manometer as shown in the following figure.

MULTIPLE POWER SOURCES MAY

FAILURE TO DO SO MAY CAUSE PROPERTY

4. With an ohm meter connected across the pressure switch terminals and with the inducer running, the switch should close and the ohm meter should show a complete circuit across the pressure switch. If the switch is not closed, compare the negative pressure to the closing point specified for the particular switch. Either the switch is defective or the inducer/venting system is inadequate.

INDUCED DRAFT BLOWER

PRESSURE SWITCH

COIL COVER

PRESSURE SWITCH

***

O F

23PC

INDUCED

DRAFT

BLOWER

HOSE

1/4" TEE

HOSE TO INDUCED DRAFT BLOWER TAP

OPEN TO ATMOSPHERE

INCLINED MANOMETER

Blower Pressure Switch

Negative Pressure Measurement

(90% Upflow Furnace Shown, Counterflow Similar)

S-311 HIGH ALTITUDE APPLICATION (USA)

When furnaces are installed at high altitude, the appropriate High Altitude Orifice or Pressure Switch Kit must be applied. This is required due to the natural reduction in the density of both the gas fuel and combustion air as altitude increases. The High Altitude Orifice Kit will provide the proper design certified input rate within the specified altitude range.

High Altitude Orifice or Pressure Switch Kits are purchased according to the installation altitude and usage of either natural or propane gas. Refer to the Technical Manual or product Specification Sheet for a tabular listing of appropriate altitude ranges and corresponding manufacturer's high altitude (Natural or Propane Gas) orifice or pressure switch kits.

In some areas the gas supplier may artificially derate the gas in an effort to compensate for the effects of altitude. If the gas is artificially derated the appropriate orfice size must be determined based on the BTU/ft3 content of the derated gas and the altitude. Refer to the National Fuel Gas Code, NFPA 54/ANSI Z223.1, and information provided by the gas supplier to determine the proper orifice size.

Page 76

SYSTEM OPERATION

S-312 CHECKING FOR DELAYED IGNITION

Delayed ignition is a delay in lighting a combustible mixture of gas and air which has accumulated in the combustion chamber.

When the mixture does ignite, it may explode and/or rollout causing burning in the burner venturi.

If delayed ignition should occur, the following should be checked. Furnace design makes this extremely unlikely unless safety controls have been by-passed or tampered with. Never by-pass or alter furnace controls.

1. Improper gas pressure - adjust to proper pressure (See S-307 CHECKING GAS PRESSURE).

2. Improper burner positioning - burners should be in locating slots, level front to rear and left to right.

3. Carry over (lighter tube or cross lighter) obstructed - clean.

4. Main burner orifice(s) deformed, or out of alignment to burner - replace.

S-313 CHECKING INTEGRATED IGNITION CON-

TROL BOARDS

NOTE: Failure to earth ground the furnace, reversing the

neutral and hot wire connection to the line (polarity), or a high resistance connection in the neutral line may cause the control to lockout due to failure to sense flame.

WARNING

O AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO THE UNIT MUST BE PROPERLY POLARIZED AND GROUNDED. BEFORE PERFORMING SERVICE LISTED BELOW.

ISCONNECT POWER

and 24 volts to the control since both must be present for the light to be on. If this step fails, check for 120 volts to the control and check the transformer and its associated wiring. If this step is successful give the control a call for heat and wait five (5) seconds or until the furnace goes into lockout. If the control detects a failure it will now be shown on the diagnostic indicator light/display. Refer to the Abnormal Op- eration section in the Sequence of Operation section of this manual for more detail on failure codes.

1. Check for 120 volts from Line 1 (Hot) to Line 2 (Neutral) at the ignition control. No voltage, check the door switch connections and wire harness for continuity.

2. With the thermostat calling for heat, check for 24 volts from W1 to C terminal on the ignition control. No voltage. Check transformer, room thermostat, and wiring.

If you have 24 volts coming off the transformer but receive approximately 13 volts on the terminal board between (C) and (R), check for blown fuse.

3. Check for 120 volts to the induced draft blower (low-stage) by measuring voltage between Pin 3 and Pin 4 (on the 5pin connector) located on circuit board. No voltage, check for loose connection in the 5-pin connector or replace ignition control.

Check for 120 volts to the induced draft blower (highstage) by measuring voltage between Pin 2 and Pin 4 (on the 5-pin connector) located on circuit board. No voltage, check for loose connection in the 5-pin connector, no call for high stage heat or replace ignition control.

The ground wire must run from the furnace all the way back to the electrical panel. Proper grounding can be confirmed by disconnecting the electrical power and measuring resistance between the neutral (white) connection and the burner closest to the flame sensor. Resistance should be less than 2 ohms.

The ignition control is a combination electronic and electromechanical device and is not field repairable. Complete unit must be replaced.

WARNING

INE VOLTAGE NOW PRESENT

These tests must be completed within a given time frame due to the operation of the ignition control. The trial for ignition period is 4 seconds.

The ignition control is capable of diagnosing many furnace failures to help in troubleshooting. The control utilizes a dual, 7-segment LED display to indicate diagnostic codes.

When the control is powered up normally the light will be on continuously. The display wil indicate "ON" when powered and in standby mode. This can be used to test for 120 volts

Page 77

SYSTEM OPERATION

2 Y2

GOODMAN PT# PCBKF105

OG Y1CW1R

HUM

b. The two-stage variable speed furnaces should have

120 Volts at the motor at all times, even without a call for cooling or heating. These motors receive their operational signals through the 4-pin wiring harness, connected between the motor and integrated control board. NOTE: For complete troubleshooting information on units using the ECM blower motors, refer to the servicing section - Checking Air Circulator Blow- ers (S-16B) in this service manual.

S-313A MEMORY CHIPS

Memory chips are a service only item and are not sent out with new equipment. They are used only in the rare occurrence where communicating equipment shared data needs to be restored.

Memory chips should not be routinely installed at the time of installation. A memory chip is not required when an individual control board or motor is replaced.

A memory chip is only required when all communicating components have been replaced with service parts containing no shared data. If either an existing control board or ECM motor needed to be replaced, the service part would upload the necessary data from the remaining communicating component. In a fully communicating system, this would include the communicating thermostat and communicating outdoor unit control board as the necessary data is stored in all communicating devices.

4. If voltage is present in Steps 1 through 3 and the induced draft blower is operating, check for 120 volts to the ignitor during the preheat cycle. Measure voltage between Pin 1 and Pin 5 (on the 5-pin connector) located on ignition control. No voltage, check low stage and high stage pressure switches or replace the ignition control board.

5. After the ignitor warmup time, begin checking for 24 volts to the gas valve. Voltage will be present for seven seconds only if proof of flame has been established.

6. If proof of flame was established voltage will be provided to the air circulation blower following the heat on delay period.

a. BEFORE replacing the ECM motor assembly or the

end bell, first check the motor with a Goodman #UTT01 UltraCheck-EZTM diaganostic tool . If the motor runs with the diagnostic tool, the motor is good. To check the end bell, see the previous variable speed testing section of this manual before replacing the end bell.

A furnace void of shared data will not function in a legacy or a fully communicating installation. The furnace display would show “d0” indicating that there is no shared data in the furnace control board. If it is ever necessary to use a memory chip, the specific memory chip for your furnace number must be used.

To use a memory chip;

1. Power down all HVAC equipment in the system.

2. As when handling any electronic components; discharge any static electricity you may be carrying by touching grounded metal.

3. Insert the memory card in the slot on the control board.

Page 78

SYSTEM OPERATION

S-314 CHECKING FLAME SENSOR

A flame sensing device is used in conjunction with the ignition control module to prove combustion. If proof of flame is not present the control will de-energize the gas valve and "retry" for ignition or lockout.

WARNING

HIGH VOLTAGE D

ISCONNECT ALL POWER BEFORE SERVICING OR

INSTALLI NG THIS UNIT. BE PRESENT. DAMAGE, PERSON AL INJURY OR DEATH.

MULTIPLE POWER SOUR CES MAY

FAILURE TO DO SO MAY CAUSE PROPERTY

1. Disconnect the flame sensor wire from the sensor.

2. Connect a micro-amp meter in series with this wire and the sensor terminal.

3. Be sure the positive side of the meter is to the flame sensor wire and the negative side of the meter is to sensor terminal.

WARNING

2 Y2

OG Y1CW1R

HUM

Memory Car d Connector

Dual 7-Segment LED’

4. Power the system back up and allow a few minutes for the network to establish communication between all devices.

5. Furnace control board will display "ON”.

6. Check operation.

7. Memory chip can be left on the control board (recommended) or removed once equipment is powered down

again.

INE VOLTAGE NOW PRESENT

4. Place the unit into a heating cycle.

5. As soon as flame is established a micro-amp reading should be evident once proof of flame (micro-amp reading) is established, the hot surface ignitor will be deenergized.

6. The Integrated Ignition controls will have 1 to 4 microamps. If the micro-amp reading is less than the minimum specified, check for high resistance wiring connections, sensor to burner gap, dirty flame sensor, or poor grounding.

7. If absolutely no reading, check for continuity on all components and if good - replace ignition control module.

NOTE: Contaminated fuel or combustion air can create a nearly invisible coating on the flame sensor. This coating works as an insulator causing a loss in the flame sense signal. If this situation occurs the flame sensor must be cleaned with steel wool.

Page 79

MAINTENANCE

WARNING

HIGH VOLTAGE

ISCONNECT ALL POWER BEFORE SERVICING OR

INSTALLI NG THIS UNIT. BE PRESENT. DAMAGE, PERSONAL INJURY OR DEATH.

MULTIPLE POWER SOURCES MAY

FAILURE TO DO SO MAY CAUSE PROPERTY

CAUTION

IF YOU MUST HANDLE THE ITNITOR, HANDLE WITH CARE. TOUCHING

THE IGNITOR BODY WITH BARE FINGERS, ROUGH HANDLING, OR VIBRATION COULD RESULT IN EARLY IGNITOR FAILURE. QUALIFIED SERVICER SHOULD EVER HANDLE THE IGNITOR.

ONLY A

ANNUAL INSPECTION

The furnace should be inspected by a qualified installer, or service agency at least once per year. This check should be performed at the beginning of the heating season. This will ensure that all furnace components are in proper working order and that the heating system functions appropriately. Pay particular attention to the following items. Repair or service as necessary.

• Flue pipe system. Check for blockage and/or leakage. Check the outside termination and the connections at the furnace.

• Combustion air intake pipe system (where applicable). Check for blockage and/or leakage. Check the outside termination and the connection at the furnace.

• Heat exchanger. Check for corrosion and/or buildup within the heat exchanger passageways.

• Burners. Check for proper ignition, burner flame, and flame sense.

• Drainage system. Check for blockage and/or leakage. Check hose connections at and internal to furnace.

• Wiring. Check electrical connections for tightness and/ or corrosion. Check wires for damage.

• Filters.

AIR FILTER

WARNING

NEVER OPERATE FURNACE WIHT OUT A FILTER INSTALL ED AS DUST

AND LINT WILL BUILD UP ON INTERNAL PARTS RESULTING IN LOSS OF EFFICIENCY, EQUIPMENT DAMAMGE, AND POSSIBLE FIRE.

Filters must be used with this furnace. Filters do not ship with these furnaces but must be provided by the installer for proper furnace operation.

Remember that dirty filters are the most common cause of inadequate heating or cooling performance.

Maintenance

Improper filter maintenance is the most common cause of inadequate heating or cooling performance. Filters should be cleaned (permanent) or replaced (disposable) every two months or as required. It is the owner's responsibility to keep air filters clean. When replacing a filter, it must be replaced with a filter of the same type and size.

Filter Removal

Depending on the installation, differing filter arrangements can be applied. Filters can be installed in the central return register, the bottom of the blower compartment (upflow only), a side panel external filter rack kit (upflow only), or the ductwork above a counterflow furnace. A media air filter or electronic air cleaner can be used as an alternate filter. The filter sizes given in the Product Design section of this manual or the product Specification Sheet must be followed to ensure proper unit performance. Refer to the following information for removal and installation of filters.

FILTER REMOVAL PROCEDURE Media Air Filter or Electronic Air Cleaner Removal

Follow the manufacturer’s directions for service.

Upright Counterflow Filter Removal

To remove filters from the ductwork above an upright counterflow installation:

1. Turn off electrical power to furnace.

2. Remove access door in ductwork above furnace.

3. Remove filters.

4. Remove blower compartment door. V acuum comp artment. Replace blower compartment door .

5. Replace filters opposite of removal.

6. Replace access door in ductwork.

Horizontal Unit Filter Removal

Filters in horizontal installations are located in the central return register.

INDUCED DRAFT AND CIRCULATION BLOWERS

The bearings in the induced draft blower and circulator blower motors are permanently lubricated by the manufacturer. No further lubrication is required. Check motor windings for accumulation of dust which may cause overheating. Clean as necessary.

Page 80

MAINTENANCE

CONDENSATE DRAINAGE SYSTEM (QUALIFIED SERVICER ONLY)

The drain tubes, trap, and field supplied drain line must be checked annually and cleaned as often as necessary to ensure proper condensate drainage.

FLAME SENSOR (QUALIFIED SERVICER ONLY)

Under some conditions, the fuel or air supply can create a nearly invisible coating on the flame sensor. This coating acts as an insulator, causing a drop in the flame sensing signal. If this occurs, a qualified servicer must carefully clean the flame sensor with steel wool. After cleaning, the flame sensor output should be as listed on the specification sheet.

BURNERS

WARNING

HIGH VOLTAGE

LECTRICAL COMPONENT S ARE CONTAINED IN BOTH

COMPARTMENTS. DEATH, DO NOT REMOVE ANY INTERN AL COMPARTMENT COVERS OR ATTEMPT ANY ADJUS TMENT. SERVICE AGENT AT ONCE IF AN ABNORM AL FLAME APPEARANCE SHOU LD DEVELOP.

Periodically during the heating season make a visual check of the burner flames. Turn the furnace on at the thermostat. Wait a few minutes since any dislodged dust will alter the normal flame appearance. Flames should be stable, quiet, soft and blue with slightly orange tips. They should not be yellow. They should extend directly outward from the burner ports without curling downward, floating or lifting off the ports.

TO AVOID ELECTRICAL SHO CK, INJURY OR

CONTACT A QUALIFIED

After the heating cycle has been in operation for at least fifteen minutes and with all other gas appliances turned off, the gas meter should be clocked.

To find the BTU input, multiply the number of cubic feet of gas consumed per hour by the heating value of the gas being used. (The calorific value of the gas being used is found by contacting your local utility.)

EXAMPLE: It is found by the gas meter, that it takes forty (40) seconds for the hand on the cubic foot dial to make one complete revolution, with all appliances off, except the furnace. Take this information and locate it on the gas rate chart. Observe the forty (40) seconds, locate and read across to the one (1) cubic foot dial column. There we find the number 90, which shows that ninety (90) cubic feet of gas will be consumed in one (1) hour.

Let's assume the local gas utility has stated that the calorific value of the gas is 1,025 BTU per cubic foot.

Multiplying the ninety (90) cubic feet by 1,025 BTU per cubic foot gives us an input of 92,250 BTUH.

Checking the BTU input on the rating plate of the furnace being tested.

EXAMPLE: INPUT: 92,000 BTU/HR OUTPUT CAP: 84,000

CAUTION

LWAYS CON NECT A MONOME TER TO THE O UTLET TAP AT THE GAS VALVE BEFORE ADJUSTING THE PRESSURE REGULATOR. SHOULD THE FINAL MANIFOLD PRESSURE VARY MORE THAN PLUS OR MINUS .3 INCH ES WATER CO LUMN FRO M 3.5 INC HES WATER COLUMN FOR NATURAL GAS OR 10 INCHES WATER COLUMN FOR PROPANE GAS.

N NO CASE

Check the Burner Flames for:

1. Stable, soft and blue.

2. Not curling, floating or lifting off.

Burner Flame

Proper equipment promotes faster, more efficient service and accurate repairs resulting in fewer call backs.

HEATING PERFORMANCE TEST

Before attempting to diagnose an operating fault, run a heating performance test and apply the results to the Service

Problem Analysis Guide.

To conduct a heating performance test, the BTU input to the furnace must be calculated.

To adjust the pressure regulator on the gas valve, turn down (clockwise) to increase pressure and input, and out (counterclockwise) to decrease pressure and input.

The dissipation of the heat transferred to the heat exchanger is now controlled by the amount of air circulated over its surface.

The amount (CFM) of air circulated is governed by the external static pressure in inches of water column of duct work, cooling coil, registers, etc., applied externally to the unit versus the motor speed tap (direct drive) or pulley adjustments of the motor and blower (belt drive).

A properly operating unit must have the BTU per hour input and CFM of air, within the limits shown to prevent short cycling of the equipment. As the external static pressure goes up, the temperature rise will also increase. Consult the proper tables for temperature rise limitation.

Page 81

MAINTENANCE

HIGH VOLTA GE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALL ING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

ALL FUEL SYSTEM CONTROL BOARD - AFE1860A

POWER SUPPLY INPUT

FURNACE DEMAND OUTPUT

BLOWER FAN DEMAND OUTPUT

POWER SUPPLY INPUT (COMMON)

SECOND STAGE FURNACE DEMAND OUTPUT

COMPRESSOR OUTPUT

SECOND STAGE COMPRESSOR OUTPUT

REVERSING VALVE OUTPUT

POWER SUPPLY OUT TO THERMOSTAT

CALL FOR REVERSING VALVE

CALL FOR COMPRESSOR

CALL FOR EMERGENCY HEAT

CALL FOR BLOWER FAN

CALL FOR FURNACE HEAT

POWER SUPPLY COMMON OUT TO THER MOSTAT

CALL FOR 2ND STAGE FURNACE HEAT

CALL FOR 2ND STAGE COMPRESSOR

POWER SUPPLY OUT TO HP CONTROL

HP CALL FOR FURNACE (DURING DEFROST)

REVERSING VALVE OUTPUT

COMPRESSOR CONTACTOR OUTPUT

POWER SUPPLY COMMON OUT TO HP C ON TR OL

ODT (OUTDOOR THERMOSTAT)

2ND STAGE COMPRESSOR DEMAND OUTPUT

P1-8

P1-7

F U R N A C E

T H E R M O S T A T

H E A T

OT-NO

OT-NC

M P

OT-C

G C W2 Y Y2 O

R O Y E G W1 C W2 Y2

R W2 O Y C

P1-4

P1-6

P1-5

P1-2

P1-3

P1-1

24VAC

P2-2

P2-1

P2-7

P2-8

P2-5

P2-9

P2-3

P2-4

P2-6

24VAC

P3-9

P3-8

P3-7

P3-2

P3-6

P3-3

P3-1

P3-4

P3-5

24VAC

POWER SUPPLY

1.0K

6.8K

+5VDC

E/W1

+VDC +5VDC

+VDC

MICROPROCESSOR

24VAC

+VDC

W1-FURN W2-HP

G-STAT

G-FURN

Y2-HP

Y2-STAT Y2-FURN

Y-ST AT Y-FURN

Y-HP

BREAK FOR ODT

1 2

ALL FUEL SYSTEM CONTROL BOARD - AFE18-60A

This wiring diagram is for reference only. Not all wiring is as shown above.

Refer to the appropriate wiring diagram for the unit being serviced.

(For use with Heat Pumps in conjunction with 80% or 90% Single-Stage or Two-Stage Furnaces)

Page 82

ACCESSORY WIRING DIAGRAMS

HIGH VOLTA GE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALL ING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

INTE GRATED IGNITION CONTROL

2 Y2

OG Y1CW1R

HUM

WHITE

BLACK

GREEN

DE-HUMIDISTAT

DE-HUMIDISTAT - DEHUM1

This wiring diagram is for reference only. Not all wiring is as shown above.

Refer to the appropriate wiring diagram for the unit being serviced.

Page 83

WIRING DIAGRAMS

GND

JUNCTION BOX

HIGH VOLTA GE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALL ING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO

DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEAT H.

(

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OLP

E MEN

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NTF

5 CIRCUIT CONNECTOR

4CIRCUITMOTOR

CONNECTOR

DIP SWITCHES

4 T

INTEG RATED

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CONTROL

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USE

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Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

Goodman ACVC96,AMVC96, GCVC96,GMVC96 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual