Goodman GMEC96, Amana ACEC96, Amana AMEC96, GCEC96 Service Instructions Manual

Service Instructions

®

Goodman® Brand GMEC96/GCEC96

& Amana

Two Stage Furnace

with multi-speed ECM Motor

®

Brand AMEC96/ACEC96

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 manufacturers installation and operation instructions.

is a registered trademark of Maytag Corporation or its related companies and

RS6612013r7

November 2017

TABLE OF CONTENTS

IMPORTANT INFORMATION ...............................3

PRODUCT IDENTIFICATION ..............................5

FURNACE SPECIFICATIONS...............................9

OPERATION INSTRUCTIONS............................10

SYSTEM OPERATION. .....................................11

ACCESSORIES.................................................44

SERVICING TABLE OF CONTENTS..................48

SERVICING ........................................................49

MAINTENANCE ..................................................66

WIRING DIAGRAMS ....................................70 -72

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

O

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

HIGH VOLTAGE D

ISCONNECT ALL POWER BEFORE SERVICING OR

INSTALLI NG T HIS UNIT. BE PRESENT . DAMAGE, PE RSONAL INJUR Y OR DEATH.

FAILU RE TO DO SO MAY CAUSE P ROPERTY

MULTIPLE P OWER SOURCE S MAY

2

IMPORTANT INFORMATION

CO can cause serious illness inc luding permanent brain damag e 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 emis iones de monóxido de carbono puede n circular a través del apa rat o cuando se opera en c ualquier modo.

El monóx ido de carbono puede caus ar enfermedade s se veras como daño cerebr al permanente ó muerte.

B10259-216

RISQUE D'EMPO ISONNEMENT AU

Cette ventilation est nécessaire pour éviter le danger d'intoxication au CO pouvant survenir si un appareil produisant du monoxyde de carb one continue de fonc tionner au sein de la zone confinée.

Le monoxyde de des

carbone peut causer des maladies graves telles que

dommages permanents au cerveau et mem e la mort.

MONOXYDE DE CARBONE

B10259-216

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.)

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.)

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.

3

IMPORTANT INFORMATION

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4

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.

* M E C 96 60 3 B N A A

12345,67,8,91011121314

Brand Minor Revision A - Amana G - Goodman

Configuration Major Revision M - U p flo w / Ho rizontal A - Initial Release C - Down flow / Hori zontal B - 1st Revision

Motor NOx V - V ariab l e Spee d ECM / ComfortNet N - Low NOx E - M ulti-Speed ECM S - Single Speed Cabinet Width

Gas Valve B - 17.5" M - Modulating C - 21" C - 2 Stage D - 24.5" S - Single Stage

AFUE 2 - 800 CFM 96 - 96% AFUE 3 - 1200 CFM 92 - 92% AFUE 4 - 1600 CFM

MBTU/h 040 - 40,000 BTU/h 060 - 60,000 BTU/h

® Brand A - Initial Release

® Brand B - 1st Revision

A - 14"

Maximum CFM

5 - 2000 CFM

5

PRODUCT IDENTIFICATION

MODEL # MFG. # DESCRIPTION

AMEC960402BNAA

AMEC96

GMEC96

AMEC960603BNAA AMEC960803BNAA AMEC961004CNAA AMEC961205DNAA

AMEC960302BNAB AMEC960402BNAB AMEC960603BNAB AMEC960803BNAB AMEC961004CNAB AMEC961205DNAB AMEC960804CNAB AMEC961005CNAB

AMEC960303ANAA AMEC960403ANAA AMEC960603ANAA AMEC960302BNAC AMEC960402BNAC AMEC960603BNAC AMEC960803BNAC AMEC960804CNAC AMEC961004CNAC AMEC961005CNAC AMEC961205DNAC

GMEC960402BNAA GMEC960603BNAA GMEC960803BNAA GMEC961004CNAA GMEC961205DNAA

GMEC960302BNAB GMEC960402BNAB GMEC960603BNAB GMEC960803BNAB GMEC961004CNAB GMEC961205DNAB GMEC960804CNAB GMEC961005CNAB

GMEC960303ANAA GMEC960403ANAA GMEC960603ANAA GMEC960302BNAC GMEC960402BNAC GMEC960603BNAC GMEC960803BNAC GMEC960804CNAC GMEC961004CNAC GMEC961005CNAC GMEC961205DNAC

®

Ama na

flow/Horizontal Left and Right, 34.5" tall, Induced Draft, Nidec multi-speed ECMmotor. Stainless Steel tubular heat exchanger. 115 volt silicon nitride igniter. Left or right gas.

Ama na

flow/Horizontal Left and Right, 34.5" tall, Induced Draft, Nidec multi-speed ECMmotor. Stainless Steel tubular heat exchanger. 115 volt silicon nitride igniter. Left or right gas.

Ama na

flow/Horizontal Left and Right, 34.5" tall, Induced Draft, Nidec multi-speed ECMmotor. Stainless Steel tubular heat exchanger. 115 volt silicon nitride igniter. Left or right gas. Control board changed from PCBBF137 to PCBBF139. New control feature gives installer multiple choices for constant fan mode.

Goodman

flow/Horizontal Left and Right, 34.5" tall, Induced Draft, Nidec multi-speed ECMmotor. Stainless Steel tubular heat exchanger. 115 volt silicon nitride igniter. Left or right gas.

Goodman

flow/Horizontal Left and Right, 34.5" tall, Induced Draft, Nidec multi-speed ECMmotor. Stainless Steel tubular heat exchanger. 115 volt silicon nitride igniter. Left or right gas. For Control board part # change to PCBBF137 with heat speed DIP switches.

Goodman

flow/Horizontal Left and Right, 34.5" tall, Induced Draft, Nidec multi-speed ECMmotor. Stainless Steel tubular heat exchanger. 115 volt silicon nitride igniter. Left or right gas. For Control board part # change to PCBBF137 with heat speed DIP s witches. Control board changed from PCBBF137 to PCBBF139. New control feature gives installer multiple CFM choices for constant fan mode.

Brand 96% Two Stage Heating / Two Stage Cooling Gas Furnace, Up

®

Brand 96% Two Stage Heating / Two Stage Cooling Gas Furnace, Up

®

Brand 96% Two Stage Heating / Two Stage Cooling Gas Furnace, Up

®

Brand 96% Two Stage Heating / Two Stage Cooling Gas Furnace, Up

®

Brand 96% Two Stage Heating / Two Stage Cooling Gas Furnace, Up

®

Brand 96% Two Stage Heating / Two Stage Cooling Gas Furnace, Up

6

PRODUCT IDENTIFICATION

MODEL # MFG. # DESCRIPTION

®

Brand 96% Two Stage Heating / Two Stage Cooling Gas Furnace, Counter

ACEC96

ACEC960403BNAA ACEC960603BNAA ACEC960803BNAA ACEC961005BNAA

Amana

flow/Horizontal Left and Right, 34.5" tall, Induced Draft, Nidec multi-speed ECM motor. Stainl ess Steel tubular heat exchanger. 115 volt silicon nitride igniter. Left or right gas. PCBBF139 Control board which gives installer multiple CFM choices for constant fan mode.

GCEC96

GCEC960403BNAA GCEC960603BNAA GCEC960803BNAA GCEC961005BNAA

Goodman

flow/Horizontal Left and Right, 34.5" tall, Induced Draft, Nidec multi-speed ECMmotor. Aluminized Steel tubular heat exchanger. 115 volt si licon nitride igniter. Left or right gas. PCBBF139 Control board which gives installer multiple CFM choices for constant fan mode.

®

Brand 96% Two Stage Heating / Two Stage Cooling Gas Furnace, Counter

7

PRODUCT IDENTIFICATION

MODEL # M FG # DESCRI PT ION

AFE18-60A

AMU1620 AMU1625 AMU2020 AMU2025

GMU1620 GMU1625 GMU2020 GMU2025

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

DCVK-20 (CVE NT - 2)

DCVK-30 (CVE NT - 3)

0170K00000S

N/A

P1251305F P1251306F P1251307F P1251308F

N/A

P1251301F P1251302F P1251303F P1251304F

P1254001F

P1254002F

N/A

Foss il Fuel Kit.

above/downstream of a gas or f ossil fuel fur nac e when used with a heat pump. It will operat e with single and two stage heat pumps and single and two stage furnaces

Med ia Air C leaner

efficiency air filtration device designed to remov e dir t, dust, pollen and other microscopic part ic les fr om the air passing through it . Flexible performance range up t o 2,0

Electronic Air C leaner

cont aminants down to .01 microns. Carbon filters (optional) r emove odors. Dual indicator lights show unit operat ion at a glance. E lec tronic proving switc h c ycle

Concentric Vent Kit

designed to allow ter minations of a dir ec t vent furnac e to be "c onc entrically" vented through a wall or roof. T his kit allows a single penetrat ion to support ter min

Side Wall Only Concentric Vent Kit

to be used with 2" - 3" vent sy stems. The vent k it must terminate out side the str uc ture. This kit is NOT intended f or use with single pipe (indirec t v ent) instal

The AF E 18- 60A c ontrol is designed for use where the indoor c oil is locat ed

. The A mana (AMU*) and G oodman (G MU*) Media Air Cleaner is a high

. The High-Ef ficiency Elec tronic Air Cleaner is designed to remov e air

. For use with Amana® Brand high efficiency f ur nac e models. This kit is

. For use with high efficiency f ur nac e models. This kit is

0170K00001S

EFR02

LPLP03

RF000142

CFSB17 CFSB21 CFSB24

N/A

P1221001

P1221002F

N/A

Side Wall Only Concentric Vent Kit

kit is to be used with 2" only vent systems. The vent kit must terminate outside the str uc ture. This kit is NOT intended f or use with single pipe (indirec t v ent) in

External Filter Rack Kit

casing, f or installation of a permanent filter. The r ac k is mounted over the indoor air blower compartment ar ea of either side panel, and pr ovide f ilter retentio

LP Gas Low Pressure Kit

80% and 90% single-stage and two- stage gas fired furnace pr oduc ts inst alled on LP gas listed in this manual. This kit inc ludes harness adaptors to work with White-Rodgers sin

Vent Drain Coupling

the internal elbow is removed. May also be used in the combustion air intak e if condensation is an issue.

Counterflow Subbase Kit

34.5 furnace model. T hese kit s are available for the following furnace widt h: 17.5" wide (CF S B 17) , 21" wide (CFSB21, and 24" Wide CF S B 21. The k it must be used to pr event excessive t emperat ur e from reaching combustible materials, if the fur nac e is installed on combustible floor . This subbase effect ively separated the furnac e base and plenum from combustile materials. T o ensure safe installation, do not install the counter flow floor base directly on c ar peting, tile or other c ombusible mat er ial other t han wood flooring.

. This kit is intended to pr ovide a loc ation, ext er nal t o the fur nac e

. Designed for applic ation on Goodman® and Amana® Brand's

. For use when the fur nac es is installed in horizontal lef t position and

. For use with Amana® Brand, Goodman® brand 96% t wo stage

. For use with high efficiency 90% f ur nac e models. This

8

FURNACE SPECIFICATIONS

*MEC96

Heating Data

High Fire Input¹ 30,000 40,000 60,000 30,000 40,000 60,000 80,000 100,000 120,000 80,000 100,000 Hi gh Fi re Outp ut¹ 28,800 38,400 57,600 28,800 38,400 57,600 76,800 96,000 115,200 76,800 96,000 Low-Fire Steady-State Input¹ 21,000 28,000 42,000 21,000 28,000 42,000 56,000 70,000 84,000 56,000 70,000 Low -Fire Stea dy-Sta te Outp ut¹ 20,160 26,880 40,320 20,160 26,880 40,320 53,760 67,200 80,640 53,760 67,200 AFUE² 9696969696969696969696 Tem pera ture Ri se Ra nge (°F) 20 - 50 20 - 50 30 - 60 20 - 50 20 - 50 25 - 55 35 - 65 35 - 65 35 - 65 25 - 55 35 - 65 Ve nt Dia mete r³ 2" - 3" 2" - 3" 2" - 3" 2" - 3" 2" - 3" 2" - 3" 2" - 3" 2" - 3" 2" - 3" 2" - 3" 2" - 3" No. of Burners 22322345645

Circul a t or Blower

Availa ble AC @ 0.5” ESP 1.5 - 3 1.5 - 3 1.5 - 3 1.5 - 2 1.5 - 3 1.5 - 3 1.5 - 3 1.5 - 4 3 - 5 2.5 - 4 3 - 5 Si ze (D x W) 11" x 6" 11" x 6" 11" x 6" 10" x 8" 10" x 8" 11" x 8" 11" x 8" 11" x 10" 11" x 11" 11" x 10" 11" x 10" Ho rs epo wer @ 1075 RPM 1/2 1/2 1/2 1/2 1/2 1/ 2 1/2 1 1 3/4 1 Speed 55555555555

Electrical Data

Min. Circuit Ampacity

Max. Overcurrent Device (amps)

Shi ppi ng Weight (lbs)

4

0303ANA

5

8.6 8.6 8.6 8 8 8 8 13. 3 13.3 11.6 13.3

15 15 15 15 15 15 15 15 15 15 15

106 107 110 111 112 115 118 140 154 123 140

*MEC96

0403ANA

*MEC96

0603ANA

*MEC96

0302BNA

0403BN AA

*MEC96

0402BNA

*CEC96

*MEC96

0603BNA

*CEC96

0603BN AA

*MEC96

0803BNA

*CEC96

0803BN AA

*MEC96

1004CNA

*CEC96

1005CNA A

*MEC96

1205DNA

*MEC96

0804CNA

*MEC96

1005CNA

Heating Data

High F ire Input¹ 40,000 60,000 80,000 100,000 High Fi re Output¹ 38,400 57,600 76,800 96,000 Low-Fire Steady-State Input¹ 28,000 42,000 56,000 70,000 Low-Fi re Steady-State Output¹ 26,880 40,320 53,760 67,200 AFUE 96 96 96 96 Tempe rature Rise Range (°F) 25 - 55 25 - 55 40 - 70 36 - 65 Vent Diameterᶾ 2" - 3" 2" - 3" 2" - 3" 2" - 3" No. of Burners 2345

Circula tor Blower

Available AC @ 0.5 ESP 1.5 - 3 1.5 - 3 1.5 - 3 3 - 5 Size (D x W) 10 x 8 10 x 8 11 x 8 11 x 10 Horsepow er @ 1075 RPM 1/2 1/2 1/2 1 HP Speed 5555

Elec trical Data

Min. Circuit Ampacity⁴ 88813.3 Max. Overcurrent Device (AMPS)⁵ 15 15 15 15

1

Natural Gas BTU/h

2

DOE AFUE based upon Isolated Combustion System (ICS)

3

Installer must supply one or two PVC pipes: one for combustion air (optional) and one for the flue outlet (required). Vent pipe must be either 2" or 3" in diameter, depending upon furnace input, number of elbows, length of run and installation (1 or 2 pipes). The optional Combustion Air Pipe is dependent on installation/code requirements and must be 2" or 3" diameter PVC.

4

Minimum Circuit Ampacity = (1.25 x Circulator Blower Amps) + ID Blower amps. Wire size should be determined in accordance with National Electric Codes. Extensive wire runs will require larger wire sizes.

5

Maximum Overcurrent Protection Device refers to maximum recommended fuse or circuit breaker size. May use fuses or

HACR-type circuit breakers of the same size as noted

Notes

• All furnaces are manufactured for use on 115 VAC, 60 Hz, single-phase electrical supply.

• Gas Service Connection 1/2" FPT

• Important: Size fuses and wires properly and make electrical

connections in accordance with the National Electrical Code and/or all existing local codes.

• For bottom return: Failure to unfold flanges may reduce airflow by up to 18%. This could result in performance and noise issues.

• For servicing or cleaning, a 24" front clearance is required. Unit connections (electrical, flue and drain) may necessitate greater clearances than minimum clearances listed above. In all cases, accessibility clearance must take precedence over clearances from the enclosure where accessibility clearances

are greater.

9

OPERA TIONS INSTRUCTIONS

Introduction

This is a Category lV furnace. This furnace uses a pressurized venting system and must be installed per National and local codes requirements and the installation manual that was shipped with the furnace.

The *MEC96 34.5" furnace is one of the products in our newly redesigned line of shorter chassis furnaces. It is available in the following sizes and suitable for up flow / horizontal installation.

*MEC960303ANA *CEC960402BNAA *MEC960403ANA *CEC960603BNAA *MEC960603ANA *CEC960803BNAA

*MEC960302BNA *CEC961005CNAA

*MEC960402BNA Suitable for counter *MEC960603BNA flow or horizontal *MEC960803BNA installation. *MEC960804CNA *MEC961004CNA *MEC961005CNA *MEC961205DNA

Safety

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

WARNING

T

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.

T

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

S

REPRODUCTIVE HARM.

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.

OR ADDITIONAL ASSISTANCE OR INFORMATION, CONSULT A

F

WARNING

HIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS WHICH

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

WARNING

age. 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

installation instructions.

The *MEC96 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).

*MEC96 furnaces are dual certified. Dual certification means that the combustion air inlet pipe is

optional and the furnace can be vented as a:

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.

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.

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 dam-

10

WARNING

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

P

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.

SYSTEM OPERATION

WARNING

T

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:

American National Standards Institute

25 West 43rd Street, 4th Floor New York, NY 10036

National Fire Protection Association

1 Batterymarch Park Quincy, MA 02169-7471

CSA International

8501 East Pleasant Valley Cleveland, OH 44131

A copy of the CAN/CGA B149 Installation Codes can be obtained from:

CSA International

178 Rexdale Boulevard Etobicoke, Ontario, Canada M9W, 1R3

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

T

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.

• Set the 90% furnace on a level floor to enable proper 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 Appli- cations and Considerations section in this manual or the installation instructions for leveling of horizontal furnaces.

• Ensure upflow or horizontal furnaces are not installed directly on carpeting, or any other combustible material. The only combustible material allowed is wood.

• Exposure to contaminated combustion air will result 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

11

SYSTEM OPERATION

hydrochloric acid cements and glues antistatic fabric softeners for clothes dryers and masonry acid washing materials

• Isolate a non-direct vent furnace if it is installed near an area frequently contaminated 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 sup- ply of combustion air, vent from a nearby uncontaminated room or from outdoors. Refer to the Combus- tion and Ventilation Air Requirements section in this manual or the installation instructions for details.

• If the furnace is used in connection with a cooling 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.

• 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.

• On counterflow installations, the air conditioning coil must be downstream on the supply (positive) side of the furnace heat exchanger.

• Counterflow Installation over a noncombustible floor. Before setting the furnace over the plenum opening, ensure the surface around the opening is smooth and level. A tight seal should be made between the furnace base and floor by using a silicone rubber caulking compound or cement grout.

• Counterflow Installation over a combustible floor. If installation over a combustible floor becomes necessary, use an accessory sub-base (see Specification Sheet applicable for your model for details). A special accessory sub-base must be used for upright counterflow unit installations over any combustible material including wood. Refer to sub-base instructions for installation details. Follow the instructions with the sub-base for proper installation. Do not install the furnace directly on carpeting, tile, or other combustible material other than wood flooring.

(NOTE: The sub-base will not be required if an air conditioning coil is installed between the supply air opening on the furnace and the floor.)

*MEC96 M INIMUM CLEA RANCES TO COM BUSTIBLE MATERIALS

POSITION* SIDES REAR FRONT BOTTOM FLUE TOP

Upflow 0" 0" 1" C 0" 1"

Horiz ontal 6" 0" 1" C 0" 6"

*CEC9 6 MINIM UM CLE ARANCE S TO CO MBUSTIB LE MATER IA LS

POSITION* SIDES REAR FRONT BOTTOM FLUE TOP

Counterflow0"0"1"NC0"

Horizontal 6" 0" 1" C 0" 6"

• C = If placed on combustible floor, floor MUST be wood only.

• NC = For installation on non-combustible floors only. A combustible subbase must be used for installations on combustible flooring.

• For servicing or cleaning, a 24" front clearance is recommended.

• Unit connections (electrical, flue, and drain) may necessitate greater clearances than the minimum clearances listed above.

• In all cases, accessibility clearance must take precedence over from the enclosure where accessibility clearances are greater.

• Approved for line contact in the horizontal position.

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.

12

SYSTEM OPERATION

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.

PROVIDE 8" MINIMUM CLEARANCE BETWEEN

CENTER ROD AND FURNACE CABINET

TO ALLOW FOR CIRCULATOR BLOWER REMOVAL.

3/8" DIAMETER

THREADED ROD

(6 PLACES)

HOLD DOWN

NUTS

SUPPORT

NUTS

GAS PIPING

2"X2"X1/8" ANGLE IRON

(3 PLACES)

ALTERNATE GAS PIPING

POSITION AS CLOSE AS POSSIBLE TO BLOWER DECK TO ALLOW FOR

CIRCULATOR BLOWER REMOVAL.

ASSURE FURNACE IS LEVEL FROM

END TO END.

ON

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.

90% Suspended Furnace Shown

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,

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;

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

all 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;

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

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

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

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

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

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;

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

common venting system must be corrected.

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.

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

A two stage heat/cool thermostat is recommended. A single stage heating thermostat may be used. It is recommended that a high quality thermostat with a "C" terminal is used to operate the furnace.

Thermostat Location

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

• Drafts, or dead spots behind doors, in corners, or under cabinets.

• 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 dehumidistat, such as an outside wall.

COMBUSTION AND VENTILATION AIR REQUIREMENTS

WARNING

OSSIBLE PROPERTY DAMAGE, PERSONAL I NJURY OR DEATH MAY OCCUR

P

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 ven (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,

13

SYSTEM OPERATION

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.

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.

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

ing equation: Required Volume

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

Required Volume

where:

I

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

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

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

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.

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

other

fan

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

9.3.2.2(2).

minimum free area of 1 in.2/1000Btu/hr (2200 mm2/kW) of the total 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 minimum dimension of air openings shall be not less than 3 in. (80 mm).

hour

= fan-assisted appliances input in Btu per hour

per hour, expressed as a decimal)

> ________ _________

other

> ________ _________

fan

3

21 ft

ACH 1000 Btu/hr

3

15 ft

ACH 1000 Btu/hr

Chimney or Gas Vent

I

other

(

I

fan

(

)

2

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:

14

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).

SYSTEM OPERATION

A

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:

(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. 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

Water Heater

Furnace

lternate

air inlet

Ventilation louvers for unheated crawl space

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.

2

/4000 Btu/hr (550 min2/kW) of

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

Inlet Air

Chimney or Gas Vent

NOTE: The ai r du ct openings must have a free area of not less than one squ are 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.

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.

2

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

appliances located in the enclosure, and

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

space.

NOTE: The single opening must have a free area of not less than one square inch per 3000 BTU of the total input rating of all equipment in the enclosure, but not less than the sum of the areas of all vent connectors in the confin ed spa ce.

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).]

Opening

Alternate Opening Location

Furnace

Water Heater

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 lo-

cated 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.

15

SYSTEM OPERATION

(c) The minimum size of outdoor opening(s) shall be the full size

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 m3/min per kW) for all appliances located within the 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.

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.

9.3.8.5 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.

Installation Positions

*MEC96 models may be installed up flow or horizontally with left or right side down. *CEC96 models may be installed down flow or horizontally with left or right side down. Do not install any furnace on its back.

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.

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 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.

9.3.8.3 Ducts shall serve a single space.

16

SYSTEM OPERATION

A

Insert fl ange. Cut 2 ½” long.

R 000142F

Leveling

Leveling ensures proper condensate drainage from the heat exchanger and induced draft blower. For proper flue pipe drainage, the furnace must be level lengthwise from end to end. The furnace should also be level from back to front or have a slight tilt with the access doors downhill (approximately 3/4") from the back panel. The slight tilt allows the heat exchanger condensate, generated in the recuperator coil, to flow forward to the recuperator coil front cover.

IR

DISCHARGE

Figure 9

E R E H

T U C

Figure 10

1. Remove screws from the vent flange.

2. Remove the internal elbow and vent pipe

3. Cut 2 1/2" from the 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 and secure with clamps.

7. Secure flange to cabinet using screws removed in step1.

Drain Trap and Lines

In horizontal applications the condensate drain trap is secured to the furnace side panel, suspending it below the furnace. A minimum clearance of 5.5" below the furnace must be provided for the drain trap. Additionally, the appropriate downward piping slope must be maintained from the drain trap to the drain location. Refer to Condensate Drain Trap and Lines section in this manual or the installation instructions for further details. 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.

Side

Return

Duct

Connection

Bottom

Return

Duct

Connection

Side

Return

Duct

Connection

UPFLOW UPRIGHT

Counterflow

Bottom Return

Duct

Connection

UPFLOW HORIZONTAL

LEFT AIR DI SCHA RGE

Bottom Return

Duct

IR

DISCHARGE

UPFLOW HORIZONTAL RIGHT AIR DISCHARGE

90% Furnace Recommended Installation Positions

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).

17

SYSTEM OPERATION

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

P

OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR IF THE CORRECT CONVERS ION KI TS ARE NOT I NST ALLED. MUST BE APPLIED TO INSURE SAFE AND PROPER FURNACE OPERATION. CONVERSIONS MUST BE PERF ORMED BY A QUALI F IE D INS TALLER O R SERV ICE AGENCY.

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

FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN BODILY INJURY OR

DEATH.

ONLY)

CAREFU LL Y RE AD AN D FOL LO W AL L I NST RU CTI ON S GI VEN IN TH IS

SECTION.

WARNING

UPON COMPLETION OF THE FURNACE INSTALLATION, CAREFULLY INSPECT THE

ENTIRE FLUE SYSTEM BOTH INSIDE AND OUTSIDE THE FURNACE TO ASSURE IT IS PROPERLY SEALED. PERSONAL INJ URY O R DE ATH DUE TO E XPOSURE TO FLUE PRO DUCTS, 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

THE APPROPRIATE KIT S

ALL

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.

Materials and Joining Methods

WARNING

O AVOID BODILY INJURY, FIRE OR EXPLOSION, SOLVENT CEMENTS MUST BE

T

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

A

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 or 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.

NOTE: This provision does not apply to the combustion 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).

18

SYSTEM OPERATION

• 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, the B149 Fuel Gas Code takes precedence over the preceding termination restrictions.

OTHER THAN

COMBUSTION AIR

TERMINATION INTAKE

NON-DIRECT VENT

VENT/FLUE TERM I NA TION

NO TERMINATIONS

ABOVE WALKWAY

GRADE OR HIGHEST

ANTICIPATED

SNOW LEV EL

FORCED AIR

INLET

10'

3"

VENT/FLUE TERMINATION

12"

DIRECT VENT

VENT/FLUE TERM INATION

4'

4' 12"

NON-DIRECT VENT

bustion 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.

(6)

(3) (5)

MODEL

*MEC960303AN

&

*MEC960403AN

*MEC960603AN

*MEC960302BN

&

*MEC960402BN

*MEC960603BN

*MEC960803BN

*MEC960804CN

*MEC961004CN

*MEC961005CN

*MEC961205DN

*CEC960403BN

*CEC960603BN

*CEC960803BN

*CEC961005CN

*MV C96/*CV C9 6 D irect V ent (2 - Pi p e) and Non-D irect V ent (1- Pi p e)

Maximum Allowable Length of Vent/Flue Pipe

12345678 2 7571676360565248 3 126 120 115 110 105 99 94 89

2 3733302622181511 3 107 102 96 91 86 81 75 70 2 100 95 90 85 80 75 70 65

3 168 161 154 147 140 133 126 119 2 5045403530252015 3 143 136 129 122 115 108 101 94 2 6055504540353025 3 113 106 99 92 85 78 71 64 2 6055504540353025 3 120 113 106 99 92 85 78 71 2 4540353025201510 3 103 96 89 82 75 68 61 54 2 4540353025201510 3 151 144 137 130 123 116 109 102 3 185 178 171 164 157 150 143 136 2 100 95 90 85 80 75 70 65 3 110 103 96 89 82 75 68 61 2 4540353025201510 3 110 103 96 89 82 75 68 61 2 353025201510 5NA 3 103 96 89 82 75 68 61 54 2 4540353025201510 3 110 103 96 89 82 75 68 61

Number of Elbows

^

Pipe Size

(4)

(in.)

90% Furnace Vent Termination Clearances

WARNING

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

T

RUBBER ELBOW IS MOUNTED EXTERNALLY TO THE FURNACE CABINET, EXTREME CARE MUST BE TAKEN TO ADEQUATELY SUPPORT FIELD-SUPPLIED 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 tables 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 com-

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.

12" MINIMUM

VENT/FLUE TEE

OR

90° ELBOW TURNED

DOWN

12" MINIMUM ABOVE

HIGHEST ANTICIPATED

SNOW LEVEL

90% Furnace Horizontal Termination (Single Pipe)

Above Highest Anticipated Snow Level

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

19

SYSTEM OPERATION

d

c

TEE (OPTIONAL)

COMBUSTION AIR INTAKE

(OPTIONAL)

*Not required for

single pipe installation

E

N

I

L

F

O

R

X

A

M

”

6

12” MIN TO ROOF OR HIGHEST ANTICIPATED SNOW LEVEL

9

12” MIN HEIGHT DIFFERENCE BETWEEN INTAKE AND VENT

.

N

I

M

”

3

-

.

10”- 24”

6” MAX

4” MIN

90º OR 45°

ELBOW

12" MIN. TO GRADE OR HIGHEST ANTICIP AT ED

SNOW LEVEL

Standard Horizontal Terminations (Dual Pipe)

12" MIN.

Horizontal Termination (Single Pipe)

Above Highest Anticipated Snow Level

ELBOWS

STRAIGHT

VENT/FLUE TEE (

TURNED DO W N or

90° ELBOW TURNE D

or

45° ELBOW

DOWN

12" MIN. ABOVE

HIGHEST ANTICI P ATED

SNOW LEVEL

OPTIONAL)

90° ELBOWS

3” - 24”

12" MIN. ABOVE

HIGHEST ANTICIPA TED

SNOW LEVEL

Alternate Horizontal Vent Termination (Dual Pipe)

90°

ELBOWS

20

3”-24” BETWEEN PIPES

12"MIN.ABOVE

HIGHEST ANTICIPATED

SNOW LEVE L

Combustion Air Intake may also be snorkeled to obtain 12” min groun

learance.

AlternateVentTerminationAboveAnticipated SnowLevel

(DualPipe)

SYSTEM OPERATION

VENT/INTAKE TERMINATIONS FOR INSTALLATION OF MUL-

TIPLE 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.

3”MIN 24”MAX

12” MIN SEPARATIO N

3” MIN

1. The vent termination must be located at least 12” above ground or normally expected snow accumulation levels.

2. Do NOT terminate over public walkways. Avoid areas where condensate may cause problems such as above planters, patios, or adjacent to windows where steam may cause fogging.

3. The vent termination shall be located at least 4’ horizontally from any electric meter, gas meter, regulator and any relief equipment. These distances apply ONLY to U.S. Installations.

4. The vent termination shall be located at least 3’ above any forced air inlet located within 10’; and at least 10’ from a combustion air intake of another appliance, except another direct vent furnace intake.

5. In Canada, the Canadian Fuel Gas Code takes precedence over the preceding termination instructions.

3" or 4" Diameter SDR-26 Pipe

2 or 2 1/2" Diameter SDR-26 Pipe

12” MIN TO GRADE OR HIGHEST ANT ICIP ATED SNOW LEVEL

Termination of Multiple Direct Vent Furnaces

9"

12"

Direct Vent

Terminal

50,000 Btuh

or less

12"

Direct Vent Terminal

More than 50,000 Btuh

FIGURE 1

(DCVK) Vent Termination Clearances

12"

Forc e d A ir Inlet

2" or 3" Diameter

Y Concentric Fitting

Rain Cap

These kits are for vertical or horizontal termination of the combustion air inlet and the exhaust vent pipes on Category IV gas-fired condensing furnaces. The DCVK-30 (CVENT-

3) kit can be used for 3” diameter pipe systems. The DCVK-

20 (CVENT-2) kit can be used for the 2” diameter pipe system. Both the combustion air inlet and the exhaust vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be installed per the instructions outlined below for vertical or horizontal termination. Vertical termination is preferred. Field supplied pipe and fittings are required to complete the installation.

3'

D

A

R

G

1. Determine the best location for the termination kit. Roof

E

termination is preferred since it is less susceptible to damage, has reduced intake contaminants and less visible vent vapors. For side termination, consideration should be given to:

a. Possible damage from the vapors to plants/shurbs,

other equipment and building materials

b. Possible damage to the terminal from foreign ob-

jects

c. Wind effects that may cause recirculation of flue

products, debris or light snow

d. Visible vent vapors.

21

SYSTEM OPERATION

Vent

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

Combustion Air

Roof Boot/Flashing (Field Supplied)

24" above roof.

Support (Field Supplied)

45 Elbow (Field Supplied)

CAUTION

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

T

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

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.

Vent

Combustion Air

Condensate Drain Lines and Drain Trap

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. The condensate which is generated must be piped to an appropriate drain location.

WARNING

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

I

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 A BLOCKED DRAIN CONDITION. CAN RESULT IN PO SSIBLE PROPE RTY DAMAGE, PERS ONAL INJURY, OR DEATH DUE TO EL ECT RIC AL S HOC K.

AILURE TO FOLLOW THESE I NSTRUCTIONS

F

HIS WILL

T

• 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.

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.

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 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/ft

3

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 for a tabular listing of appropriate altitude ranges and corresponding manufacturer’s pressure switch kits.

22

SYSTEM OPERATION

PROPANE GAS CONVERSION

WARNING

P

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

T

A

LL

This unit is configured for natural gas. The appropriate manufacturer’s propane gas conversion kit, must be applied for propane gas installations.

Refer to the specification sheet for the model you are servicing. Refer to the “propane gas and/or High Altitude Installa- tions” section for details.

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.

NOTE: The gas supply pressure on White-Rodgers "G/J" model gas valve, can be checked with a gas pressure test kit (Part #0151K00000S) available through our authorized distributors.

The gas valve has a manual ON/OFF control located on the valve itself. This control may be set only to the “ON” or “OFF” position. Refer to the Lighting Instructions Label or the “Put- ting the Furnace Into Operation” section of this manual or the installation instructions for use of this control during start up and shut down periods.

GAS PIPING CONNECTIONS

CAUTION

T

O AVOID POSSIBLE UNS ATISFACTORY OPERATION OR EQUIPMENT DAMAGE DUE TO UNDERFIRING OF EQUIPMENT, USE THE PROPER SIZE OF NATURAL/PROPANE GAS PIPING NEEDED WHEN RUNNI NG PIPE FRO M THE METER/TANK TO THE FURNACE.

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 Gas Capacity of Pipe

In Cubic Feet of Gas Per Hour (CFH)

Length of

Pip e in Feet

10 20 30 40 50 60 70 80 90

100

(Pr es s ur e 0.5 psi g or le s s and pres s ur e d r op of 0.3" W.C.; B as ed on 0. 60 S p ec ific Gravity Gas)

CFH =

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

1/2" 3/ 4" 1" 1 1/4" 1 1/2" 132 278 520 1050 1600

92 190 350 730 1100 73 152 285 590 980 63 130 245 500 760 56 115 215 440 670 50 105 195 400 610 46 96 180 370 560 43 90 170 350 530 40 84 160 320 490 38 79 150 305 460

No minal Black Pipe Size

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.

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 .

23

SYSTEM OPERATION

GAS PIPING CHECKS

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

WARNING

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

T

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).

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

Refer to the following illustration for typical propane gas installations and piping.

First Stage Regulator

200 PSIG Maximum

5 to 15 PSIG (20 PSIG Max.)

Continuous

Second Stage Regulator

11" W.C.

Typical Propane Gas Installation

PROPANE GAS TANKS AND PIPING

WARNING

PROPANE GAS IS HEAVIER THAN AIR AND ANY LEAK ING GAS CAN SETTLE IN

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

O PREVENT PROPERTY DAMAGE,

T

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, please refer to the warning on this page.

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.

WARNING

I

F THE GAS FURNACE IS INS TALLED IN A BASEMENT, AN E XCAVATED AREA OR A CONFINED SPACE, IT IS STRONG LY RECOMMENDED TO CONTACT A PROPANE SUPPLIER TO INSTALL A GAS DETECTING WARNING DEVICE IN CASE OF A GAS LEAK.

•

SINCE PROPANE GAS I S HEAVI ER THAN AIR, ANY LE AKING GAS C AN

SETTLE I N ANY LOW ARE AS OR CONFINED S PACES.

PROPANE GAS ODORANT MAY FADE, MAKING THE GAS UNDETECTABLE

• EXCEPT WIT H A WARNING DEVI CE.

WARNING

AN UNDETECTED GAS LEAK WILL CREATE A D ANGER 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

24

SYSTEM OPERATION

WARNING

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

I

FIRE OR EXPLOSION MAY RE SULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

O NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND

–

D

LIQUIDS IN TH E VICINITY OF THIS OR ANY OTHER APPLIANCE. –

WHAT TO DO IF YOU SMELL GAS

•

• PHONE IN YOUR BUILDING.

• PHONE.

• DEPARTMENT.

–

NSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIF IED INS TALLER ,

I

SERVICE AGENCY OR THE GAS SUPPLIER.

Sizing Betw ee n First and Second Stage Regul ator*

Ma ximum P r op ane C apacit ies li ste d ar e ba sed on 2 p sig pr e ss ur e dr o p at 10 ps ig se ttin g. C apa cities in 1,00 0 BT U/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 - multi ply by 1.130 To convert to capacities at 5 psig settings - multiply by 0.879

Sizing Betw ee n Second or S ec ond Stage Re gulator & Appliance*

Maximum Pr op ane Capacities li ste d are ba sed on 1 /2" W.C. press u re drop at 11" W.C. setting. C apa c it i es in 1, 00 0 BTU/ho ur .

Pipe or Tubing

Len gth

Feet

10 39 92 199 329 501 2 75 567 1 ,071 2, 205 3,307 20 26 62 131 216 346 1 89 393 732 1,496 2,299 30 21 50 107 181 277 1 52 315 590 1,212 1,858 40 19 41 90 145 233 129 267 504 1,039 1,559 50 18 37 79 131 198 114 237 448 913 1,41 7 60 16 35 72 1,211 18 7 103 217 409 8 34 1,275

80 13 29 62 104 155 89 185 346 724 1,06 6 100 11 26 55 90 138 78 162 307 6 30 976 125 10 24 48 81 122 69 146 275 5 67 866 150 9 21 43 72 109 63 132 252 511 787 200 8 19 39 66 100 54 112 209 439 665 250 8 17 36 60 93 48 100 185 3 90 590

*Data in accordance with NFPA pam phlet No. 54

O NOT TRY TO LIGHT ANY APPLIANCE.

D

O NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY

D

MMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR’S

I

FOLLOW THE GA S SUPPLIER ’S INSTRUCTI ONS.

F YOU CANNOT REACH YOUR G AS SUPPLIER, CALL T HE FIRE

I

Tubing Size, O.D. Type L

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

Tubing Siz e, 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 Pi p e Size

Schedule 40

Nominal Pipe Size

Schedule 40

Propane Gas Piping Charts

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 UN IT MUST BE

PROPERLY POLARIZED AND GROUNDED.

WARNING

HIGH VOLTAGE D

ISCO NNECT ALL POWER BEFORE SERVI CING OR

INSTALLI NG THI S UNI T. BE PRESENT. DAMAGE, PERSONAL INJURY OR DEATH.

FAILURE TO DO SO MAY CAUSE PROPERTY

MULTIPLE POWER SOURCES MAY

CAUTION

L

ABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS.

WIRING ERRORS CAN COUSE IMPR OPER AND DAN GEROUS OPERAT ION.

ERIFY PROPER OPERATION AFTER SERVICING.

V

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.

25

SYSTEM OPERATION

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.

N

G

I

N

W

R

A

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.

The furnace is shipped configured for a right side (left side for counterflow) electrical connection with the junction box located inside the burner compartment. To make electrical connections through the opposite side of the furnace, the junction box must be relocated to the other side of the burner compartment prior to making electrical connections.

ACCESSORY LOAD SPECIFICATIONS

Electronic

Air Cleaner

Humidifier

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.

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 electronic air cleaner terminals (EAC) are energized with 115 volts whenever the circulator blower is energized.

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 this manual, the installation manual, or on the blower door for further details of 115 Volt and 24 Volt wiring.

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, TH E

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

NATIONAL ELECTRIC CODE .

115 VOLT LINE CONNECTION OF ACCESSORIES (ELECTRONIC AIR CLEANER)

WARNING

HIGH VOLTAGE D

ISCONNECT ALL POWER BEFORE SERVI CING OR

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

MULTIPLE POWER

FAILURE TO DO S O MAY CAUSE

THERMOSTAT WIRING

The *MEC96 furnace has W1 & W2 terminals for connection of a two stage heating thermostat. If desired, a thermostat with only one stage of heat may be used. As shipped, the furnace S1-1 switch is OFF; S1-2 switch is ON. This is the correct position to use a single stage heating thermostat with auto timing transition to high fire.

R

Furnace

R

Y C

Remote Condensing Unit

(Single-Stage Cooling)

Thermostat - Single -Stage Heating with Single-Stage Cooling

NOTE: To apply a single-stage Heating Thermostat, the thermostat selector switch on the Integrated Control Module must be set on single-stage.

Integrated

Control Module

26

SYSTEM OPERATION

r

R

Furnace

Integrated

Control Module

Y C

Remo te Condensing Unit

(Single -St age Cool in g)

R

Thermostat - Two-Stage Heating with Single-Stage Cooling

Y2

Y

Y2

Remote Cond ensing Unit

(Two-Stage Cooling)

W1 W2

Furnace

Integrated

Control Module

Thermostat - Two-Stage Heating with Two-Stage Cooling

Thermostat Wiring Diagrams

SINGLE-STAGE HEATING THERMOSTAT APPLICATION

A single-stage thermostat with only one heating stage may be used to control this furnace. The application of a singlestage thermostat offers 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 10 or 20 minute time delay or a load based variable time between 1 and 12 minutes (AUTO mode). If the AUTO mode 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.

TWINNING

Using the “TWIN” terminals and proper wiring enables two *MEC96 furnaces of the same model and size to be twinned. Twinning allows simultaneous operation of two furnaces and forces the indoor blower motors of each furnace to operate synchronously into a common duct system. Using the twinning function will require only field installed wiring with no external kits or parts.

· The staging DIP switches and speed tap DIP switches must be set the same on both furnaces.

NOTE: Each furnace must be connected to its own 115 VAC power supply. The L1 connection toeach furnace must be in phase (connected to circuit breakers on the same 115 VAC service panel phase leg). To verify that the furnaces are in phase, check from L1 to L1 on each furnace with a voltmeter. If the furnaces are in phase, the voltage between both furnaces will be ZERO.

Room

Thermostat

Y2

Y

W

W2

R

G

C

Furnace 1

Ylo

Y

W

W2

R

G

C

Furnace 2

Ylo

Y

W

W2

R

G

C

DIP Switch

Group

S1

* = Factory Posit ion

Purpose Switch Group Function

The rmostat

setup

Heating Fan Off

Del ay

*Factory Setting

Staging and Blower Off Delay DIP Switches PCBBF137

DIP S witch

Numbe

1, 2

3, 4

Stag in g and Blo w er Of f Delay Dip Sw itc hes PCBBF139

Heat Stagin g /

Blow er Heat Off

1 Stg Stat 10 min de lay ON OFF

S3

1 Stg Stat 20 min de lay ON ON

S3

Purpose

Delay

2 Sta ge S tat O FF OFF

Auto Off* ON*

90 OF F OFF 120 OFF ON 150 ON* O FF* 180 ON ON

10 Minutes 1 ON 2 OFF 20 Minutes 1 ON 2 ON

90 Seconds 3 OFF 4 OFF 120 Seconds 3 OFF 4 ON 150 Seconds 3 ON* 4 OFF* 180 Seconds 3 ON* 4 ON

Function

Auto 1 OFF* 2 ON*

2 Stage 1 OFF 2 OFF

Dip Sw itch

1234

CIRCULATOR BLOWER SPEED ADJUSTMENT

WARNING

HIGH VOLTAGE

ISCONNECT ALL POWER BEFOR CHANGING SPEED TAPS.

D

ULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO

M

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

This furnace is equipped with a multi-speed ECM motor. Two wiring harnesses connect the motor to the integrated control board and furnace power supply. The line voltage (115 VAC) power supply to the motor is constant and not switched by the control board. Motor operation is also dependent on a 24 VDC signal on one of the four speed taps on the motor. The airflow tables for heating and cooling speeds show the relationship between airflow (CFM) and external static pressure for each size furnace.

27

SYSTEM OPERATION

WARNING

TO

AVOID PERSONAL INJURY OR DEATH DUE TO ELECTR ICA L SHOCK

TURN

OFF

POWER TO THE FURNACE BEFORE CHANGING SPEED TAPS

Circulator Blower Speed Facts

1. Motor speed Tap wiring must remain in factory position on the control board and motor.

2. There are 4 speed Tap wires to the motor T1, T2, T3, T4.

3. There are 5 speeds available, depending on DIP switch settings and found in air flow table for each size furnace.

4. Heating input (W1/ W2) always has priority over all other thermostat input.

5. Cooling input (YLo/ Y) has priority over continuous fan input.

6. Continuous fan input (G) has lowest priority.

*The blower speed wiring connections must remain in factory position.

1. Refer to the air flow table for your specific model furnace.

2. If a cooling or heat pump condensing unit is being used in conjunction with this furnace, the three DIP switches in S2 are used to select the proper cooling speeds to match the outdoor unit size. Typical CFM requirements are 400 CFM / Ton.

1. Turn OFF power to the furnace.

2. Select the cooling blower speeds that match the installation requirements from the airflow table in this manual or the Installation Manual, If factory cooling speeds do not match the installation requirements, the dip switch settings must be changed from factory position

3. Turn ON power to furnace.

4. Verify proper temperature rise in heat modes and CFM in cooling modes

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. If the furnace is installed without filters, and is not covered by the warranty.

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

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

UPRIGHT FILTER INSTALLATIONS

Depending on the installation and/or customer preference, differing filter arrangements can be applied. Filters can be installed in the central return register and a side panel external filter rack kit (upflow filter kit # EFR02 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.

28

SYSTEM OPERATION

DIP SWITCH SETTINGS

Thermostat Selection Switches

Heating Fan Off Delay

Heating CFM Switches

Cooling CFM Switches

PCBBF137 CONTROL BOARD DIP SWITCHES

1

S1

2

3

DIP

Switch

Numbe r

1, 2

3, 4

Purp os e

Heat

Staging /

Dela y

Blowe r

Hea t Off

Dela y

120 Se conds 3 OFF 4 ON 150 Se conds 3 ON* 4 OFF * 180 Se conds 3 ON* 4 ON

Switch

4

1

S3

1

2

Group

S1

2

* = Fa ctory Pos iti on

3

1

S2

2

3

Function

Auto 1 OFF* 2 ON* 10 Minute s 1 ON 2 OFF 20 Minute s 1 ON 2 ON

2 Stage 1 OFF 2 OFF

90 Se conds 3 OF F 4 OFF

Cooling CFM Switches

Heating CFM Switches

Continuous Fan CFM Switches

Thermostat Selection Switches

PCBBF139 CONTROL BOARD DIP SWITCHES

1

S1

2

3

4

1

S2

2

3

4

1

S3

Purpose

Thermostat

Setup

Heating Fan

Off Del a y

* FACTORY

SETTING

Switch

Group

1 Stg S tat 10 min delay ON OFF

S3

1 Stg S tat 20 min delay ON ON

S3

2

Function

2 Stage S tat OFF OFF

Auto OFF* ON*

90 OFF OFF 120 OFF ON 150 ON* OFF* 180 ON ON

Dip S wi tch

1234

Heating Fan Off Delay

3

4

29

SYSTEM OPERATION

Y

F

DIP SWITCH SETTINGS

PCBBF137 PCBBF139 *MEC960303AN - COOLING

DIP Switches

S2-1 S2-2 S2-3

**OFF OFF OF F **OFF OFF OFF

ON OFF OFF ON OFF OFF

ON ON OFF / OFF ON ON ON ON OFF

OFF ON OFF^ OFF ON OFF^

OFF OFF ON^ OFF OFF ON^

NA OFF ON ON^

ON OFF ON ON OFF ON

ON ON ON^ ON ON ON^

PCBBF137 PCBBF139 *MEC960303AN - CONTINUOUS FAN

DIP Switches

NA

ALL POSITIONS NA

PCBBF137

DIP Swit ches

S3- 1 S3-2

**OFF OFF **OFF OFF

ON OFF ON OFF

ON ON ON ON

OFF ON OFF ON

PCBBF139

DIP Swit ches

S1- 4 S2 - 1

DIP Switches

S1-1 S1-2 S1-3

DIP Switches

S2-2 S2-3 S2-4

**OFF OFF OFF

ON OFF OF

ON ON OF OFF ON OF OFF OFF ON

OFF ON ON

ON OFF ON

ON ON ON

Static

Tstat Call CFM Rise CFM Rise CFM Rise CFM CFM CFM

W1 W2 W1 W2 W1 W2 W1 W2

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

CFM Rise CFM Rise

623 42 393 N/ A 755 35 627 45 653 40 507 N/ A 755 35 627 45 653 40 507 N/ A

914 28 805 32 914 28 805 32

1070 25 975 27

Static

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

Ts tat Call CFM CFM CFM CFM CFM CFM CFM CFM

Ylo

Static

914 874 841 805

1070 1040 1005 975 942 915 883 849

653 597 552 507 460 410 366 326 914 874 841 805 772 732 696 657 653 597 552 507

1070 1040 1005 975

914 874 841 805 623 506 451 393 343 293 N/A N/A 914 874 841 805

653 597 552 507 460 410 366 326 623 506 451 393 343 293 N/A N/A 755 710 672 627

1070 1040

653 597 552 507

1005 975 942 915 883 849

672 627 491 447

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

772 732 696 657

460 410 366 326 942 915 883 849 772 732 696 657

772 732 696 657 582 534755 710 672 627 491 447

582 534

582 534755 710 460 410 366 326

491 447

Ts tat Call CFM CFM CFM CFM CFM CFM CFM CFM

G G G G G G G G G

623 506 451 393 343 293 N/A N/A 755 710 672 627 582 534 491 447 653 597 552 507 460 410 366 326 914 874 841 805 772 732 696 657

1070 1040 1005 975 942 915 883 849

623 506 451 393 343 293 N/A N/A 623 506 451 393 343 293 N/A N/A 623 506 451 393 343 293 N/A N/A 623 506 451 393 343 293 N/A N/A

*MEC960303AN - HEATING

506 N/A 451 N/A 343 N/A 293 N/A N/A 710 37 672 42 582 49 534 491 447 597 44 552 47 460 N/A 410 366 326 710 37 672 42 582 49 534 491 447 597 44 552 47 460 N/A 410 366 326 874 30 841 31 772 34 732 696 657 874 30 841 31 772 34 732 696 657

1040 25 1005 26 942 28 915 883 849

*NOT RECOMMENDED **Factory Default SINGLE STAGE COOLING^

30

SYSTEM OPERATION

F

DIP SWITCH SETTINGS

PCBBF137 PCBBF139 *MEC960403AN - COOLING

DIP Switches

S2-1 S2-2 S3-3

**OFF OFF OFF **OFF OFF OFF

ON OFF OFF ON OFF OFF

ON ON OFF / OFF ON ON ON ON OFF

OFF ON OFF^ OFF ON OFF^

OFF OFF ON OFF OFF ON

NA OFF ON ON^

ON OFF ON ON OFF ON

ON ON ON^ ON ON ON^

DIP Switches

S1-1 S1-2 S1-3

Static

Ts tat Call CFM CFM CFM CFM CFM CFM CFM CFM

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

914 874 841 805 772 732 696 657

1070 1040 1005 975 942 915 883 849

653 597 552 507 460 410 366 326

914 874 841 805 772 732 696 657

653 597 552 507 460 410 366 326

1070 1040 1005 975 942 915 883 849

914 874 841 805 772 732 696 657 721 679 635 591 552 505 463 422

914 874 841 805 772 732 696 657 1191 1168 113 5 1112 10 8 1 10 5 5 10 2 4 998 653 597 552 507 460 410 366 326

721 679 635 591 552 505 463 422 1191 1168 113 5 1112 10 8 1 10 5 5 10 2 4 998

1091 1061 1026 996 962 936 903 869

1191 1168 113 5 1112 10 8 1 10 5 5 10 2 4 998 653 597 552 507 460 410 366 326

PCBBF137 PCBBF139 *MEC960403AN - CONTINUOUS FAN

DIP Switches

NA

ALL POSITIONS NA

PCBBF137

DIP Swit ches

S3- 1 S3-2

**OFF OFF **OFF OFF

ON OFF ON OFF

ON ON ON ON

OFF ON OFF ON

PCBBF139

DIP Swit ches

S1- 4 S2 - 1

Tstat Call CFM Rise CFM Rise CFM Rise CFM CFM CFM

S1-1 S1-2 S1-3

Static

W1 W2 W1 W2 W1 W2 W1 W2

DIP Switches

**OFF OFF OFF

ON OFF OF

ON ON OFF OFF ON OF OFF OFF ON

OFF ON ON

ON OFF ON

ON ON ON

Static

Ts tat Call CFM CFM CFM CFM CFM CFM CFM CFM

G G G G G G G G G

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

CFM Rise CFM Rise

721 48 591 N/A 1191 2 9 1112 31 653N/A 507N/A 1191 2 9 1112 31 653N/A 507N/A

914 38 805 43

1070 33 975 36

679 N/A 635 N/A 552 N/A 505 463 422 1168 30 1135 31 1081 32 1055 1024 998 597 N/A 552 N/A 460 N/A 410 366 326 1168 30 1135 31 1081 32 1055 1024 998 597 N/A 552 N/A 460 N/A 410 366 326 874 40 841 41 772 45 732 696 657 874 40 841 41 772 45 732 696 657

1040 34 1005 35 942 37 915 883 849

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

721 679 635 591 552 505 463 422 1191 1168 113 5 1112 10 8 1 10 5 5 10 2 4 998 653 597 552 507 460 410 366 326

914 874 841 805 772 732 696 657

1070 1040 1005 975 942 915 883 849

721 679 635 591 552 505 463 422

*MEC960403AN - HEATING

*NOT RECOMMENDED **Factory Default SINGLE STAGE COOLING^

31

SYSTEM OPERATION

Y

YloY

Y

YloY

Y

F

DIP SWITCH SETTINGS

PCBBF1 37 PCBBF 139 *MEC96060 3AN - COO L ING

DIP Switches

S2-1 S2-2 S3-3

DIP Sw itche s

S1-1 S1-2 S1-3

**OFF OFF OFF **OFF OFF OFF

ON OFF OFF ON OFF OFF

ON ON OFF / OFF ON ON ON ON OFF

OFF ON OFF^ OFF ON OFF ^

OFF OFF ON OFF OFF ON

NA OFF ON ON^

ON OFF ON ON OFF ON

ON ON ON ^ ON ON ON^

Static

Tstat Call CFM CFM CFM CFM CFM CFM CFM CFM

lo

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

880 838 794 763

1056 1026 991 961 929 894 864 829

697 654 600 557 880 838 794 763 722 689 644 606 697 654 600 557 508 460 419 371

1056 1026 991 961

880 838 794 763

1254 1230 1199 1 171 11 39 1115 1086 1053

880 838 794 763 722 689 644 606

1330 1301 1274 1244

697 654 600 557 1254 1230 1199 1 171 11 39 1115 1086 1053 1330 1301 1274 1244 1227 1191 1163 1132 1056 1026 991 961 929 894 864 829 1330 1301 1274 1244

697 654 600 557

PCBBF1 37 PCBBF 139 *MEC96060 3AN - CONTINUOUS F AN

DIP Switches

DIP Sw itche s

S1-1 S1-2 S1-3

**OFF OFF OFF

ON OFF OF

ON ON OFF

NA

OFF ON OF OFF OFF ON

OFF ON ON ON OFF ON

ON ON ON

ALL POSITIONS NA

Static

Tstat Call CFM CFM CFM CFM CFM CFM CFM CFM

G G G G G G G G G

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

12 54 1230 119 9 1171 113 9 1330 1301 1274 1244 1227 1191 1163 1132

697 654 600 557 508 460 419 371

880 838 794 763 722 689 644 606 1056 1026 991 961 929 894 864 829 1254 1230 1199 1 171 11 39 1115 1086 1053 1254 1230 1199 1 171 11 39 1115 1086 1053 1254 1230 1199 1 171 11 39 1115 1086 1053 1254 1230 1199 1 171 11 39 1115 1086 1053

722 689 644 606

508 460 419 371

929 894 864 829 722 689 644 606

1227 1191 1163 1132 508 460 419 371

1115 1086 1053

PCBBF137 PCBBF139

DIP Swit ches

S3 -1 S3- 2

**OFF OFF **OFF OFF

ON OFF ON OFF

ON ON ON ON

OFF ON OFF ON

DI P Swit ches

S1-4 S2 - 1

Static

Tstat Call CFM Rise CFM Rise Rise CFM Rise

W1 W2 W1 W2 W1 W2 W1 W2

*NOT RECOMMENDED **Factory Default SINGLE STAGE COOLING^

*MEC960603AN - HE ATING

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

CFM Rise CFM

1254 42 1171 1330 39 1244

697 N/A 557

1330 39 1244

697 N/A 557 880 N/A 763 880 N/A 763

1056 49 961

1230 42 1199 43 44 1139 46 1115 1086 1301 39 1274 41 42 1227 42 1191 1163 1132

654 N/A 600 N/A N/A 508 N/A 460 419 371

1301 39 1274 41 42 1227 42 1191 1163 1132

654 N/A 600 N/A N/A 508 N/A 460 419 371 838 N/A 794 N/A N/A 722 838 N/A 794 N/A N/A 722 N/A 689 644

1026 51 997 52 54 929 56 894 864 829

CFM CFM CFM

N/A 689 644

1053

606 606

32

SYSTEM OPERATION

DIP SWITCH SETTINGS

PCBBF139

DIP Switches

S1-1 S1-2 S1-3

**OFF OFF OFF

ON OFF OFF

ON ON OFF

OFF ON OFF^

OFF OFF ON^

OFF ON ON

ON OFF ON

ON ON ON^

*CEC960403BN - CO O L I NG

Static

Tsta t Call CFM CFM CFM CFM CFM CFM CFM CF M

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

647 576 511 449 387 335 280 252 1229 1181 1150 1117 1078 1035 1002 964 1137 1096 1056 1018 981 940 897 859

647 576 511 449 387 335 280 252 1137 1096 1056 1018 981 940 897 859 1229 1181 1150 1117 1078 1035 1002 964

647 576 511 449 387 335 280 252

743 688 628 572 515 459 408 364

647 576 511 449 387 335 280 252

939 894 846 806 759 706 661 614 1137 1096 1056 1018 981 940 897 859

743 688 628 572 515 459 408 364

939 894 846 806 759 706 661 614 1229 1181 1150 1117 1078 1035 1002 964

939 894 846 806 759 706 661 614 1137 1096 1056 1018 981 940 897 859

PCBBF139

DIP Switches

S2-2 S2-3 S2-4

**OFF OFF OFF

ON OFF OFF

ON ON OFF

OFF ON OFF

OFF OFF ON

OFF ON ON ON OFF O N

ON ON ON

PCBBF139

DIP Switches

S1-4 S2 -1

**OFF OFF

*ON OFF

*ON ON

OFF ON

Static

Tstat Call CFM Rise CFM Rise CF M Rise CFM Ri se CFM Rise CF M CFM CFM

*CEC960 403 BN - CO NTI NUOUS FAN

Static

Tstat CallCFMCFMCFMCFMCFMCFMCFMCFM

G G G G G G G G

W1 W2 W1 W2 W1 W2 W1 W2

743 33 688 36 628 40 572 44 515 48 459 408 364 939 38 894 40 846 42 806 44 759 47 706 661 614

1137 NA 1096 NA 1056 NA 1018 NA 981 N/A 940 897 859

939 38 894 40 846 42 806 44 759 47 706 661 614

1137 NA 1096 NA 1056 NA 1018 NA 981 N/A 940 897 859

647 55 576 NA 511 NA 449 NA 387 NA NA NA NA 647 38 576 43 511 49 449 55 387 64 335 280 252

1229 29 1181 30 1150 31 1117 32 1078 33 10 35 1002 964

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

743 688 628 572 515 459 408 364

939 894 846 806 759 706 661 614 1137 1096 1056 1018 981 940 897 859

647 576 511 449 387 335 280 252 1229 1181 1150 1117 1078 1035 1002 964

743 688 628 572 515 459 408 364

*CEC960403BN - HEATING

0.40.1 0.2 0.3

0.5

0.6 0.7 0.8

*NOT RECOMMENDED **Factory De fault SINGLE STAGE COOLING^

33

SYSTEM OPERATION

DIP SWITCH SETTINGS

PCBBF137 PCBBF139

DIP Switches

S2-1 S 2-2 S 2 -3

**OFF OFF OFF **OFF OFF OFF

ON OFF OFF ON OFF OFF

ON ON OFF / OFF ON ON ON ON OFF

OFF ON OFF^ OFF ON OFF^

OFF OFF ON OFF OFF ON

NA OFF ON ON

ON OFF ON^ ON OFF ON^

ON ON ON^ ON ON ON^

DIP Switches

S1-1 S 1-2 S 1 -3

PCBBF137 PCBBF139

DIP Switches

NA

ALL POSITIONS NA

DIP Switches

S2-2 S 2-3 S 2 -4

**OFF OFF OFF

ON OFF OFF

ON ON OFF

OFF ON OFF

OFF OFF ON

OFF ON ON ON OFF ON ON ON ON

*CEC960603BN - COO LI NG

Static

Tstat Ca ll CFM CFM CFM CFM CFM CFM CFM CFM

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

1149 1104 1057 1017 963 918 865 822 1236 1189 1149 1101 1066 1017 969 928

782 629 547 469 396 333 N/A N/A

1149 1104 1057 1017 963 918 865 822

782 629 547 469 396 333 N/A N/A 1236 1189 1149 1101 1066 1017 969 928 1149 1104 1057 1017 963 918 865 822

894 846 780 720 660 603 554 505 1149 1104 1057 1017 963 918 865 822 1328 1287 1249 1215 1170 1131 1085 1046

782 629 547 469 396 333 N/A N/A

894 846 780 720 660 603 554 505 1328 1287 1249 1215 1170 1131 1085 1046 1236 1189 1149 1101 1066 1017 969 928 1328 1287 1249 1215 1170 1131 1085 1046

782 629 547 469 396 333 N/A N/A

*CEC9 6 0 6 03 BN - CONT INUOUS F AN

Static

Tstat Ca ll CFM CFM CFM CFM CFM CFM CFM CFM

G G G G G G G G G

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

894 846 780 720 660 603 554 505 1328 1287 1249 1215 1170 1131 1085 1046

782 629 547 469 396 333 290 251 1149 1104 1057 1017 963 918 865 822 1236 1189 1149 1101 1066 1017 969 928

894 846 780 720 660 603 554 505

PCBBF137 PCBBF139

DIP Switches

S3-1 S3 -2

**OFF OFF **OFF OFF

ON OFF ON OFF

ON ON ON ON

OFF ON OFF ON

DIP Switches

S1-4 S2 -1

*NOT RECOMMENDED **Factory De fault SINGLE STAGE COOLING^

34

Static

Tstat Cal l CFM Rise CFM Rise CF M Rise CFM Rise CFM Rise CFM CFM CFM

W1 W2 W1 W2 W1 W2 W1 W2

0.1 0.2 0.3

894 41 846 44 780 47 720 51 660 56 603 554 505

1328 40 1287 41 1249 42 1215 43 1170 45 1131 1085 1046

782 47 629 NA 547 N/A 469 N/A 396 N/A N/A N/A N/A

1328 40 1287 41 1249 42 1215 43 1170 45 1131 1085 1046

782 47 629 NA 547 N/A 469 N/A 396 N/A N/A N/A N/A 1149 46 1104 48 1057 50 1017 52 963 55 918 865 822 1149 46 1104 48 1057 50 1017 52 963 55 918 865 822 1236 43 1189 44 1149 46 1101 48 1066 50 1017 969 928

*CEC960603BN - HEATING

0.4 0.5

0.6 0.7 0.8

SYSTEM OPERATION

DIP SWITCH SETTINGS

PCBBF137 PCBBF139

DIP Switches

S2-1 S2-2 S2-3

**OFF OFF OFF

ON OFF OFF

ON ON OFF / OF F ON ON

OFF ON OFF

OFF OFF ON

NA

ON OFF ON^

ON ON ON^

S1-1 S1-2 S1-3 **OFF OFF OFF

PCBBF137 PCBBF139

DIP Switches

NA

ALL POSITIONS NA

S2-2 S2-3 S2-4

**OFF OFF OFF

DIP Switches

ON OFF OFF

ON ON OFF

OFF ON OFF

OFF OFF ON

OFF ON ON

ON OFF ON^

ON ON ON^

DIP Switches

ON OFF OFF

ON ON OFF

OFF ON OFF

OFF OFF ON

OFF ON ON ON OFF ON

ON ON ON

**EC960803BN - COOLING

Stat ic

Tstat Call CFM CFM CF M CFM CFM CFM CFM CFM

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

894842784726682618562519

1111 1068 1025 984 941 885 860 801

750644569507442388328N/A 894842784726682618562519 750644569507442388328N/A

1111 1068 1025 984 941 885 860 801

894842784726682618562519

1221 1172 1128 1087 1049 1005 959 922

894842784726682618562519

1311 1293 1249 1203 1172 1122 1088 1041

750644569507442388328N/A 1221 1172 1128 1087 1049 1005 959 922 1311 1293 1249 1203 1172 1122 1088 1041 1111 1068 1025 984 941 885 860 801 1311 1293 1249 1203 1172 1122 1088 1041

750644569507442388328N/A

**EC960803BN - CONTINUOUS FAN

Static

Tstat Call CFM CFM CF M CFM CFM CFM CFM CFM

G G G G G G G G G

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

1221 1172 1128 1087 1049 1005 959 922 1311 1293 1249 1203 1172 1122 1088 1041

750 644 569 507 442 388 328 288

894 842 784 726 682 618 562 519 1111 1068 1025 984 941 885 860 801 1221 1172 1128 1087 1049 1005 959 922 1221 1172 1128 1087 1049 1005 959 922 1221 1172 1128 1087 1049 1005 959 922 1221 1172 1128 1087 1049 1005 959 922

PCBBF137 PCBBF139

DIP Switches

S3-1 S3-2

**OFF OFF

ON OFF*

ON ON*

OFF ON

DIP Switches

S1-4 S2-1

**OFF OFF

ON OFF*

ON ON*

OFF ON

Static

Tstat Call CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM CFM CFM

W1 W2 W1 W2 W1 W2 W1 W2

*NOT RECOMMENDED **Factory Default SINGLE STAGE COOLING^

0.10.20.30.40.5

**EC960803BN - HEATING

1221 40 1172 42 1128 44 10 87 45 1049 47 1005 959 922 1311 54 1293 54 1249 56 12 03 58 1172 60 1122 1088 1041

750 66 644 N/A 569 N/A 507 N/A 442 N/A 388 328 N/A

1311 54 1293 54 1249 56 12 03 58 1172 60 1122 1088 1041

750 N A 644 N/A 569 N/A 507 N/A 442 N/A 388 328 N/A 894 N/A 842 N/A 784 N/A 726 N/A 682 N/A 618 562 519 894 55 842 59 784 NA 726 NA 682 N/A 618 562 519

1111 63 1068 66 1025 69 984 NA 941 NA 885 N/A 801

0.6 0.7 0.8

35

SYSTEM OPERATION

DIP SWITCH SETTINGS

PCBBF137 PCBBF139

DIP Switches

S2-1 S2-2 S2-3 **OFF OFF OFF

ON OFF OFF^

ON ON OFF / OF F ON ON

OFF ON OFF

OFF OFF ON

NA

ON OFF ON^

ON ON ON^

S1-1 S1-2 S1-3 **OFF OFF OFF

PCBBF137 PCBBF139

DIP Switches

NA

ALL POSITIONS NA

S2-2 S2-3 S2-4

**OFF OFF OFF

DIP Switches

ON OFF OFF^

ON ON OFF

OFF ON OFF

OFF OFF ON

OFF ON ON^

ON OFF ON^

ON ON ON^

DIP Switches

ON OFF OFF

ON ON OFF

OFF ON OFF

OFF OFF ON

OFF ON ON ON OFF ON

ON ON ON

*MEC960804CN - COOLING

Stat ic

Tstat Call CFM CFM CF M CFM CFM CFM CFM CFM

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

1185 1121 1058 992 933 868 808 750 1727 1691 1642 1600 1545 1504 1449 1410 1408 1337 1279 1218 1167 1112 1062 999 1185 1121 1058 992 933 868 808 750 1408 1337 1279 1218 1167 1112 1062 999 1727 1691 1642 1600 1545 1504 1449 1410 1185 1121 1058 992 933 868 808 750 1281 1220 1152 1096 1031 978 914 856 1185 1121 1058 992 933 868 808 750 1839 1790 1757 1699 1665 1615 1568 1527 1408 1337 1279 1218 1167 1112 1062 999 1281 1220 1152 1096 1031 978 914 856 1839 1790 1757 1699 1665 1615 1568 1527 1727 1691 1642 1600 1545 1504 1449 1410 1839 1790 1757 1699 1665 1615 1568 1527 1408 1337 1279 1218 1167 1112 1062 999

*MEC960804CN - CONTINUOUS FAN

Static

Tstat Call CFM CFM CF M CFM CFM CFM CFM CFM

G G G G G G G G G

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

1281 1220 1152 1096 1031 978 914 856 1839 1790 1757 1699 1665 1615 1568 1527 1408 1337 1279 1218 1167 1112 1062 999 1185 1121 1058 992 933 868 808 750 1727 1691 1642 1600 1545 1504 1449 1410 1281 1220 1152 1096 1031 978 914 856 1281 1220 1152 1096 1031 978 914 856 1281 1220 1152 1096 1031 978 914 856 1281 1220 1152 1096 1031 978 914 856

PCBBF137 PCBBF139

DIP Switches

S3-1 S3-2 **OFF OFF

ON OFF*

ON ON*

OFF ON

DIP Switches

S1-4 S2-1

**OFF OFF

ON OFF*

ON ON*

OFF ON

Static

Tstat Call CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM CFM CFM

W1 W2 W1 W2 W1 W2 W1 W2

*NOT RECOMMENDED **Factory De fault SINGLE STAGE COOLING^

36

0.10.20.30.4

1281 39 1220 41 1152 43 10 96 45 1031 48 978 914 856 1839 39 1790 40 1757 40 16 99 42 1665 43 1615 1568 1527 1408 35 1337 37 1279 39 12 18 41 1167 43 1112 1062 999 1839 39 1790 40 1757 40 16 99 42 1665 43 1615 1568 1527 1408 35 1337 37 1279 39 12 18 41 1167 43 1112 1062 999 1185 NA 1121 NA 1058 NA 992 NA 933 NA NA NA NA 1185 42 1121 44 1058 47 992 50 933 53 868 1449 1410 1727 41 1691 42 1642 43 16 00 44 1545 46 1504 1449 1410

*MEC960804CN - HEATING

0.5

0.6 0.7 0.8

SYSTEM OPERATION

DIP SWITCH SETTINGS

PCBBF137 PCBBF139

DIP Switches

S2-1 S2-2 S2-3

**OFF OFF OFF

ON OFF OFF^

ON ON OFF / OF F ON ON

OFF ON OFF

OFF OFF ON

NA

ON OFF ON^

ON ON ON^

S1-1 S1-2 S1-3

**OFF OFF OFF

PCBBF137 PCBBF139

DIP Switches

NA

ALL POSITIONS NA

S2-2 S2-3 S2-4

**OFF OFF OFF

DIP Switches

ON OFF OFF^

ON ON OFF

OFF ON OFF

OFF OFF ON

OFF ON ON^

ON OFF ON^

ON ON ON^

DIP Switches

ON OFF OFF

ON ON OFF OFF ON OFF

OFF OFF ON

OFF ON ON ON OFF ON

ON ON ON

*MEC961004CN - COOLING

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

CFM CFM CFM CFM CFM CFM CFM CFM

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

1312 1235 1170 1101 1037 962 880 820 1772 1713 1662 1609 1540 1498 1452 1399 1004 890 805 710 620 553 474 406 1312 1235 1170 1101 1037 962 880 820 1004 890 805 710 620 553 474 406 1772 1713 1662 1609 1540 1498 1452 1399 1312 1235 1170 1101 1037 962 880 820 1522 1464 1402 1338 1280 1230 1167 1101 1312 1235 1170 1101 1037 962 880 820 1861 1803 1749 1698 1653 1594 1549 1504 1004 890 805 710 620 553 474 406 1522 1464 1402 1338 1280 1230 1167 1101 1861 1803 1749 1698 1653 1594 1549 1504 1772 1713 1662 1609 1540 1498 1452 1399 1861 1803 1749 1698 1653 1594 1549 1504 1004 890 805 710 620 553 474 406

*MEC961004CN - CONTINUOUS FAN

Static

Tstat Call CFM CFM CF M CFM CFM CFM CFM CFM

G G G G G G G G G

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

1522 1464 1402 1338 1280 1230 1167 1101 1861 1803 1749 1698 1653 1594 1549 1504 1004 890 805 710 620 553 474 406 1312 1235 1170 1101 1037 962 880 820 1772 1713 1662 1609 1540 1498 1452 1399 1522 1464 1402 1338 1280 1230 1167 1101 1522 1464 1402 1338 1280 1230 1167 1101 1522 1464 1402 1338 1280 1230 1167 1101 1522 1464 1402 1338 1280 1230 1167 1101

PCBBF137 PCBBF139

DIP Switches

S3-1 S3-2

**OFF OFF

ON OFF*

ON ON* ON ON*

OFF ON

DIP Switches

S1-4 S2-1

**OFF OFF

ON OFF*

OFF ON

Static

Tstat Call CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM CF M CFM

W1 W2 W1 W2 W1 W2 W1 W2

*NOT RECOMMENDED **Factory De fault SINGLE STAGE COOLING^

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

*MEC961004CN - HEATING

1522 40 1464 42 1402 44 13 38 46 1280 48 1230 1167 1101 1861 47 1803 49 1749 50 16 98 52 1653 53 1594 1549 1504 1004 NA 890 NA 805 N/A 710 N/A 620 N/A 553 474 406 1861 47 1803 49 1749 50 16 98 52 1653 53 1594 1549 1504 1004 NA 890 NA 805 N/A 710 N/A 620 N/A 553 474 406 1312 NA 1235 N/A 1170 N/A 1101 N/A 1037 N/A 962 880 820 1312 47 1235 50 1170 53 11 01 56 1037 59 962 880 820 1772 50 1713 51 1662 53 16 09 55 1540 57 1498 1452 1399

37

SYSTEM OPERATION

DIP SWITCH SETTINGS

PCBBF139 * CEC961005CN - CO O LING

DIP Switches

S1-1 S1-2 S1-3

**OFF OFF OFF

ON OFF OFF

ON ON OFF

OFF ON OFF^

OFF OFF ON

OFF ON ON^

ON OFF ON

ON ON ON^

Static

Tsta t Call CFM CFM CF M CFM CFM CFM CFM CFM

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

1637 1577 1528 1467 1410 1369 1307 1256 2069 2009 1978 1932 1923 1876 1834 1773 1477 1422 1364 1301 1244 1190 1135 1078 1637 1577 1528 1467 1410 1369 1307 1256 1477 1422 1364 1301 1244 1190 1135 1078 2069 2009 1978 1932 1923 1876 1834 1773 1637 1577 1528 1467 1410 1369 1307 1256 1300 1234 1175 1109 1052 992 928 866 1637 1577 1528 1467 1410 1369 1307 1256 1866 1817 1774 1729 1684 1637 1593 1552 1477 1422 1364 1301 1244 1190 1135 1078 1300 1234 1175 1109 1052 992 928 866 1866 1817 1774 1729 1684 1637 1593 1552 2069 2009 1978 1932 1923 1876 1834 1773 1866 1817 1774 1729 1684 1637 1593 1552 1477 1422 1364 1301 1244 1190 1135 1078

0.10.20.30.40.50.60.70.8

PCBBF139

DIP Switches

S2-2 S2-3 S2-4

**OFF OFF OFF

ON OFF OFF

ON ON OFF OFF ON OFF

OFF OFF ON

OFF ON ON ON OFF O N

ON ON ON

PCBBF139

DIP Switches

S1-4 S2-1

**OFF OFF

ON OFF

ON ON*

OFF ON

Static

Tstat Call CFM Rise CFM Rise CF M Rise CFM Rise CF M Rise CF M CFM CF M

*CEC961 005 CN - CO NTI NUOUS FAN

Static

Tsta t Cal l CFM CFM CFM CFM CFM CFM CFM CFM

G G G G G G G G

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

1300 47 1234 50 1175 52 1109 56 1052 59 992 928 866

W1

1866 47 1817 48 1774 50 1729 51 1684 52 16 37 1593 1552

W2

1477 42 1422 43 1364 45 1301 47 1244 49 11 90 1135 1078

W1

1866 47 1817 48 1774 50 1729 51 1684 52 16 37 1593 1552

W2

1477 42 1422 43 1364 45 1301 47 1244 49 11 90 1135 1078

W1

1637 54 1577 56 1528 58 1467 60 1410 62 13 69 1307 1256

W2

1637 38 1577 39 1528 40 1467 42 1410 44 13 69 1307 1256

W1

2069 43 2009 44 1978 44 1932 46 1923 46 18 76 1834 1773

W2

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

1300 1234 1175 1109 1052 992 928 866 1866 1817 1774 1729 1684 1637 1593 1552 1477 1422 1364 1301 1244 1190 1135 1078 1637 1577 1528 1467 1410 1369 1307 1256 2069 2009 1978 1932 1923 1876 1834 1773 1300 1234 1175 1109 1052 992 928 866 1300 1234 1175 1109 1052 992 928 866 1300 1234 1175 1109 1052 992 928 866

*CEC961005CN - HEATING

*NOT RECOMMENDED **Factory De fault SINGLE STAGE COOLING^

38

SYSTEM OPERATION

DIP SWITCH SETTINGS

PCBBF137 PCBBF139

DIP Switches

S2-1 S2-2 S2-3 **OFF OFF OFF

ON OFF OFF^

ON ON OFF / OF F ON ON

OFF OFF ON

NA

ON OFF ON^

ON ON ON^

S1-1 S1-2 S1-3

**OFF OFF OFF

ON OFF OFF^

PCBBF137 PCBBF139

DIP Switches

NA

ALL POSITIONS NA

S2-2 S2-3 S2-4

**OFF OFF OFF

ON OFF OFF

OFF OFF ON

DIP Switches

ON ON OFF

OFF ON OFFOFF ON OFF

OFF OFF ON

OFF ON ON^

ON OFF ON^

ON ON ON^

DIP Switches

ON ON OFF OFF ON OFF

OFF ON ON ON OFF ON

ON ON ON

*MEC961005CN - COOLING

Stat ic

Tstat Call CFM CFM CF M CFM CFM CFM CFM CFM

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

1384 1324 1271 1204 1145 1088 1029 985

2008 1963 1944 1916 1876 1839 1801 1759

1438 1366 1309 1254 1163 1133 1077 1013

1384 1324 1271 1204 1145 1088 1029 985

1438 1366 1309 1254 1163 1133 1077 1013

2008 1963 1944 1916 1876 1839 1801 1759

1384 1324 1271 1204 1145 1088 1029 985

1283 1219 1162 1109 1036 974 917 864

1384 1324 1271 1204 1145 1088 1029 985

1811 1772 1733 1690 1644 1590 1551 1492

1438 1366 1309 1254 1163 1133 1077 1013

1283 1219 1162 1109 1036 974 917 864

1811 1772 1733 1690 1644 1590 1551 1492

2008 1963 1944 1916 1876 1839 1801 1759

1811 1772 1733 1690 1644 1590 1551 1492

1438 1366 1309 1254 1163 1133 1077 1013

*MEC961005CN - CONTINUOUS FAN

Static

Tstat Call CFM CFM CF M CFM CFM CFM CFM CFM

G G G G G G G G G

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

1283 1219 1162 1109 1036 974 917 864

1811 1772 1733 1690 1644 1590 1551 1492

1438 1366 1309 1254 1163 1133 1077 1013

1384 1324 1271 1204 1145 1088 1029 985

2008 1963 1944 1916 1876 1839 1801 1759

1283 1219 1162 1109 1036 974 917 864

PCBBF137 PCBBF139

DIP Switches

S3-1 S3-2

**OFF OFF

ON OFF*

ON ON*

OFF ON

DIP Switches

S1-4 S2-1 **OFF OFF

ON OFF*

ON ON*

OFF ON

Static

Tstat Call CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM CFM CFM

W1 W2 W1 W2 W1 W2 W1 W2

*NOT RECOMMENDED **Factory De fault SINGLE STAGE COOLING^

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

*MEC961005CN - HEATING

1283 48 1219 51 1162 53 11 09 56 1036 59 974 917 864 1811 49 1772 50 1733 51 16 90 52 1644 54 1590 1551 1492 1438 43 1366 45 1309 47 12 54 49 1163 53 1133 1077 1013 1811 49 1772 50 1733 51 16 90 52 1644 54 1590 1551 1492 1438 43 1366 45 1309 47 12 54 49 1163 53 1133 1077 1013 1384 64 1324 NA 1271 NA 1204 NA 1145 NA 1088 1029 985 1384 44 1324 47 1271 48 12 04 51 1145 54 1088 1029 985 2008 44 1963 45 1944 45 19 16 46 1876 47 1839 1801 1759

39

SYSTEM OPERATION

DIP SWITCH SETTINGS

PCBBF137 PCBBF139

DIP Switches

S2-1 S2-2 S2-3 **OFF OFF OFF

ON OFF OFF^

ON ON OFF / OF F ON ON

OFF ON OFF

OFF OFF ON

NA

ON OFF ON^

ON ON ON^

S1-1 S1-2 S1-3 **OFF OFF OFF

PCBBF137 PCBBF139

DIP Switches

NA

ALL POSITIONS NA

S2-2 S2-3 S2-4

**OFF OFF OFF

DIP Switches

ON OFF OFF^

ON ON OFF

OFF ON OFF

OFF OFF ON

OFF ON ON^

ON OFF ON^

ON ON ON^

DIP Switches

ON OFF OFF

ON ON OFF

OFF ON OFF

OFF OFF ON

OFF ON ON ON OFF ON

ON ON ON

*MEC961205DN - COOLING

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

CFM CFM CFM CFM CFM CFM CFM CFM

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

Ylo

Y

1399 1327 1259 1185 1118 1051 980 913 1683 1628 1565 1511 1445 1387 1340 1276 1106 1017 946 855 764 681 605 N /A 1399 1327 1259 1185 1118 1051 980 913 1106 1017 946 855 764 681 605 N /A 1683 1628 1565 1511 1445 1387 1340 1276 1399 1327 1259 1185 1118 1051 980 913 1796 1753 1697 1645 1589 1536 1478 1425 1399 1327 1259 1185 1118 1051 980 913 2211 2162 2122 2076 2029 1986 1964 1942 1106 1017 946 855 764 681 605 N /A 1796 1753 1697 1645 1589 1536 1478 1425 2211 2162 2122 2076 2029 1986 1964 1942 1683 1628 1565 1511 1445 1387 1340 1276 2211 2162 2122 2076 2029 1986 1964 1942 1106 1017 946 855 764 681 605 N /A

*MEC961205DN - CONTINUOUS FAN

Static

Tstat Call CFM CFM CF M CFM CFM CFM CFM CFM

G G G G G G G G G

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

1796 1753 1697 1645 1589 1536 1478 1425 2211 2162 2122 2076 2029 1986 1964 1942 1106 1017 946 855 764 681 605 550 1399 1327 1259 1185 1118 1051 980 913 1683 1628 1565 1511 1445 1387 1340 1276 1796 1753 1697 1645 1589 1536 1478 1425 1796 1753 1697 1645 1589 1536 1478 1425 1796 1753 1697 1645 1589 1536 1478 1425 1796 1753 1697 1645 1589 1536 1478 1425

PCBBF137 PCBBF139

DIP Switches

S3-1 S3-2 **OFF OFF

ON OFF*

ON ON*

OFF ON

DIP Switches

S1-4 S2-1

**OFF OFF

ON OFF*

ON ON*

OFF ON

Static

Tstat Call CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM CFM CFM

W1 W2 W1 W2 W1 W2 W1 W2

*NOT RECOMMENDED **Factory De fault SINGLE STAGE COOLING^

40

0.10.20.30.40.5

*MEC961205DN - HEATING

1796 41 1753 42 1697 44 16 45 45 1589 47 1536 1478 1425 2211 48 2162 49 2122 50 20 76 51 2029 52 1986 1964 1942 1106 NA 1017 NA 946 N/A 855 N/A 764 N/A NA NA N/A 2211 48 2162 49 2122 50 20 76 51 2029 52 1986 1964 1942 1106 67 1017 73 946 N/A 855 N/A 764 N/A NA NA N/A 1399 NA 1327 N/A 1259 N/A 1185 N/A 1118 N/A NA NA NA 1399 53 1327 56 1259 59 11 85 62 1118 NA NA NA NA 1683 63 1628 65 1565 NA 1511 NA 1445 NA NA NA NA

0.6 0.7 0.8

SYSTEM OPERATION

WARNING

TO

AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK

TURN

OFF

POWER TO THE FURNACE BEFORE CHANGING SPEED TAPS

Circulator Blower Speed Facts

cuitry.

· Line polarity is checked.

,

.

· The control then enters standby waiting for a call for heat or cool.

· The Furnace status LED will display a slow green flash signaling standby mode

1. Motor speed Tap wiring must remain in factory position on the control board and motor.

2. There are 4 speed Tap wires to the motor T1, T2, T3, T4.

Refer to Minimum Filter Area tables to determine filter area requirement. NOTE: Filters can also be installed elsewhere in the duct system such as a central return.

Horizontal Installations

Filter(s) must be installed external to the furnace casing for horizontal 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 (EFR02)

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 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 cleaning 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. A full line of air filtration and indoor air quality products are available and can be seen at www.goodmanmfg.com.

SEQUENCE OF OPERATION

POWER UP:

· When power is supplied, the control will energize the

Red LED, microcomputer runs its self-check routine.

· The control will check the status of the gas valve cir-

HEAT MODE:

Call For 1st Stage Heat

· On a call for first stage heat, the thermostat contacts close signaling the control module.

· The microcomputer runs its self-check routine.

· The Amber LED will display a slow flash signaling normal heat operation.

· The control module checks the high limit (and/or auxiliary limit) switch(es) for normally closed contacts.

· The control checks the low pressure switch for a shorted condition.

· The gas valve relay status is checked for proper operation. Once the low pressure switch is detected open, the inducer blower is energized at high speed and the humidifier is enabled.

· The low pressure switch is checked for closure.

· Once the low pressure switch is closed, the pre-purge period begins. The inducer will be energized at high speed for the pre-purge period.

· Following the completion of pre-purge, the inducer switches to low speed and the igniter warm up period begins.

· After completion of the igniter warm up period:

- Trial for ignition begins.

- The first stage of the gas valve is energized.

· The igniter is de-energized when flame is sensed or at the conclusion of the ignition activation period (IAP), whichever comes first.

· When flame is sensed, the delay to heat on period begins timing.

· Retry counter is zeroed, if after 10 seconds the flame is sensed:

- Control enters normal operating loop where all

inputs are continuously checked.

· After the delay to heat on period, the circulator fan is energized at the low heat speed.

· The air cleaner will be energized with the circulator.

· If the call for heat is lost while the control is in the trial for ignition period without flame being detected, the control will turn off the gas valve and igniter. The control then enters the post-purge routine. The post-purge time will be increased to 60 seconds. After completing the post-purge, the control resumes normal operation.

41

SYSTEM OPERATION

CALL FOR 2ND STAGE AFTER FIRST STAGE:

. The inducer motor is enabled at high speed.

· The pressure switches are checked for closure. Closure of the second stage pressure switch will energize the high fire stage of the gas valve.

· The high speed circulator output is energized.

· NOTE: A call for 2nd stage without a call for 1st stage will be ignored, and a three amber flash code will be displayed on the LED. This error code will only be stored in memory once during a single power cycle.

2ND STAGE SATISFIED, FIRST STAGE STILL CALLED:

· When the second stage of the thermostat is satisfied, the inducer blower is reduced to low speed which deenergizes the second stage of the gas valve.

· After the high heat off delay expires, the circulator is reduced to low heat speed.

SIMULTANEOUS CALL FOR LOW AND HIGH HEAT

A call for both stages of heat will establish low fire before going to high fire

Operation Using a Single Stage Heating Thermostat

Using a single stage thermostat, the options for high fire delay are: 10 minutes; 20 minutes; or auto

· The automatic second stage logic is a method of energizing the second stage valve based on the recent average of the heating duty cycle. During a typical heating day there will be at least one call for heat within a 3 hour period, and usually much more often. During this mode the low to high stage delay is determined by using the average calculated duty cycle from the table below. Once the specified delay time has expired the second stage valve will be energized

· On the heating cycle following a period of 3 hours (or greater) in which there is no call for heat, the second stage valve will energize based on the average calculated duty cycle prior to the three hour no call for heat. If the average calculated duty cycle is less than 50%, then the low to high stage delay will be determined from the table below. In this case, an assumption is made that the outside temperature is fairly mild and the long time between calls for heat was due to a low thermal loss in the building. Going quickly to second stage heat is not required in this instance.

· If the average calculated duty cycle is 50% or greater, then the heating cycle will be treated as if high stage is needed and the transition from low to high stage delay will happen quickly. In this case an assumption is made that the outside temperature is cold and that the thermostat is likely coming out of setback. Since assumptions are being made during this heating cycle the duty cycle for this heat cycle will not be used in the average calculate d duty cycle formula for future

heating cycles.

· The duty cycle is calculated every cycle and used during the next cycle. The equation for the duty cycle is calculated as follows: Duty Cycle = (Time the appropriate stage is ON) / (Time of the complete cycle).

· The average calculated duty cycle is determined by averaging the previous average calculated duty cycle with the duty cycle from the previous cycle. This places a large emphasis on the previous cycle but allows a large variation in any one duty cycle to be averaged out after just a few complete heating cycles.

· If there is no load activity for 24 hours or more then set the Duty Cycle = 100%

· The initial default average calculated duty cycle = 50%

Duty Cy c le % Valve O u t put Dem and

0-38 1 38-50 1 50-62 1 62-75 1 75-88 1

88-100 1

Purpose Switch Group Function

Heating Fan Off

Delay

Purpose Switch Group Function

Heating Fan Off

Delay

*Factory Setting

Stage, 12 m inute 2

st

Stage, 10 m inute 2

st

St age, 7 mi nut e 2

st

St age, 5 mi nut e 2

st

St age, 3 mi nut e 2

st

St age, 1 mi nut e 2

st

Blower Off Delay Dip Switches PCBBF137

90 OFF OFF

S1

Blower Off Delay Dip Switches PCBBF139

S3

120 O FF ON 150 ON* O FF* 180 ON ON

90 OFF OFF 120 O FF ON 150 ON* O FF* 180 ON ON

nd

Stage Average

nd

St age Average to Heavy

nd

Stage Heavy

nd

Stage Heavy

nd

Stage Light St age Light to Average

Dip S witch

1234

Dip S witch

1234

Heat Mode Blower Off Delay Timing

COOLING MODE: LOW STAGE COOLING MODE SEQUENCE:

· On a call for lo cool, the Ylo and G thermostat contacts close signaling the control module.

· The LED will display a “GREEN”1 flash

· The compressor and condenser fan are energized. The compressor is connected to the Ylo terminal of the control module.

42

SYSTEM OPERATION

· The circulator fan is energized at lo cool speed after a cool on delay. The electronic air cleaner will also be energized.

· After the thermostat is satisfied, the compressor is de-energized

· Following the 60 second Cool Mode Fan Off Delay period, the cool circulator and air cleaner relay are de-energized.

· When the call for “Ylo”and “G”are presented simultaneously, the control will honor the Cool On delay and keep the circulator de-energized. After the Cool On delay, the circulator fan and air cleaner relays are energized. The circulator fan is energized at the cool speed. If a call for “G”is present prior to a call for “Ylo”, the circulator will remain at the FAN circulator speed during the Cool On delay.

SINGLE COOLING STAGE THERMOSTAT OR 2ND STAGE COOLING MODE SEQUENCE.

· On a call for cool, the Y and G thermostat contacts close signaling the control module.

· The LED will display a “GREEN”2 flash

· The compressor and condenser fan are energized. The compressor is connected to the Y terminal of the control module.

· The circulator fan is energized at cool speed after a cool on delay. The electronic air cleaner will also be energized.

· After the thermostat is satisfied, the compressor is de-energized and the Cool Mode FanOff Delay period begins.

· Following the 60 second Cool Mode Fan Off Delay period, the cool circulator and air cleaner relay are de-energized

MANUAL FAN ON:

· On a call for Fan, the G thermostat contacts close signaling the control module.

· The LED will display a solid “GREEN”

· When a call for G is received, the control will energize the circulator in low heat speed after the fan on delay time expires. The electronic air cleaner will also be energized at this time.

· When the thermostat fan switch is moved to the ON position, the circulator blower is energized at low heat speed and the electronic air cleaner is also energized

· When the thermostat fan switch is moved back to the AUTO position, the circulator fan and air cleaner relay are de-energized and the control awaits a thermostat call for heat or cool.

· Exception: During the Cool “On”delay, the control will not respond to the fan input. If the fan was called prior to the call for cool, the circulator will remain energized during the Cool “On”delay.

· If the fan is called prior to a call for heat, the circulator

will remain energized during the entire call for heat sequence.

Combustion Quality Combustion quality can be affected by several factors. Major

factors are venting and draining. 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 supply air to affect combustion

7. If heat exchanger integrity is uncertain, follow procedures in Service Bulletin SF-041

43

ACCESSORIES

*CEC961005BNAA • • • • • • • • • • • TBD TBD TBD TBD TBD

* indicat es bot h AA and AB models

*CEC960603BNAA • • • • • • • • • TBD TBD TBD TBD TBD

*CEC960803BNAA • • • • • • • • • • • TBD TBD TBD TBD TBD

AMEC961005CNAB • • • • • • • • • • • 1 1

*CEC960403BNAA • • • • • • • • • • • TBD TBD TBD TBD TBD

*MEC960303ANA* • • • • • • • • • • • n/a n/a n/a n/a n/a

*MEC960403ANA* • • • • • • • • • • • 1 1

*MEC960603ANA* • • • • • • • • • • • 1 1

*MEC960302BNA* • • • • • • • • • • • n/a n/a n/a n/a n/a

*MEC960402BNA* • • • • • • • • • • • 1 1

*MEC960603BNA* • • • • • • • • • • • 1 1

*MEC960803BNA* • • • • • • • • • • • 1 1

*MEC961004CNA* • • • • • • • • • • • 1 1

*MEC961205DNA* • • • • • • • • • 1 1

AMEC960804CNAB • • • • • • • • • • • 1 1

DESCRIPTION

NUMBER

MODEL

EFR External Filter

Rack

Dual Fu el Kit

Media Air Cleaners

El ect ronic Air Cleaner

Counterflow

Su b base 17.5"

Counterflow

Su bbase 21"

Concentric Side Wall

Flush Mount Vent Kit

(3")

Concentric Side Wall

Flush Mount Vent Kit

(2")

Concentric Vent Kit

(2")

EFR02

AFE18-60A

AMU / GMU

ASAS / GSAS

CFSB17

CFSB21

0170K00000S

0170K00001S

DCVK-20

(CVENT-2)

*MEC 96 and *CEC96 Mod el Furnace A ccessories

Concentric Vent Kit

(3")

Propane Gas

Con ver si o n Kit

Propane Gas

Con ver si o n Kit

LP Low P r essure Sh ut

Off Kit

Ven t Drain Coupling

HASFK-1

1 =above 7000 f t

HASFK-2

HASFK-3

HASFK-1

HASFK-2

DCVK-30

(CVENT-3)

LPM30

LPM08

LPLP03

RF000142

High Altitude

Nat G as

High Altitude

Nat G as

High Altitude

Nat G as

High Altitude

LP Gas

High Altitude

LP Gas

44

ACCESSORIES

EXTERNAL FILTER RACK KIT

EFR01 EXTERNAL FILTER RACK KIT

Used on Models

90% Upflow Model Fu rnaces

OF UNIT

( EFR02 )

FRONT

OF UNIT

BASE

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 KIT

(0170K00000S/0170K00001S)

Description

This side wall only vent kit #0170K00000S is to be used with 2” - 3” vent systems. The #0170K00001S is a side wall vent kit that is to used with 2" vent systems ONLY. 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-by-side 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).

Horizontal Installation

Vertical Installation

45

ACCESSORIES

CONCENTRIC VENT CONVERSION KIT

( DCVK-20

( CVENT-2 ) ( CVENT-3 )

The DCVK-20 (2") or the DCVK30 (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*).

Roof Boot/Flashing (Field Supplied)



 DCVK-30 )



Combustion Air

Vent

Maintain 12" (18" for Canada) minimum clearance above hig hest anticipated snow level. Maximum of 24" above roof.

Support (Fie ld Supplied)

45 Elbow (Field Supplied)

Combustion Air

Vent

Combus tion A ir

Strap (Field Supplied)

45 Elbow (Field Supplied)

DCVK

DCVK (Vertical Installation)

Combustion Air

Vent

Flush to

1" maximum

46

(Horizontal Installation)

ACCESSORY WIRING DIAGRAMS

HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING 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

F U R N A C E

T H E R M O S T A T

H E A T

P U M P

R W1 G C W2 Y Y2 O

R O Y E G W1 C W2 Y2

R W2 O Y

C OT-NO OT-NC OT-C

Y2

P1-8

P1-7

P1-4

P1-6

P1-5

P1-2

P1-3

P1-1

P2-2

P2-1

P2-7

P2-8

P2-5

P2-9

P2-3

P2-4

P2-6

P3-9

P3-8

P3-7

P3-2

P3-6

P3-3

P3-1

P3-4

P3-5

24VAC

F1

3A

C

24VAC

C

POWER SUPPLY

1.0K

6.8K

+5VDC

E/W1

O

Y

+VDC +5VDC

+VDC

K1

K2

Q1

MICROPROCESSOR

24VAC

+VDC

K4

Q2

W1-FURN W2-HP

G-STAT

G-FURN

Y2-HP

Y2-STAT Y2-FURN

Y-ST AT Y-FURN

Y-HP

K3

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)

47

SERVICING

SERVICE NUMBERS

S-1 CHECKING VOLT AGE................................................................................................................................. 55

S-2 CHECKING WIRING.................................................................................................................................... 55

S-3A THERMOSTA T AND WIRING ....................................................................................................................... 55

S-3B HEA TING ANTICIPA TOR .............................................................................................................................. 55

S-4 CHECKING TRANSFORMER AND CONTROL CIRCUIT.............................................................................. 56

S-16A CHECKING AIR CIRCULATOR BLOWER MOT OR (EEM) ........................................................................... 56

S-200 CHECKING DUCT STA TIC........................................................................................................................... 56

S-201 CHECKING TEMPERATURE RISE ............................................................................................................. 57

S-300 CHECKING PRIMARY LIMIT CONTROL...................................................................................................... 57

S-301 CHECKING AUXILIARY LIMIT CONTROL .................................................................................................... 58

S-302 CHECKING FLAME ROLLOUT CONTROL .................................................................................................. 60

S-303 INDUCED DRAFT BLOWER MOTOR.......................................................................................................... 60

S-304 CHECKING GAS VAL VE (REDUNDANT) .................................................................................................... 60

S-305 CHECKING MAIN BURNERS ...................................................................................................................... 61

S-308 CHECKING HOT SURFACE IGNIT OR ......................................................................................................... 64

S-309 CHECKING FOR FLASHBACK ................................................................................................................... 64

S-310 CHECKING PRESSURE SWITCH............................................................................................................... 64

S-31 1 HIGH ALTITUDE APPLICA TION (USA)......................................................................................................... 65

S-312 CHECKING FOR DELAYED IGNITION ........................................................................................................ 65

S-313 CHECKING INTEGRATED IGNITION CONTROL BOARDS........................................................................ 65

S-314 CHECKING FLAME SENSOR................................................................................................................... 66

48

SERVICING

V

As more and more electronic's are introduced to the Heating Trade, Polarization of incoming power and phasing of primary to secondary voltage on transformers becomes more important.

Polarization has been apparent in the Appliance industry since the introduction of the three prong plug, however, the Heating Industry does not use a plug for incoming power, but is hard wired.

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.

CHECKING FOR PHASING - PRIMARY TO SECONDARY OF UNMARKED TRANSFORMERS*

METER READS 24 VOLTS

.

VOLT / OHM METER

METER READS 120 VOLTS

VOLT / OHM METER

INCOMING POWER

GND

METER READS 0 VOLTS

GND

VOLT / OHM METER

THIS IS THE COMMON OR NEUTRAL LEG

METER READS 120 VOLTS

THIS IS L1 OR THE HOT POWER LEG

These then should be wired to the furnace accordingly.

D

N

G

VOLT / OHM METER

C

R

N

L1

C

R

TRANSFORMER

D

N

G

SECONDARY

VOLT / OHM METER

LINE VOLTAGE (NEUTRAL)

PRIMARY

LINE VOLTAGE L1 (HOT)

READS 144 VOLTS - OUT OF PHASE

OLT / OHM

METER

READS 96 VOLTS - IN PHASE

D

N

G

C

R

OLT / OHM

METER

N

L1

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.

*NOTE: For flame rectification the common side of the secondary voltage (24 V) is cabinet grounded. If you were to bench test a transformer the primary neutral and secondary common must be connected together for testing purposes.

Some transformers will display phasing symbols as shown

D

N

G

C

NEUTRAL

in the illustration to the left to assist in determining proper transformer phasing.

Checking for polarization and phasing should become a

24 V

R

120 V

L1

habit in servicing. Let's start now. NOTE: Newer integrated ignition controls have a diagnos-

tic flash code for reversed polarity (Refer to Troubleshoot-

PHASING SYMBOL

ing-Diagnostic Chart for LED Codes).

49

SERVICING

Seconds

for On e

Revolution

1/4

cu/ft

1

One

CUBIC FEET

G AS RATE -- CUBIC FEE T PER HOUR

Size of Test Dial

1/2

cu/ft1cu/ft2cu/ft5cu/ft

Seconds

for One

Revolution

1/4

cu/ft

1

Size of Test Dial

1/2

cu/ft1cu/ft2cu/ft5cu/ft

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

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

-- -- 116 232 581

28 56 113 225 563

-- -- 109 218 545

26 53 106 212 529

-- -- 103 206 514

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

25 50 100 200 500

-- -- 97 195 486

23 47 95 189 474

-- -- 92 185 462

22 45 90 180 450

-- -- -- 176 439

21 43 86 172 429

-- -- -- 167 419

-- 41 82 164 409

20 40 80 160 400

-- -- 78 157 391

19 38 76 153 383

-- -- 75 150 375

-- -- -- 147 367

18 36 72 144 360

-- -- -- 141 355

-- -- 69 138 346

17 34 -- 136 340

-- -- 67 133 333

-- -- -- 131 327

16 32 64 129 321

-- -- -- 126 316

-- 31 62 124 310

-- -- -- 122 305

15 30 60 120 300

50

SERVICING

Se rvice Problem No Heat Unsatisfact ory He a t

POSSIBLE CAUSE

DOTS IN AN ALYSIS

GUIDE INDICATE

"POSSIBLE CAUSE"

Power Failure Blown Fuse Loose Connection Shor t ed or Broken W ires No Low Voltage Faulty Thermostat Faulty Transforme r Poo r or High Resistan ce Ground Improper Heat Anticipator Setting Improper Thermostat Location Faulty L imit or Roll Out Switch Faulty Flame S ensor F au l ty Ig niti o n C o nt ro l Gas Valve or Gas Suppl y S hu t Off F au l ty In du ce d Dr af t Bl owe r Faulty Blo wer Motor (PSC) Broken or Shorted Ignitor Di rty Flame Sensor, Low UA Stu ck Ga s V a lv e Faulty Gas Valve Open Aux il i a r y Lim it Improper Air Flow or Distribution Cycl i ng on Limit Delayed Ig ni t i on Flashb ack Orific e Size Gas Pr es sure Cracked H eat Exchan ger Furnace Und ers ized Furnace Ove rsiz ed Faulty Pr essu r e Sw i t ch Blocked or Restricted Flue Open Rol l Out S witch Bouncing On Pressure Switch

SYMPTOM

Burner Won't Igni te

System Will Not Start

Burner Ignites-Lock s Out

Burner Shuts Off prior to T'Stat being Satisfied

•

•••••

•

••

•

•••

•

••

•

•••

••

•• •

••••

•••

••

•

Long Cycles

Short Cycles

Too Much Heat

Soot and /or Fum es

N ot Enough Hea t

•• ••

•

•• •

•

••

•

Test Volta ge Test Volta ge Check Wiri ng Check Wiri ng Check T ransfor m er Che ck Ther mostat Check T ransfor m er Measure Ground Resistance Adjust Heat Anticipator Setting Relocate Thermos tat Test Contro l Test Flame Sensor Test Contro l Turn Valves to On Position Te st In du ce d Dr af t Mo to r Test Blower Motor (PSC) Test Ig nitor Clean Flame Sensor Replac e Gas Val v e Replac e Gas Val v e Reset Control Check Duct Static Chec k Cont rols & T emperature Rise Test for Delayed Ignition Test for Flashba ck Check Orifices Che ck Gas Pressure Check Burner Flames Replace with Proper Size Furnace Replace with Proper Size Furnace Test Pre ssur e Switch Check Flue /Drawdown Pressure Test Flame Roll Out Con trol Test Negative Pressure

Test Method

Remedy

See Service Procedure Reference

S-1 S-4 S-2

S-3A

S-4

S-3A

S-4

S-17B

S-3B

S-316

S- 3 0 0 / S- 30 2

S-314 S-313 S-317 S-303

S-16A,B,C

S-308 S-314 S-304 S-304 S-301 S-200

S- 2 0 1 / S- 30 0

S-312 S- 3 0 9 / S- 31 1 S- 3 0 6 / S- 31 1

S-307

S-305

S-318

S-310

S-302

S-310

51

TROUBLESHOOTING

Symptoms

•Furnace fails to operate

•Control board LED is off

Green

LED Code

•Non e •None •None

Amber

LED Code

Red

LED Code

Fault Description Check Cautions

•Defective disconnect switch

•defective door switch • No 115 volt power •No 24 v olt power

•Determine cause and restore proper high and low volt power supply

•Confirm electrically safe condition before proceeding wi th repairs

•Furnace is waiting for a call

•Furnace fan only is runni ng

•Normal operation with low stage call for cooling (Ylo & G)

•Normal operation with high or singl e stage call for cooli ng (Y & G)

•Normal operation with low stage call for heat (W1)

•Normal operation with high or single stage call for heat

•Furnace does not operate, three Amber flashes on control board

•Furnace does not operate, four Amber flashes on control board

•Furnace does not operate, rapid Amber flashes on control board

•Solid ON •None •None

•Rapid Fl ash •None •None

•One repe ati ng flash

•Two repe ati ng flashes

•Non e

•None •Rapid •None •Low flame sense current

•No ne •No ne

•On e repe ating flash

•Two repe ating flashes

•Three repe ating flashes

•Fo ur repe ating flashes

•None

•None •W2 call present without W1

•None

•Furnace is not receiving a call

•Furnace is receiving a cal l for fan (24 volts on G terminal

•Normal operation with low stage call for cooling (Ylo & G)

•Normal operation with high or single stage call for cooling (Y & G)

•Normal operation with low stage call for heat ( W1)

•Normal operation with high or single stage call for heat

•Ylo or Y call present without G

•None Required

•Faulty thermostat or thermostat wiring or improperly connected thermostat wires

•Dirty / coated flame rod, poor flame, improper gas pressure, poor flame sense wire or connections

•Confirm electrically safe condition before proceeding wi th work

•Confirm electrically safe condition before proceeding wi th repairs

•Clean flame rod with steel wool. Confirm electrically safe condition before proceeding with repairs

•Furnace does not operate, one Red flash on control board

•Furnace does not operate, two Red flashes on control board, possible inducer operation

•Furnace does not operate, three Red flashes on control board

•Non e •None

52

•One repe ating flash

•Two repe ating flashes

•Thre e repe ating flashes

•Flame sensed when no flame should be present

•Pressure switch stuck closed

•Low fire pressure s witch stuck open

•Gas valve stuck open, improper wiring to gas valve, shorted flame rod or wire

•Faulty pressure switch, pressure swi tch wires shorted, control board inducer relay stuck closed

•Faulty pressure switch, pressure switch or tubing or wiring / connection, control board inducer relay failed, vent pipe restriction / excessive elbows or length

•Confi rm electrical and gas safe conditi ons before proceeding with repairs

•Confirm electrically safe condition before proceeding wi th repairs

TROUBLESHOOTING

g cy

Symptoms

•Furnace does not operate, four Red flashes on control board

•Furnace does not operate, five Red flashes on control board

•Furnace does not operate, six Red flashes on control board

•Furnace does not operate, seven Red flashes on control board

•Furnace does not operate, eight Red flashes on control board

•Furnace does not operate, nine Red flashes on control board

•Furnace does not operate, ten Red flashes on control board

Green

LED Code

•Non e •No ne

Amber

LED Code

Red

LED Code

•Four repe ati ng flashes

•Five repe ati ng flashes

•Six repe ati ng flashes

•Seven repe ati ng flashes

•Eight repe ati ng flashes

•Nine repe ati ng flashes

•Ten repe ati ng flashes

Fault Description Check Cautions

•Open limit circuit, main limit, aux limit, or roll out switch

•Limit & rollout circuit open for 15 minutes. Open control board fuse or rollout switch

•Pressure switch cycling lockout, pressure swi tch has opened 5 times in the same heatin

•Lockout - excessive retries from flame not being proven during trial for ignition

• Lockout - e xcessive recycl es from flame proving being lost after being proven

•Improper grounding or reve rse polarity

•Gas valve current dete cted with no call for heat

cle

•Temperature rise, duct static, gas pressure, burner alignment, orifice plate position, wiring to all limits

•Control board fuse, Temperature rise, duct static, gas pressure, burner alignment, orifice plate position, wiring to all limits

•Excessive venting restriction, leaking pressure swi tch tubing

•Gas pressure, gas valve, front cover pressure switch, flame rod

•115 volt hot & ne utral supply to furnace reve rsed, hot wire (door switch & L1 on control board) must read 115 volts to ground & neutral. Neutral wire should measure 0 volts to ground

•Verify gas valve is not receiving voltage from an electrical short. If valve wiring is corre ct replace control board

•Confirm electrically safe condition before proceeding with repairs

•Confirm electrical and gas safe conditions before proceeding with repai rs

•Confirm electrically safe condition before proceeding with repairs

•Confirm electrical and gas safe conditions before proceeding with repai rs

•Furnace does not operate, eleven Red flashes on control board, inducer running

•Furnace does not operate, twelve Red flashes on control board

•Furnace does not operate, control board Red LED on solid

•Furnace does not operate, control board Red LED rapid flash

•Furnace does not operate, control board Red LED with three double flashes

•Ele ven

•Non e •No ne

•None •None •Solid ON •Control board internal fault •Replace control board

•None •None •Rapid Flash •Twinning error •Correct twinning wiring

•Non e •No ne

repe ati ng flashes

•Twelve repe ati ng flashes

•Three double flashes

•Open limit switch circuit for more than 5 minutes

•Control board igniter relay not energizing igniter

•Second stage pressure switch stuck open

•Re-set main power and check indoor blower operation

•Replace control board

•Verify pressure switch function & tubing, verify inducer operating and pulling enough vacuum to engage switch

•Confirm electrically safe condition before proceeding with repairs

53

DIAGNOSTIC CHART

Refer to the Troubleshooting Chart in the back of this manual for assistance in determining the source of unit operational problems.

External Lockout

- A control lockout resulting from an external fault sensed by the control, such as an unsuccessful recycle or retry period, or a limit trip. Once in External Lockout, the control will shut down for a period of one hour before attempting another trial for ignition.

Internal Lockout

- A failure internal to the control board.

FAULT RECALL

Retrieving Fault Codes

To retrieve fault codes, push and release the “LAST ERROR” button for more than 1/5 second and less than 5 seconds (the LED will indicate this period by solid GREEN for 1/5 second to 5 seconds). The LED will flash up to five stored fault codes, beginning with the most recent. If there are no fault codes in memory, the LED will flash two green flashes. The control will flash the most recent error first and the oldest error last. If multiple faults exist there will be 2 seconds between codes. Solid LED error codes will not be displayed.

Fault Code Reset

To clear the fault code memory, push and hold the “LAST ERROR” button for more than 5 seconds and less than 10 seconds (the LED will indicate this period by RAPID GREEN FLASH for 5 seconds to 10 seconds). The LED will flash three green flashes when the memory has been cleared.

The ignition control is equipped with a momentary push button switch that can be used to display on the diagnostic LED the last five faults detected by the control. The control must be in Standby Mode (no thermostat inputs) to use the feature.

Depress the push button switch for approximately 2 seconds. Release the switch when the LED is turned off. The diagnostic LED will then display the flash codes associated with the last five detected faults. The order of display is the most recent fault to the least recent fault.

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 one flash diagnostic LED code. If the furnace is in “lockout”, it can be reset in any of the following ways.

1. Automatic reset. The integrated control module will automatically reset itself and attempt to resume normal operations following a one hour lockout period.

2. Manual power interruption. Interrupt 115 volt power to the furnace for 1 - 20 seconds.

3. Manual thermostat cycle. Lower the thermostat so that there is no longer a call for heat then reset to previous setting. Interrupt thermostat signal to the furnace for 1 - 20 seconds.

SERVICING

S-1 CHECKING VOLTAGE

CHECKING THERMOSTAT, WIRING AND ANTICIPATOR

WARNING

HIGH VOLTAGE

ISCONNECT ALL POWER BEFORE SERVICI NG OR

D

CHANGING ANY E LECTRI CAL WI RING. SOURCES MAY BE PRESENT. PROPERTY DAMAGE, PERS ONAL INJURY OR DEATH.

MULTIPLE POWER

FAILURE TO DO SO MAY CAUSE

1. Remove cover from the Junction Box and gain access to incoming power lines.

With Power ON:

WARNING

INE VOLTAGE NOW PRESENT

L

2. 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.

3. No reading - indicates open wiring, open fuse, no

power, or faulty Door Interlock Switch from unit to fused disconnect service. Repair as needed.

4. With ample voltage at line voltage connectors, ener-

gize the furnace blower motor by jumpering terminals R to G on the integrated ignition control.

5. With the blower motor in operation, the voltage

should be 1 15 volts ± 10 percent.

6. 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.

7. After completing check and/or repair , replace Junc-

tion Box cover and reinstall the service panel doors.

8. 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.

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):

WARNING

INE VOLTAGE NOW PRESENT

L

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 thermo-

stat and wiring. Repair or replace as necessary .

If checking the furnace in the air conditioning mode, proceed as follows.

7. With power off, Jumper terminals R to Y

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

The heating anticipator on older thermostats 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. Modern thermostats do not have this type of heat anticipator. Many have a selector switch to adjust the number of cycles per hour.

55

SERVICING

S-4 CHECKING TRANSFORMER AND Control CIR-

CUIT

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 NNECT ALL POWER BEFORE SERVI CING OR

CHANGING ANY ELECTRICAL WIRING. SOURCES MAY BE PRESENT. PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

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):

LINE VOLTAGE NOW PRESENT

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.

MULTIPLE POWER

FAILURE TO DO SO MAY CAUSE

WARNING

S-16A CHECKING AIR CIRCULATOR BLOWER

MOTOR (MULTI-SPEED ECM MOTOR)

WARNING

ISCONNECT

D

1. Remove blower compartment door to gain access to the circulator blower motor and integrated ignition control.

2. Check for any obstruction that would keep the fan wheel / fan motor from turning.

3. Check wiring, the motor has two wiring harnesses, a main harness and a control harness. The main pin harness has: White neutral wire connected to the Neutral terminal on the control board. Black wire connected to the CIRC H terminal on the control board. Red wire connected to the COM terminal, which is a female spade connection next to the T1 – T4 wires on the control board. Green ground wire connected to cabinet ground The control harness has: Blue wire connected to T1 on the control board. Red wire connected to T2 on the control board. Orange wire connected to T3 on the control board. Black wire connected to T4 on the control board. The multi-speed ECM motor requires a line voltage power supply (black connected to CIRC H and white connected to neutral on the control board) as well as a signal on one of the speed taps (T1-T4). The speed tap voltage is D.C. and can vary depending on S2 DIP switch selection. The voltage reading from any one of the speed taps is referenced between the female COM terminal next to the speed taps on the control board. From COM to T1 or T2, 3-7 VDC when energized. From COM to T3, 13-14 VDC when energized. From COM to T4, 3-7 or 13-14 VDC depending on S2 settings.

POWER B EFORE SE RVICING.

ALL

WARNING

LINE VOLTAGE NOW PRESENT

WARNING

HIGH VOLTAGE

ISCONNECT ALL POWER BEFORE SERVICING OR

D

INSTALLI NG THIS UNIT. BE PRESENT. DAMAGE, PERSONAL INJURY OR DEATH.

MULTIPLE POWER SOURCES MAY

FAILURE TO DO SO MAY CAUSE PROPERTY

56

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.

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.

SERVICING

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. 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

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 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:

RETURN AIR

Checking Temperature Rise

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

All primary limit controls are nonadjustable, automatic reset, bi-metal type limit control. Refer to the following drawing for the location of the primary limit.

57

SERVICING

PRIMARY LIMIT

CONTROL

Primary Limit Control Location

(90% Upflow Furnace Shown)

The following drawing illustrates the style of limit switches used on the 90% furnaces.

ENCLOSED DISK

If the limit circuit opens five times within a single call for heat, the furnace will go into lockout for one hour. The RED LED will display a FOUR flash code during this time. The control board can be reset by cycling 115 volt power to the furnace.

If the limit circuit opens and does not close within five minutes, the control assumes the blower has failed the RED LED will flash ELEVEN times.

If the limit circuit opens and does not close within fifteen minutes, the control assumes the manual rollout or fuse has opened and the RED LED will flash FIVE times. The control will enter a one hour lockout and the inducer will run continuously.

In an open limit condition the red LED will flash as described above but the error code will not be stored in memory until the limit resets or until 15 minutes has elapsed. So if the limit resets in less than 5 minutes a four flash code will be stored. If the limit resets in more than 5 but less than 15 minutes, an eleven flash code will be stored. If the limit is still open after 15 minutes, a five flash code will be stored.

FRONT VIEW SIDE VI EW

Primary Limit Control Style

(90% Furnaces)

WARNING

HIGH VOLTAGE D

ISCONNECT ALL POWER BEFORE SERV I CING OR

CHANGING A NY ELE CTRI CAL WI RIN G. SOURCES MAY BE PRESENT. PROPERTY DAMAGE, PERSONAL I NJURY OR DEATH.

MULTI PLE 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.

LIMIT FAULT CODES

If the control detects the high limit circuit open, the RED LED will flash FOUR times and energize the inducer and indoor blower.

VOLT / OHM ME T E R

COLOR IDENTIFYING TAB

Testing Primary Limit Control

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.

S-301 CHECKING AUXILIARY LIMIT CONTROL

The auxiliary limit control is designed to prevent furnace operation in case of main blower failure in horizontal 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.

58

SERVICING

AUXI L IARY LIMI T CONTROL

VOLT / OHM METE R

BLOWER HOUSING

AUXILIARY LIMIT CONTROL

Auxiliary Limit Control Location

WARNING

HIGH VOLTAGE

ISCONNECT ALL POWER BEFORE SERVICING OR

D

INSTALLI NG THIS UNIT. BE PRESENT. DAMAGE, PERSON AL INJURY OR DEATH.

MULTIPLE POWER SOURCES MAY

FAILURE TO DO SO MAY CAUSE PROPERTY

1. Remove blower compartment door to gain access to the auxiliary .

2. Remove the wires from the auxiliary limit control terminals.

3. Using an ohmmeter, test for continuity across the two terminals.

RED RESET BUTTON

COLOR IDENTIFYING TAB

Testing Auxiliary Limit Control

59

SERVICING

302 CHECKING FLAME ROLLOUT CONTROL

A temperature activated manual reset control is mounted to the manifold assembly as shown in the following illustration.

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.

1. Remove the burner compartment door to gain access to the rollout switch(es) mounted to burner bracket.

2. Reset the manual roll out switch

3. Remove wires from roll out switch

4. Using an ohmmeter, check for continuity across the switch.

5. If the switch will not close after manually resetting, it must be replaced.

6. Measure the voltage between each side of the rollout control and ground during the ignition attempt. 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.

7. After check and/or replacement of rollout switch, reinstall burner compartment door and verify proper unit operation.

S-303 INDUCED DRAFT BLOWER Motor

WARNING

HIGH VOLTAGE

ISCONNECT ALL POWER BEFORE SERVICING OR

D

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 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. Touch 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 in-

duced draft motor , reinstall burner compartment door .

7. Turn on electrical power and verify proper unit opera-

tion.

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.

60

SERVICING

Two stage gas valves always require 24 volts between common and low fire (main coil) to open. Also, 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

S-305 CHECKING MAIN 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.

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.

S-306 CHECKING ORIFICES

*MEC96/*CEC96 model furnaces have factory installed #45 natural gas orifices (except *MEC/*CEC96030 which has #50).

The only time resizing is required is when a reduction in firing rate is required for an increase in altitude or a furnace is being converted for use with LP gas.

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

D

ISCONNECT

1. Check orifice visually for distortion and/or burrs.

2. Check orifice size with orifice sizing drills.

ALL G

AS AND ELECTRICAL POWER SUPPLY.

A

D

ISCONNECT

34.5" Burner

WARNING

ALL G

AS AND ELECTRICAL POWER SUPPLY.

GAS STREAM

B

The length of Dimension "A" determines the angle of Gas Stream "B".

DENT OR BURR

GAS

STREAM

B

A dent or burr will cause a severe deflection of the gas stream.

S-307 CHECKING GAS PRESSURE

Gas Supply Pressure Measurement

GAS PRESSURE TEST

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.

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.

61

SERVICING

INLET OUTLET

Gas Valve On/Off Sele c tor Switch

White-Rodgers Model 36J54 (Two-Stage)

t

e

r

n

o

a

m

e

o

m

Inlet Pressure Boss

e

t

e

r

M

o

H

s

e

Outlet

Pressure Boss

n

O

/

High Fire Regulator

Adjust

g

e

h

i

H

i

T

e

m

r

c

t

h

S

i

w

f

l

r

o

i

C

F

I

n

(

)

a

H

l

Common Terminal(C)

Regulator

Low Fire Regulator Adjust

o

C

a

x

T

e

r

m

Vent

a

i

n

l

a

Open to

Atmosphere

a

M

n

White-Rodgers Model 36J54 Connected to Manometer

If supply pressure differs from table, make the necessary adjustments to pressure regulator, gas piping size, etc., and/or consult with local gas utility.

5. Turn OFF gas to furnace at the manual shutoff valve

and disconnect manometer. Reinstall plug before turning on gas to furnace.

6. Turn OFF any unnecessary gas appliances stated in

step 3.

GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT

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.

Gas Line

Gas Shutoff Valve

Gas Line To Furnace

l

o

i

C

l

)

M

(

Drip Leg Cap With Fitting

Manometer Hose

Open To Atmosphere

1. Turn OFF gas to furnace at the manual gas shutoff valve external to the furnace.

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. See WhiteRodgers 36J54 gas valve figure for location of inlet pressure tap.

INLET GAS SUPPLY PRESSURE

Natural Gas M inimum: 4.5" w.c. Maximum: 10.0" w.c.

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

NOTE: If measuring gas pressure at the drip leg, a field-

supplied hose barb fitting must be installed prior to making the hose connection. If using the inlet pressure tap on the White-Rodgers 36J54 gas valve, then use the 36G/J V alve Pressure Check Kit, Part No. 0151K00000S.

3. Turn ON the gas 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 Inlet Gas Supply Pressure table.

Manometer

Measuring Inlet Gas Pressure (Alt. Method)

CAUTION

TO

PREVENT UNRELIABLE OPERATION OR EQUIPM EN T DAMAGE, THE GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE

. O

NLY MINOR ADJUSTMENTS SHOULD BE MADE BY ADJUSTING

THE GAS VALVE PRESSURE REGU L ATOR

.

1. Turn OFF gas to furnace at the manual gas shutoff valve external to the furnace.

2. Turn off all electrical power to the system.

3. Outlet pressure tap connections: White-Rodgers 36J54 valve: Back outlet pressure test

screw (inlet/outlet pressure tap) out one turn (counterclockwise, not more than one turn).

4. Attach a hose and manometer to the outlet pressure tap (White-Rodgers valve).

5. Turn ON the gas supply.

62

SERVICING

g

6. Turn on power and close thermostat “R” and “W1” contacts to provide a call for low stage heat.

7. Measure the gas manifold pressure with burners firing. Adjust manifold pressure using the Manifold Gas Pressure table shown below .

8. Remove regulator cover screw from the low (LO) outlet pressure regulator adjust tower and turn screw clockwise to increase pressure or counterclockwise to decrease pressure. Replace regulator cover screw.

9. Close thermostat “R”, “W1” and “W2” contacts to provide a call for high stage heat.

10. Remove regulator cover screw from the high (HI) outlet pressure regulator adjust tower and turn screw clockwise to increase pressure or counterclockwise to decrease pressure. Replace regulator cover screw.

1 1. Turn off all electrical power and gas supply to the

system.

12. Remove the manometer hose from the hose barb fitting or outlet pressure tap.

13. Replace outlet pressure tap: White-Rodgers 36J54 valve: Turn outlet pressure test

screw in to seal pressure port (clockwise, 7 in-lb minimum).

14. Turn on electrical power and gas supply to the system.

15. Close thermostat contacts “R” and “W1/W2” to energize the valve.

High Fire

Regulator Vent

Gas Valve On/Off Selector Switch

Regulator Adjust

Low Fire Regulator Adjust

Honeywell Model VR9205 (Two-Stage)

Measuring Gas Pressure: Two-Stage Valves Cont'd

Common

e

m

t

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p

O

p

s

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A

m

M

t

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m

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e

o

H

s

r

Terminal(C)

High Fire Coil Terminal (HI)

Low Fire Coil Terminal (LO)

Inlet Pressure Tap 1/8 NPT

Manifold Gas Pressure

Gas

N a tural Low Sta

h Stage 3.2 - 3.8" w.c. 3.5" w.c.

Hi

Propane Low Sta

h Stage 9.7 - 10.3" w .c.10.0" w.c.

Hi

e 1.6 - 2.2" w .c. 1.9" w.c.

e 5.7 - 6.3" w .c. 6.0" w.c.

Range Nominal

Using a leak detection solution or soap suds, check for leaks at outlet pressure tap plug (Honeywell valve) or screw (White-Rodgers valve). Bubbles forming indicate a leak. SHUT OFF GAS AND REPAIR ALL LEAKS IMMEDIATELY!

NOTE: For gas to gas conversion, consult your dealer for appropriate conversion.

CAUTION

T

O PREVENT UNRELIABL E OPERATI ON OR E QUIPMENT DAMAGE, T HE INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNI T RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING.

Outlet Pressure Tap 1/8 NPT

Honeywell Model VR9205 Connected to Manometer

1. Remove regulator cover screw from the low (LO) outlet pressure regulator adjust tower and turn screw clockwise to increase pressure or counterclockwise to decrease pressure. Replace regulator cover screw.

a. Close thermostat “R” and “W” contacts to provide a

call for heat.

b. 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.

c. Turn off all electrical power and gas supply to the

system.

d. Remove the manometer hose from the outlet pres-

sure boss.

63

SERVICING

e. Remove the 1/8" NPT hose barb fitting from the outlet

pressure tap. Replace the outlet pressure boss plug and seal with a high quality thread sealer.

WARNING

HIGH VOLTAGE D

ISCONNECT ALL ELECTRICAL POWER AND SHUT OFF GAS SUPPLY

BEFORE SERVICING OR INSTALLING.

2. Turn on gas to furnace and check for leaks. If leaks are found, repair and then reinstall burner compartment door.

3. Turn on electrical power and verify proper unit operation. Make sure furnace operates at the proper manifold pressure at both high and low stage outputs.

Manifold Gas Pressure

Gas Rate Range N ominal

Nat ural Gas

HIGH VOLTAGE D

ISCONNECT

SUPPLY BEFORE SERVICI NG OR INSTALLING THIS UNIT.

MULTI PLE PO WER SOU RCES MA Y BE PRES ENT. FAILURE TO

DO SO MAY CAUSE PRO PERTY DAMAGE, P ERSONAL INJURY OR DE ATH.

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

ALL

ELECTRICAL POWER AND SHUT O FF GAS

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 SWITCH

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 inducer pressure switch, this furnace has 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 D

ISCONNECT

BEFORE SERVICI NG OR INSTA LLING.

Propane Gas

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.

S-308 CHECKING HOT SURFACE IGNITOR

120V Silicon Nitride Igniter - *M/CEC96 use a 120V sili-

con nitride igniter for ignition. The normal operating tempera-

ture is approximately 2156°F - 2678°F. At room tempera-

ture the igniter ohm reading should be from 37-68 ohms.

7. 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.

8. After checking and/or replacing of hot surface ignitor,

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 figures.

4. With an ohm meter connected across the pressure switch terminals; 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.

64

SERVICING

*

***

M

1

O F

*

F

23PC

ON

**

COIL COVER

PRESSURE SWITCH

INDUCED

DRAFT

BLOWER

INDUCED DRAFT BLOWER

PRESSURE SWITCH

HOSE

1/4" TEE

HOSE TO INDUCED DRAFT BLOWER TAP

OPEN TO ATMOSPHERE

INCLINED MANOMETER

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

CONTROL BOARDS

NOTE: Failure to earth ground the furnace, reversing the neu-

tral 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.

Blower Pressure Switch

Negative Pressure Measurement

S-311 HIGH ALTITUDE APPLICATION (USA)

The furnace as shipped requires no change to run between 0 - 7500 feet. Do not attempt to increase the firing rate by changing orifices or increasing the manifold pressure below 7500 feet. feet. This can causepoor combustion and equipment failure. High altitude installations above 7500 feet. feet 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 gasfuel and the combustion air at higher altitude.

For installations above 7500 feet. feet, please refer to your distributor for required kit(s). Contact the distributor 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.

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.

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.

Furnace design makes this extremely unlikely unless safety controls have been by-passed or tampered with. Never by-

pass or alter furnace controls. If delayed ignition should occur, the following should be

checked:

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.

WARNING

T

O AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO THE UNIT MUST BE PROPERLY POLARIZED AND GROUNDED. BEFORE PERFORMING SERVICE LISTED BELOW.

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.

These tests must be completed within a given time frame due to the operation of the ignition control.

The ignition control is capable of diagnosing many furnace failures to help in troubleshooting. The trial for ignition period is 4 seconds.

Goodman® Brand and Amana® Brand Two-Stage

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. Check for 24 volts from W 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 120 volt outputs on the 5 pin harness. Pin 1 = HSI Hot Pin 2 = Inducer High Pin 3 = Inducer Low Pin 4 = Inducer N Pin 5 = HSI N

D

ISCONNECT POWER

65

SERVICING

ST1

K3

R97

Q6

R200

59- 5043 REV . D

S1

1 2 3 4

OFF

S2

1 2 3

OFF ON

DS1

STAT US

3

LAST

ERROR

SW3

4

ST3

WARNING

M

ULTIP LE POWE R SOUR CES MAY

T1

T2

E14

E13

K11

K2 K1

R78 2

R78 4

R93

R96

R95

R92

Q2

W39

W3

R201

R586

R50

R588

R39

R40

R49

R204

R35

Y

W10 GL1

M2

ON

W40

R570

R581

R562

R563

R584

Q13

Q11

R564

R573

R553

2

R10

Yl0

Y

R

E2

R27

R130

R11

R13

T4E9T3

E190

R78 3

R89

R94

Q3

Q72

FLAM E

CURRENT

W15

W16

W1

W19

W46

W7

R566

R578

R568

R580

R557

R76

R118

W52

R38

R71

R115

W2

R29

R3

R15

W1

R

E3W1E31

W20

W37

CAUTION - 120V

E10

L1

ST5

E8

EAC-H

R781

E35

E36

C14

R82

W49

R4

W2R

CIRC-H

R88

W35

Q71

R202

+

W33

(1VDC=1 uA )

Q9

E12

U3

R31

C

R18

R17

R12 R16

R2

E15

E29

K10

Q7

W34

C60

R81

GCTWIN

E5GE4

E6

TW IN

W36

W22

XFMR

E16

R79

HUM

E28

E17

W18

NEUTRALS

E18

R

V

K8

E21

E20

E19

ST2

2

HIGH VOLTAGE D

ISCONNECT INSTALLING TH IS U NIT. BE PRESENT.

ALL

POWER BEFORE SERVICING OR

F

AILURE TO DO SO MAY CAUSE PROPERTY

DAMAGE, PERSON AL INJ URY OR DEATH .

Flame current can be measured in two ways:

K6

E40

R73

R74

W32

W51

CR13

Q60

W12

W29

RV3

RV4

C13

K4

R58

C11

ST6

E22

ST4

F1

E26 E27

W4

R60

Q5

W11

Q70

C15

W31

W53

Q4

R59

R41

R87

E32

G

W14

W44

R78

W13 W30

R61

K5

R85

R77

Q10

K9

Q14

R780

R70

R53

R524

R63

R75

9

R

R119

R91

E39

L

2

W24

R65 R21

R33

R54

R44

1. Putting a D.C. microamp meter in series with the flame rod

2. Putting a D.C. volt meter across the two solder pads in the flame current section of the control board.

1 D.C. volt = 1 microamp.

IGN SYSTEM 24VAC 60Hz. 0.5A MAX

Flame Current

Solder Pads

PCBBF133 Control Board

4. After the ignitor warmup time, begin checking for 24 volts to the gas valve. Voltage will be present for four seconds only if proof of flame has been established.

5. If proof of flame was established voltage will be provided to the air circulation blower following the heat on delay period.

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.

66

WARNING

INE VOLTAGE NOW PRESENT

L

3. 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.

4. 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.

5. 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.

MAINTENANCE

WARNING

HIGH VOLTAGE

ISCONNECT ALL POWER BEFORE SERVICING OR

D

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 and internal to 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

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 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.

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.

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.

Filter Sizing Chart

Model Minimum Recommended Filter Size^

*MEC960303AN* 1 - 16 X 25 Side or 1 - 14 X 25 Bottom *MEC960403AN* 1 - 16 X 25 Side or 1 - 14 X 25 Bottom *MEC960603AN* 1 - 16 X 25 Side or 1 - 14 X 25 Bottom *MEC960302BN* 1 - 16 X 25 Side or Bottom *MEC960402BN* 1 - 16 X 25 Side or Bottom *MEC960603BN* 1 - 16 X 25 Side or Bottom *MEC960803BN* 1 - 16 X 25 Side or Bottom *MEC960804CN* 1 - 16 X 25 Side or Bottom *MEC961004CN* 1 - 16 X 25 Side or Bottom *MEC961005CN* 1 - 20 X 25 Bottom / 2 - 16 X 25 Side Return *MEC961205DN* 1 - 20 X 25 Bottom / 2 - 16 X 25 Side Return

*CEC960403BN* 2 - 10 X 20 or 1 - 16 X 25 Top Return *CEC960603BN* 2 - 10 X 20 or 1 - 16 X 25 Top Return *CEC960803BN* 2 - 10 X 20 or 1 - 16 X 25 Top Return *CEC961005BN* 2 - 14 X 20 or 1 - 20 X 25 Top Return

^ Larg er f ilters may be used, f ilters may a lso be centrally located

67

MAINTENANCE

CONDENSATE DRAINAGE SYSTEM (QUALIFIED SERVICER ONLY)

The drain tubes, standpipe, 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

E

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.

TO AVOID ELECTRICAL SHO CK, INJURY OR

CONTACT A QUALIFIED

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.

Check the Burner Flam es for :

1. Stable, soft and blue.

2. Not curling, floating or lifting off.

Burner Flame

TEST EQUIPMENT

Proper test equipment for accurate diagnosis is as essential as regular hand tools.

The following is a must for every service technician and service shop.

1. Dial type thermometers or thermocouple meter (optional) - to measure dry bulb temperature.

2. Amprobe - to measure amperage and voltage.

3. Volt-Ohm Meter - testing continuity , capacitors, and motor windings.

4. Inclined Manometer - to measure static pressure, pressure drop across coils, filters, and draft.

5. Water Manometer (12") - to test gas inlet and manifold pressure.

Other recording type instruments can be essential in solving abnormal problems, however, in many instances they may be rented from local sources.

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.

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

Should the figure you calculated not fall within five (5) percent of the nameplate rating of the unit, adjust the gas valve pressure regulator or resize orifices.

68

MAINTENANCE

A / GMEC96 Pressure Switch Trip Points And Usage Chart

Coil Cover

ID Blower

Mod el

*MEC960303ANAA - 0.08 ± .04 - 0.16 0130F00647 - 0.15 ± .05 - 0.30 - 0.40 ± .05 - 0.55 0130F00643

*MEC960403ANAA - 0.08 ± .04 - 0.16 0130F00647 - 0.10 ± .05 - 0.25 - 0.20 ± .05 - 0.35 0130F00645

*MEC960603ANAA - 0.10 ± .05 - 0.25 0130F00646 - 0.10 ± .05 - 0.25 - 0.25 ± .07 - 0.40 0130F00645

*MEC960302BNAB - 0.08 ± .04 - 0.16 0130F00486 - 0.67 ± .05 - 0.82 - 1.15 ± .07 - 1.36 0130F00472

*MEC960402BNAA / AB - 0.08 ± .04 - 0.16 0130F00486 - 0.72 ± .05 - 0.87 - 0.97 ± .05 - 1.12 0130F00471

*MEC960603BNAA / AB - 0.10 ± .05 - 0.25 0130F00481 - 0.92 ± .05 - 1.07 - 1.47 ± .07 - 1.68 0130F00473

*MEC960803BNAA / AB - 0.10 ± .05 - 0.25 0130F00481 - 0.72 ± .05 - 0.87 - 1.47 ± .07 - 1.68 0130F00474

*MEC961004CNAA / AB - 0.10 ± .05 - 0.25 0130F00481 - 0.67 ± .05 - 0.82 - 1.15 ± .07 - 1.36 0130F00472

*MEC961205DNAA / AB - 0.10 ± .05 - 0.25 0130F00481 - 0.50 ± .05 - 0.67 - 1.15 ± .07 - 1.36 0130F00446

*CEC960403BNAA - 0.10 ± .05 - 0.25 0130F00429 - 0.92 ± .05 -1.07 - 1.47 ± .07 - 1.68 0130F00435

*CEC960603BNAA - 0.10 ± .05 - 0.25 0130F00429 - 0.92 ± .05 -1.07 - 1.47 ± .07 - 1.68 0130F00435

*CEC960803BNAA - 0.10 ± .05 - 0.25 0130F00429 - 0.70 ± .05 - 0.87 - 1.47 ± .07 - 1.68 0130F00436

*CEC964005CNAA - 0.10 ± .05 - 0.25 0130F00429 - 067 ± .05 - 0.82 - 1.15 ± .07 - 1.36 0130F00434

Set Point on Max Make Pressure Low Fire Low Fire High Fire High Fire Low / High

Pressure Fall Pressure On Switch Set Point on Max Make Set Point on Max Make Pressure Switch

(PF) W.C. Rise W.C. Part # Pressure Fall Pressure On Pressure Fall Pressure On Assembly

(PF) W.C. Ris e W.C. (PF) W.C. Rise W.C. Part #

69

WIRING DIAGRAMS

GRD

GN

*MEC96 - REV AA

JUNCTION BOX

R

S

E

T

B

D

H

T

O

GY

PU

OR

S

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A

C

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R

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I

BR

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R

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2

1

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C

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C

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WH

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HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO

DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEAT H.

B

K

R

D

O

R

B

L

5

3

2

14

CIRCULATOR

A

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71

WIRING DIAGRAMS

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HIGH VOLTAGE!

DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS

UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO

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LOW VOLTAGE(24V)

LOW VOLTAGE FIELD

HI VOLTAGE (115V)

2

3

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7

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HI VOLTAGE FIELD

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WARNING:DISCONNECT POWER BEFORE SERVICING. WIRING TO UNIT MUST BE PROPER LY POLARIZE AND GROUNDED.

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OVERCURRENT

PROT. DEVICE

JUNCTION

TERMINAL

INTERNAL TO

D

T

INTEGRATEDCONTROL MODULE

Y

R

A O

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, Y

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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.

72

Goodman GMEC96, Amana ACEC96, Amana AMEC96, GCEC96 Service Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual