Goodman GMEC96, AMEC96 User Manual

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Page 1

Service Instructions

Goodman® Brand GMEC96

& Amana

Two Stage Furnace

with multi-speed ECM Motor

Brand AMEC96

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

RS6612013

August 2014

Page 2

TABLE OF CONTENTS

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

PRODUCT IDENTIFICATION ........................ 7 - 8

INSTALLATION CONSIDERATIONS ........... 9 - 26

SYSTEM OPERATION ...............................27 - 33

ACCESSORIES..........................................34 - 37

SERVICING TABLE OF COnTENTS.................38

SERVICING .. .............................................. 39 - 56

MAINTENANCE ............................................57- 58

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

PREVENT THE RISK OF PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, DO NOT STORE COMBUSTIBLE MATERIALS OR USE GASOLINE OR OTHER FLAMMABLE LIQUIDS OR VAPORS IN THE VICINITY OF THIS APPLIANC E

OODMAN WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES YOU ASSUME RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROPERTY DAMAGE WHICH MAY RESULT REQUIRE A LICENSE TO INSTALL OR SERVICE HEATING AND AIR CONDITIONING EQUIPMENT

. IF

YOU INSTALL OR PERFORM SERVICE ON THIS UNIT

. M

ANY JURISDICTIONS

WARNING

HIGH VOLTAGE D

ISCONNEC T ALL POWER BEFORE SERVICING OR

INSTALLI NG THIS UNIT .

BE PRESEN T.

DAMAGE, PER SONAL INJURY OR DEATH.

MULTIPLE POWER SOURCES MAY

FAILURE TO DO SO MAY CAUSE PROPERTY

Page 3

IMPORTANT INFORMATION

DANGER

CARBON MONOX IDE POISONING HAZARD

Special warning for installation of furnaces or air handling units in enclosed area such as garages, utility rooms or parking areas. Carbon monoxide prod ucing devices (such as automobile, space heater , gas water heate r , etc.) Should not be operated in enclosed area s such as unventilate d garages or utility rooms because of the danger of carbon monoxide (CO) poisoning resulting from the exhaust emissions. If a furnace or air handler is installed in an enclosed area and a carbon monoxide producing de vice is operated therein, there must be adequate direct outside ventilation. Carbon monoxide emissions can be ( re)cir culated through out the structure if the furnace or air handler is operating in any mode. CO can cause serious illness including permanent brain damage or death.

RISQUE D'EMPOISONNEMENT AU MONOXYDE DE CARBONE

vertissement special au sujet de l'installation d'appareils de chauffage ou de traitement d'air dans des endroits clos, tets les gara g es , les locaux d'entr etien et les stationnements. Evitez de mettre en marche les appareils prod uisant du monoxyde de carbone (tels que les automobile, les appareils de chauffage autonome,etc.) dans des endroits non ventilés tels que les d'empoisonnement au monoxyde de carbone. Si vous devez faire fonctionner ces appareils dans un endroit clos, assures-vous qu'il y ait une ventilation directe provenant de l'exterie . Les émissions de monoxyde de carbone peuvent etre recircules dan s les endroits clos, si l'appareil de chauffage ou de traitement d'air sont en marche. Le monoxyde de carbone peut causer des maladies graves telles que des dommages permanents au cerveau et meme la mort.

RIESGO DE INTOXICACIÓN POR MONÓXIDO DE CARBONO

Advertencia especial para la instalación de calentadores ó maneja oras de aire en áreas cerradas como estaciona mientos ó cuart os de servicio. Los equipos ó aparatos que producen monóxido de carbono (tal como automóvil, calentador de gas, calentador de agua por medio de gas, etc) no deben ser operados en áreas cerradas debido al riesgo de enve nenamiento por monóx i d o de ca rb on o (C O ) qu e resu lta de las emisiones de ga se s de co mb us t i ón. Si el equipo ó aparato se opera en dichas áreas, debe existir una adecuada ventilac ón directa al exterior. Las emisiones de monóxido de carbono pueden circular a través del aparato cuando se opera en cualquier modo. El monóxido de carbono puede causar enfermedades severas como daño cerebral permanent e ó muer te .

DANGER

PELIGRO

0140M00020-D

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.

Page 4

IMPORTANT INFORMATION

FOR Y OUR S AFETY READ BEFORE OPERATING

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

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

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

WHAT TO DO IF YOU SMELL GAS

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

If you cannot reach your gas supplier,

call the fire department.

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

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

OPERATING INSTRUCTIONS

1. STOP! Read the safety information

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the appliance.

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

5. Remove control access panel.

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

GAS CONTROL SWITCH SHOWN IN "ON" POSITION

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

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

9. Replace control access panel.

10. Turn on all electric power to the appliance.

11. Set the thermostat to the desired setting.

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

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to its lowest setting.

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

3. Remove control access panel.

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

5. Replace control access panel.

WARNING: Improper alteration, service or

maintenance can cause injury or property damage.

Refer to the user's information manual provided with this

consult a qualified or the gas supplier.

This furnace must be

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

Code, ANSI Z223.1.

For indoor installation.

PGB & PGJ For outdoor installation only .

If notWARNING:

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

California to cause cancer.

FOR YOUR SAFETY

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

0140F00001P

Page 5

IMPORTANT INFORMATION

CONSIGNES DE SECURITE - LIRE

AVANT D'ALLUMER L'APPAREIL

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

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

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

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

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

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

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

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

'allumez paz le bruleur manuellement.

0140F00002P

1. UN INSTANT! Lisez d'abord les consignes

INSTRUCTIONS DE SERVICE

d e securi te ci-dessus.

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

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

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

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

6. Mettez la commande de gaz a la position

ARRET ("OFF").

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

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

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

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

11. Reglez le thermostat a le temperature desiree.

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

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

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

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

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

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

ARRET DU GAZ

Commande de gaz en position

"MARCHE"

Page 6

IMPORTANT INFORMATION

M L

B N

Page 7

PRODUCT IDENTIFICATION

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

* M E C 96 060 3 B N A A

1 2 3 4 5,6 7,8,9 10 11 12 13 14

Brand

A - Amanaﬁ Brand

A - Amana® Brand

G - Goodmanﬁ Brand

G - Goodman® Brand

Motor

NOx

AFUE

MBTU/h

MODEL # MFG. # DESCRIPTION

AM E C060302BNAA

AMEC96

GM EC9 6

AM E C960402BNAA AM E C060603BNAA AM E C960803BNAA AM E C961004CNA A AMEC961205DNAA

GMEC06 0302BNAA GMEC96 0402BNAA GMEC06 0603BNAA GMEC96 0803BNAA GMEC96 1004CNA A GMEC961205DNAA

Amana® Brand 96% Two Stage Heating / Two Stage Cooling Gas Furnace, Up flow/Horiz ontal Left and Right, 34.5" tall, Induced Draft, Nidec multi-speed ECM motor. Stainless Steel tubular heat exchanger. 115 volt silicon nitride igniter. Left or right gas ent

Goodman ® Br and 96 % Two Sta ge Heat ing / Two Stage Cooling Gas Fu rnace, Up flow/Horiz ontal Left and Right, 34.5" tall, Induced Draft, Nidec multi-speed ECM motor. Al uminized S t eel t ubular heat exchanger. 115 volt silicon nitride igniter. Left or right gas

Page 8

PRODUCT IDENTIFICATION

MODEL # MFG # DESCRIPTION

AFE18-60A

AMU1 620 AMU1 625 AMU2 020 AMU2 025

GMU1620 GMU1625 GMU2020 GMU2025

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

DCVK-20

DCVK-30

N/A

P 1251305F P 1251306F P 1251307F P 1251308F

N/A

P 1251301F P 1251302F P 1251303F P 1251304F

P 1254001F

P 1254002F

Fossil Fuel Kit.

above/do wnstream of a gas or fo ssil fuel f urnace when used wit h a h eat pump. I t will operate with single and two stage heat pumps and single and two stage f ur na c es. The AFE 18- 60 A control will turn the he at pump unit of f when the f ur nace is turned on. An ant ishort c ycle feature initiate s a 3 minute timed off d elay when the compressor goes of f.

Media Air Cleaner

efficienc y air fil trat ion device designed to r emove dirt, dust, pollen and other microscopic particles from th e a ir passing thro ugh it. Flexible performance range up to 2,0 00 CFM capac ity. The air cl eaner should be installed in t he syst em so that a ll the sy stem air is circ u lated t hr ough the air cleaner. The air cleaner will onl y remove the airborne cont a minants delivered to it. Max imum perf or mance is obt ained when the syst em blower is set for c o ntinuous operat ion. Carbon filt er s (optional) ar e available.

Electronic Air Cleane r

air co ntaminants down to .01 microns. Car bo n filters (optional) r emove odors. Dual indicator lights show unit operation at a glan c e. Elec tronic pr oving switch cycles the air cleaner On/Off wit h the sy stem fa n. Durable powde r - c o at paint finish resists corrosion.

Concentric Vent Kit

is design ed to allow t er minat ion s of a dir e c t vent furnace to be " c oncentr ically" vented thr o ugh a wall or roof . Thi s kit allows a single penetration to support terminations for bo th the vent/ f l ue and t he combustion air intake pipe. The DCVK-20 ( 2") and DCVK-30 (3" ) k its are ce r tified for models listed above. See specif ic a tion sheets on future models for use of the vent kit.

The AFE18-60A cont r ol is designed for use where the indoor coil is located

. The Amana (AMU*) and Goodman (GMU*) Media Air Cleaner is a high

. The High-E ffi c iency Electronic Air Cleaner is designed to r emove

. For use with Aman a® B r an d high efficiency furnace models. This kit

0170K00000S

0170K00001S

EFR0 2

LPLP03

RF000142

N/A

P1221001

P 1221002F

N/A

Side W all Only Concentr ic Vent Kit

is to be used with 2" - 3" v e nt syste ms. The vent k it must ter minate outside the str uc ture. This kit is NOT intended for use with single pipe (indir ec t vent) insta llat ion s.

Side W all Only Concentr ic Vent Kit

This kit is to be used with 2" only vent systems. The vent kit must terminate outside the structure. T his kit is NOT intended f or use wit h single pipe ( ind ir ect vent) insta llations.

External Filter Rack Kit

casing, for installation of a per manent filter . The r ack is moun ted over the indoor air blower c ompartment area of eithe r side panel, and provide filt e r r etention as well as a location for att aching ret urn air duct work.

LP Gas Low Pressure Kit

80% and 90% single-stage a nd two-stage gas f ired fur nac e pr o duc ts installed on LP ga s listed in t hi s manual. T hi s kit includes harness adaptors to w or k with White-Rodgers single & two stage gas valves,Honeywell single and two-stage g as valves, as well as modulat ing gas valves.

Ve nt Dr ain Coupling

the in ternal elbow is removed.

. This kit is intended to provide a location, ex ternal to the furnace

. Designed for app lic at ion on Goodman® and A mana® Br and's

. For use when t he furnac es is installed in horizontal left posit ion an d

. For use with high effic i enc y furnace models. This kit

. For use with high effic i enc y 90% fur nac e models.

Page 9

INSTALLATION CONSIDERATIONS

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.

*MEC960302BNAA *MEC960402BNAA *MEC960603BNAA *MEC960803BNAA *MEC961004CNAA *MEC961205DNAA

Safety

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

WARNING

O PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION,

ADJUSTMENT, ALTERATI ON, SERVICE OR MAINTENANCE, RE FER TO THIS

MANUAL.

QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.

OR ADDITIONAL ASSISTANCE OR INFORMATION, CONSULT A

WARNING

HIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS WHICH

MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE KNOWN TO THE

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

REPRODUCTIVE HARM.

WARNING

TO PREVENT POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH

DUE TO ELECTRICAL SHOCK, THE FURNACE MUST BE LOCATED TO PROTECT

THE ELECTRICAL COMPO NENTS FROM WATER.

Charge (ESD) Precautions

NOTE: Discharge body’s static electricity before touching

unit. An electrostatic discharge can adversely affect electrical components.

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

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

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

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

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

Product Application

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

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

Retail stores, Nursing homes, Hotels/motels, Common or

office areas. In such applications, the furnace must be installed

with the 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.

WARNING

OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE,

EXPLOSION, SMOKE, SOOT, CONDENSTAION, ELECTRICAL SHOCK OR CARBON

MONOXIDE MAY RESULT FROM IMPROPER INSTALLAT ION, REPAIR, OPERATION,

OR MAINTENANCE OF THIS PRODUCT.

Page 10

INSTALLATION CONSIDERATIONS

WARNING

O PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE,

DO NOT INSTALL THIS 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 1430 Broadway New York, NY 10018 National Fire Protection Association 1 Batterymarch Park Quincy, MA 02269

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 EQUIPMENT DAMAGE, P ROPERTY DAMAGE, PERSONAL

INJURY OR DEATH, THE FO LLOWING BULLET POINTS 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

• Provide provisions for venting combustion products

NOTE: The length of flue and/or combustion air piping can

• Locate the 90% furnace so that the condensate can

• Set the 90% furnace on a level floor to enable proper

• Ensure upflow or horizontal furnaces are not installed

• Exposure to contaminated combustion air will result

typical operating sound level of a furnace is deemed objectionable, an optional sound reduction kit is available. Consult your local distributor for more details.

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.

be a limiting factor in the location of the furnace.

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.

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

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

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

Page 11

INSTALLATION CONSIDERATIONS

cleaning solutions (such as perchloroethylene) printing inks paint removers varnishes hydrochloric acid cements and glues antistatic fabric softeners for clothes dryers and masonry acid washing materials

• 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 ac-

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.

cess 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.

MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS

POSITION SIDES REAR FRONT BOTTOM FLUE TOP

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

Horiz ontal 6" 0" 1" C 0" 4"

• C = if plac ed on combustible floor, the floor MU ST be wood ONLY.

• For servic ing or cleaning, a 24" front cleara nce is recommended.

• Unit connections (electric al, fl ue, and drain) may nec essitate great er c l earances th an the min i mum c learanc es listed above

• In all case, a c cessibility clearance must take precedence o v er from the enclosure where accessitilit y clearances are gre ater.

• Approved for line con tact in t he horizontal positi on.

Page 12

INSTALLATION CONSIDERATIONS

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.

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

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

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

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 un-

• Hot or cold air from registers.

• Radiant heat from the sun.

• Light fixtures or other appliances.

• Radiant heat from a fireplace.

• Concealed hot or cold water pipes, or chimneys.

• Unconditioned areas behind the thermostat and de-

COMBUSTION AND VENTILATION AIR REQUIREMENTS

OSSIBLE PROPERTY DAMAGE, PERSONAL I NJURY OR DEATH MAY OCCUR

IF THE FURNACE I S NOT PROVIDED WITH ENOUGH FRESH AIR FOR PROPER

COMBUSTION AND VENTILATION OF FLUE GASES. MOST HOMES REQUIR E

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

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

common venting system must be corrected.

der cabinets.

humidistat, such as an outside wall.

WARNING

Page 13

INSTALLATION CONSIDERATIONS

space with other gas appliances, such as a water heater, ensure there is an adequate supply of combustion and ventilation air for the other appliances. Refer to the latest edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1 (Section 9.3), or CAN/CGA B149 Installation Codes (Sections 7.2, 7.3, or 7.4), or applicable provisions of the local building codes for determining the combustion air requirements for the appliances.

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.

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.

Required Volume

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

Required Volume

where:

other

fan

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

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

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

9.3.2.2(2).

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

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

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

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

> ________ _________

other

> ________ _________

fan

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

hour

= fan-assisted appliances input in Btu per hour

per hour, expressed as a decimal)

21 ft

ACH 1000 Btu/hr

15 ft

ACH 1000 Btu/hr

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

Chimney or Gas Vent

Furnace

other

(

Water Heater

)

fan

)

Opening

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

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

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

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

equation:

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).

Page 14

INSTALLATION CONSIDERATIONS

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).]

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

Chimney or Gas Vent

Water Heater

Furnace

Outlet air duct

Inlet air duct

NOTE: The air du ct openings must have a free area of not less than one sq uare i nch per 2000 BTU of the total input rating of all equipment in the enclosure*.

Chimney or Gas Vent

Ventilation louvers (each end of attic)

NOTE: Th e 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 equipment in the enclosure.

Outlet Air

Water Heater

lternate

air inlet

Furnace

Ventilation louvers for unheated crawl space

Inlet Air

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

Inlet Air from Ventilated Crawl Space and Outlet Air

to Ventilated Attic.

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 equipment in the enclosure.

Outlet Air

Water Heater

Furnace

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

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.

/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 confined space.

Chimney or Gas Vent

Water Heater

Furnace

Opening

Alternate Opening Location

Figure A.9.3.3.2 All Combustion Air

From Outdoors through Single Combustion Air Opening.

9.3.4 Combination Indoor and Outdoor Combustion Air. The use

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

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

From Outdoors through Ventilated Attic.

(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-

(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).]

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.

Page 15

INSTALLATION CONSIDERATIONS

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).

9.3.5 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.

9.3.8.3 Ducts shall serve a single space.

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.

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

9.3.6 Mechanical Combustion Air Supply. Where all combustion air

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

/min per kW) for all appliances located within

9.3.8.6 Horizontal upper combustion air ducts shall not slope downward toward the source of combustion air.

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

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

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

Horizontal Applications and Considerations

Horizontal applications, in particular, may dictate many of the installation’s specifics such as airflow direction, ductwork connections, flue and/or combustion air pipe connections, etc. The basic application of this furnace as a horizontal furnace differs only slightly from an upright installation.

Horizontal Installations

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

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

When installing a *MEC96 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.

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

Page 16

INSTALLATION CONSIDERATIONS

R 000142F

Insert flange. Cut 2 ½” lo n g.

E R E H

T U C

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.

DISCHARGE

Side

Return

Duct

Connection

Bottom

Return

Duct

Connection

Side

Return

Duct

Connection

UPFLOW UPRIGH

Vent/Flue Pipe Cuts

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.

Bottom Return

Duct

Connection

UPFLOW HORIZONTAL

LEFT AIR DISCHARGE

Bottom Return

Duct

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).

Page 17

INSTALLATION CONSIDERATIONS

Freeze Protection

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

Propane Gas and/or High Altitude Installations

WARNING

OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR IF

THE CORRECT CONVERS ION KITS ARE NOT I NSTALLED.

MUST BE APPLIED TO INSURE SAFE AN D PROPER FURNACE OPERATI ON.

CONVERSIONS MUST BE PERFORMED BY A QUALIFIED INSTALLER OR SERVICE

AGENCY .

THE APPROPRIATE KITS

ALL

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.

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

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

Materials and Joining Methods

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

KEPT AWAY FROM ALL IGNITION SOURCES (I.E., SPARKS, OPEN FLAMES, AND

EXCESSIVE HEAT) AS THEY ARE COMBUSTIBLE LIQUIDS.

CEMENT VAPORS OR CONTACT WITH SKIN AND/OR EYES.

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.

WARNING

VOID BREATHING

VENT/FLUE PIPE AND COMBUSTION AIR PIPE

WARNING

AILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN BODILY INJURY OR

DEATH.

ONLY)

CAREFULLY READ AND FOLLOW ALL INSTRUCTIONS GIVEN IN THIS

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 I NJURY OR DEATH D UE TO EXPOSURE TO FLUE PRODUCTS,

INCLUDING CARBON MONOXIDE.

LEAKS IN THE FLUE SYSTEM CAN RESULT IN SERIOUS

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

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).

Page 18

INSTALLATION CONSIDERATIONS

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

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

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

NOTE: In Canada, 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'

VENT/FLUE TERMINATION

12"

DIRECT VENT

VENT/FLUE TERM INATION

12"

NON-DIRECT VENT

90% Furnace Vent Termination Clearances

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 combustion air intake to prevent inadvertent blockage. The tee or elbows used in the vent/flue termination must be included when determining the number of elbows in the piping system.

Unit In pu t

(Btu)

40,000

60,000

80,000 "B" 2 o r 2 1/2 75 70 65 60 55 50 45 40 80,000 "B" 3 200 193 186 179 172 165 158 151

80,000 "C" 2 o r 2 1/2 25 20 15 10 5 N/A N/A N/A 80,000 "C" 3 200 193 186 179 172 165 158 151

100,000 2 or 2 1/2 25 20 15 10 5 N /A N/A N/A 100,000 3 200 193 186 179 172 165 158 151 120,000 2 or 2 1/2 45 40 35 30 25 20 15 10 120,000 3 95 90 85 80 75 70 65 60

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.

*MEC96 Dire c t Ven t (2 - Pipe) an d N on-Direct Vent (1- Pi p e)

M aximum A l l owable Length of Vent / Fl ue Pi pe

& Combu stion Air Pi p e (ft )

Pipe Si ze

(4)

(in .)

or 2 1/2

12345678

120 115 110 105 100 95 90 85

95 90 85 80 75 70 65 60

Number of Elbows

(1) (2)

(3) (5)

(6)

WARNING

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

RUBBER ELBOW IS MOUNTED EXTERNALLY TO THE FURNACE CABINET,

EXTREME CARE MUST BE TAKEN TO ADEQUATELY SUPPORT FIELD-SUPPLIED

VENT/FLUE PIPIN G, AS DAMAGE CAN RESULT IN LEAKS CAUSING BODILY

INJURY OR DEATH DUE TO EXPOSURE T O FLUE GASES, INCLUDING CARBON

MONOXIDE.

12" MINIMUM

VENT/FLUE TEE

90° ELBOW TURNED

DOWN

12" MINIMUM ABOVE

HIGHEST ANTICIPATED

SNOW LEVEL

90% Furnace Horizontal Termination (Single Pipe)

Above Highest Anticipated Snow Level

Page 19

INSTALLATION CONSIDERATIONS

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

10”- 24”

6” MAX

COMBUSTION AIR INTAKE

(OPTIONAL)

*Not required for

single pipe installation

INTAKE

SCREEN

OPTIONAL

12” MIN TO ROOF OR HIGHEST ANTICIPATED SNOW LEVEL

12" MIN.

STRAIGHT

TEE (OPTIONAL)

12” MIN HEIGHT DIFFERENCE BETWEEN INTAKE AND VENT

”

ELBOWS

4” MIN

90º OR 45°

ELBOW

SCREEN

(OPTIONAL)

12" MIN. TO GRADE OR HIGHEST ANTICIPATED

SNOW LEVEL

Standard Horizontal Terminations (Dual Pipe)

90° ELBOWS

3” - 24”

AI R INTAKE

SCREEN

(OPTIONAL)

VENT/FLUE TEE (

45° ELBO W

TURNED DOWN or

90° ELBO W TURNED

12" MIN. ABOVE

HIGHEST ANTICIPATED

SNOW LEVEL

Horizontal Termination (Single Pipe)

Above Highest Anticipated Snow Level

DOWN

OPTIONAL)

12" MIN. ABOVE

HIGH EST ANT ICIPATED

SNOW LEVEL

Alternate Horizontal Vent Termination (Dual Pipe)

90° ELBOWS

3”-24” BETWEEN PIPES

AIR INTAKE

SCREEN

(OPTIONAL)

1 2" MIN. ABOVE

HIGH EST ANTI CIPATED

SNOW LEVEL

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

Alternate Vent Termination Above Anticipated Snow Level

(Dual Pipe)

Page 20

INSTALLATION CONSIDERATIONS

VENT/INTAKE T ERMINATIONS F OR I NSTALLATION OF M UL-

TIPLE D IRECT V ENT F URNACES

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” - 24”

12” MIN SEPARATION

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

3” MIN

OPTIONAL INTAKE SCREENS

12” MIN TO GRADE OR HIGHEST ANTICIPATED SNOW LEVEL

Termination of Multiple Direct Vent Furnaces

12"

Direct Vent

Terminal

50,000 Btuh

or less

12"

Direc t Ve nt T erm inal

More than 50,000 Btuh

FIGURE 1

12"

Forc ed 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.

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

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.

(DCVK) Vent Termination Clearances

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

Page 21

INSTALLATION CONSIDERATIONS

Vent

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

Combustion Air

Roof Boot/Flashing (Field Supplied)

Vent

24" above roof.

Support (Field Supplied)

45 Elbow (Field Supplied)

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 DRAIN TRAP MUST BE MOUNTED ON

THE OPPOSITE S IDE OF THE UNIT FROM THE JUNCTION BOX.

REDUCE THE RISK OF WATER REACHING THE JUNCTION BOX I N TH E EV ENT OF

A BLOCKED DRAIN CONDITION.

CAN RESULT IN POSSIBLE PROPERTY DAMAGE, P ERSONAL INJURY, OR DEATH

DUE TO ELECT RIC AL SHOC K.

AILURE TO FOLLOW THESE I NSTRUCTIONS

HIS WILL

• 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.

CAUTION

O PREVENT UNRELI ABLE OPERATION OR EQUIPMENT D AMAGE, THE INLET

GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE

WITH ALL OTHE R HOUSEHOLD GAS FIRED APPLI ANCES OPERATING.

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

INLET GAS SUP PLY PRESSURE

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

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

HIGH ALTITUDE DERATE

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

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

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

In some areas the gas supplier may artificially derate the gas in an effort to compensate for the effects of altitude. If the gas is artificially derated, the appropriate orifice size must be determined based upon the BTU/ft

content of the derated gas and the altitude. Refer to the National Fuel Gas Code, NFPA 54/ANSI Z223.1, and information provided by the gas supplier to determine the proper orifice size.

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

Page 22

INSTALLATION CONSIDERATIONS

PROPANE GAS CONVERSION

WARNING

OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR IF

THE CORRECT CONVERSION KITS ARE NOT INSTALLED.

MUST BE APPLIED TO I NSURE SAFE AND PROPER FURNACE OPERATION.

CONVERSIONS MUST BE PERFORMED BY A QUALIFIED INSTALLER OR SERVICE

AGENCY.

HE APPROPRIATE KITS

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

O AVOID POSSIBLE UNS ATISFACTO RY OPERATI ON OR EQUIPMENT DAMAGE

DUE TO UNDERFIRING OF EQUIPMENT, USE THE PROPER SIZE OF

NATURAL/PROPANE GAS PIPING NEEDED WHEN RUNNING P IPE 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.

Length of

Pip e in Feet

(Pr es s ur e 0.5 psi g or le s s and p re s s u r e dr op of 0.3" W. C.; Based on 0.60 S p ec ific Gravity Gas)

CFH =

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 .

Natural Gas C apacity of Pipe

In Cubic Feet of Gas Per Ho ur (CFH)

No minal Black Pip e Size

1/2" 3/4" 1" 1 1/4" 1 1/ 2"

10 20 30 40 50 60 70 80 90

100

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

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

Page 23

INSTALLATION CONSIDERATIONS

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

OR OPEN FLAME TO TEST FOR LEAKS.

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

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

PROPANE GAS TANKS AND PIPING

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

WARNING

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

ANY LOW AREAS OR CONFINED SPACES.

PERSONAL INJURY, OR DEATH DUE TO FIRE OR EXPLOSION CAUSE D BY A

PROPANE GAS LEAK, INSTALL A GAS DETECTION WARNING DE VICE.

O PREVENT PROPERTY DAMAGE,

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

F THE GAS FURNACE IS INSTALLED IN A BASEMENT, A N EXCAVATED

AREA OR A CONFINED SPACE, IT IS STRONGLY RE COMMENDED TO

CONTACT A PROPANE SUPPLIER TO INSTALL A GAS DETECTING

WARNING DEVICE IN CASE OF A GAS LEAK.

•

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

SETTLE IN ANY LOW AREAS OR CONFINED SPACES.

PROPANE GAS ODORANT MAY FADE, MAKING THE GAS UNDETECTABLE

•

EXCEPT WITH A WARNING DEVICE.

WARNING

AN UNDETECTED GAS LEAK WILL CREATE A DANGER OF EXPLOSI ON

OR FIR E.

IF THE PRESENCE OF GAS IS SUSPECTED, FOLLOW THE

INSTRUCTIONS ON THE COVER OF THIS MANUAL.

COULD RESULT IN

SERIOUS PERSONAL INJURY OR DEATH.

FAILURE TO DO SO

Page 24

INSTALLATION CONSIDERATIONS

WARNING

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

FIRE OR EXPLOSION MAY RE SULT CAUSING PROPERTY D AMAGE, PERSONAL

INJURY OR LOSS OF LIFE.

O NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND

–

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 ,

SERVICE AGENCY OR THE GAS SUPPLIER.

Sizing Between First and Second Stage Regulator*

Ma ximum P r op ane C apacit ies li sted are based on 2 ps ig pr e ssur e dr o p at 10 psig s e tting. C apa cities in 1,00 0 BT U/hour .

O NOT TRY TO LIGHT ANY APPLIANCE.

O NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY

MMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR’S

FOLLOW THE GA S SUPPLIER ’S INSTRUCTI ONS.

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

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

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

PROPERLY POLARIZED AND GROUNDED.

WARNING

Pipe o r 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 - multi ply by 0.879

Sizing Between Second or Second S tage Regulator & Appli ance*

Maximum Pr op ane Capacities li ste d are ba sed on 1 /2 " W. C. pressu re drop a t 11" W.C. setting. C apa c ities in 1,00 0 BT U/ hour .

Pi pe or Tu bing

Len gth

Feet

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

10 39 92 199 329 50 1 2 75 567 1,071 2, 205 3,307 20 26 62 131 216 34 6 1 89 393 732 1,496 2,299 30 21 50 107 181 27 7 1 52 315 590 1,212 1,858 40 19 41 90 145 233 1 29 267 504 1,039 1,559 50 18 37 79 131 198 1 14 237 448 913 1,417 60 16 35 72 1,211 18 7 1 03 217 409 834 1,275

80 13 29 62 104 155 89 185 346 7 24 1,066 100 11 26 55 90 138 78 162 307 630 976 125 10 24 48 81 122 69 146 275 567 866 150 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 48 100 185 390 59 0

*Data in accordance with NFPA pam phlet No. 54

Tub ing Size, O .D. Typ e L

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

Tu bin g Siz e, O.D . Type L

Nominal Pipe Size

Sc he dule 40

Nomin al

Pipe S ize

Schedule 40

Propane Gas Piping Charts

WARNING

HIGH VOLTAGE D

ISCONNECT ALL POWER BEFORE SERVICING OR

INSTALLI NG THIS UNIT.

BE PRESENT.

DAMAGE, PERSONAL INJURY OR DEATH.

MULTIPLE POWER SOURCES MAY

FAILURE TO DO SO MAY CAUSE PROPERTY

CAUTION

ABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS.

WIRING ERRORS CAN COUSE IMPROPER AND DAN GEROUS OPERATION.

ERIFY PROPER OPERATION AFTER SERVICING.

WIRING HARNESS

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

115 VOLT LINE CONNECTIONS

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

Page 25

INSTALLATION CONSIDERATIONS

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.

IN 90% FURNACE UPRIGHT UPFLOW INSTALLATIONS, THE DRAIN 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 OF 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.

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 the Technical 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, INJURY, OR DEATH, THE

FURNACE MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH LOCAL

CODES OR, IN THEIR ABSENCE, WITH THE LATEST EDITION OF THE

ATIONAL ELECTRIC CODE.

115 VOLT LINE CONNECTION OF ACCESSORIES (ELECTRONIC AIR CLEANER)

WARNING

HIGH VOLTAGE D

ISCONNECT ALL POWER BEFORE SERVICING OR

CHANGING A NY ELECTRICAL WI RING.

SOURCES MAY BE PRESENT.

PROPERTY DAMA GE, PERSONAL INJURY OR DEATH.

MULTIPLE POWER

FAILURE TO DO S O MAY CAUS E

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.

Furnace

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

ACCESSORY LOAD SPECIFICATIONS

Ele ctr onic

Air Clea ner

Hum idifier

1.0 Amp maximum at 120 VAC

Furnace

Integrated

Control Module

Y C

Remo te Condensing Unit

(Single -St age Cool in g)

Thermostat - Two-Stage Heating with Single-Stage Cooling

Page 26

INSTALLATION CONSIDERATIONS

Remote Cond ensing Unit

(Two-Stage Cooling)

Thermostat - Two-Stage Heating with Two-Stage Cooling

Thermostat Wiring Diagrams

W1 W2

Furnace

Integrated

Control

Module

SINGLE-STAGE H EATING T HERMOSTAT A PPLICATION

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.

Room

Thermostat

G C

Furnac e 1

Ylo

Furnace 2

Ylo

R G

CIRCULATOR BLOWER SPEED ADJUSTMENT

WARNING

HIGH VOLTAGE

ISCONNECT ALL POWER BEFOR CHANGING SPEED TAPS.

ULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO

SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

Staging DIP S witches

DIP Switch S1-1 S1-2 Heat Staging

OFF OFF 2 Stage Stat* ON OFF 10 min delay

(factory setting) OFF ON AUTO

ON ON 20 min delay

* no high fire wi th out W2 call

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.

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.

WARNING

AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL 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. T1 terminal is always energized for Low Heat / Constant Fan speed.

5. T2 terminal is always energized for High Heat speed.

6. T3 terminal is always energized in Low Cooling.

7. T4 terminal is always energized in High Cooling.

Page 27

SYSTEM OPERATION

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

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

10.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 heating and cooling blower speeds that match the installation requirements from the airflow table in this manual or the Service 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

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

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.

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, the warranty will be voided.

Upflow furnaces with air delivery of less than 1800 CFM:

Use one side return or one bottom return ductwork connection.

Page 28

SYSTEM OPERATION

*MEC960302BN

G W1 W2 Ylo

Ylo

FACTORY

SETTING

All DIP Switch Positions

OFF OFF OFF

ON OFF OFF

ON ON OFF

OFF ON OFF

OFF OFF ON

OFF ON ON

DIP SWITCH SETTING

0.50.1 0.2 0.3 0.4

CFMRiseCFMRiseCFMRise CFMRiseCFMRise CFMCFMCFM

0.6 0.7 0.8

870 658 548 469 413 349 293 N/A 870 21 658 28 548 34 469 40 413 45 349 293 N/A 885 30 821 32 755 35 684 39 621 43 557 508 461 874 697 612 533 470 414 361 303

1146 1097 1049 1002 941 895 846 787

874 697 612 533 470 414 361 303 928 868 810 743 670 614 560 505

928 868 810 743 670 614 560 505

1146 1097 1049 1002 941 895 846 787

928 868 810 743 670 614 560 505 870 658 548 469 413 349 293 N/A

928 868 810 743 670 614 560 505 885 821 755 684 621 557 508 461

874 697 612 533 470 414 361 303

1146 1097 1049 1002 941 895 846 787

FACTORY

SETTING

ON OFF ON

ON ON ON

*MEC960402BN

All DIP Switch Positions

OFF OFF OFF

ON OFF OFF

ON ON OFF

OFF ON OFF

OFF OFF ON

Ylo

885 821 755 684 621 557 508 461

1146 1097 1049 1002 941 895 846 787

Ylo

885 821 755 684 621 557 508 461

874 697 612 533 470 414 361 303

DIP SWITCH SETTING

0.1 0.2

CFMRiseCFMRiseCFMRise CFMRiseCFMRiseCFMCFMCFM

847 694 611 535 471 415 357 313

847 29 694 36 611 41 535 47 471 53 415 357 313

989 36 932 38 882 40 819 43 773 46 695 650 586

Ylo

856 667 546 466 413 357 302

1143 1095 1046 996 946 890 834 778

Ylo

856 667 546 466 413 357 302

960 898 840 780 711 659 596 547

Ylo

960 898 840 780 711 659 596 547

1143 1095 1046 996 946 890 834 778

Ylo

960 898 840 780 711 659 596 547

847 694 611 535 471 415 357 313

Ylo

960 898 840 780 711 659 596 547

989 932 882 819 773 695 650 586

0.3 0.4 0.5

0.6 0.7 0.8

N/A

OFF ON ON

ON OFF ON

ON ON ON

Ylo

856 667 546 466 413 357 302

1143 1095 1046 996 946 890 834 778

Ylo

989 932 882 819 773 695 650 586

1143 1095 1046 996 946 890 834 778

Ylo

989 932 882 819 773 695 650 586

856 667 546 466 413 357 302

N/A

Page 29

SYSTEM OPERATION

*MEC960603BN

All DIP Switch Positions

FACTORY

SETTING

All DIP Switch Positions

OFF OFF OFF

W1 W2 Ylo

DIP SWITCH SETTING

0.1 0.2

CFM Ri se CF M Rise CFM Rise CFM Ri se CFM Ri se CFM CFM CFM

894 846 780 720 660 603 554 505

0.3

0.4

0.5

0.6 0.7 0.8

894 42 846 44 780 48 720 52 660 57 603 554 505

1328 40 1287 41 1249 43 1215 44 1170 46 1131 1085 1046

782 629 547 469 396 333

1236 1189 1149 1101 1066 1017 969 928

N/A N/A

FACTORY

SETTING

ON OFF OFF

ON ON OFF

OFF ON OFF

OFF OFF ON

OFF ON ON

ON OFF ON

ON ON ON

*MEC960803BN

All DIP Switch Positions

OFF OFF OFF

Ylo

782 629 547 469 396 333

1149 1104 1057 1017 963 918 865 822

Ylo

1149 1104 1057 1017 963 918 865 822

1236 1189 1149 1101 1066 1017 969 928

Ylo

1149 1104 1057 1017 963 918 865 822

894 846 780 720 660 603 554 505

Ylo

1149 1104 1057 1017 963 918 865 822

1328 1287 1249 1215 1170 1131 1085 1046

Ylo

782 629 547 469 396 333

1236 1189 1149 1101 1066 1017 969 928

Ylo

1328 1287 1249 1215 1170 1131 1085 1046

1236 1189 1149 1101 1066 1017 969 928

Ylo

1328 1287 1249 1215 1170 1131 1085 1046

782 629 547 469 396 333

DIP SWITCH SETTING

0.1 0.2 0.3

CFM Ri se CF M Rise CFM Rise CFM Rise CFM Rise CFM CFM CFM

1221 1172 1128 1087 1049 1005 959 922

1221 41 1172 42 1128 44 1087 46 1049 47 1005 959 922

1311 54 1293 55 1249 57 1203 59 1172 61 1122 1088 1041

Ylo

750 644 569 507 442 388 328

1111 1068 1025 984 941 885 N/A 801

0.4

0.5

0.6 0.7 0.8

N/A N/A

N/A

ON OFF OFF

ON ON OFF

OFF ON OFF

OFF OFF ON

OFF ON ON

ON OFF ON

ON ON ON

Ylo

750 644 569 507 442 388 328

894 842 784 726 682 618 562 519

Ylo

894 842 784 726 682 618 562 519

1111 1068 1025 984 941 885 N/A 801

Ylo

894 842 784 726 682 618 562 519

1221 1172 1128 1087 1049 1005 959 922

Ylo

894 842 784 726 682 618 562 519

1311 1293 1249 1203 1172 1122 1088 1041

Ylo

750 644 569 507 442 388 328

1111 1068 1025 984 941 885 N/A 801

Ylo

1311 1293 1249 1203 1172 1122 1088 1041

1111 1068 1025 984 941 885 N/A 801

Ylo

1311 1293 1249 1203 1172 1122 1088 1041

750 644 569 507 442 388 328

N/A

Page 30

SYSTEM OPERATION

*MEC961004CN

G W1 W2 Ylo

Ylo

FACTORY

SETTING

All DIP Switch Positions

OFF OFF OFF

ON OFF OFF

ON ON OFF

OFF ON OFF

OFF OFF ON

OFF ON ON

DIP SWITCH SETTING

0.1 0.2 0.3

CFM Rise CFM Rise CFM Rise CFM Rise CFM Ri se CFM CFM CFM

0.4

0.5

0.6 0.7 0.8

1522 1464 1402 1338 1280 1230 1167 1101 1522 41 1464 43 1402 44 1338 47 1280 49 1230 1167 1101 1861 48 1803 49 1749 51 1698 52 1653 54 1594 1549 1504 1004 890 805 710 620 553 474 406 1772 1713 1662 1609 1540 1498 1452 1399

1004 890 805 710 620 553 474 406 1312 1235 1170 1101 1037 962 880 820

1312 1235 1170 1101 1037 962 880 820 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 1772 1713 1662 1609 1540 1498 1452 1399

FACTORY

SETTING

ON OFF ON

ON ON ON

*MEC961205DN

All DIP Switch Positions

OFF OFF OFF

ON OFF OFF

ON ON OFF

OFF ON OFF

Ylo

1861 1803 1749 1698 1653 1594 1549 1504

1772 1713 1662 1609 1540 1498 1452 1399

Ylo

1861 1803 1749 1698 1653 1594 1549 1504

1004 890 805 710 620 553 474 406

DIP SWITCH SETTING

0.1 0.2

CFM Ri se CFM Rise CFM Ri se CFM Rise CFM Rise CFM CFM CFM

1796 1753 1697 1645 1589 1536 1478 1425

1796 42 1753 43 1697 44 1645 45 1589 47 1536 1478 1425

2211 48 2162 49 2122 50 2076 51 2029 53 1986 1984 1942

Ylo

1106 1017 946 855 764 681 605 N/A

1683 1628 1565 1511 1445 1387 1340 1276

Ylo

1106 1017 946 855 764 681 605 N/A

1399 1327 1259 1185 1118 1051 980 913

Ylo

1399 1327 1259 1185 1118 1051 980 913

1683 1628 1565 1511 1445 1387 1340 1276

Ylo

1399 1327 1259 1185 1118 1051 980 913

1796 1753 1697 1645 1589 1536 1478 1425

0.3 0.4

0.5

0.6 0.7 0.8

OFF OFF ON

OFF ON ON

ON OFF ON

ON ON ON

Ylo

1399 1327 1259 1185 1118 1051 980 913

2211 2162 2122 2076 2029 1986 1984 1942

Ylo

1106 1017 946 855 764 681 605 N/A

1683 1628 1565 1511 1445 1387 1340 1276

Ylo

2211 2162 2122 2076 2029 1986 1984 1942

1683 1628 1565 1511 1445 1387 1340 1276

Ylo

2211 2162 2122 2076 2029 1986 1984 1942

1106 1017 946 855 764 681 605 N/A

Page 31

SYSTEM OPERATION

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.

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 circuitry.

· 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

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.

Page 32

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

· 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 thi s heat cycle w ill not b e 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%

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.

Duty Cycle % Va lve Output De mand

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

88-100 1

Position Purpose Silkscreen

3-4

Stage, 12 m inute 2

Stage, 10 m inute 2

St age, 7 mi nut e 2

St age, 5 mi nut e 2

St age, 3 mi nut e 2

St age, 1 mi nut e 2

Heat OFF

Delay

3,4

Stage Light

St age Light to Average

Stage Average

St age Average to Heavy

Stage Heavy

Function

90 seconds OFF OFF 120 sec onds Off On 150 sec onds On * Off * 180 sec onds ON ON

Heat Mode Blower Off Delay Timing

Page 33

SYSTEM OPERATION

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.

· 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.

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.

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

Page 34

ACCESSORIES

GME95 & AMEH96 FURNACE ACCESSORIES

MODEL

NUMBER

Description

*MEC960302BNAA ●●●● ● ●

*MEC960402BNAA ●●●● ● ●

*MEC960603BNAA ●●●● ● ●

*MEC960803BNAA ●●●● ● ●

*MEC961004CNAA ●●●● ● ●

*MEC961205DNAA ●●●● ●

MODEL

NUMBER

EFR02 AFE18- 60 A AMU / GMU

EFR

Exte rnal

Filter Rack

DCVK- 2

(CVENT- 2)

Dual Fuel

Kit

DCVK- 30

(CVENT- 3)

Med ia Air

Cleaners

LPM08 LPLP03 RF000142 FTK04

ASAS /

GSAS

Elec tronic

Air

Cleaner

0170K00000S 0170K00001S

Concentric

Side Wall Flush Mount Ve nt Kit (3")

Concentric

Side Wall Flush Mount Vent Kit (2")

Description

*MEC960302BNAA ●●●● ● ●

*MEC960402BNAA ●●●● ● ●

*MEC960603BNAA ●●●● ● ●

*MEC960803BNAA ●●●● ● ●

*MEC961004CNAA ●●●● ● ●

*MEC961205DNAA ●●● ● ●

●

Approved Accessory for this model

Concentric

Vent Kit

(2")

Conc entric

Vent Kit

(3")

Propane

Gas

Conversion

Kit

Not Approved for this model

LP Low

Pre ssure

Shut Of

Kit

Vent Drain

Coupling

(2) W/R & HW 2 stg valve (4) 7,000 - 11,0 00 ft altitude (5) 7,000 - 9,000 ft al titude (6) 9,001 - 11,000 ft altitude

Twinning

Kit

Page 35

ACCESSORIES

EXTERNAL FILTER RACK KIT

EFR01 EXTERNAL FILTER RACK KIT

Used on Models

90% Upflow Model Fu rnaces

FRONT

OF UNIT

BASE

OF UNIT

( EFR02 )

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

Page 36

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

(Vertical Installation)

Combustion Air

Vent

Flush to

1" maximum

(Horizontal Installation)

Page 37

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

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

POWER SUPPLY

1.0K

6.8K

+5VDC

E/W1

+VDC +5VDC

+VDC

MICROPROCESSOR

24VAC

+VDC

W1-FURN W2-HP

G-STAT

G-FURN

Y2-HP

Y2-STAT Y2-FURN

Y-ST AT Y-FURN

Y-HP

BREAK FOR ODT

1 2

ALL FUEL SYSTEM CONTROL BOARD - AFE18-60A

This wiring diagram is for reference only. Not all wiring is as shown above.

Refer to the appropriate wiring diagram for the unit being serviced.

(For use with Heat Pumps in conjunction with 80% or 90% Single-Stage or Two-Stage Furnaces)

Page 38

SERVICING

SERVICE NUMBERS

S-1 CHECKING VOLT AGE................................................................................................................................. 45

S-2 CHECKING WIRING .................................................................................................................................... 45

S-3A THERMOST AT AND WIRING ....................................................................................................................... 45

S-3B HEATING ANTICIPA TOR .............................................................................................................................. 45

S-4 CHECKING TRANSFORMER AND CONTROL CIRCUIT.............................................................................. 46

S-16A CHECKING AIR CIRCULAT OR BLOWER MOTOR (EEM) ........................................................................... 46

S-200 CHECKING DUCT ST A TIC ........................................................................................................................... 46

S-201 CHECKING TEMPERA TURE RISE ............................................................................................................. 45

S-300 CHECKING PRIMARY LIMIT CONTROL...................................................................................................... 45

S-301 CHECKING AUXILIARY LIMIT CONTROL .................................................................................................... 48

S-302 CHECKING FLAME ROLLOUT CONTROL .................................................................................................. 50

S-303 INDUCED DRAFT BLOWER MOTOR.......................................................................................................... 50

S-304 CHECKING GAS V AL VE (REDUNDANT) .................................................................................................... 50

S-305 CHECKING MAIN BURNERS...................................................................................................................... 51

S-306 CHECKING ORIFICES ................................................................................................................................51

S-307 CHECKING GAS PRESSURE..................................................................................................................... 51

S-308 CHECKING HOT SURF ACE IGNITOR ......................................................................................................... 54

S-309 CHECKING FOR FLASHBACK ................................................................................................................... 54

S-310 CHECKING PRESSURE CONTROL ........................................................................................................... 54

S-31 1 HIGH ALTITUDE APPLICATION (USA)......................................................................................................... 55

S-312 CHECKING FOR DELA YED IGNITION ........................................................................................................ 55

S-313 CHECKING INTEGRA TED IGNITION CONTROL BOARDS........................................................................ 55

S-314 CHECKING FLAME SENSOR................................................................................................................... 56

Page 39

SERVICING

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

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.

VOLT / OHM METER

TRANSFORM ER

SECONDARY

VOLT / OHM METER

LIN E VOLTA GE (NEUTRAL)

PRIMARY

LI NE VOLTA GE L1 (HOT)

READS 144 VOLTS - OUT OF PHASE

OLT / OHM

METER

READS 96 VOLTS - IN PHASE

OLT / OHM

METER

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

NEUTRAL

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

Checking for polarization and phasing should become a

24 V

120 V

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).

Page 40

SERVICING

Seconds

for One

Revolution

1/4

cu/ft

One

CUBIC FEET

GAS RATE -- CU BIC FEET PER HOUR

Size of Test Dial

1/2

cu/ft1cu/ft2cu/ft5cu/ft

Seconds

for One

Revolution

1/4

cu/ft

Size of Test Dial

1/2

cu/ft1cu/ft2cu/ft5cu/ft

11 12

13 14

15 16

17 18

19 20

21 22

23 24

25 26

27 28

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

37 38

39 40

41 42

43 44

45 46

47 48

49 50

51 52

53 54

56 57

58 59

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

Page 41

SERVICING

Service P roblem No Heat Unsatisfactory Heat

POSSIBLE CAUSE

DOTS IN ANALYSIS

GUIDE INDICATE

"POSSI BL E C AUSE"

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 Co nt rol 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 Dirty 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 Delaye d Ignit i on Flashb ack Orific e Size Gas Pr es sure Cracked H eat Exchan ger Furnac e U nd ers ized Furnac e Ov e rsi zed Faul ty 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 Ignite

Syst em Wi ll Not Start

Burner Ignites-Locks Out

Burner Shuts Off prior to T'Stat being Satisfied

•

•••••

•

••

•

•••

•

••

•

•••

••

•• •

••••

•••

••

•

Long Cycles

Short Cycles

Too Much Heat

Not Enough Heat

Soot and /or Fumes

•• • •

•

•• •

•

••

•

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 Or ifices Che ck Ga s 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-3 B

S- 316

S-300 / S-302

S- 314

S- 313

S- 317

S- 303

S-16A,B,C

S- 308

S- 314

S- 304

S- 301

S- 200

S-201 / S-300

S- 312

S-309 / S-311

S-306 / S-311

S- 307

S- 305

S- 318

S- 310

S- 302

S- 310

Page 42

TROUBLESHOOTING

Symptoms

•Furnace fails to operate

•Control board LED is off

Green

LED Code

•None •None •None

Amber

LED Code

Red

LED Code

Fault Description Check Cautions

•D efective disconnec t s w itch

•defective door s witc h • No 115 volt power •No 24 volt power

•D et ermine cause a n d restor e proper high and low volt power supply

•Confirm elec trically safe condition before proceeding with repairs

•F urnace is w aiting for a call

•Furnace fan only is running

•Normal operation with low s t age call fo r co o li n g (Ylo & G)

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

•Normal operation with low s t age call fo r heat (W1)

•Normal operation with high or single stage call for h eat

•Furnace does not oper a t e, t h r ee A m ber flashes on c ontrol board

•Furnace does not oper a t e, fo u r Amber flashes on c ontrol board

•Furnace does not oper a t e, r apid Amb er flashes on c ontrol board

•Solid ON •None •Non e

•Rapid Flash •None •None

•One repeating flash

•Two repeating flashes

•None

•None •Rapid •None •Low flame sense current

•None •None

•One repeating flash

•Two repeating flashes

•Three repeating flashes

•Four repeating flashes

•None

•None •W2 call present without W1

•None

•Furnace is not receiving a call

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

•N o rma l o p e rat io n w it h low stage call fo r co o l in g (Ylo & G)

•Normal operation with high or sin g le st a g e call for c o o ling (Y & G)

•N o rma l o p e rat io n w it h low stage c all for heat (W1)

•Normal operation with high or sin g le st a ge call for heat

•Ylo or Y call present without G

•N one R eq uired

•Faulty thermostat or thermostat wiring or improperly connec ted thermostat wir es

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

•Confirm elec trically safe condition before proceeding with work

•Confirm elec trically safe condition before proceeding with repairs

•Clea n fla m e r o d wit h steel woo l. Co n f ir m elec t rically s a f e cond i tion before proceeding with repairs

•Furnace does not oper a t e, o n e R ed fla s h on control board

•Furnace does not oper a t e, t wo Red flashes on c ontrol board, possible inducer operation

•Furnace does not oper a t e, t h r ee R ed flashes on c ontrol board

•None •None

•One repeating flash

•Two repeating flashes

•Three repeating flashes

•Flame sens ed when no flame s ho u ld b e p r es en t

•Pressure switc h stuc k closed

•Low fire pressure switch stuck op en

•Ga s valve stuck open, improper wir ing to gas valve, shorted flame r od or wire

•Fau lty pr essu r e switc h, pressure switch wires shorted, control board inducer relay stuck c losed

•Fau lty pr essu r e switc h, pressure switc h or tubing or wiring / connection, c ontr ol board inducer relay fa iled, vent pipe restriction / exc essive elbows or length

•Confirm elec trical and gas safe conditions before proceeding with repairs

•Confirm elec trically safe condition before proceeding with repairs

Page 43

TROUBLESHOOTING

g cy

Symptoms

•Furnac e does not operate, four Red flashes on c ont rol board

•Furnac e does not operate, five Red flashes on c ont rol board

•Furnac e does not operate, six Red flashes on control board

•Furnac e does not operate, seven Red flashes on c ont rol board

•Furnac e does not oper ate, eigh t R ed flashes on c ont rol board

•Furnac e does not operate, nine R ed flashes on c ont rol board

•Furnac e does not operate, ten Red flashes on control board

Green

LED Code

•None •None

Amber

LED Code

Red

LED Code

•Four repeating flashes

•Five repeating flashes

•Six repeating flashes

•Seven repeating flashes

•Eight repeating flashes

•Nine repeating flashes

•Ten repeating flashes

Fault Description Check Cautions

•Open limit circuit, main limit, aux limit, or r oll out switch

•L im it & rollout circu it o p en for 15 minutes. Open control board fuse or rollout switc h

•Pressure switch cycling lockout, pressure switch has open ed 5 times in t h e same heatin

•Loc kout - excessive retries from flame not being pr oven during trial for ignition

• Lockout - excessive recycles from flame proving being lost after being proven

•Improper grounding or reverse polarity

•Gas valve current detected with no call for hea t

cle

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

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

•E xc essive venting restrictio n, leaking pressur e switch tubing

•Ga s pressure, gas valve, fr ont cover pressure switch, flame rod

•115 volt hot & neutral supply to furnace reversed, hot wire (door switch & L1 on control board) must read 11 5 volts to ground & neutral. Neutral wire should measure 0 volts to ground

•Ver ify g as valve is n o t receivin g v olta g e from an elect r ical sh o rt. If valve wiring is correct replace control board

•C o n fir m electrically sa fe condition before proceeding with repairs

•C o n fir m electrical an d gas safe conditions before proceeding with repairs

•C o n fir m electrically sa fe condition before proceeding with repairs

•C o n fir m electrical an d gas safe conditions before proceeding with repairs

•Furnac e does not oper ate, eleven R ed flashes on control board, inducer running

•Furnac e does not oper ate, twelv e R ed flashes on c ont rol board

•Furnac e does not operate, control board Red LED on solid

•Furnac e does not operate, control board Red LED ra pid flash

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

•Eleven

•None •None

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

•None •None •Rapid Flash •Twinning error •Corr ect twinning wiring

•None •None

repeating flashes

•Twelve repeating flashes

•Three double flashes

•Open limit switch circuit for more tha n 5 minutes

•Control board igniter relay not en er gizing ig n it er

•S econd s t age pr es su re switch stuck open

•Re-set main power and check indoor blower operation

•Replace control board

•Verify pr ess u re switc h function & tubing, verify inducer operating and pulling enough vacuum to engage switch

•C o n fir m electrically sa fe condition before proceeding with repairs

Page 44

DIAGNOSTIC C HART

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 R ECALL

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 F ROM L OCKOUT

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.

Page 45

SERVICING

S-1 CHECKING VOLTAGE

CHECKING THERMOSTAT, WIRING

AND ANTICIPATOR

WARNING

HIGH VOLTAGE

ISCONNECT ALL POWER BEFORE SERVICING OR

CHANGING ANY ELECTRICAL WIRING.

SOURCES MAY BE PRESENT.

PROPERTY DAMAGE, PERSONAL 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

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

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.

Page 46

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

ISCONNECT ALL POWER BEFORE SERVICING 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

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, 6-7 VDC when energized. From COM to T3, 13-14 VDC when energized. From COM to T4, 6-7 or 13-14 VDC depending on S2 settings.

POWER BEFORE SERVICING.

ALL

WARNING

LINE VOLTAGE NOW PRESENT

WARNING

HIGH VOLTAGE

ISCONNECT ALL POWER BEFORE SERVICING OR

INSTALLING THIS UNIT.

BE PRESENT.

DAMAGE, PERSONAL INJURY OR DEATH.

MULTIPLE POWER SOURCES MAY

FAILURE TO DO SO MAY CAUSE PROPERTY

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.

Page 47

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.

Page 48

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 VIEW

Primary Limit Control Style

(90% Furnaces)

WARNING

HIGH VOLTAGE D

ISCONNECT ALL POWER BEFORE SERV ICING OR

CHANGING A NY ELECTRICAL WI RING.

SOURCES MAY BE PRESENT.

PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

MULTIPLE POWER

FAILURE TO DO SO MAY CAUSE

1. Remove burner compartment door to gain access to the primary limit.

2. Remove low voltage wires at limit control terminals.

3. With an ohmmeter, test between these two terminals as shown in the following drawing. The ohmmeter should read continuous unless heat exchanger temperature is above limit control setting. If not as above, replace the control.

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.

Page 49

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

INSTALLING THIS UNIT.

BE PRESENT.

DAMAGE, PERSONAL 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

Page 50

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)

The control is designed to open should a flame roll out occur. An over firing condition or flame impingement on the heat shield may also cause the control to open. If the rollout control opens, the air circulation blower will run continuously.

WARNING

INE VOLTAGE NOW PRESENT

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

2. Reset the manual 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

INSTALLING THIS UNIT.

BE PRESENT.

DAMAGE, PERSONAL INJURY OR DEATH.

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. T ouch one probe of the ohmmeter to the motor frame

(ground) and the other probe in turn to each lead. If the windings do not test continuous or a reading is

obtained to ground, replace the motor .

5. If the windings have a continuity reading, reconnect

wires. Turn power on to the furnace and turn the thermostat on in the heating mode. Check voltage for 1 15V at the induced draft motor terminals during the trial for ignition. If you have 1 15V and the motor does not run, replace the induced draft motor .

6. After completing check and/or replacement of 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.

Page 51

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 model furnaces have factory installed #45 natural gas orifices (except *MEC96030 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

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.

ISCONNECT

34.5" Burner

WARNING

ALL G

AS AND ELECTRICAL POWER SUPPLY.

GAS STREAM

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

DENT OR BURR

GAS

STREAM

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

S-307 CHECKING GAS PRESSURE

Gas Supply Pressure Measurement

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.

Page 52

SERVICING

INLET OUTLET

Gas Valve On/Off Sele c tor Switch

White-Rodgers Model 36J54 (Two-Stage)

Inlet Pressure Boss

Outlet

Pressure Boss

High Fire Regulator

Adjust

(

)

Common Terminal(C)

Regulator

Low Fire Regulator Adjust

Vent

Open to

Atmosphere

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 A DJUSTMENT

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

)

(

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 Minimum: 4.5" w.c. Max im um : 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

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.

Page 53

SERVICING

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

o e

Terminal(C)

High Fire Coil Terminal (HI)

Low Fire Coil Terminal (LO)

Inlet Pressure Tap 1/8 NPT

Manifold Gas Pressure

Gas

Natural Low Sta

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

Propane Low Sta

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

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

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

Range Nom inal

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

O PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE

INLE T GAS SUPPLY PRESSURE MUST BE AS SPECIFIE D ON THE UNIT

RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES

OPERATI NG.

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.

Page 54

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 Nominal

Natural Gas

HIGH VOLTAGE D

ISCONNECT

SUPPLY BEFORE SERVICI NG OR INSTALLING THIS UNIT.

MULTI PLE POWER SO URCES MAY B E PRESENT. FAILUR E TO

DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

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 OFF GAS

The steady state current at 120V is 0.37 to 0.68 amps.

8. After checking and/or replacing of hot surface ignitor, reinstall burner compartment door and verify proper unit operation.

S-309 CHECKING FOR FLASHBACK

Flashback will also cause burning in the burner venturi, but is caused by the burning speed being greater than the gasair flow velocity coming from a burner port.

Flashback may occur at the moment of ignition, after a burner heats up or when the burner turns off. The latter is known as extinction pop.

Since the end results of flashback and delayed ignition can be the same (burning in the burner venturi) a definite attempt should be made to determine which has occurred.

If flashback should occur, check for the following:

1. Improper gas pressure - adjust to proper pressure (See S-307 CHECKING GAS PRESSURE)..

2. Check burner for proper alignment and/or replace burner.

3. Improper orifice size - check orifice for obstruction.

S-310 CHECKING PRESSURE 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 SERVICING OR INSTALLING.

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 - *MEC96 furnaces use a 120V

silicon nitride igniter for ignition. The normal operating tem-

perature is approximately 2156°F - 2678°F. At room tem-

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

7. Place unit in heating cycle, measure current draw of ignitor during preheat cycle.

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.

Page 55

SERVICING

***

O F

23PC

COIL COVER

PRESSURE SWITCH

INDUCED

DRAFT

BLOWER

INDUCED DRAFT BLOWER

PRESSURE SWITCH

HOSE

1/4" TE E

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

O AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO THE UNIT

MUST BE PROPERLY POLARIZED AND GROUNDED.

BEFORE PERFORMING SERVICE LISTED BELOW.

ISCONNECT POWER

The ground wire must run from the furnace all the way back to the electrical panel. Proper grounding can be confirmed by disconnecting the electrical power and measuring resistance between the neutral (white) connection and the burner closest to the flame sensor. Resistance should be less than 2 ohms.

The ignition control is a combination electronic and electromechanical device and is not field repairable. Complete unit must be replaced.

WARNING

INE VOLTAGE NOW PRESENT

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

The 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 (*MEC96)

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

Page 56

SERVICING

59-5043 REV. D

T4E9T3

E190

R783

R89

R94

Q72

FLAME

CURRENT

W15

W16

W19

W46

R566

R578

R568

R580

R557

R76

R118

R82

W52

R38

R71

R115

R29

R15

W2 R

W20

W37

CAUTION - 120V

W49

ST1

R97

R200

1 2 3 4

OFF

1 2 3

OFF ON

DS1

STATU S

LAST

ERROR

SW3

ST3

E14

E13

K11

K2 K1

R782

R784

R93

R96

R95

R92

W39

R201

R586

R50

R588

R39

R40

R49

R204

R35

W10

GL1

W40

R570

R581

R562

R563

R584

Q13

Q11

R564

R573

R553

R10

Yl0

E31

R27

R130

R11

R13

E10

ST5

CIRC-H

EAC-H

R781

R88

Q71

W35

R202

E35

E36

W33

(1VDC=1u A)

C14

E12

R31

R18

R17

R12 R16

HUM

XFMR

E28

E16

E15

E29

W18

K10

W34

C60

C15

W31

W53

R79

R81

R85

R77

R780

R59

R63

R41

R75

R87

GCTWIN

E5GE4

TWIN

W36

E32

W14

W22

R33

R44

NEUTRALS

E18

E17

W11

Q70

W13 W30

R61

Q10

Q14

R70

R53

R524

R119

R91

E39

W24

R65

R21

R54

E21

E20

E19

ST2

HIGH VOLTAGE D

ISCONNECT

INSTALLING TH IS UNIT.

BE PRESENT.

ALL

POWER BEFORE SERVICING OR

AILURE TO DO SO MAY CAUSE PROPERTY

WARNING

ULTIP LE POWER SOUR CES MAY

DAMAGE, PERSONAL INJURY OR DEATH.

Flame current can be measured in two ways:

E40

R60

W44

R78

R58

R73

R74

Q60

C11

W12

W29

ST6

W32

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 24 VAC 60Hz. 0.5A MAX

Flame Current

Solder Pads

E22

RV3

RV4

W51

C13

CR13

ST4

E26 E27

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.

WARNING

LINE VOLTAGE NOW PRESENT

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.

Page 57

MAINTENANCE

WARNING

HIGH VOLTAGE D

ISCONNECT ALL POWER BEFORE SERVICING OR

INSTALLING 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. T OUCHING

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 WIHTOUT A FILTER INSTALLED AS DU ST

AND LINT WILL BUILD UP ON INTERNAL PAR TS RE SULTI NG 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.

Page 58

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

COMPARTMENTS .

DEATH, DO NOT REMOVE ANY INTERNAL COMPARTMENT COVERS

OR ATTEMPT ANY ADJUSTMENT.

SERVICE AGENT AT ONCE IF AN ABNORM AL FLAME

APPEARANCE SHOU LD DEVELOP .

TO AVOID ELECTRICAL SHOCK, 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.