Intertek ACVC96, AMVC96, GCVC96, GMVC96 Service Instructions Manual

Service Instructions
®
34.5" Chassis
ACVC96/AMVC96
GCVC96/GMVC96
Gas
Furnaces
This manual is to be used by qualified, professionally trained HVAC technicians only. Goodman does not assume any responsibility for property damage or personal injury due to improper service procedures or services performed by an unqualified person.
The material in this manual does not supercede manufacturer's installation and operation instructions
is a registered trademark of Maytag Corporation or its related companies and is used under license. All rights reserved.
RS6612010
August 2014
Copyright © 2014 Goodman Company, L.P.
TABLE OF CONTENTS
IMPORTANT INFORMATION..................................... 2 - 5
PRODUCT IDENITIFICATION .................................. 6 - 10
ACCESSORIES .................................................... 11 - 13
INSTALLATION CONSIDERATIONS...................... 14 - 39
SYSTEM OPERATION.......................................... 40 - 44
TROUBLESHOOTING ........................................... 45 - 50
SYSTEM OPERATION COMFORTNET™ ............ 51 - 56
SERVICING .......................................................... 57 - 75
MAINTENANCE ................................................... 76 - 77
ACCESSORY WIRING DIAGRAMS ..................... 78 - 79
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
WARNING
T
O PREVENT THE RISK OF PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH, DO NOT STORE COMBUSTIBLE MATER IALS OR USE GASOLINE OR OTHER FLAMMABLE LIQUIDS OR VAPORS IN THE VICINITY OF THIS APPL IANCE.
WARNING
G
OODMAN WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES.
I
F YOU INSTALL OR PERFORM SERVICE ON THIS UNIT, YOU ASSUME RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROPERTY DAMAGE W HICH
MAY RESULT.
M
ANY JURISDICTIONS REQUIRE A LICENSE TO INSTALL O R SERVICE HEATING AND A IR CONDITIONING EQUIPMENT.
WARNING
HIGH VOLTAG E D
ISCONNECT ALL POWER BEFOR E SERVICING OR
INSTALLING THIS UNIT. BE PR ESENT. DAMAGE, PERSO NAL INJURY OR DEATH.
FAILURE TO DO SO M AY CAU SE PROPERTY
MULTIPLE POWER SOURCES MAY
2
IMPORTANT INFORMATION
Speci al Warning for Installation of Furnace or Air Handling Units in Enclosed A reas such as Garage s, Utility Ro oms or Parki ng A r eas
Carbon monoxide producing devices (such as an auto mobile, space heater, gas water heater, etc.) should not be operated in enclosed areas such as un ve n tilated garages, ut ility rooms or parking areas because of the danger of carbon mo noxide (CO) poisoning resulting from the exhaust emissions. If a furnace or air handler is installed in an enclosed area such as a garage, utility room or parking area and a carbon monoxide producing device is operated therein, there must be adequate, direct outside ventilation.
This ventilation is necessary to avoid the danger of CO poisoning which can occur if a carbon monoxide producing device continues to operate in the enclosed area. Carbon monoxide emissions can be (re)circu l a ted throughout the structure if t he furnace or air han dler is operating in any mode.
CO can cause serious illness in clud ing per man e nt brain dama ge or deat h.
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.)
(Not a technical assistance line for dealers.) Your telephone company will bill you for the call.
CONSUMER INFORMATION LINE
AMANA® BRAND PRODUCTS
TOLL FREE
1-877-254-4729 (U.S. only)
email us at:
hac.consumer.affairs@amanahvac.com
fax us at: (731) 856-1821
(Not a technical assistance line for dealers.)
Outside the U.S., call 1-713-861-2500.
3
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
other flammable vapors and liquids in the vicinity of this or any other app liance.
4
Do not store or use gasoline or
0140F00001P
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"
^
5
PRODUCT IDENTIFICATION
The model and manufacturing number are used for positive identification of component parts used in manufacturing. Please use these numbers when requesting service or parts information.
G M V C 96 080 4 C N A A
PRODUCT
TYPE :
G: Go od m a n A: Amana®
Brand
D: A m ana®
Distinctions™ Brand
M: Upflo w/Horizon tal D: De cidated Downflow C: Downfl ow/Horiz on tal H: High Air Flow
FURNACE
TYPE
E: T wo-Stage/ S: Single-Stage / V: T wo Stage/ Spee d
H: Two Sta ge Gas Valve -
SUPPLY TYPE
COMMUNICATION FEATURE
C: 4-Wire Communicatio n Ready
X-13 Mot or Multi-Speed Varia ble-
Multi-Speed
NOMI NAL I NPUT
040: 40,000 Bt uh 060: 60,000 Bt uh 080: 80,000 Bt uh 100: 100,000 Bt uh 120: 120, 000 B tu h
AFUE
8: 80% 9: 90%
95: 95 %
AIRFLOW
CA PABILITY
@ 0.5" E SP
3: 12 00 4: 16 00 5: 20 00
CABINET
WIDTH
A: 14" B: 17- 1 /2" C: 21 " D: 24 - 1 /2"
MAJOR REVIS ION
A: In itial R e le ase
MI NOR REVI S ION
A: In itial R e le ase
ADDITIONAL
FEA TURE S
N: Natural Gas X: L o w N O x
6
PRODUCT IDENTIFICATION
MODEL: GMVC96 REV AA
Equipment Ty pe Goodman Brand Residential Gas Furnace Heating Stages Two Cooling Stages Two Control Type ClimateTalk Blowe r Motor Type 4 Wire Variable Speed ECM
GMV C96
Installation Positions BTUH Input Low Fire (X 1000) BTUH Input High Fire (X 1000) A/C Capable Tons Cabinet Hig ht " Cabinet Width " Heating CFM @ 100% Firing Rate Draft Inducer Gas Valve 24 VAC Heating Inputs 24 VAC Cooling Input s Primary He at Exchanger
Accessory Terminals
Gas Line Entry
Revision Attributes
Two Speed Two Stage W1 / W2 Y1 / Y2 Alum inized Steel EAC terminal, Field Powered H UM IN / HUM OUT terminals, Single Hu m termi nal
powered simultaneously with draft inducer, AUX circuit Left or Right
First revision of 34.5" two stage commu nicating capable up flow furnace
MODEL: AMVC96
Equipment Type Amana Brand Residential Gas Furnace Heating Stages Two Cooling Stages Two Con tro l Type ClimateTalk Blower Motor Type 4 Wire Variable Speed ECM
™ or Conventional 24 Volt
0403BN 0603BN 0803BN 0804CN 1005CN 1205DN
UF, Hor L/R UF, Hor L/R UF, Hor L/R UF, Hor L/R UF, Hor L/R UF, Hor L/R
30 45 60 60 75 90 40 60 80 80 100 120
1.5 - 3 1.5 - 3 1.5 - 3 2 - 4 1.5 - 5 2 - 5
34.5 34.5 34.5 34.5 34.5 34.5
17.5 17.5 17.5 21 21 24.5 553 1059 1316 1337 1870 1940
REV AA
™ or Conventional 24 Volt
MODEL: GCVC96 REV AA
Equipment Typ e Goodman Brand Residential Gas Furnace Heating St a ge s Two Cooling Stages Two Con t rol Type ClimateTalk
™ or Conventional 24 Volt
Blow e r Mo tor Ty p e 4 Wire Variable Speed ECM
GCV C9 6
Installati on P ositions CF, Hor L/R CF, Hor L/R CF, Hor L/R CF, Hor L/R CF, Hor L/R CF, Hor L/R BTUH Input Low Fire (X 1000) 30 45 60 60 75 90 BTUH Input Hi gh Fire (X 1000) 40 60 80 80 100 120 A/C Capable Tons 1.5 - 3 1.5 - 3 2 - 4 2 - 4 2 - 5 2 - 5 Cabinet Hi ght " 34.5 34.5 34.5 34.5 34.5 Cabinet Width " 17.5 17.5 21 21 24.5 Heating CFM @ 100% Firing Rate 1059 950 1146 1325 1797 1827 Draft Inducer Gas V alve 24 VAC Heating Inputs 24 VAC Cooling Inputs Primar y Heat Exchanger
Accessory Terminals
Gas L ine Entry
Revisi o n Attr i butes
0403BN 0603BN 0803BN 0804CN 1005CN 1205DN
Two Speed Two Stage W1 / W2 Y1 / Y2 Aluminized Steel EAC termina l, Field Powered HUM IN / HUM OUT terminals, Single Hum term inal
powe red simultaneously wit h draft inducer, AUX circuit
Left or Right
First revi sion of 34.5" modulating counter fl ow furnace
MODEL: ACVC96 REV AA
Equipment Ty pe Amana Bra nd Residential Gas Furnac e Heating Stages Two Coo lin g Stages Two Cont ro l Ty pe ClimateTalk Blowe r M o tor Type 4 Wire Variable Speed ECM
™ or Conventional 24 Volt
AMVC96
Ins tallation Positions BTUH Input Low Fire (X 1000) BTUH Input High Fi re (X 1000) A/C Capable Tons Cabinet Hight " Cabinet Width " Heating CFM @ 100% Firing Rate Draft Inducer Gas Valve 24 VAC Heating Inputs 24 VAC Cooling Inputs Primary Heat Exchanger
Accessory Terminals
Gas Line Entry
Revi sion Attributes
0403BN 0603BN 0803BN 0804CN 1005CN 1205DN
UF, Hor L/R UF, Hor L/R UF, Hor L/R UF, Hor L/R UF, Hor L/R UF, Hor L/R
30 45 60 60 75 90 40 60 80 80 100 120
1.5 - 3 1.5 - 3 1.5 - 3 2 - 4 1.5 - 5 2 - 5
34.5 34.5 34.5 34.5 34.5 34.5
17.5 17.5 17.5 21 21 24. 5
553 1059 1316 1337 1870 1940 Two Speed Two Stage W1 / W2 Y1 / Y2 Stainless Steel EAC terminal, Field Powered HUM IN / HUM OUT term i nals, Single Hum terminal
powered simultaneously with draft induce r, AUX circuit Left or Right
Firs t r evision o f 34.5" two st ag e c o mmunicating c apable u p flow furn ac e
ACVC96
Inst allatio n Positi o n s CF, Hor L/R CF, Hor L/R CF, Hor L/R CF, Hor L/R CF, Hor L/R CF, Hor L/R BTUH Input Low Fire (X 1000) 30 45 60 60 75 90 BTUH Input High Fire (X 1000) 40 60 80 80 100 120 A/C Capable Tons 1.5 - 3 1.5 - 3 2 - 4 2 - 4 2 - 5 2 - 5 Cabinet Hight " 34.5 34.5 34. 5 34.5 34.5 Cabinet Width " 17.5 17.5 21 21 24.5 Heating CFM @ 100% Firing Rate 1059 950 1146 1325 1797 1827 Draft Inducer Gas Valve 24 VAC Heating Inputs 24 VAC Cooling Inputs Primary Heat Ex changer
Accessory Terminals
Gas Line Entry
Revision Attributes
0403BN 0603BN 0803BN 0804CN 1005CN 1205DN
Two Speed Two Stage W1 / W2 Y1 / Y2 Stainless Steel EAC terminal, Field Powered HUM IN / HUM OUT term in als, Singl e Hum terminal
powered simul taneously with draft inducer, AUX circuit
Left or Right
First revision of 34.5" modulating counter flow furnace
7
PRODUCT IDENTIFICATION
MODE L # MFG # DESCRIPTION
AFE18-60A
AMU1620 AMU1625 AMU2020 AMU2025
GMU1620 GMU1625 GMU2020 GMU2025
ASAS-10 ASAS-11 ASAS-12 ASAS-18
CFSB17 CFSB21 CFSB24
N/A
P1251305F P1251306F P1251307F P1251308F
N/A
P1251301F P1251302F P1251303F P1251304F
N/A
Fo ssil Fuel K it.
above/do wnstream of a gas or f ossil fuel f urnace when used wit h a hea t pump. It will operate with single and t wo stage hea t pumps and single and two stage f urnaces. The AFE 18-60A cont rol will tu r n the heat pu mp unit off wh en the f ur nace is turned on. An ant i- short cycle feature initiates a 3 minute timed off d elay when the compressor goes of f.
Med ia Air Cl eaner.
fur n ac e models. The Amana (A MU*) and Goodman (GMU*) Media Air Cleaner is a high 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 u p to 2, 000 C FM capac ity. The air cl eaner should be installed in the system so that all the sy stem air is circ ulated thr ou gh t he air c leaner . The air cle aner will only remove t he air b orne contaminant s delivered to it. Maximum per formance is obtained when the syst em blower is set f or cont in uous operation. Carbon filters (opt io nal) are available.
Electronic Air Cleaner.
Brand furnace models. T he H igh- Efficiency Electronic Air Cleaner i s designed to r emove air cont aminant s down to .01 micr ons. Car b on filt er s (optional) re move odors. D ual in dic ator lights show unit operation a t a glance. Electronic pr o ving switch cycles the air c lea ner On/ Off with the system f an . Durable powder-coat paint finish resists corrosion.
C ounterflow S ubbase K it.
models ACV C9 an d GCVC9. These kits are available for the fo llow ing furnac e wid ths: 17.5" wide (CFSB17) , 21" w ide (CFS B 21) and 24" wide (CFSB24) . The kits must b e used t o pr event excessi ve temperat ur e from r eaching combustible mater ials, if the furnace is installed on a combustible f loor . T his subbase effec tively separate d the furnace base and plenum fro m combustible materia ls. To ensure safe installation, d o not install the counterf low floor base directly on car peting, tile, or other combustible material other than wood f looring.
The AFE18-60A cont r o l is designed for use where the i ndoor coil is located
For use with c ur r ent ar c hitect ur al gr ey Goodman® and A mana® B r and
For use with current ar chitectural grey Goodman® and Amana®
For use with select Goodman® and Amana ® B r and 34.5" furnac e
CTK01AA
CTK01BA
CTK01AA
CTK01BA
Communicating Thermostat Kit-
for use with c ompat ible Amana® B rand or Goodman® Brand Air Handlers or Furnaces and outdoo r split AC or Heat Pump units. T his the r mostat supports up to three stages of he at, two stages of co oling, dual f uel app lic ations, dehumidification, filter maintenan c e r eminders, outdoo r temperature display an d advanced menus including diagnostic s. The CT K 01 AA k it includes a communicating touchscree n thermostat and sub base, 230V-24V 40va tr an sfor mer, ter minal bloc k s(2), wire jumpers, mounting screws, insta llation manual and homeowner guide.
Communicating Thermostat Kit-
for use with c ompat ible Amana® B rand or Goodman® Brand Air Handlers or Furnaces and outdoo r split AC or Heat Pump units. T his the r mostat supports up to three stages of he at, two stages of co oling, dual f uel app lic ations, dehumidification, filter maintenan c e r eminders, outdoo r temperature display an d advanced menus including diagnostic s. The CT K 01 B A kit includes a communicating touchscree n thermostat and sub base, t erminal blocks(2), installat ion manual and homeowner gui de.
Digit ally communic ating touchscreen thermostat . Designed
Digit ally communic ating touchscreen thermostat . Designed
8
PRODUCT IDENTIFICATION
MODE L # MFG # DES C RIPTI O N
CTK02**
CTK03AA
CTK03AB
CTK04
CTK02**
CTK03AA
CTK03AB
CTK04AA
C ommu nicat ing Thermo st at Kit-
use with compat ibl e Amana ® Brand or Goodman® Bran d Air Handlers or Furnaces and out door split AC or Heat Pump units. The CTK02** th er mostat featu r es a f ull c o lor high def ini tion display , advanced programming options including hu midif ic ation control & heat and cool maximum temperatur e set tings, a USB plug allowing dealer s t he abilit y to insert pre-progr ammed operat in g par amet ers and dealer info r mat ion by use of an onlin e da ta entry system.
C ommu nicat ing Thermo st at Kit-
fr o m Honeywell. De signed f or use with c ompat ib le Amana® Brand or Goodman® Bra nd Air Handlers or Furnaces and outdoor split AC or Heat P ump unit s. The CTK 0 3AA thermostat featu r es f ull color high definition display and can be used with RedLINK wireless a ccessor ies.
C ommu nicat ing Thermo st at Kit-
fr o m Honeywell. De signed f or use with c ompat ib le Amana® Brand or Goodman® Bra nd Air Handlers or Furnaces and outdoor split AC or Heat P ump unit s. The CTK 0 3AB thermost at fe atures full c o lor hig h definit ion display and ca n be u sed with RedLI NK wi r ele ss accessor i es and added c apa bilty to c ontrol the HUM IN - HUM OUT relay.
C ommu nicat ing Thermo st at Kit-
fr o m Honeywell. De signed f or use with c ompat ib le Amana® Brand or Goodman® Bra nd Air Handlers or Furnaces and outdoor split AC or Heat P ump unit s. The CTK04 thermo stat f eatures full c olo r hi gh definition display and can be used wit h Red LINK wireless accessories a nd adde d c ap abilty to contr ol the HUM IN - HUM OUT r e lay. Split system inverter c apabl e.
Digit ally communic a ting t her mostat . Designed for
Digit ally communic a ting t ouc hscr een thermostat
Digit ally communic a ting t ouc hscr een thermostat
Digit ally communic a ting t ouc hscr een thermostat
DCVK-20
(CVENT-2)
DCVK-30
(CVENT-3)
0170K00000S
0170K00001S
DEHUM1
N/A
N/A
N/A
P1227801F
Concentric Vent Kit.
designed to allow terminations of a dir ec t vent furnace to be "concent rically" vented through a wall or roof. This kit allows a sing le pen etrat ion to support terminations f or both the vent/flu e and the combustion air intake pipe. The DCVK-20 ( 2") and DCVK-30 (3" ) ki t s are cer tified for models list ed above. See specificat ion sheet s on fut ur e models for use of the vent k i t.
Side Wall Only Concentric Vent K it
used with 2" - 3" vent systems. The vent k it must ter minat e outside the structure. This kit is NOT int end ed for use with single pipe (i ndirect vent) insta llations.
Side Wall Only Concentric Vent K it
used only with 2" vent systems. The vent k it must ter minat e ou tside the stru c ture. This kit is NOT int end ed for use with single pipe (i ndirect vent) insta llations.
Dehumidistat.
fur nac e models. W all mounted, 24 volt humidit y contro l available as a Dehumidistat used to reduc e t he air flow in the air c onditioning mode when necessar y to lower the humidity in an occupied home to pr e vent dew build- up associated with high humidity levels. T his control featur es a moisture-sensitive nylon element and al so provides positive ON-O FF set tings for manual oper ation. The control is a normally closed switch that opens on humidity rise causing t he bl ower to switch to a lower speed t o c on trol t h e humidity within the structure.
For use with Amana® B rand 90% f ur nac e models. This kit is
. F or use with 90% f ur nac e models. This kit is to be
. F or use with 90% f ur nac e models. This kit is to be
For use with Goodman® and Amana® Brand two-stage variable speed
9
PRODUCT IDENTIFICATION
MODEL # MFG # DESCRIPTION
EFR02
HASFK-1
LPLP03
LPM-08
N/A
N/A
N/A
N/A
External Filt er Rack Kit.
speed gas furnace models. This kit is intended to provide a locat ion, external to the furnace casing, f or installation of a permanent filter. The rack is mount ed over the indoor air blower compartment area of eit her side panel, and provide filter retention as well as a locat ion f or att ac hing r et ur n air duc t wor k.
High Altitude Natural Gas Kit.
stage furnac e models. These kits are required when inst alling t he f ur nac es abov e t heir maximum r ated altit ude. T he or if ic es in the kit have been select ed as a result of t esting wit h t he American Gas A ssociation. They will pr ovide appropriate der ating at the altit ude listed in the High Altit ude Char ts as shown in the installations of the kit.
LP Gas Low Pressure Kit.
fur nace produc ts installed on LP gas listed in this manual. This k it includes harness adaptors to work wit h W hit e- Rodgers single & two stage gas valves,Honeywell single and two-stage gas v alves, as well as modulating gas valves.
LP Conversion Kit.
models using a Whit e- Rodger s 36J54,, 2-stage gas v alve kit. Includes regulator springs,
1.25mm orifices, instruc tions and a label to show the furnace has been c onverted to L.P.
For use with G oodman® and A mana® Brand 90% upflow variable
Used on selected Goodman® Brand and Amana® B r and 90% two
Designed for applicat ion on Goodman® and A mana® Brand' s gas
For use with Goodman® and Amana® Brand 34.5" 2-stage variable speed
10
ACCESSORIES
96% C om Furn ace Accessories
Model
Number
Description
*MVC960403BN**XXXX X
*MVC960603BN**XXXX X
*MVC960803BN**XXXX X
*MVC960804CN**XXXX X
*MVC961005CN**XXXX X
*MVC961205DN**XXXX X
*CVC960403BN** X X X X X
*CVC960603BN** X X X X X
*CVC960804CN**XXXXX
*CVC961005CN**XXXXX
*CVC961205DN** X X X X X
Model
Number
Description
*MVC960403BN**XXXXXXXX *MVC960603BN**XXXXXXXX *MVC960803BN**XXXXXXXX *MVC960804CN**XXXXXXXX *MVC961005CN**XXXXXXXX *MVC961205DN**XXXXXXXX *CVC960403BN**XXXXXXXX *CVC960603BN**XXXXXXXX *CVC960804CN**XXXXXXXX *CVC961005CN**XXXXXXXX *CVC961205DN**XXXXXXXX
AFE180- 60A AMU / GMU EFR02 ASAS / GSAS CFSB17 CFSB21 CFSB24 RF000142
Fossil
Fuel
Kit
CTK01* CTK02 * CTK0 3 * CTK04 * 0 170K0 0 0 0 0 S 0170K0 0 0 01S
Com.
Thermostat
Kit
Media Air Cleaners
Com
Thermostat
Kit
Modulating,
High Def
Externa l
Filter Rack
Com
Thermosta
Kit
Modulating,
High Def
Electronic
Air
Cleaner
Com
Thermosta t
Kit
Modulating,
High Def
Downflow Subba se
17.5"
Conce ntric
Side Wall
Vent Kit (3")
Downflow
Subbase
21"
Conce ntric
Side Wall
Vent Kit (2")
Downflow
Subbase
24.5"
DCVK- 20
(CVENT- 2 )
Conce ntric
Vent Kit (2")
Drain
Coupling
Kit
DCVK- 30
(CVENT- 3 )
Conce ntric
Vent Kit (3")
Model
Number
Description Dehumidista t L.P. Kit
*MVC960403BN**XXXX
*MVC960603BN**XXXX
*MVC960803BN**XXXX
*MVC960804CN**XXXX
*MVC961005CN**XXXX
*MVC961205DN**XXXX
*CVC960403BN**XXXX
*CVC960603BN**XXXX
DEHUM1 LP M- 0 8 LPLP0 3 HASFK- 1
Low LP
Tank
Protection
High Altitude
Kit
11
ACCESSORIES
EXTERNAL FILTER RACK (EFR02)
96% Upflow Model Furnaces
FRONT
OF UNIT
BASE
OF UNIT
UNIT SIDE
PANEL
RETURN AIR
CUTOUT AREA
SLOTS IN FILTER CLEAR SCREWS
ON UNIT
BLOWER DECK
SCREWS
LOWER EDGE
SCREW
FILTER RACK ASSEMBLY
(FACE FILTER OPENING
TOWARDS FRONT
OF UNIT)
SIDE WALL VENT KITS (0170K00000S) (0170K00001S)
Description 0170K00000S
This side wall only vent kit #0170K00000S is to be used with 2” - 3” vent systems. This kit is NOT intended for use with single pipe (indirect vent) installations.
The vent kit must terminate outside the structure and may be installed with the intake and exhaust pipes located side-by­side or with one pipe above the other.
See the section in this manual under "Vent Flue and Combustion Air Pipe Terminations" for more information or consult the Installation Instructions (IO-635).
0170K00001S
This vent kit is to be used with 2” vent systems. The vent kit must terminate outside the structure and may be installed with the intake and exhaust pipes located side-by side or with one pipe above the other. This kit is NOT intended for use with single pipe (indirect vent) installations.
See the section in this manual under "Vent Flue and Combustion Air Pipe Terminations" for more information or consult the Installation Instructions (IO-805).
Horizontal Installation
12
Vertica l I n s tallatio n
ACCESSORIES
CONCENTRIC VENT CONVERSION KIT
The CVENT-2 (DCVK20) (2") or the CVENT-3 (DCVK-30) (3") is a concentric vent kit approved with furnaces listed in this manual.
This concentric vent kit allows for vertical or horizontal vent termination. The illustrations give a brief view of the kit and its application.
See the section in this manual under "Vent Flue and Combustion Air Pipe Terminations" for more information or consult the Installation and Operating Instructions (IO-619*).
Vent
Maintain 12" (18" for Canada) minimum clearance above highest anticipated snow level. Maximum of
Combustion Air
24" above roof.
Roof Boot/Flashing (Field Supplied)
Support (Field Supplied)
45 Elbow (Field Supplied)
Vent
Combustion Air
DCVK (Vertical Installation)
AFE18-60A Dual Fuel Accessory
When installing the communicating capable furnace with a heat pump, the preferred installation would include a com­municating thermostat. A communicating thermostat pro­vides control of gas heat and heat pump operation and elimi­nates the need for a separate dual fuel control. A legacy dual fuel thermostat could also be used with 24 volt wiring to control the gas furnace and heat pump. If a communicating thermostat or legacy dual fuel thermostat are not used, the AFE18-60A kit must be added to provide control of the equip­ment. This control is mounted indoors near the furnace and provides terminals for thermostat, furnace, and heat pump wiring. The AFE18-60A may be used with or without a sepa­rate outdoor thermostat.
CFSB17, 21, 24 Counter Flow Base
The CFSB base must be used when installing a *CVC96 furnace in the vertical position on a combustible floor with­out a coil under the furnace.
Vent
Combustion Air
Strap (Field Supplied)
45 Elbow (Field Supplied)
Combustion Air
Flush to
1" maximum
DCVK (Horizontal Installation)
LPLP03 Low LP Gas Pressure Shut-off Kit
Installation of the LPLP03 kit is recommended on every L.P. converted furnace to protect the furnace against low L.P. gas supply pressure. Low L.P. supply pressure can cause poor combustion and carbon in the heat exchanger. The LPLP03 kit will open the electrical circuit to the gas valve in the event of low supply pressure. The kit contains a pres­sure switch, gas fittings and electrical harness to connect the switch in series with the gas valve.
LPM-08 LP Conversion Kit
This furnace is factory equipped to operate on Natural Gas but may be field converted to operate on L.P. gas. To con­vert a *MVC96 or *CVC96 furnace to operate on L.P. gas, the LPM-08 conversion kit must be used. The LPM-08 kit contains a set of 1.25 mm orifices to replace the factory installed natural gas orifices and a set of springs to convert the gas valve to L.P. gas.
OT18-60A Outdoor Thermostat
For use in a legacy dual fuel installation to lock-out the heat pump at a selected temperature.
Vent
13
INST ALLATION CONSIDERA TIONS
Safety
Please adhere to the following warnings and cautions when installing, adjusting, altering, servicing, or operating the fur­nace.
WARNING
T
O PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION, ADJUSTMENT, ALTERATI ON, SERV ICE OR MAINTENANCE, R EFER TO THI S MANUAL. QUALIFIED INSTALLE R, SERVICE AGENCY OR THE GAS SUPPLIER.
OR ADDITIONAL ASSISTANCE OR INFORMATION, CONSULT A
F
WARNING
HIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS WHICH
T
MAY CAUSE SERI OUS ILLNESS OR DEATH AN D WHICH ARE KNOWN TO THE
S
TATE OF CALIFORNIA TO CAUSE CANCER, BI RTH DEFECTS OR OTHER
REPRODUCTIVE HARM.
WARNING
TO PREVENT POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH
DUE TO ELECTRICAL SHOCK, THE FURNACE MUST BE LOCATED TO PROTECT THE ELEC TRICA L COMPON ENTS FROM WAT ER.
Charge (ESD) Precautions NOTE: Discharge body’s static electricity before touching
unit. An electrostatic discharge can adversely affect electri­cal components.
Use the following precautions during furnace installation and servicing to protect the integrated control module from dam­age. By putting the furnace, the control, and the person at the same electrostatic potential, these steps will help avoid exposing the integrated control module to electrostatic dis­charge. This procedure is applicable to both installed and uninstalled (ungrounded) furnaces.
1. Disconnect all power to the furnace. Do not touch the integrated control module or any wire connected to the control prior to discharging your body’s electrostatic charge to ground.
2. Firmly touch a clean, unpainted, metal surface of the furnace near the control. Any tools held in a person’s hand during grounding will be discharged.
3. Service integrated control module or connecting wiring following the discharge process in Step 2. Use caution not to recharge your body with static electricity; (i.e., do not move or shuffle your feet, do not touch ungrounded objects, etc.). If you come in contact with an ungrounded object, repeat Step 2 before touching control or wires.
4. Discharge any static electricity from your body to ground before removing a new control from its container. Follow Steps 1 through 3 if installing the control on a furnace. Return any old or new controls to their containers before touching any ungrounded object.
Product Application
This product is designed for use as a residential home gas furnace. It is not designed or certified for use in mobile home, trailer, or recreational vehicle applications.
This furnace can be used in the following non-industrial commercial applications: Schools, Office buildings, Churches,
Retail stores, Nursing homes, Hotels/motels, Common or office areas. In such applications, the furnace must be installed
with the
Goodman® Brand and Amana® Brand 90% furnaces are ETL certified appliances and are appropriate for use with natural or propane gas. (NOTE: If using propane gas, a pro­pane conversion kit is required).
Dual certification means that the combustion air inlet pipe is optional and the furnace can be vented as a:
To ensure proper installation, operation and servicing, thor­oughly read the installation and service manuals for specif­ics pertaining to the installation, servicing and application of this product.
POSSIBLE PROPERTY DAMAGE, PERSONAL IN JURY OR DEATH DUE TO FIRE,
EXPLOSION, SMOKE, S OOT, CONDENSTAION, E LECTRICAL SHOCK OR CARBON MONOXIDE MAY RESULT FROM IM PROPER INSTALLATION, RE PAIR, OPERATI ON, OR MAINTENANCE OF THI S PRODUCT.
T
O PREVENT PROPERTY DAMAGE, PERSONAL INJ URY OR DEATH D UE TO FIRE, DO NOT INSTALL T HIS FURNACE IN A MOBILE HOME, TRAILER, OR RECREATIONAL VEHICLE.
To ensure proper furnace operation, install, operate, main­tain and service the furnace in accordance with the installa­tion, operation and service instructions, all local building codes and ordinances. In their absence, follow the latest edition of the National Fuel Gas Code (NFPA 54/ANSI Z223.1), and/or CAN/CGA B149 Installation Codes, local plumbing or waste water codes, and other applicable codes.
A copy of the National Fuel Gas Code (NFPA 54/ANSI Z223.1) can be obtained from any of the following:
installation instructions.
Non-direct vent (single pipe) central forced air furnace in which combustion air is taken from the installation area or from air ducted from the outside or,
Direct vent (dual pipe) central forced air furnace in which all combustion air supplied directly to the furnace burn­ers through a special air intake system outlined in this manual and the installation instructions.
WARNING
WARNING
American National Standards Institute 1430 Broadway New York, NY 10018
14
INST ALLATION CONSIDERA TIONS
National Fire Protection Association 1 Batterymarch Park Quincy, MA 02269
The rated heating capacity of the furnace should be greater than or equal to the total heat loss of the area to be heated. The total heat loss should be calculated by an approved method or in accordance with “ASHRAE Guide” or “Manual J-Load Calculations” published by the Air Conditioning Con­tractors of America.
Location Requirements and Considerations
WARNING
O PREVENT POSSIBLE EQUI PMENT DAMAGE, PROPERTY DAMAGE, PERSONAL
T
INJURY OR DEATH, THE FO LLOWING BULLET P OINTS MUST BE OBSERVED WHEN INSTALLING THE UNIT.
Follow the instructions listed below when selecting a fur­nace location. Refer also to the guidelines provided in the Combustion and Ventilation Air Requirements section in this manual or the installation instructions for details.
Centrally locate the furnace with respect to the pro­posed or existing air distribution system.
Ensure the temperature of the return air entering the furnace is between 55°F and 100°F when the furnace is heating.
If the furnace is installed in an application where the typical operating sound level of a furnace is deemed objectionable, an optional sound reduction kit is avail­able. Consult your local distributor for more details.
Provide provisions for venting combustion products outdoors through a proper venting system. Special consideration should be given to vent/flue pipe routing and combustion air intake pipe when applicable.
90% Furnaces: Refer to the Vent/Flue Pipe and Com- bustion Air Pipe -Termination Locations section in this
manual or the installation instructions for appropriate termination locations. Also for 90% furnaces, refer to the Vent/Flue Pipe and Combustion Air Pipe -Termi- nation Locations section in this manual or the instal­lation instructions to determine if the piping system from furnace to termination can be accomplished within the guidelines given. NOTE: The length of flue and/or combustion air piping can be a limiting factor in the location of the furnace.
Locate the 90% furnace so that the condensate can be piped at a downward slope away from the furnace to the drain. Do not locate the furnace or its conden­sate drainage system in any area subject to below freezing temperatures without proper freeze protec­tion. Refer to the Condensate Drain Lines and Trap section in this manual or the installation instructions for further details.
Set the 90% furnace on a level floor to enable proper condensate drainage. If the floor becomes wet or damp at times, place the furnace above the floor on a con­crete base sized approximately 1-1/2" larger than the base of the furnace. Refer to the Horizontal Applica- tions and Considerations section in this manual or the installation instructions for leveling of horizontal furnaces.
Ensure upflow or horizontal furnaces are not installed directly on carpeting, or any other combustible mate­rial. The only combustible material allowed is wood.
A special accessory subbase must be used for up­right counterflow unit installations over any combus­tible material (including wood). Refer to subbase in­structions for installation details. (NOTE: A subbase will not be required if an air conditioning coil is located beneath the furnace between the supply air opening and the combustible floor.
Exposure to contaminated combustion air will result in safety and performance-related problems. Do not install the furnace where the combustion air is ex­posed to the following substances:
chlorinated waxes or cleaners chlorine-based swimming pool chemicals water softening chemicals deicing salts or chemicals carbon tetrachloride halogen type refrigerants cleaning solutions (such as perchloroethylene) printing inks paint removers varnishes hydrochloric acid cements and glues antistatic fabric softeners for clothes dryers and masonry acid washing materials
Isolate a non-direct furnace from an area 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 supply of combustion air, vent from a nearby uncontaminated room or from outdoors. Re­fer to the Combustion and Ventilation Air Require- ments section in this manual or the installation in­structions for details.
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.
15
INST ALLATION CONSIDERA TIONS
If the furnace is installed in a residential garage, posi­tion the furnace so that the burners and ignition source are located not less than 18 inches (457 mm) above the floor. Protect the furnace from physical damage by vehicles.
If the furnace is installed horizontally, the furnace ac­cess doors must be vertical so that the burners fire horizontally into the heat exchanger. Do not install the unit with the access doors on the “up/top” or “down/ bottom” side of the furnace.
Clearances and Accessibility
Installations must adhere to the clearances to combustible materials to which this furnace has been design certified. The minimum clearance information for this furnace is pro­vided on the unit’s clearance label. These clearances must be permanently maintained. Refer to Specification Sheet for minimum clearances to combustible materials. Clearances must also accommodate an installation’s gas, electrical, and drain trap and drain line connections. If the alternate combustion air intake or vent/flue connections are used on a 90% furnace, additional clearances must be provided to accommodate these connections. Refer to Vent Flue Pipe and Combustion Air Pipe section in this manual or the in­stallation instructions for details. NOTE: In addition to the required clearances to combustible materials, a minimum of 24 inches service clearance must be available in front of the unit.
A furnace installed in a confined space (i.e., a closet or utility room) must have two ventilation openings with a total minimum free area of 0.25 square inches per 1,000 BTU/hr of furnace input rating. One of the ventilation openings must be within 12 inches of the top; the other opening must be within 12 inches of the bottom of the confined space. In a typical construction, the clearance between the door and door frame is usually adequate to satisfy this ventilation re­quirement.
Furnace Suspension
If suspending the furnace from rafters or joist, use 3/8" threaded rod and 2”x2”x1/8” angle iron as shown in the fol­lowing figure. If the furnace is installed in a crawl space it must also be suspended from the floor joist or supported by a concrete pad. Never install the furnace on the ground or allow it to be exposed to water. The length of rod will depend on the application and the clearances necessary.
3/8" DIAMETER
THREADED ROD
HOLD DOWN
NUTS
SUPPORT
NUTS
GAS PIPING
2"X2"X1/8" ANGLE IRON
(3 PLACES)
EXISTING FURNACE REMOVAL
NOTE: When an existing furnace is removed from a venting
system serving other appliances, the venting system may be too large to properly vent the remaining attached appli­ances.
The following vent testing procedure is reproduced from the
American National Standard/National Standard of Canada for Gas-Fired Central Furnaces ANSI Z21.47, latest edition, CSA-2.3b, latest edition Section 1.23.1.
The following steps shall be followed with each appliance connected to the venting system placed in operation, while any other appliances connected to the venting system are not in operation:
a. Seal any unused openings in the venting system; b. Inspect the venting system for proper size and horizontal pitch,
c. In so far as practical, close all building doors and windows and all
d. Follow the lighting instructions. Place the appliance being in-
e. Test for draft hood equipped spillage at the draft hood relief
f. After it has been determined that each appliance connected to the
g . If improper venting is observed during any of the above tests, the
Corrections must be in accordance with the latest edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1 and/or CSA B149 Installation Codes.
PROVIDE 8" MINIMUM CLEARANCE BETWEEN
CENTER ROD AND FURNACE CABINET
TO ALLOW FOR CIRCULATOR BLOWER REMOVAL.
ASSURE FURNACE IS LEVEL FROM
END TO END.
90% FURNACES MAKE SURE
ON
THE UNIT HAS A SLIGHT
FORWARD TILT WITH THE FRONT
OF THE FURNACE 0"-3/4"
BELOW THE BACK OF THE FURNACE.
CONDENSATE
DRAIN
TILT OUTWARD TO ALLOW FOR
DOOR AND CIRCULATOR BLOWER
REMOVAL.
(6 PLACES)
ALTERNATE GAS PIPING
POSITION AS CLOSE AS POSSIBLE TO BLOWER DECK TO ALLOW FOR
CIRCULATOR BLOWER REMOVAL.
90% Suspended Furnace Shown
as required by the National Fuel Gas Code, ANSI Z223.1 or the CSA B149 Installation Codes and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition;
doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers;
spected in operation. Adjust thermostat so appliance shall oper­ate continuously;
opening after 5 minutes of main burner operation. Use the flame of a match or candle;
venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous conditions of use;
common venting system must be corrected.
16
INST ALLATION CONSIDERA TIONS
If resizing is required on any portion of the venting system, use the appropriate table in Appendix G in the latest edition of the National Fuel Gas Code ANSI Z223.1 and/or CSA B149
Installation Codes.
Thermostat Requirements
The optional CTK0*** thermostat kit may be used with ComfortNet™ compatable furnaces (ACVC, AMVC, GCVC, GMVC models). Refer to System Operation - ComfortNet™ System for details.
NOTE: A single-stage thermostat with only one heating stage can be used to control a two-stage furnace. The ap­plication of a single-stage thermostat does not offer "true" thermostat driven two-stage operation, but provides a timed transition from low to high fire. The furnace will run on low stage for a fixed period of time before stepping up to high stage to satisfy the thermostat's call for heat. The delay period prior to stepping up can be set at either 5 or 10 min­utes through the DIP switch adjacent to the Heat Off delay DIP switches on the integrated control module. To use a single-stage thermostat, turn off power to the furnace, move the thermostat selection jumper on the integrated contro module from the "two-stage" position to the "single-stage" position, turn power back on. Refer to DIP switch charts on pages 41 & 42.
NOTE: A single-stage thermostat with only one heating stage may be used to control ComfortNet™ compatible furnaces (ACVC, AMVC, GCVC, GMVC models). The application of a single-stage thermostat does not offer “true” thermostat­driven two-stage operation, but provides a timed transition from low to high fire. The furnace will run on low stage for a fixed period of time before stepping up to high stage to sat­isfy the thermostat’s call for heat. The delay period prior to stepping up can be set at either a fixed 5 minute time delay or a load based variable time between 1 and 12 minutes (AUTO mode). If the AUTOmode is selected, the control averages the cycle times of the previous three cycles and uses the average to determine the time to transition from low stage to high stage.
To use a single-stage thermostat, turn off power to the fur­nace, move the thermostat selection DIP switch to the OFF position. Set the desired transition time by setting the tran­sition delay DIP switch to the desired ON/OFF position. Turn power back on. Refer to DIP switch charts on pages 41 &
42.
Dehumidistat Requirements
A dehumidistat can be used in conjunction with the two­stage variable speed furnace to lower the humidity in the conditioned space. The dehumidistat will improve dehumidi­fication of the conditioned air by prompting the furnace to reduce the speed of the circulator blower during operation in the cooling mode. To be compatible with these furnaces, a dehumidistat must operate on 24 VAC and utilize a switch
which opens on humidity rise. Refer to Electrical Connec- tions - 24 Volt Dehumidistat Wiring section in this manual or the installation instructions for correct installation proce­dure.
Thermostat and Dehumidistat Location
In an area having good air circulation, locate the thermostat and dehumidistat (if applicable) about five feet high on a vi­bration-free inside wall. Do not install the thermostat or de­humidistat where it may be influenced by any of the follow­ing:
Drafts, or dead spots behind doors, in corners, or un-
Hot or cold air from registers.
Radiant heat from the sun.
Light fixtures or other appliances.
Radiant heat from a fireplace.
Concealed hot or cold water pipes, or chimneys.
Unconditioned areas behind the thermostat and de-
Consult the instructions packaged with the thermostat and dehumidistat for mounting instructions and further precau­tions.
COMBUSTION AND VENTILATION AIR REQUIREMENTS
OSSIBLE PROPERTY DAMAGE, PERSONAL I NJURY OR DEATH MAY OCCUR
P
IF THE FURNACE I S NOT PR OVIDED WITH ENOUGH FRESH AIR FOR PROPER COMBUSTION AND VENTIL ATION OF F LUE GASES. MOST HOMES REQUI RE OUTSIDE AIR BE SUPPLIED TO THE FURNACE AREA.
Improved construction and additional insulation in buildings have reduced heat loss by reducing air infiltration and es­cape around doors and windows. These changes have helped in reducing heating/cooling costs but have created a prob­lem supplying combustion and ventilation air for gas fired and other fuel burning appliances. Appliances that pull air out of the house (clothes dryers, exhaust fans, fireplaces, etc.) increase the problem by starving appliances for air.
When the furnace is installed as a direct vent (2-pipe) fur­nace, no special provisions for air for combustion are re­quired. However, if this furnace is to be installed in the same space with other gas appliances, such as a water heater, ensure there is an adequate supply of combustion and ven­tilation air for the other appliances. Refer to the latest edi­tion of the National Fuel Gas Code NFPA 54/ANSI Z223.1 (Section 9.3), or CAN/CGA B149 Installation Codes (Sec­tions 7.2, 7.3, or 7.4), or applicable provisions of the local building codes for determining the combustion air require­ments for the appliances.
der cabinets.
humidistat, such as an outside wall.
WARNING
17
INST ALLATION CONSIDERA TIONS
Most homes will require outside air be supplied to the fur­nace area by means of ventilation grilles or ducts connect­ing directly to the outdoors or spaces open to the outdoors such as attics or crawl spaces.
The following information on air for combustion and ventilation is reproduced from the National Fuel Gas Code NFPA 54/ANSI
Z223.1 Section 9.3.
9.3* Air for Combustion and Ventilation.
9.3.1 General.
9.3.1.1 Air for combustion, ventilation, and dilution of flue gases for
appliances installed in buildings shall be obtained by application of one of the methods covered in 9.3.2 through 9.3.6. Where the requirements of 9.3.2 are not met, outdoor air shall be introduced in accordance with methods covered in 9.3.3 through 9.3.6.
Exception No. 1: This provision shall not apply to direct vent appliances.
9.3.1.2 Appliances of other than natural draft design and other than Category 1 vented appliances shall be provided with combustion, ven­tilation, and dilution air in accordance with the appliance manufacturer’s instructions.
9.3.1.3 Appliances shall be located so as not to interfere with proper circulation of combustion, ventilation, and dilution air.
9.3.1.4 Where used, a draft hood or a barometric draft regulator shall be installed in the same room or enclosure as the appliance served so as to prevent any difference in pressure between the hood or regulator and the combustion air supply.
(2) For fan-assisted appliances, calculate using the following equation:
Required Volume
where:
I
other
I
fan
ACH = air change per hour (percent of volume of space exchanged
(3) For purposes of this calculation, an infiltration rate greater than
0.60 ACH shall not be used in the equations in 9.3.2.2(1) and
9.3.2.2(2).
9.3.2.3 Indoor Opening Size and Location. Openings used to connect indoor spaces shall be sized and located in accordance with the follow­ing:
(1)*Combining spaces on the same story. Each opening shall have a
minimum free area of 1 in. input rating of all appliances in the space but not less than 100 in. (0.60m2). One opening shall commence within 12 in. (300 mm) of the top, and one opening shall commence within 12 in. (300 mm) of the bottom, of the enclosure [see Figure A.9.3.2.3(1)]. The mini- mum dimension of air openings shall be not less than 3 in. (80 mm).
NOTE: Each opening must have a free area of not less than one square inch per 1000 BTU of the total input rating of all equip­ment in the enclosure, but not less than 100 square inches.
3
> ________ _________
fan
15 ft
ACH 1000 Btu/hr
I
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)
2
/1000Btu/hr (2200 mm2/kW) of the total
Chimney or Gas Vent
2
9.3.1.5 Makeup air requirements for the operation of exhaust fans, kitchen ventilation systems, clothes dryers, and fireplaces shall be considered in determining the adequacy of a space to provide combustion air require­ments.
9.3.2 Indoor Combustion Air . The required volume of indoor air shall be determined in accordance with the method in 9.3.2.1 or 9.3.2.2 ex­cept that where the air infiltration rate is known to be less than 0.40 ACH, the method in 9.3.2.2 shall be used. The total required volume shall be the sum of the required volume calculated for all appliances located within the space. Rooms communicating directly with the space in which the appliances are installed through openings not furnished with doors, and through combustion air openings sized and located in accordance with 9.3.2.3, are considered a part of the required volume.
9.3.2.1* Standard Method. The minimum required volume shall be 50 ft 3 per 1,000/Btu/hour (4.8m3/kW).
9.3.2.2* Known Air Infiltration Rate Method. Where the air infiltra­tion rate of a structure is known, the minimum required volume shall be determined as follows:
(1) For appliances other than fan-assisted, calculate using the following
equation: Required Volume
> ________ _________
other
3
21 ft
I
other
ACH 1000 Btu/hr
(
)
Opening
Water Heater
Furnace
Opening
Figure A.9.2.3.3.(1) All Combustion Air from Adjacent
Indoor Spaces through Indoor Combustion Air Openings.
(2) Combining spaces in different stories. The volumes of spaces in
different stories shall be considered as communicating spaces where such spaces are connected by one or more openings in doors or floors having a total minimum free area of 2 in.2/1000 Btu/hr (4400 mm2/kW) of total input rating of all appliances.
9.3.3 Outdoor Combustion Air. Outdoor combustion air shall be pro­vided through opening(s) to the outdoors in accordance with the meth­ods in 9.3.3.1 or 9.3.3.2. The minimum dimension of air openings shall not be less than 3 in. (80 mm).
9.3.3.1 Two Permanent Openings Method. Two permanent open­ings, one commencing within 12 in. (300 mm) of the top and one com­mencing within 12 in. (300 mm) of the bottom, of the enclosure shall be provided. The openings shall communicate directly, or by ducts, with the outdoors or spaces that freely communicate with the outdoors, as follows:
18
INST ALLATION CONSIDERA TIONS
A
(1)*Where directly communicating with the outdoors or where commu-
nicating to the outdoors through vertical ducts, each opening shall have a minimum free area of 1 in. total input rating of all appliances in the enclosure. [See Figure
A.9.3.3.1(1)(a) and Figure A.9.3.3.1(1)(b).]
Chimney or Gas Vent
Water Heater
Furnace
lternate
air inlet
Ventilation louvers for unheated crawl space
Figure A.9.3.3.1(1)(a) All Combustion Air Fr om Outdoors -
Inlet Air from Ventilated Crawl Space and Outlet Air
to Ventilated Attic.
2
/4000 Btu/hr (550 min2/kW) of
Ventilation louvers (each end of attic)
NOTE: The inlet and outlet a ir openings must each have a free area of not less than one square inch per 4000 BTU of the total input rating of all equipment in the enclosure.
Outlet Air
Inlet Air
9.3.3.2* One Permanent Opening Method. One permanent open­ings, commencing within 12 in. (300 mm) of the top of the enclosure, shall be provided. The appliance shall have clearances of at least 1 in. (25 mm) from the sides and back and 6 in. (150 mm) from the front of the appliance. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors (see Figure A.9.3.3.2) and shall have a minimum free area of the following: (1) 1 in.
appliances located in the enclosure, and
(2) Not less than the sum of the areas of all vent connectors in the
space.
Chimney or Gas Vent
NOTE: The air duct openings must have a free a r ea o f not less than one square inch per 2000 BTU of the total input rating of all equipment in the enclosure*.
Furnace
Water Heater
Outlet air duct
Inlet air duct
Figure A.9.3.3.1(2) All Combustion Air From Outdoors
through Horizontal Ducts.
2
/3000 Btu/hr (700 mm2 per kW) of the total input rating of all
Chimney or Gas Vent
Ventilation louvers (each end of attic)
NOTE: The inlet and outlet air openings must each have a free area of not less than one square inch per 4000 BTU of the total input rating of all equipmen t in the enclosure.
Outlet Air
Water Heater
Furnace
Inlet air duct [ends 1 ft (300 mm) above floor]
Figure A.9.3.3.1(1)(b) All Combustion Air
From Outdoors through Ventilated Attic.
(2)*Where communicating with the outdoors through horizontal ducts,
each opening shall have a minimum free area of 1 in.2/2000 Btu/hr (1100 min2/kW) of total input rating of all appliances in the enclo­sure. [See Figure A.9.3.3.1(2).]
NOTE: The single opening must have a free area of not less than one square inch per 30 00 BT U o f the total in p ut rat i ng of all equip­ment in th e enclosure, but not less than the sum of the areas of all vent connecto rs in the confined space.
Chimney or Gas Vent
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]:
(1) Indoor Openings: Where used, openings connecting the interior
spaces shall comply with 9.3.2.3.
(2) Outdoor Opening(s) Location. Outdoor opening(s) shall be located
in accordance with 9.3.3.
(3) Outdoor Opening(s) Size. The outdoor opening(s) size shall be
calculated in accordance with the following:
(a) The ratio of the interior spaces shall be the available volume of
all communicating spaces divided by the required volume.
(b) The outdoor size reduction factor shall be 1 minus the ratio of
interior spaces.
19
INST ALLATION CONSIDERA TIONS
(c) The minimum size of outdoor opening(s) shall be the full size
of outdoor opening(s) calculated in accordance with 9.3.3, multiplied by the reduction factor. The minimum dimension of air openings shall not be less than 3 in. (80 mm).
9.3.8.4 Ducts shall not serve both upper and lower combustion air openings where both such openings are used. The separation between ducts servicing upper and lower combustion air openings shall be main­tained to the source of combustion air.
9.3.5 Engineered Installations. Engineered combustion air installa­tions shall provide an adequate supply of combustion, ventilation, and dilution air and shall be approved by the authority having jurisdiction.
9.3.6 Mechanical Combustion Air Supply. Where all combustion air is provided by a mechanical air supply system, the combustion air shall be supplied form outdoors at the minimum rate of 0.35 ft3/min per 1000 Btu/hr (0.034 m space.
9.3.6.1 Where exhaust fans are installed, additional air shall be provided to replace the exhausted air.
9.3.6.2 Each of the appliances served shall be interlocked to the me­chanical air supply system to prevent main burner operation where the mechanical air supply system is not in operation.
9.3.6.3 Where combustion air is provided by the building’ s mechanical ventilation system, the system shall provide the specified combustion air rate in addition to the required ventilation air.
9.3.7 Louvers, Grilles, and Screens.
9.3.7.1 Louvers and Grilles. The required size of openings for com-
bustion, ventilation, and dilution air shall be based on the net free area of each opening. Where the free area through a design of louver or grille or screen is known, it shall be used in calculating the size opening required to provide the free area specified. Where the louver and grille design and free area are not known, it shall be assumed that wood louvers will have 25 percent free area, and metal louvers and grilles will have 75 percent free area. Nonmotorized louvers and grilles shall be fixed in the open position.
3
/min per kW) for all appliances located within the
9.3.8.5 Ducts shall not be screened where terminating in an attic space.
9.3.8.6 Horizontal upper combustion air ducts shall not slope down-
ward toward the source of combustion air.
9.3.8.7 The remaining space surrounding a chimney liner, gas vent, spe­cial gas vent, or plastic piping installed within a masonry, metal, or factory built chimney shall not be used to supply combustion air.
Exception: Direct vent appliances designed for installation in a solid fuel-burning fireplace where installed in accordance with the manufacture’s installation instructions.
9.3.8.8 Combustion air intake openings located on the exterior of the building shall have the lowest side of the combustion air intake openings located at least 12 in. (300 mm) vertically from the adjoining grade level.
Horizontal Applications and Considerations
Horizontal applications, in particular, may dictate many of the installation’s specifics such as airflow direction, duct­work connections, flue and/or combustion air pipe connec­tions, etc. The basic application of this furnace as a hori­zontal furnace differs only slightly from an upright installa­tion. When installing a furnace horizontally, additional con­sideration must be given to the following:
9.3.7.2 Minimum Scree Mesh Size. Screens shall not be smaller than 1/4 in. mesh.
9.3.7.3 Motorized Louvers. Motorized louvers shall be interlocked with the appliance so they are proven in the full open position prior to main burner ignition and during main burner operation. Means shall be provided to prevent the main burner form igniting should the louver fail to open during burner startup and to shut down the main burner if the louvers close during burner operation.
9.3.8 Combustion Air Ducts. Combustion air ducts shall comply with
9.3.8.1 through 9.3.8.8.
9.3.8.1 Ducts shall be constructed of galvanized steel or a material hav­ing equivalent corrosion resistance, strength, and rigidity.
Exception: Within dwellings units, unobstructed stud and joist spaces shall not be prohibited from conveying combustion air, provided that not more than one fireblock is removed.
9.3.8.2 Ducts shall terminate in an unobstructed space, allowing free movement of combustion air to the appliances.
9.3.8.3 Ducts shall serve a single space.
90% Horizontal Furnace Shown
20
INST ALLATION CONSIDERA TIONS
Installation Positions
*MVC96 models may be installed up flow or horizontally with left or right side down. *CVC96 models may be installed down flow or horizontally with left or right side down. Do not install any furnace on its back.
Horizontal Installations
1. Horizontal installations require 5.5" under the furnace to accommodate the drain trap.
2. Horizontal furnaces must be installed with ¾” slope from back to front to permit condensate flow towards the front of the furnace.
When installing a *MVM97 horizontally with the left side down, there are two options for connecting the vent pipe to the furnace.
1. Venting may be connected to the furnace vent pipe fit­ting on the original top (now the end) of the furnace
2. The internal vent pipe and elbow may be removed from the furnace to permit the vent to exit the top (original side) of the furnace. If this option is used, an RF000142 Vent-Drain coupling must be used to keep condensate from collecting in the inducer assembly.
Refer to the following instructions and illustration.
1. Remove screws from vent flange.
2. Remove internal elbow and vent pipe.
3. Cut pipe 2 1/2” from flange.
4. Remove cabinet plug adjacent to inducer outlet and in­stall an original cabinet vent hole.
5. Install RF000142 coupling on inducer outlet.
6. Install flanged vent section removed in step 2 & secure with clamps.
7. Secure flange to cabinet using screws removed in step
1.
E R E
H T
U C
Vent/Flue Pipe Cuts
R 000142F
Insert flange. Cut 2 ½” long.
90% Furnace Recommended Installation Positions
NOTE: Alternate "vertical" piping connections can not be used when an upflow 90% furnace is installed with supply air discharging to the right or when a counterflow furnace is installed with supply discharging to the left. In this case, use the standard flue and combustion air piping connec­tions
21
INST ALLATION CONSIDERA TIONS
Alternate Electrical and Gas Line Connections
The furnaces have provisions allowing for electrical and gas line connections through either side panel. In horizontal ap­plications the connections can be made either through the “top” or “bottom” of the furnace.
Drain Pan
A drain pan must be provided if the furnace is installed above a conditioned area. The drain pan must cover the entire area under the furnace (and air conditioning coil if applicable).
Freeze Protection
If the drain trap and drain line will be exposed to tempera­tures near or below freezing, adequate measures must be taken to prevent condensate from freezing. NOTE: The use of insulation and/or heat tape is recommended. Failure to provide proper condensate drainage can result in property damage.
Propane Gas and/or High Altitude Installations
WARNING
P
OSSIBLE PRO PERTY DA MAGE, PERSO NAL IN JURY OR DEATH MAY OCCUR IF THE CORRECT CONV ERSI ON KITS ARE NOT IN STALLE D. MUST BE APPLIE D TO I NSURE SAFE AN D PROPER FURNAC E OPERAT ION. CONVERSIONS MUS T BE PERFORMED BY A QUALIF IE D INSTA LLER OR SERV ICE AGENCY.
THE APPROPRIATE KI TS
ALL
WARNING
UPON COMPLETION OF THE FURNA CE INSTALLATIO N, CAREFULLY I NSPECT THE
ENTIRE FLUE SYSTEM BO TH INSIDE AND OUTSIDE THE FURNACE TO ASS URE IT IS PROPERLY SEALED. PERSONAL INJURY OR DE ATH DUE TO EXPOS URE TO FLUE PRODUCTS, INCLUDING CARBON MONOXIDE.
LEAKS IN THE FLUE SYSTEM CAN RESULT IN SERIOUS
A condensing gas furnace achieves its high level of efficiency by extracting almost all of the heat from the products of combustion and cooling them to the point where condensa­tion takes place. Because of the relatively low flue gas tem­perature and water condensation requirements, PVC pipe is used as venting material.
This furnace must not be connected to Type B, BW, or L vent or vent connector, and must not be vented into any portion of a factory built or masonry chimney except when used as a pathway for PVC as described later in this sec­tion. Never common vent this appliance with another appli­ance or use a vent which is used by a solid fuel appliance.
It is the responsibility of the installer to follow the manufac­turers’ recommendations and to verify that all vent/flue pip­ing and connectors are compatible with furnace flue prod­ucts. Additionally, it is the responsibility of the installer to ensure that all piping and connections possess adequate structural integrity and support to prevent flue pipe separa­tion, shifting, or sagging during furnace operation.
This furnace is shipped from the factory configured for natu­ral gas at standard altitude. Propane gas installations re­quire an orifice change to compensate for the energy con­tent difference between natural and propane gas.
High altitude installations may require both a pressure switch and an orifice change. These changes are necessary to com­pensate for the natural reduction in the density of both the gas fuel and the combustion air at higher altitude.
Refer to the Accessories Charts in this manual or product Specification Sheet for a tabular listing of appropriate manufacturer’s kits for propane gas and/or high altitude in­stallations. The indicated kits must be used to insure safe and proper furnace operation. All conversions must be per­formed by a qualified installer, or service agency.
VENT/FLUE PIPE AND COMBUSTION AIR PIPE
WARNING
F
AILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN BODILY INJURY OR
DEATH.
CAREFULLY READ AND FOLLOW ALL INSTRUCTIONS GIVEN IN THIS
SECTION.
Materials and Joining Methods
WARNING
T
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.
A
VOID BREATHING
Precautions should be taken to prevent condensate from freezing inside the vent/flue pipe and/or at the vent/flue pipe termination. It is our recommendation that all vent/flue piping exposed to temperatures below 35°F for extended periods of time should be insulated with 1/2” thick closed cell foam. Also all vent/flue piping exposed outdoors in excess of the terminations shown in this manual (or in unheated areas) should be insulated with 1/2” thick closed cell foam. Inspect piping for leaks prior to installing insulation.
The following bullets and diagram describe the restrictions concerning the appropriate location of vent/flue pipe and com­bustion air intake pipe (when applicable) terminations. Re­fer to the installation instructions for specific details on ter­mination construction.
All terminations must be located at least 12 inches above ground level or the anticipated snow level.
Vent terminations must terminate at least 3 feet above any forced air inlet located within 10 feet.
22
INST ALLATION CONSIDERA TIONS
NOTE: This provision does not apply to the combus-
tion air intake termination of a direct vent application.
The vent termination of a non-direct vent application must terminate at least 4 feet below, 4 feet horizon­tally from, or 1 foot above any door, window, or gravity air inlet into any building.
The vent termination of a direct vent application must terminate at least 12 inches from any opening through which flue gases may enter a building (door, window, or gravity air inlet).
The vent termination of vent pipe run vertically through a roof must terminate at least 12 inches above the roof line (or the anticipated snow level) and be at least 12 inches from any vertical wall (including any antici­pated snow build up).
A vent termination shall not terminate over public walk­ways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves, or other equipment.
The combustion air intake termination of a direct vent application should not terminate in an area which is frequently dusty or dirty.
NOTE: In Canada, CAN B149.1 Fuel Gas Code takes pre­cedence over the preceding termination restrictions.
OTHER THAN
COMBUSTION AIR
TERMINATION INTAKE
NON-DIRECT VENT
VENT/FLUE TERMINATION
NO TERMINATIONS ABOVE WALKWAY
3"
GRADE OR HIGHEST
ANTICIPATED
SNOW LEVEL
FORCED AIR
INLET
10'
12"
12"
DIRECT VENT
VENT/FLUE TERMINATION
12"
VENT/FLUE TERMINATION
4'
4' 12"
NON-DIRECT VENT
90% Furnace Vent Termination Clearances
Direct Vent Installations
On upflow units secure the combustion air intake pipe di­rectly to the air intake coupling. On counterflow units se­cure the combustion air intake pipe to the air intake cou­pling using the rubber coupling and worm gear hose clamps provided with the unit. The counterflow rubber coupling al­lows service removal of air intake piping internal to the fur­nace blower compartment. The combustion air intake pipe can also be secured directly to the counterflow unit air in­take pipe coupling.
Non-Direct Vent Installations
A minimum of one 90° elbow must be installed on the com­bustion air intake “coupling” to guard against inadvertent blockage.
HE RUBBER ELBOW IS NOT DESIGNED TO SUPPORAT A LOAD. WHEN THE
T
RUBBER ELBOW IS MOUNTED EXTERNALLY TO THE FURNACE CABINET, EXTREME CARE MUST BE TAKEN TO ADEQUATELY SUPPORT FIELD-SUPPLI ED VENT/FLUE PIPING, AS DAMAGE CAN RESULT IN LEAKS CAUSING BODILY INJURY OR DEATH DUE TO EXPOSURE TO FLUE GASES, INCLUDING CARBON MONOXIDE.
Vent/Flue Pipe Lengths (Non-Direct Vent) and Diam­eters
Refer to the following table for applicable length, elbows, and pipe diameter for construction of the vent/flue pipe sys­tem of a non-direct vent installation. In addition to the vent/ flue pipe, a single 90° elbow must be secured to the com­bustion air intake to prevent inadvertent blockage. The tee or elbows used in the vent/flue termination must be included when determining the number of elbows in the piping sys­tem.
Vent/Flue and Combustion Air Pipe Lengths and Diam­eters
Refer to the following table for applicable length, elbows, and pipe diameter for construction of the vent/flue and com­bustion air intake pipe systems of a non-direct vent (single pipe) installation. The number of elbows tabulated repre­sents the number of elbows and/or tees in each (Vent/Flue & Combustion Air Intake) pipe. Elbows and/or tees used in the terminations must be included when determining the num­ber of elbows in the piping systems.
If the combustion air intake pipe is to be installed above a finished ceiling or other area where dripping of condensate will be objectionable, insulation of the combustion air pipe may be required. Use 1/2” thick closed cell foam insulation such as Armaflex or Insultube where required.
Vent/Flue Pipe Terminations
The vent/flue pipe may terminate vertically, as through a roof, or horizontally, as through an outside wall.
Vertical vent/flue pipe termination should be as shown in the following figures. Refer to Vent/Flue Pipe and Combustion Air Pipe - Termination Locations section in this manual or the installation instructions for details concerning location restrictions. The penetration of the vent through the roof must be sealed tight with proper flashing such as is used with a plastic plumbing vent.
WARNING
23
INST ALLATION CONSIDERA TIONS
Horizontal vent/flue pipe terminations should be as shown in the following figure. Refer to Vent/Flue Pipe and Combus- tion Air Pipe - Termination Locations section in this manual or the installation instructions for details concerning loca­tion restrictions. A 2 3/8" diameter wall penetration is re­quired for 2" diameter pipe while a 3 1/2" diameter hole is required for 3" diameter pipe. To secure the pipe passing through the wall and prohibit damage to piping connections, a coupling should be installed on either side of the wall and solvent cemented to a length of pipe connecting the two couplings. The length of pipe should be the wall thickness plus the depth of the socket fittings to be installed on the inside and outside of the wall. The wall penetration should be sealed with silicone caulking material.
In a basement installation, the vent/flue pipe can be run be­tween joist spaces. If the vent pipe must go below a joist and then up into the last joist space to penetrate the header, two 45° elbows should be used to reach the header rather than two 90° elbows.
NOTE: Terminate both pipes in the same pressure zone (same side of roof, no major obstacle between pipes, etc).
TEE (OPTIONAL)
COMBUSTION AIR INTAKE
(OPTIONAL)
*Not required for
single pipe installation
E
N
I
L
F
O
O
R
INTAKE
SCREEN
OPTIONAL
12” MIN TO ROOF OR HIGHEST ANTICIPATED SNOW LEVEL
6
9
12” MIN HEIGHT DIFFERENCE BETWEEN INT AKE AND VENT
3
-
.
X
A
M
.
N
I
M
90% Furnace Horizontal Termination (Single Pipe)
Direct Vent (Dual Pipe) Piping
Direct vent installations require both a combustion air in­take and a vent/flue pipe. The pipes may be run horizontally and exit through the side of the building or run vertically and exit through the roof of the building. The pipes may be run through an existing unused chimney; however, they must extend a minimum of 12 inches above the top of the chim­ney. The space between the pipes and the chimney must be closed with a weather tight, corrosion resistant flashing. Both the combustion air intake and a vent/flue pipe termina­tions must be in the same atmospheric pressure zone. Re­fer to Vent/Flue and Combustion Air Pipe - Termination Lo- cations or Concentric Vent Termination section in this manual or the installation instructions for specific details on termi­nation construction.
*MVC9 6/*CVC 9 6 Direct Vent (2 - Pipe) and N on-Direct Vent (1- Pip e)
Unit Input
(Btu)
12" MINIMUM
VENT/FLUE TEE
90° ELBOW TURNED
12" MINIMUM ABOVE
HIGHEST ANTICIPATED
SNOW LEVEL
OR
DOWN
Above Highest Anticipated Snow Level
Maximum Allowable Length of Vent/Flue Pipe
& Comb u stion Air Pipe (ft )
Pipe Size
(4)
(in .)
12345678
Number of Elbows
(1) (2)
(3) (5)
(6)
ELBOWS
STRAIGHT
24
40,000
60,000
80,000 "B" 2 or 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 or 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
2
or 2 1/2
2
or 2 1/2
120 115 110 105 100 95 90 85
95 90 85 80 75 70 65 60
INST ALLATION CONSIDERA TIONS
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.
Vent/Flue and Combustion Air Pipe Terminations
VENT/FLUE AND COMBUSTION AIR PIPE TERMINATIONS
The vent/flue and combustion air pipes may terminate verti­cally, as through a roof, or horizontally, as through an out­side wall.
Vertical pipe terminations should be as shown in the follow­ing figure. Refer to Section IX, Vent/Flue Pipe and Com- bustion Pipe - Termination Locations for details concerning location restrictions. The penetrations through the roof must be sealed tight with proper flashing such as is used with a plastic plumbing vent.
Horizontal terminations should be as shown in the following figure. Refer to Vent/Flue Pipe and Combustion Pipe - Ter- mination Location section in this manual or the installation instructions for location restrictions. A 2 3/8" diameter wall penetration is required for 2" diameter pipe while a 3 1/2" diameter hole is required for 3" diameter pipe. To secure the pipe passing through the wall and prohibit damage to piping connections, a coupling should be installed on either side of the wall and solvent cemented to a pipe connecting the two couplings. The pipe length should be the wall thickness plus the depth of the socket fittings to be installed on the inside and outside of the wall. The wall penetration should be sealed with silicone caulking material.
90% Alternate Horizontal Vent Termination (Dual Pipe)
Vent & Combustion Air Intake Measurements for Stan­dard Horizontal Terminations (Dual Pipe)
Center to center = 10” min / 24” max. Vertical separation: 0” - 24” Vent termination from wall = 8” min / 12” max. Combustion air intake from wall = 6” max. Vent and intake clearance to ground
90° ELBOWS
3” - 24”
AIR INTAKE
SCREEN
(OPTIONAL)
12" MIN. ABOVE
HIGHEST ANTICIPATED
SNOW LEVEL
10”- 24”
6” MAX
4” MIN
90º OR 45°
ELBOW
SCREEN
(OPTIONAL)
12" MIN. TO GRADE OR HIGHEST ANTICIPATED
SNOW L EVEL
Standard Horizontal Terminiations (Dual Pipe)
or anticipated snow level = 12” min.
25
INST ALLATION CONSIDERA TIONS
90° ELBOWS
3”-24” BETWEEN PIPES
AIR INTAKE
SCREEN
(OPTIONAL)
12" MIN . AB OVE
HIGHEST ANTICIPA TED
SNOW LEVEL
Combustion Air Intake may also be snorkeled to obtain 12” min ground clearance.
90% Furnace Alternate Vent Termination
Above Anticipated Snow Level (Dual Pipe)
In a basement installation, the pipes may be run between the joist spaces. If the pipes must go below the joist and then up into the last joist space to penetrate the header, two 45° elbows should be used to reach the header rather than two 90° elbows.
VENT/INTAKE TERMINATIONS FOR INSTALLATION OF MULTIPLE DIRECT VENT FURNACES
If more than one direct vent furnace is to be installed verti­cally through a common roof top, maintain the same mini­mum clearances between the exhaust vent and air intake terminations of adjacent units as with the exhaust vent and air intake terminations of a single unit.
If more than one direct vent furnace is to be installed hori­zontally through a common side wall, maintain the clear­ances as in the following figure. Always terminate all ex­haust vent outlets at the same elevation and always termi­nate all air intakes at the same elevation.
Condensate Drain Lines and Drain Trap
A condensing gas furnace achieves its high level of efficiency by extracting heat from the products of combustion to the point where condensation takes place. The condensate must be collected in the furnace drain trap and routed to an appropri­ate drain location in compliance with local and national codes.
Follow the bullets listed below when installing the drain system. Refer to the following sections for specific details concerning furnace drain trap installation and drain hose hook ups.
The drain trap supplied with the furnace must be used.
The drain trap must be primed at time of installation.
The drain line between furnace and drain location must meet local and nation codes.
The drain line between furnace and drain location must maintain a 1/4 inch per foot downward slope toward the drain.
Do not trap the drain line in any other location than at the drain trap supplied with the furnace.
If the drain line is routed through an area which may see temperatures near or below freezing, precautions must be taken to prevent condensate from freezing within the drain line.
If an air conditioning coil is installed with the furnace, a common drain may be used. An open tee must be in­stalled in the drain line, near the cooling coil, to relieve positive air pressure from the coil’s plenum. This is nec­essary to prohibit any interference with the function of the furnace’s drain trap.
WARNING
N UPRIGHT UPFLOW INS TALLATIONS, THE DRA IN TRAP MUST BE MOUNTED ON
I
THE OPPOSITE S IDE OF THE UNIT FROM THE JUNC TION BOX . REDUCE THE RIS K OF WATER REACH ING THE JUNCTION BOX I N THE EVENT OF
trap.
A BLOCKED DRAIN CONDITION. CAN RESULT I N POSSIBLE PRO PERTY DAMAGE, PERS ONAL INJURY, OR DEATH DUE TO EL ECT RI CAL S HOC K.
AILURE TO FOLLOW THESE I NSTRUCTIONS
F
HIS WILL
T
3” - 24”
12” MIN SEPARATION
3” MIN
OPTIONAL INTAKE SCREENS
12” MIN TO GRADE OR HIGHEST ANTICIPATED SNOW LEVEL
90% Furance Horizontal Venting of Multiple Units
(Dual Pipe)
26
GAS SUPPLY AND PIPING
The furnace rating plate includes the approved furnace gas input rating and gas types. The furnace must be equipped to operate on the type of gas applied. This includes any con­version kits required for alternate fuels and/or high altitude.
CAUTION
O PREVENT UNRELI ABLE OPE RATION OR EQUIP MENT DAMAGE, THE INLE T
T
GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE WITH ALL OTHE R HOUSEHOL D GAS FIRED APPLIANCES O PERATING.
INST ALLATION CONSIDERA TIONS
Inlet gas supply pressures must be maintained within the ranges specified below. The supply pressure must be con­stant and available with all other household gas fired appli­ances operating. The minimum gas supply pressure must be maintained to prevent unreliable ignition. The maximum must not be exceeded to prevent unit overfiring.
INLET GAS SUPPLY PRESSURE
Natural Gas Minimum: 4.5" w.c. Maximum: 10.0" w.c.
Propane Gas Minimum: 11.0" w.c. Maximum: 13.0" w.c.
HIGH ALTITUDE DERATE
When this furnace is installed at high altitude, the appropri­ate High Altitude orifice kit must be applied. This is required due to the natural reduction in the density of both the gas fuel and combustion air as altitude increases. The kit will provide the proper design certified input rate within the speci­fied altitude range.
High altitude kits are purchased according to the installa­tion altitude and usage of either natural or propane gas. Refer to the product Specification Sheet or Technical Manual for a tabular listing of appropriate altitude ranges and corre­sponding manufacturer’s high altitude (Natural, Propane gas, and/or Pressure Switch) kits.
Do not derate the furnace by adjusting the manifold pres­sure to a lower pressure than specified on the furnace rat­ing plate. The combination of the lower air density and a lower manifold pressure will prohibit the burner orifice from drawing the proper amount of air into the burner. This may cause incomplete combustion, flashback, and possible yel­low tipping.
In some areas the gas supplier may artificially derate the gas in an effort to compensate for the effects of altitude. If the gas is artificially derated, the appropriate orifice size must be determined based upon the BTU/ft3 content of the derated gas and the altitude. Refer to the National Fuel Gas Code, NFPA 54/ANSI Z223.1, and information provided by the gas supplier to determine the proper orifice size.
A different pressure switch may be required at high altitude regardless of the BTU/ft3 content of the fuel used. Refer to the product Specification Sheet or Technical Manual for a tabular listing of appropriate altitude ranges and correspond­ing manufacturer’s pressure switch kits.
MANIFOLD
DESCRIPTION: This kit is designed for gas-fired units con-
verted to propane gas use. The Propane Low Pressure (LPLP03) Kit monitors the gas line pressure with a pressure switch and disables the unit's gas valve if the line pressure drops below acceptable levels.
GAS VALVE
This unit is equipped with a 24 volt gas valve controlled dur­ing furnace operation by the integrated control module. As shipped, the valve is configured for natural gas. The valve is field convertible for use with propane gas by using the ap­propriate propane gas conversion kit. Taps for measuring the gas supply pressure and manifold pressure are provided on the valve.
Low (Main) Common High
White-Rodgers 2-Stage Valve
PROPANE GAS CONVERSION
WARNING
P
OSSIBLE PROPERTY DAMAGE, PERS ONAL INJURY OR DEATH MAY OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INST ALLED. MUST BE APPLIED TO I NSURE SAFE AND P ROPER FURNACE OPERATION. CONVERSIONS MUST BE PERFORMED BY A QUALIFIED INSTALL ER OR SERVICE AGENCY.
HE APPROPRIATE KITS
T
A
NOTE: The gas supply pressure on White-Rodger "J" model gas valve, used on single and two stage fur­naces, can be checked with a gas pressure test kit (Part #0151K00000S) available through our authorized dis­tributors.
LL
27
INST ALLATION CONSIDERA TIONS
GAS PIPING CONNECTIONS
CAUTION
T
O AVOID POSSI BLE UNSATISFACTO RY OPERATION OR EQU IPMENT DAMAGE DUE TO UNDERFIRING O F EQUIPMENT, US E THE PROPER SIZ E OF NATURAL/PROPANE GAS PIP ING NEEDED WHEN RUNNING PIPE FR OM THE METER/TANK TO THE FURN ACE.
The gas piping supplying the furnace must be properly sized based on the gas flow required, specific gravity of the gas, and length of the run. The gas line installation must comply with local codes, or in their absence, with the latest edition of the National Fuel Gas Code, NFPA 54/ANSI Z223.1.
Natural Ga s Capacity of Pip e
In Cubic Feet of Gas Per Hour (CFH)
Length of Nominal Black Pipe Size
Pipe in Feet 1/2" 3/4" 1" 1 1/4" 1 1/2"
10 132 278 520 1050 1600 20 92 190 350 730 1100 30 73 152 285 590 980 40 63 130 245 500 760 50 56 115 215 440 670 60 50 105 195 400 610 70 46 96 180 370 560 80 43 90 170 350 530 90 40 84 160 320 490
100 38 79 150 305 460
(Pressure 0.5 psig or less and pressure drop of 0. 3" W.C.; Based on 0.60 Specific Gravity Gas)
CFH =
BTUH Furnace Input Heating Value of Gas (BTU/Cubic Foot)
4. Install a drip leg to trap dirt and moisture before it can enter the gas valve. The drip leg must be a minimum of three inches long.
5. Install a 1/8" NPT pipe plug fitting, accessible for test gage connection, immediately upstream of the gas supply connection to the furnace.
6. Use two pipe wrenches when making connection to the gas valve to keep it from turning. The orientation of the gas valve on the manifold must be maintained as shipped from the factory .
7. Install a manual shutoff valve between the gas meter and unit within six feet of the unit. If a union is in­stalled, the union must be downstream of the manual shutoff valve, between the shutoff valve and the fur­nace.
8. Tighten all joints securely.
To connect the furnace to the building’s gas piping, the in­staller must supply a ground joint union, drip leg, manual shutoff valve, and line and fittings to connect to gas valve. In some cases, the installer may also need to supply a transi­tion piece from 1/2" pipe to a larger pipe size.
The following stipulations apply when connecting gas piping. Refer to the following figures for typical gas line connections to the furnace.
1. Use black iron or steel pipe and fittings for the building piping.
2. Use pipe joint compound on male threads only. Pipe joint compound must be resistant to the action of the fuel used.
3. Use ground joint unions.
28
INST ALLATION CONSIDERA TIONS
GAS PIPING CHECKS
Before placing unit in operation, leak test the unit and gas connections.
WARNING
TO AVOID THE POSSIBLITY OF EXPLOSION OR FIRE, NEVER USE A MATCH
OR OPEN FLAME TO TEST FOR LEAKS.
Check for leaks using an approved chloride-free soap and water solution, an electronic combustible gas detector, or other approved testing methods.
NOTE: Never exceed specified pressures for testing. Higher pressure may damage the gas valve and cause subsequent overfiring, resulting in heat exchanger failure. Disconnect this unit and shutoff valve from the gas supply piping system before pressure testing the supply piping system with pres­sures in excess of 1/2 psig (3.48 kPa). Isolate this unit from the gas supply piping system by closing its external manual gas shutoff valve before pressure testing supply piping sys­tem with test pressures equal to or less than 1/2 psig (3.48 kPa).
PROPANE GAS TANKS AND PIPING
All propane gas equipment must conform to the safety stan­dards of the National Board of Fire Underwriters, NBFU Manual 58.
For satisfactory operation, propane gas pressure must be 10 inch WC at the furnace manifold with all gas appliances in operation. Maintaining proper gas pressure depends on three main factors:
1. Vaporization rate, depending on temperature of the liq­uid, and “wetted surface” area of the container or con­tainers.
2. Proper pressure regulation. (Two-stage regulation is rec­ommended for both cost and efficiency).
3. Pressure drop in lines between regulators, and between second stage regulator and the appliance. Pipe size will depend on length of pipe run and total load of all appli­ances.
Complete information regarding tank sizing for vaporization, recommended regulator settings, and pipe sizing is avail­able from most regulator manufacturers and propane gas suppliers.
Use pipe dope approved for use with L.P. gas. Refer to the following illustration for typical propane gas in-
stallations and piping.
WARNING
ROPANE GAS IS HEAVIER THAN AIR AND ANY LEAKING GAS CAN SETTLE IN
P
ANY LOW AR EAS OR CO NFIN ED SPACE S. PERSONAL INJURY, OR DEATH DU E TO FIRE OR EXPLOSI ON CAUSED BY A PROPANE GAS LEAK, INSTALL A GAS DETE CTION WARNING DEVICE.
TO PREVENT PROPERTY DAMAGE,
A gas detecting warning system is the only reliable way to detect a propane gas leak. Iron oxide (rust) can reduce the level of odorant in propane gas. Do not rely on your sense of smell. Contact a local propane gas supplier about installing a gas detecting warning system. If the presence of gas is suspected, adhere to the instructions in the following warn­ing.
WARNING
F THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A
I
FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOS S OF LIF E.
O NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND
D
LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE. –
WHAT TO DO IF YOU SMELL GAS
• PHONE IN YOUR BUILDING.
PHONE.
• DEPARTMENT.
NSTALLATI ON AN D SER VICE MUST BE PERF ORMED BY A QU ALIFI ED I NSTAL LER,
I
SERVICE AGENCY OR THE GAS SUPPLIER.
O NOT TRY TO LIGHT ANY APPLIANCE.
D
O NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY
D
MMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR’S
I
OLLOW THE GAS SUPPLIER’S INSTRUCTIONS.
F
F YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE
I
:
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
I
F THE GAS FURNA CE IS INS TALLED IN A BASEMENT, A N EXCAVATED AREA OR A CONFINED SPACE, IT IS ST RONGLY RECOMMENDED TO CONTACT A PROPANE SUPPLIER TO INSTALL A GAS DETECTING WARNING DEVICE IN CASE OF A GAS LEAK.
SINCE PROPANE GAS I S HEAVIER THAN AIR, ANY LEAKING G AS CAN
SETTLE IN ANY LOW AREAS OR CONFINED SPACES.
PROPANE GAS ODORANT MAY FADE, MAKING THE GAS UNDETECTABLE
EXCEPT WITH A WARNING DEV ICE.
WARNING
AN UNDETECTED GAS LEAK WILL CREATE A DANGER OF EXPLOSI ON
OR FIR E.
IF THE PRESENCE OF GAS IS SUSPECTED, FOLLOW THE
INSTRUCTIONS ON THE COVER OF THIS MANUAL. COULD RESULT IN
SERIOUS PERSONAL INJURY OR DEATH.
FAILURE TO DO SO
29
INST ALLATION CONSIDERA TIONS
WARNING
F THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A
I
FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOS S OF LIF E.
O NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND
D
LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE. –
WHAT TO DO IF YOU SMELL GAS
• PHONE IN YOUR BUILDING.
PHONE.
• DEPARTMENT.
NSTALLATI ON AN D SER VICE MUST BE PERF ORMED BY A QU ALIFI ED I NSTAL LER,
I
SERVICE AGENCY OR THE GAS SUPPLIER.
Sizing Between First and Second S ta ge R eg ul at or *
Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting. Capacities in 1,000 BTU/hour.
Pipe or Tubing Length
Feet
10 730 1,700 3,200 5,300 8 ,300 3,200 7,500 20 500 1,100 220 3,700 5,800 2,200 4,200 30 400 920 2,00 0 2,900 4,700 1,800 4,000 40 370 850 1,70 0 2,700 4,100 1,600 3,700 50 330 770 1,50 0 2,400 3,700 1,500 3,400 60 300 700 1,30 0 2,200 3,300 1,300 3,100
80 260 610 1,20 0 1,900 2,900 1,200 2,600 100 220 540 1,000 1,700 2,600 1,000 2,300 125 200 490 900 1,400 2,300 900 2,100 150 190 430 830 1,300 2,100 830 1,900 175 170 400 780 1,200 1,900 770 1,700 200 160 380 730 1,100 1,800 720 1,500
To convert to capacities at 15 psig settings - multiply by 1.130 To convert to capacities at 5 psig settings - multiply by 0.879
O NOT TRY TO LIGHT ANY APPLIANCE.
D
O NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY
D
MMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR’S
I
OLLOW THE GAS SUPPLIER’S INSTRUCTIONS.
F
F YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE
I
Tubing Size, O.D . Type L
3/8" 1/2" 5/8" 3/4" 7/8" 1/2" 3/4"
:
Nominal Pipe Size
Schedule 40
When installing a propane storage tank, the contractor must consider proper tank sizing, safety, efficiency, ground char­acteristics and aesthetics. For a residential customer, the size may range from 100-1,000 gallons, depending on house­hold use. Typically, a 500 gallon tank is ample for an aver­age four-bedroom home. However, it is best to consult your local propane supplier to ensure the proper sizing for pro­pane storage requirements. Determining the correct tank size for each household is a function of demand, economy, efficiency and convenience. It is a process that requires cooperation between the propane supplier and customer.
ELECTRICAL CONNECTIONS
WARNING
TO AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO THE UNIT MUST BE
PROPERLY POLARIZED AND GROUNDED.
WARNING
HIGH VOLTAGE D
ISCO NN E CT ALL POWER BEFORE SERVI CING OR
INSTALLING THIS UNIT. BE PRESENT. DAMAGE, PERSONAL INJ URY OR DEATH.
L
ABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS.
WIRING ERRORS CAN COUSE IMPR OPER AND DAN GEROUS OPERAT ION. VERIFY PROPER OPERATION AFTER SERVICING.
MULTIPLE POWER SOURCES MAY
FAILURE TO DO SO MAY CAUSE PROPERTY
CAUTION
Sizing Between Second or Second St ag e Regula tor & App l iance*
Maximum Propane Capacities lis ted are based on 1/2" W.C. pressure drop at 11" W.C. setting. Capacities in 1,000 BTU/hour.
Pipe or Tubing Length
Feet
10 39 92 199 329 501 275 567 1,071 2,205 3,307 20 26 62 131 216 346 189 393 732 1,496 2,299 30 21 50 107 181 277 152 315 590 1,212 1,858 40 19 41 90 145 233 129 2 67 504 1,039 1,559 50 18 37 79 131 198 114 2 37 448 913 1,417 60 16 35 72 1,211 187 103 217 40 9 834 1,275
80 13 29 62 104 155 89 1 85 346 724 1,066 100 11 26 55 90 138 78 1 62 307 630 976 125 10 24 48 81 122 69 1 46 275 567 866 150 9 21 43 72 109 63 1 32 252 511 787 200 8 19 39 66 100 54 1 12 209 439 665 250 8 17 36 60 93 48 1 00 185 390 590
*Data in accordance with NFPA pa m phlet No. 54
Tubing Size, O.D. Type L
3/8" 1/2" 5/8" 3/4" 7/8" 1/2" 3/4" 1" 1-1/4" 1-1/2"
Nominal Pipe Size
Schedule 40
Propane Gas Piping Charts
30
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.
INST ALLATION CONSIDERA TIONS
Use a separate fused branch electrical circuit containing prop­erly sized wire, and fuse or circuit breaker. The fuse or cir­cuit breaker must be sized in accordance with the maxi­mum overcurrent protection specified on the unit rating plate. An electrical disconnect must be provided at the furnace location.
NOTE: Line polarity must be observed when making field connections.
Humidifier 1.0 Amp maximum a t 120 VAC Electro nic Air Cleaner 1.0 Amp maximum at 120 VAC
Turn OFF power to the furnace before installing any acces­sories. Follow the humidifier or air cleaner manufacturers’ instructions for locating, mounting, grounding, and control­ling these accessories.
Accesso ry Loa d Specifications
N
G
I
N
W
R
A
IN 90% FURNACE UPRIGHT UP FLOW INSTALLATIONS, THE DRA IN TRAP MUST
BE MOUNTED ON THE OPPOSITE SIDE OF THE UNIT FROM THE JUNCTION BOX.
THIS WILL REDUCE THE RISK OF WATER REACHING THE JUNCTION
BOX IN THE EVENT O F A BLOCKED DRAIN CONDITION.
Connect hot, neutral, and ground wires as shown in the wir­ing diagram located on the unit’s blower door. Line polarity must be observed when making field connections. Line volt­age connections can be made through either the right or left side panel.
NOTE: Wire routing must not interfere with circulator blower operation, filter removal, or routine maintenance.
WARNING
TO AVOID THE RISK OF ELECTRICAL SHOCK, INJ URY, OR DEATH, T HE
FURNACE MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH LOCAL CODES OR, IN THEIR ABSENCE, WITH THE LATEST EDITION OF THE
N
ATIONAL ELECTRIC CODE.
115 VOLT LINE CONNECTION OF ACCESSORIES (HUMIDIFIER AND ELECTRONIC AIR CLEANER)
WARNING
HIGH VOLTAGE
ISCONNECT
D
CHANGING A NY ELECT RICAL WIRIN G. SOURCES MAY BE PRESENT. PROPERTY DAMA GE, PERSONA L INJURY OR DEATH.
POWER BEF ORE SERVI CING OR
ALL
MULTIPLE POWER
FAILURE TO DO S O MAY CAUSE
HUMIDIFIER CONNECTION OPTIONS
24 volt thermostat
Option 1: Use the single HUM terminal to supply 115 VAC
to a humidifier transformer. This terminal is pow­ered anytime there is a call for heat.
Option 2: Use the brown wire coming off the common side
of the pressure switch to supply 24 VAC to hu­midifier
Option 3: The HUM IN / HUM OUT terminals are dry con-
tacts that will close during a call for heat. To power a humidifier with these contacts The HUM IN contact can be fed with 24vac from the R ter­minal or line voltage from the L1 terminal.
Communicating Thermostat
CTK01: The CTK01 is not capable of supplying a call for humidity; therefore if a humidifier is used it must be con­trolled by a separate humidistat. The recommended wiring is one of the methods shown with a 24 volt thermostat.
CTK02 is capable of generating a call for humidity. See dia­gram for wiring. The user is now provided with 3 modes of operations which can be selected within the thermostat user menu.
1. ON: Humidifier is turned on with a heat demand.
2. OFF: Humidifier remains off (relay never closes).
3. IND: Humidifier will cycle with humidification demand, in­dependent of heat demand. This mode allows the user to select one of 4 fan speeds (25, 50, 75, and 100%).
CTK03AA, does notprovide a call for humidity when used with the 2 stage communicating furnaces. The single HUM terminal on the PCBKF103 or PCBKF104 control board will provide a line voltage output when the inducer is running.
CTK03AB and CTK04, can provide a humidity call to the PCBKF103 or PCBKF104 control board relay and operate the HUM IN - HUM OUT dry contacts.
All communicating furnaces have an integrated igni­tion control that is equipped with line voltage acces­sory terminals for controlling power to an optional field­supplied humidifier and/or electronic air cleaner.
HUMIDIFIER WIRING
Accessory wiring connections are to be made through the 1/4" quick connect terminals provided on the furnace inte­grated control module. The Humidifier and Electronic Air Cleaner hot and neutral terminals are identified as HUM and EAC. All field wiring must conform to applicable codes. Con­nections should be made as shown in OPTIONAL ACCES­SORIES, Accessories Wiring figure.
31
INST ALLATION CONSIDERA TIONS
Accessories Wiring
If it is necessary for the installer to supply additional line voltage wiring to the inside of the furnace, the wiring must conform to all local codes, and have a minimum temperature rating of 105°C. All line voltage wire splices must be made inside the furnace junction box.
The integrated control module humidifier terminal (HUM) is ener­gized with 115 volts whenever the induced draft blower is ener­gized. The integrated control module electronic air cleaner ter­minals (EAC) are energized with 115 volts whenever the circula­tor blower is energized.
In addition, the control is equipped with a dedicated humidi­fication relay which is available through ¼ inch terminals HUM-IN and HUM-OUT. Similar to the HUM terminal, when utilizing legacy connections, this relay will be closed during normal heating operation (115VAC must be present on the HUM-IN terminal to take advantage of HUM-OUT). How­ever, the control can provide additional humidification fea­tures when wired to a communicating thermostat (1, 2, R, C connections). If the communicating thermostat is not ca­pable of providing a humidification call, this dedicated relay will function exactly as mentioned above with a legacy setup. If the communicating thermostat is capable of providing a humidification call the user is now provided with 3 modes of operations which can be selected within the thermostat user menu.
1. ON: Humidifier is turned on during a call for heat along with a call for humidity
2. OFF: Humidifier remains off (relay never closes).
3. IND: Humidifier will cycle with humidification demand, independent of heat demand. This mode allows the user to select one of 4 fan speeds (25, 50, 75, and 100%).
NEUTRAL
HUM-IN
HUM-OUT
24 VOLT HUMIDIFIER
A 24 volt hum circuit may be powered off of the n/c side of the low fire pressure. If added in the field, the wiring must conform to all local and national codes. Connect the COM side of the humidifier to the C terminal on the furnace control board (or to the COM side of the 24 VAC transformer). Do not connect 115V humidifier to these terminals.
AUXILIARY ALARM SWITCH:
The control is equipped with a 24VAC Auxiliary Alarm Input (12 inch purple / white wire attached to pin 6 of 15 pin con­nector) which can be utilized with communicating mode set­ups (typically used for condensate switch wiring but could be used with compatible C02 sensors or Fire Alarms).
Legacy mode use
In a legacy system (Non-communicating), this auxiliary alarm input is not operational. Any auxiliary alarm switch must be used to interrupt Y1 signal either to IFC or to UC.
Communication mode use
This feature can be activated or deactivated through the ther­mostat user menus. By default, an AUX switch is normally closed and opens when the water level in the evaporator coil base pan reaches a particular level. The control will respond by turning off the outdoor compressor and display the proper fault codes. If the AUX switch is detected closed for 30 sec­onds, normal operation resumes and error messages are no longer displayed. Installer must wire control voltage (24VAC) to AUX switch to ensure the Auxiliary Alarm Input has 24VAC during normal operation.
24 VOLT THERMOSTAT WIRING NOTE: Low voltage connections can be made through ei-
ther the right or left side panel. Wire routing must not inter­fere with circulator blower operation, filter removal, or routine maintenance.
A 40 V.A. transformer and an integrated electronic control are built into the furnace to allow use with most cooling equip­ment. Consult the wiring diagram, located in the Technical Manual or on the blower door for further details of 115 Volt and 24 Volt wiring.
32
INST ALLATION CONSIDERA TIONS
Thermostat Wiring - Two-Stage Variable Speed ComfortNet™ Furnaces
As a two-stage non-communicating furnace, the furnace integrated control module provides terminals for both “W1” and “W2”, and “Y1” and “Y2” thermostat connections. This allows the furnace to support the following system applica­tions: ‘Two-Stage Heating Only’, ‘Two-Stage Heating with Single Stage Cooling’, and ‘Two-Stage Heating with Two­Stage Cooling’. Refer to the following figures for proper connections to the integrated control module.
Low voltage connections can be made through either the right or left side panel. Thermostat wiring entrance holes are located in the blower compartment. The following figure shows connections for a “heat/cool system”.
This furnace is equipped with a 40 VA transformer to facili­tate use with most cooling equipment. Consult the wiring diagram, located on the blower compartment door, for fur­ther details of 115 Volt and 24 Volt wiring.
NOTE: For single stage cooling applications, a jumper may be required between Y1 and Y2 at the furnace control in order to achieve the desired single stage cooling airflow. Consult the blower performance tables to determine if the required single stage cooling airflow can be delivered at low stage (Y1 input) or high stage (Y2 input). Additionally, use of ramping profile features require a jumper between Y1 and O when used with a straight cooling unit.
NOTE: Thermostat “R” required if outdoor unit is equipped with a Comfort Alert™ module or if the out door unit is a part of the ComfortNet family of equipment AND is wired as a legacy system.
In a Non-Dual Fuel
Application, Place Jumper
Between Y1 and O For
Proper Dehumidification
Operation and Proper
Ramping Profile Operation
Y
Thermostat
Single Stage Heating with
Single Stage Cooling
In a Non-Dual Fuel
Application, Place Jumper
Between Y1 and O For
Proper Dehumidification
Operation and Proper
Ramping Profile Operation
In a Non-Dual Fuel
Application, Place Jumper
Between Y1 and O For
Proper Dehumidification
Operation and Proper
Ramping Profile Operation
Thermostat
Two-Stage Heating
with
Y
Y C
Remote
Condensing Unit
(Single-Stage Cooling)
R
R
Single-Stage Cooling
NEU
Dehumidistat
[Optional]
Furnace Integrated
Control Module
Two-Stage Heating wit h Single-Stage Cooling
W2
Y2
W1
Y2
Y2
Remote
Condensing Unit
(Two-Stage Cooling)
Two-Stage Heating with Two-Stage Cooling
W1 W2
NEU
Thermostat
Two- Stage Heating
()
with
Two-Stage Cooling
Furnace Integrated
Control Module
Dehumidistat
[Optional]
Thermostat Wiring Diagrams
R
R
Y C
Remote
Condensing Unit
(Single-Stage Cooling)
Single Stage Heating with Single Stage Cooling
To apply a single-stage Heati ng Thermostat,
NOTE:
the thermostat selector switch on the Integrated Control Module be set on single-stage.
NEU
Furnace Integrated
Dehumidistat
[Optional]
must
Control Module
33
INST ALLATION CONSIDERA TIONS
CFM CHART
Model Tap
*MVC960403BN*
*MVC960603BN*
*MVC960803BN*
*MVC960804CN*
*MVC961005CN*
*MVC961205DN*
*CVC960403BN*
*CVC960603BN
*CVC960803BN
*CVC960804CN*
*CVC961005CN*
*CVC961205DN*
Low
Stage
Cool
A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A 405 624 758 1057 B 549 808 815 1146 C 678 994 882 1256 D 784 1177 946 1349 A B C D A B C D A B C D
403 596 422 494 527 796 471 553 675 974 521 601 803 1192 574 676 398 599 667 953 557 817 740 1059 696 1007 808 1158 810 1212 881 1260 403 629 855 1202 540 806 923 1316 705 10 23 1033 1389 819 12 30 1063 1396 513 789 867 1228 660 967 939 1337 791 11 82 1016 1430 913 13 75 1077 1516 564 820 1256 1818 784 11 33 1292 1870 982 14 64 1316 1910
1259 1736 1358 195 7
547 867 1329 1891
831 11 60 1362 1940 1020 1467 1390 196 8 1278 1910 1440 202 8
449 655 682 957
569 807 750 1059
716 998 820 1155
854 1207 888 1251
433 656 687 938
541 790 751 950
686 972 814 986
806 1195 874 992
556 837 889 1234
714 1022 944 1325
838 12 06 1019 1442
991 14 75 1068 1528
524 784 1209 1759
744 10 78 1249 1797
927 13 88 1277 1840 1185 1766 1300 188 1
540 854 1284 1744
870 11 23 1310 1827 1000 1399 1350 186 0 1235 1804 1388 191 8
High
Stage
Cool
Low
Stage
Heat
High
Stage
Heat
34
AIRFLOW TABLE
INST ALLATION CONSIDERA TIONS
DIP SWITCHES - FURNACES EQUIPPED WITH PCBKF103 / PCBKF104
Switch Bank Purpose Function
90 Off Off 120 150 Off On 180 On On
2 Stage S tat 2 Stage S tat On Off
AOffOff BOnOff COffOn D
Add 5%
Minus 5% On Off
Add 10% Off On
Minus 10% On On
A BOnOff COffOn DOnOn AOffOff B COffOn DOnOn
Disabled
Enabled On
Disabled
Enabled On
25% Off Off 50% 75% Off On
100% On On
S1
S3
S4
S5
Heati n g Off Delay
Thermostat
Setup
Cooling Airflow
Trim
Rampi ng Profile
Heating A i rflow
Dehum
Trim
Continuous F an
1 St g Stat 5 m i n del ay Off O ff
1 Stg St at auto del ay Off On
Dip Swit ch
1234
On Off
On On
On On
Off Off
Off Off
On Off
Off
Off
On Off
* = Factory Setting
35
INST ALLATION CONSIDERA TIONS
Single-Stage Thermostat Application
A single-stage thermostat with only one heating stage may be used to control this furnace. The application of a single­stage thermostat does not offer “true” thermostat-driven two­stage operation, but provides a timed transition from low to high fire. The furnace will run on low stage for a fixed period of time before stepping up to high stage to satisfy the thermostat’s call for heat. The delay period prior to stepping up can be set at either a fixed 5 minute time delay or a load based variable time between 1 and 12 minutes (AUTO mode). If the AUTOmode is selected, the control averages the cycle times of the previous three cycles and uses the average to determine the time to transition from low stage to high stage.
To use a single-stage thermostat, turn off power to the fur­nace, move the thermostat selection DIP switch to the OFF position. Set the desired transition time by setting the tran­sition delay DIP switch to the desired ON/OFF position. Turn power back on. Select preferences on S1 #3 and #4 DIP switches.
24 Volt Dehumidistat Wiring (Not needed if a communicating thermostat is used)
The optional usage of a dehumidistat allows the furnace’s circulator blower to operate at a slightly lower speed (85% of desired speed) during a combined thermostat call for cool­ing and dehumidistat call for dehumidification. This can be done through an independent dehumidistat or through a thermostat’s DEHUM terminal (if available). This lower blower speed enhances dehumidification of the conditioned air as it passes through the AC coil. For proper function, a dehumi­distat applied to this furnace must operate on 24 VAC and utilize a switch which opens on humidity rise.
To install/connect a dehumidistat:
1. Turn OFF power to furnace.
2. Secure the dehumidistat neutral wire (typically the white lead) to the terminal marked “DEHUM” on the furnace integrated control module.
3. Secure the dehumidistat hot wire (typically the black lead) to the terminal marked “R” on the furnace integrated control module.
4. Secure the dehumidistat ground wire (typically the green lead) to the ground screw on the furnace junction box. NOTE: Ground wire may not be present on all dehumi­distats.
5. Turn ON power to furnace.
To enable the dehumidify function on the integrated control module, set the dehumidification ENABLE dipswitch from OFF to ON.
Once the switch is set, the dehumidify function is enabled during a combination call for cooling (T-Stat) and dehumidi­fication (DEHUM-Stat).
For a furnace equpped with aPCBKF101 or PCBKF102 con­trol board, select preferences on S5 #9 DIP switch.
For a furnace equipped with a PCBKF103 or PCBKF104 control board, select preferences on S5 #1 DIP switch.
Fossil Fuel Applications
This function is automatically configured and controlled when using a communicating thermostat.
Furnaces can be used in conjunction with a heat pump in a fossil fuel application. A fossil fuel application is where an outdoor temperature sensor determines the most cost effi­cient means of heating (heat pump, gas furnace, or both).
A heat pump thermostat with two stages of heat is required to properly use the single-stage furnace with a heat pump. A heat pump thermostat with three stages of heat is re­quired to properly use the two-stage furnace with a heat pump. Refer to dual fuel, AFE-18-60A installation manual (IO-627) for additional wiring instructions.
CONTINUOUS FAN OPERATION
Continuous fan speed is selectable from a communicating thermostat or by DIP switches when using a conventional thermostat. ----------------------------
CIRCULATOR BLOWER SPEED ADJUSTMENT
HIGH VOLTAGE
ISCONNECT ALL POWER BEFOR CHANGING SPEED TAPS.
D
ULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO
M
SO MAY CAUSE PROPERTY D AMAGE, PERSO NAL INJURY OR DEATH .
Blower set up is automatically configured in a fully commu­nicating system. Adjustments can also be made at the communicating thermostat. Set up blower speeds with DIP switches when using a conventional thermostat.
This furnace is equipped with a multi-speed circulator blower. This blower provides ease in adjusting blower speeds. The heating blower speed is shipped set at “B”, and the cooling blower speed is set at “D”. These blower speeds should be adjusted by the installer to match the installation require­ments so as to provide the correct heating temperature rise and correct cooling CFM.
Use the dual 7-segment LED display adjacent to the dipswitches to obtain the approximate airflow quantity. The airflow quantity is displayed as a number on the display, rounded to the nearest 100 CFM. The display alternates airflow delivery indication and the operating mode indica­tion.
COOLING CFM Example: The airflow being delivered is 1225 CFM. The
display indicates 12. If the airflow being delivered is 1275, the display indicates 13.
1. Determine the tonnage of the cooling system installed with the furnace. If the cooling capacity is in BTU/hr divide it by 12,000 to convert capacity to TONs.
WARNING
36
INST ALLATION CONSIDERA TIONS
Example: Cooling Capacity of 30,000 BTU/hr.
30,000/12,000 = 2.5 Tons
2. Determine the proper air flow for the cooling system. Most cooling systems are designed to work with air flows between 350 and 450 CFM per ton. Most manufactur­ers recommend an air flow of about 400 CFM per ton.
Example: 2.5 tons X 400 CFM per ton = 1000 CFM
The cooling system manufacturer’s instructions must be checked for required air flow. Any electronic air cleaners or other devices may require specific air flows, consult instal­lation instructions of those devices for requirements.
3. Knowing the furnace model, locate the high stage cool­ing air flow charts in the Specification Sheet applicable to your model. Look up the cooling air flow determined in step 2 and find the required cooling speed and adjust­ment setting. -----------------------------------
4. Locate the blower speed selection DIP switches on the integrated control module. Select the desired “cooling” speed tap by positioning switches S3 1 and 2 appropri­ately. ------------------------------------------
NOTE: Trim function must also be inabled on S5 #2 DIP
switch.
RAMPING PROFILE
5.The multi-speed circulator blower also offers several cus­tom ON/OFF ramping profiles. These profiles may be used to enhance cooling performance and increase com­fort level. ------------------------------------
Refer to the bullet points below for a description of each ramping profile. Verify CFM by noting the number dis­played on the dual 7-segment LED display.
OFF
Profile D ramps up to 50% of the demand for 1/2 minute, then ramps to 85% of the full cooling demand airflow and operates there for approximately 7 1/2 minutes. The motor then steps up to the full demand airflow. Profile D has a 1/2 minute at 50% airflow OFF delay.
OFF
HEATING SPEED
1.Select the heating speed for your model from the heating speed chart in the Specification Sheet. The adjust setting (already established by the cooling speed selection) deter­mines which set of speeds are available.
The selected speed must provide a temperature rise within the rise range listed with the particular model.
Select Heating Speed preferences on S4 #7 & #8 DIP Switches. Verify CFM by noting the number displayed on the dual 7-segment LED display.
In general lower heating speeds will: reduce electrical con­sumption, lower operating sound levels of the blower, and increase the outlet air temperature delivered to the home. The speeds available allow the blower performance to be optimized for the particular homeowner’s needs.
100% CFM
OFF
OFF
Profile A provides only an OFF delay of one (1) minute at 100% of the cooling demand airflow.
OFF
100% CFM 100% CFM
1 min
OFF
Profile B ramps up to full cooling demand airflow by first stepping up to 50% of the full demand for 30 sec­onds. The motor then ramps to 100% of the required airflow. A one (1) minute OFF delay at 100% of the cooling airflow is provided.
OFF
50% CFM
1/2 min
100% CFM
100% CFM
OFF
1 min
Profile C ramps up to 85% of the full cooling demand airflow and operates there for approximately 7 1/2 min­utes. The motor then steps up to the full demand air­flow. Profile C also has a one (1) minute 100% OFF delay.
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.
The following two charts show the bottom and side return filter sizes available for each size furnace. Larger sizes are also acceptable.
37
INST ALLATION CONSIDERA TIONS
SIDE RETUR N BOTTOM RETUR N
Cabinet
Width
(In.)
Nominal
Filter
Size (In.)
All 16x25x1 400 14" 14X25X1 350
Approx.
Flow Area
(In.)
Cabinet
Width
(In.)
17-1/2 14X25X1 350
24-1/2 20X25X1 500
Nominal
Filter
Size (In.)
21 16x25x1 400
Approx.
Flow Area
(In.)
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.
Filter Sizing Chart
Model Minimum Filter Size
*MVC960403BN** 20 X 24 *MVC960603BN** 20 X 25 *MVC960803BN** 18 X 36 *MVC960804CN** 24 x 30 *MVC961005CN** 24 X 36
*MVC961205DN** 2 (20 X 25) *CVC960403BN** 20 X 24
*CVC960603BN** 20 X 25 *CVC960804CN** 18 X 36 *CVC961005CN** 24 x 30 *CVC961205DN** 2 (20 X 25)
One inch throwaway filters should be sized for a face veloc­ity of 300 feet per minute or less (14x25x1 throwaway = 730 CFM maximum, 16x25x1 throwaway = 830 CFM maximum, 18x25x1 throwaway = 940 CFM maximum, 20x25x1 throw­away = 1040 CFM maximum) All other filters should be sized according to their manufacturer's instructions.
To find the miminum filter requirement (in2) for either perma­nent or disposable filters divide the required airflow (CFM) by the rated velocity of the filter, either 300ft/min for dispos­able filter or 600ft/min for permanent filter. Multiply the num­ber by 144 in.2 to obtain the minimum filter requirement (in2).
EXAMPLE:
Filter Size (in2) =
1400 CFM x 144 i n
600 ft./min. (Permanent)
2
Upflow furnaces with air delivery of less than 1800 CFM:
Use one side return or one bottom return ductwork connec­tion.
Upflow furnaces with air delivery of 1800 CFM or higher:
Use two side returns or one side return and one bottom return connection.
Guide dimples locate the side and bottom return cutout lo­cations. Use a straight edge to scribe lines connecting the dimples. Cut out the opening on these lines. An undersized opening will cause reduced airflow. For bottom return con­nection, remove the bottom of the cabinet before setting the furnace on the raised platform or return air duct.
A closed return duct system must be used, with the return duct connected to the furnace. NOTE: Ductwork must never be attached to the back of the furnace. Supply and return connections to the furnace may be made with flexible joints to reduce noise transmission, if desired. If a central return is used, a connecting duct must be installed between the unit and the utility room wall so the blower will not interfere with combustion air or draft. The room, closet, or alcove must not be used as a return air chamber.
When the furnace is used in connection with a cooling unit, the furnace should be installed in parallel with or on the up­stream side of the cooling unit to avoid condensation in the heating element. With a parallel flow arrangement, the damp­ers or other means used to control the flow of air must be adequate to prevent chilled air from entering the furnace and, if manually operated, must be equipped with means to pre­vent operation of either unit unless the damper is in the full heat or cool position.
When the furnace is heating, the temperature of the return air entering the furnace must be between 55°F and 100°F.
UPRIGHT FILTER INSTALLATIONS
Depending on the installation and/or customer preference, differing filter arrangements can be applied. Filters can be installed in the central return register and a side panel exter­nal filter rack kit (upflow filter kit # EFR01). As an alternative a media air filter or electronic air cleaner can be used as the requested filter. Refer to the following minimum filter require­ment charts for determination of the minimum filter area to ensure proper unit performance. The following figures show possible filter locations. NOTE: A ductwork access door must be used in counterflow applications to allow filter removal. If the filter rack is used, the side of the plenum must be at least as tall as dimension "A" shown in the following illustra­tion. For dimension of "A" refer to the following chart.
Filter Size (in
Filter Size = 672in
Filter Size = 336in
2
) =
1400 CFM x 144 i n
300 (Disposabl e) ft. /min.
2
Dispos abl e
2
Permanent
38
2
INST ALLATION CONSIDERA TIONS
COUNTERFLOW FILTER INSTALLATION
This furnace has provisions for the installation of return air filters at the counterflow top return. The furnace will accom­modate the following filter sizes depending on cabinet size:
Return Air
Optional
Access
Door
"A" Min
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.
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.
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 (EFR01)
The external filter rack kit is intended to provide a location external to the furnace casing, for installation of a perma­nent filter on upflow model furnaces. The rack is designed to mount over the indoor blower compartment area of either side panel, and provide filter retention as well as a location for attaching return air ductwork.
39
SYSTEM OPERATION
NORMAL SEQUENCE OF OPERATION POWER UP
The normal power up sequence is as follows:
115 VAC power applied to furnace.
Integrated control module performs internal checks.
Integrated control module displays 8 8 on dual 7-seg­ment display LED’s.
Integrated control module monitors safety circuits con­tinuously.
Furnace awaits call from thermostat. Dual 7-segment LED’s display ON while awaiting call from thermo- stat.
HEATING MODE
The normal operational sequence in heating mode is as fol­lows:
R and W1 (or R and W1/W2) thermostat contacts close, initiating a call for heat.
Integrated control module performs safety circuit checks.
Induced draft blower is energized on high speed for a 15-second prepurge. Humidifier terminal is energized with induced draft blower.
Induced draft blower steps to low speed following prepurge. Low stage pressure switch contacts are closed.
Igniter warm up begins upon step to low speed and presence of closed low stage pressure switch con­tacts.
Gas valve opens at end of igniter warm up period, de­livering gas to burners and establishing flame.
Integrated control module monitors flame presence. Gas valve will remain open only if flame is detected.
If the thermostat call is for low heat, gas valve and induced draft blower will continue on low stage. If the call is for high heat, the gas valve and induced draft blower will change to high stage.
Circulator blower is energized on heat speed follow­ing a thirty (30) second blower on delay. The circula­tor blower requires thirty seconds to ramp up to full speed. Electronic air cleaner terminal is energized with circulator blower.
Furnace is now operating on the specified stage called for by the two-stage thermostat.
Furnace runs, integrated control module monitors safety circuits continuously.
If the two-stage thermostat changes the call from low heat to high heat, the integrated control module will immediately switch the induced draft blower, gas valve, and circulator blower to their high stage settings.
If the two-stage thermostat changes the call from high heat to low heat, the control will immediately switch the induced draft blower and gas valve to their low
stage settings. The circulator blower will remain on high heating speed for thirty (30) seconds before switching to the low heat circulating speed.
R and W1 (or R and W1/W2) thermostat contacts open, completing the call for heat.
Gas valve closes, extinguishing flame.
Induced draft blower is de-energized following a fif­teen second post purge. Humidifier terminals are de­energized.
Circulator blower continues running for the selected heat off delay period (90, 120, 150 or 180 seconds). The speed run during this period depends on the last heat call provided by the thermostat.
If the last call for heat was a call for low heat, the air circulator motor will run on low heat speed for the du­ration of the heat off delay period (90, 120, 150 or 180 seconds).
If the last call for heat was a call for high heat, the air circulating motor will run on the high heating speed for thirty (30) seconds and then switch to the low heat­ing speed for the balance of the heat off delay period (60, 90, 120 or 150 seconds).
Circulator blower and electronic air cleaner terminal is de-energized.
Circulator blower ramps down to OFF during the 30 seconds following the heat off delay period.
Furnace awaits next call from thermostat.
COOLING MODE
The normal operational sequence in cooling mode is as fol­lows:
R and Y1/G or Y2/G thermostat contacts close, initi­ating a call for cool.
Integrated control module performs safety circuit checks.
Outdoor fan and compressor are energized to their appropriate speed.
Circulator blower is energized on the appropriate cool speed at the level and time determined by the se­lected ramping profile. Electronic air cleaner terminal is energized with circulator blower.
Furnace circulator blower and outdoor cooling unit run their appropriate speeds, integrated control module monitors safety circuits continuously.
R and Y1/G or Y2/G thermostat contacts open, com­pleting the call for cool.
Outdoor fan and compressor are de-energized.
Circulator blower continues running during a cool off delay period. The OFF delay time and airflow level are determined by the selected ramping profile.
Electronic air cleaner terminal and circulator blower are de-energized.
Furnace awaits next call from thermostat.
40
SYSTEM OPERATION
FAN ONLY MODE
The normal operational sequence in fan only mode is as follows:
R and G thermostat contacts close, initiating a call for fan.
Integrated control module performs safety circuit checks.
Circulator blower is energized on continuous fan speed following a five (5) second delay. Electronic air cleaner terminal is energized.
Circulator blower runs, integrated control module moni­tors safety circuits continuously.
R and G thermostat contacts open, completing the call for fan.
Circulator blower is de-energized. Electronic air cleaner terminal is de-energized.
DEHUMIDIFICATION MODE
The normal operational sequence in dehumidification mode is as follows:
1. R and Y1/G or Y1+Y2/G thermostat contacts close, initiaing a call for cool.
2. Integrated control module performs safety circuit checks.
3. Outdoor fan and compressor are energized to their ap­propriate speed.
4. Circulator blower is energized on the appropriate cool speed at the level and time determined by the selected ramping profile. Electronic air cleaner terminals are en­ergized with circulator blower.
5. Furnace circulator blower and outdoor cooling unit run their appropriate speed, integrated control module moni­tors safety circuits continuously.
6. Dehumidistat opens on humidity rise allowing the fur­nace circulator blower to operate at 85% of the cooling speed during combined thermostat call for cooling and dehumidistat call for dehumidification.
7. Humidistat opens on humidity fall allowing furnace cir­culator blower to switch back to normal cooling speed.
8. R and Y1/G or Y1+Y2/G thermostat contacts open, com­pleting the call for cool.
9. Outdoor fan and compressor are de-energized.
10. Circulator blower continues running during a cool off de­lay period. The OFF delay time and airflow level are de­termined by the selected ramping profile.
11. Electronic air cleaner terminals and circulator blower are de-energized.
12. Furnace awaits next call from thermostat.
HEATING - ABNORMAL OPERATION
The following presents the probable causes of questionable furnace operation and how to fix them. Look through the observation window in the blower access door and make a note of the error code displayed on the dual 7-segment dis-
play. Next, refer to the Troubleshooting Chart - ComfortNet™ on the following pages for an interpretation of the code dis­played on the LED's for a description of the problem.
NOTE: Use caution when reading the diagnostic codes from the furnace control's dual, 7-segment LED's. The position of the control within the furnace can lead to a misinterpreta­tion of the error codes. With the control in an orienation as shown below, codes on the dual, 7-segment LED's are read left to right.
2 Y2
1
Memory Card Connector
Dual 7-Segment LED’s
OG Y1CW1R
HUM
DE
W2
1. Internal Control Failure with Integrated Ignition Control. Check for voltage to the furnace and low volt­age at the control board. Check for blown fuse on the control board. If the control determines it has an internal fault, it enters a locked-out state. Any of the situations mentioned will cause the dual, 7-segment LED's to be off. The control board should only be replaced only after all other checks from the Troubleshooting Chart - ComfortNet™ have been verified.
2. System Lockout. If a flame is not sensed during the first seven (4) seconds after the gas valve is energized, the control turns off the gas. There will then be a 30 second delay while the induced draft blower is energized to purge the heat exchanger. The ignitor will again be energized and preheated for an additional (1) second. The gas valve will then be energized. If flame is not sensed
41
SYSTEM OPERATION
the gas valve will be de-energized and another purge will occur and a third ignitor warm up for an additional (2) seconds will occur. The control will cycle the gas valve a total of three (3) times before it determines it cannot establish measurable combustion and enters a locked out state. The diagnostic error code for this problem is E0. The control can be reset and brought out of lockout mode by turning the thermostat off for more than (5) sec­onds and less then (20) seconds and then back on. It can also be reset by turning off the electrical disconnect switch to the furnace for a minimum of 5 seconds.
NOTE: The control board will automatically reset one hour after lockout occurs. If the furnace frequently has to be re­set, it means that a problem exists that should be corrected. Refer to Troubleshooting Chart - ComfortNet™ on the fol- lowing pages for aid in determining the cause.
3. Low Stage Pressure Switch Stuck Closed. If the con- trol senses the low stage pressure switch is closed when the induced draft blower is off, it waits until the fault is corrected. The diagnostic error code for this problem is E1. The probable cause is either a faulty pressure switch or wiring.
4. Low Stage Pressure Switch Stuck Open. If, after the induced draft blower is energized, the low stage pres­sure switch does not close within 5 minutes, the control will go into a 1-hour lockout. The control will automati­cally reset fro lockout and restart the ignition sequance. The diagnostic error code for this problem is E2. The probable causes are either disconnected hose to the pressure switch, faulty pressure switch or wiring, re­stricted air intake or flue piping.
5. Open Primary, Auxiliary, or Rollout Limit. If the limit control opens, the air circulator blower and induced draft blower will be turned on until the limit closes. The diag­nostic error code for this problem is E3. The probable cause is either low conditioned air flow due to dirty filter or resistance in duct work, faulty limit, faulty blower, blower speed set to low, misaligned burners, faulty in­duced draft blower, or blocked flue.
6. Flame Sensed with No Call for Heat. If the control senses a flame when the gas valve is de-energized, it will run the air circulation blower and the induced draft blower continuously with no further furnace operation. The diagnostic error code for this condition is E4. The probable causes are either a short to ground in flame sense circuit, miswiring, lingering burner flame or a slow closing gas valve.
7. Open Fuse. If the control detects an open fuse, it will inhibit all furnace operation, except the display of the error code. The diagnostic error code for this condition is E5. The probable cause is a short in the low voltage wiring, either internal to the furnace or external to the furnace.
8. Low Flame Sense Signal. If the furnace continues to operate and the micro-amp signal from the flame sensor falls below specified level. The diagnostic error code for this problem is E6. The probable cause is either a coated/ oxidized sensor, incorrectly positioned senser in burner flame or lazy burner flame due to improper gas pressure or combustion air.
9. Check Igniter or No Ground Condition. Check for broken or improperly connected igniter. Check for proper ground and correct. The diagnostic error code for this problem is E7.
10. High Stage Pressure Switch Stuck Closed. If the con­trol fails to operate at high stage heat when commanded to do so, the high stage pressure switch is stuck closed. For this condition, the furnace will operate at low stage only, regardless of the thermostat demand. The diag­nostic error code for this condition is E8. The probable cause is sticking high stage pressure switch contacts or a short in the high stage pressure switch wiring.
11. High Stage Pressure Switch Stuck Open. This con- dition can occur if the pressure switch hose is blocked or pinched. Check for blocked flue and/or inlet air pipe. Blocked drain, weak induced draft blower and malfunc­tioning pressure switch are possible. The diagnostic error code for this problem is E9 followed by a pause.
12. Reversed Polarity. If the 115V or 24V AC power leads are reversed, the furnace will fail to operate. The diag­nostic error code for this problem is EA. The probable cause is either the 115V AC power to furnace or inte­grated control module is reversed, the 24V AC wires to transformer are reversed, or poor unit ground.
13. No Shared Data. The control does not contain any shared data. Shared data sets contain all the informa­tion required to drive the variable speed motor as well as calculate airflow demands. The furnace cannot function without the approriate shared data set. The diagnostic error code for the this condition is d0. A memory card must be used to populate shared data to the control. Contact your distributor to obtain the appropriate memory card for your particular furnace model.
NOTE: Turn off power to the furnace prior to inserting memory card onto the control. With memory card inserted onto con­trol, turn power to furnace on. Control has accepted memory card data once control displays ON on the dual, 7-segment display. Memory card may be left on control or removed and used on another furnace of the same model. Turn power off to furnace prior to removing memory card.
14. Invalid Memory Card Data. This condition occurs if the control rejects the shared data set on a memory card. Memory cards are model specific. If a memory card for a different model is used to populate data to a specific furnace, if will be rejected by the control. If us­ing a memory card to populate shared data to a control, ensure the memory card is specific to the furnace. The diagnostic error code for this condition is d4
.
42
SYSTEM OPERATION
NOTE: Turn off power to the furnace prior to inserting memory
card onto the control. With memory card inserted onto con­trol, turn power to furnace on. Control has accepted memory card data once control displays ON on the dual, 7-segment display. Memory card may be left on control or removed and used on another furnace of the same model. Turn power off to furnace prior to removing memory card.
15. ECM Blower Motor Not Running. This condition oc­curs if the control fails to detect the ECM blower motor running when it should be running. The furnace will not operate if the control detects the blower motor is not running when it should be running. The diagnostic error code for this condition is b0. The probable cause loose or disconnected wiring between the motor and control, an open inductor (3/4 Hp and 1 Hp motors only), or a failed ECM blower motor (see section S-16C in Servic- ing).
16. ECM Motor Communciations Lost. This condition oc- curs if the furnace control cannot communicate with the ECM blower motor. The furnace will not operate if the control cannot communicate with the blower motor. The diagnostic error code for this condition is b1. The prob­able cause loose or disconnected wiring between the motor and control, a failed ECM blower motor (see sec­tion S-16C in Servicing), or a failed control.
17. Motor Horsepower Mismatch. This condition occurs if the horsepower of the motor connected to the control does not match the motor horsepower specified in the shared data set. The furnace will not operate is there is a motor horsepower mismatch. The diagnostic error code for this condition is b2.
Verify that the installed motor is the correct motor for the furnace model. Obtain the correct motor for the fur­nace model. Verify the shared data set is correct for the furnace. The shared data set may be corrected using the appropriate memory card. Contact your distributor for the correct memory card. See 13 and 14 above for additional memory card information.
18. ECM Motor Operating in a Limiting Condition. This condition will occur if the ECM operates in a power, speed, or temperature limiting condition. The furnace will continue operating at reduced performance. The di­agnostic error code for the this condition is b3.
Power Limit. In attempting to deliver the airflow demand, the motor may exceed its rated output power. The mo­tor will reduce its output to prevent exceeding its power limit. This will result in lower than demanded airflow. This will occur under high loading conditions. High load­ing conditions could be due to blocked/clogged filters, blocked or restrictive ductwork, or undersized ductwork.
Speed Limit. In attempting to deliver the airflow demand, the motor may exceed its maximum speed of 1500 RPM. The motor will reduce its speed to prevent exceeding its maximum. This will result in lower than demanded air­flow. A blocked inlet, lightly loaded or no load condi­tions could cause high motor speeds.
Temperature Limit. In attempting to deliver the airflow demand, the motor may exceed its temperature limit. The motor will reduce its output in an attempt to reduce its temperature. This will result in lower than demanded airflow. A high ambient temperatue at a high loading condition is the most probable cause. Reduce the am­bient temperature and/or motor loading/demand.
19. Motor Trips. This condition occurs if the ECM motor senses a loss of control or becomes overloaded. The furnace may halt operation if the motor shuts down for a trip condition. The diagnostic error code for this condi­tion is b4.
Loss of Control (Lost Rotor Trip). This occurs if a sud­den change in speed or torque is detected. The motor will shut down and restart if this condition is encoun­tered. Possible causes are abnormal loading conditions due to sudden blockages of the duct system or sudden high increases in the loading on the motor.
Overload (Current Trip). This occurs if the motor be­comes overloaded due to high loading conditions. The motor will shut down and restart if this condition is en­countered. High loading conditions could be due to blocked/clogged filters, blocked or restrictive ductwork, or undersized ductwork.
20. Motor Locked Rotor. This condition occurs if the mo­tor fails to start after (10) consecutive attempts. The furnace will not operate if the ECM blower motor fails to start. The diagnostic error code for this condition is b5. The probable cause is an obstruction in the blower hous­ing or wheel, siezed motor bearings, or a failed blower motor.
21. Motor Volts. This condition occurs if the line voltage is too low or too high, or if the motors power module gets too hot. The ECM motor will shut down while the abnor­mal condition is present. If the abnormal condition is cleared, the motor will restart. The furnace will be inop­erable while the motor is off.
Over Voltage. If the line voltage exceeds 140VAC, the motor will shut down due to an over voltage condition. Verify the line voltage to the furnace is within the range specified on the rating plate.
Under Voltage. If the line voltage is less than 70VAC, the motor will shut down due to an under voltage condi­tion. Verify the line voltage to the furnace is within the range specified on the rating plate.
Over Temperature. A high ambient temperatue or a high loading condition is the most probable cause. Reduce the ambient temperature and/or motor loading/demand.
43
SYSTEM OPERATION
22. Motor Parameters. This condition occurs if the motor does not receive all the information is requires to operate or an event occurs that prevents the motor from running, or the motor fails to start for (40) consecutive attempts. The diagnostic error code for the this condition is b7. Probable causes are intermittent wiring connection be­tween the control and motor, an error with the furnace control, or any of the conditions described in 19, 20, or 21 above.
23. Low Indoor Airflow. This condition occurs if the indoor airflow falls below a calculated minimum value. The mini­mum airflow value is calculated from factors defined in
the shared data set. If the airflow falls below the calcu­lated minimum, the furnace will continue to operate with the reduce airflow. If the furnace was operating at high stage, it will stage back to low in an effort to remedy the condition. The furnace will halt operation if the airflow falls to 0 CFM.
The diagnostic error code for the this condition is b9. Probable causes are blocked/clogged filters, blocked or restrictive ductwork, or undersized ductwork.
44
TROUBLESHOOTING
Symptoms of Abnormal
Operation (Legacy &
ComfortNet™ Thermostat)
• Furnace fails to operate
• Integrated control module LED display provides no signal.
• ComfortNet™ thermostat “Call for Service” icon illuminated
• ComfortNet™ thermostat scrolls “Check Furnace” message
• LED display indicates On On • Normal operation None No ne • Normal operation • None • Normal operation
• Furnace fails to operate
• Integrated control module LED display provides E0 error code.
• ComfortNet™ thermostat “Call for Service” icon illuminated.
• ComfortNet™ thermostat scrolls “Check Furnace” message.
• Furnace fails to operate.
• Integrated control module LED display provides E1 error code.
• ComfortNet™ thermostat “Call for Service” icon illuminated.
• ComfortNet™ thermostat scrolls “Check Furnace” message.
Diagnostic/ Status LE D
Codes
None • No 115 power to
E0 • Furnace l ock out
E1 • Low stage pressure
Fault Description
furnace or no 24 volt power to integrated control module
•Blown fuse or circuit breaker
• Integrated control module has an internal fault
due to an excessive number of ignition “retries” (3 total)
switch circuit is closed at start of heating cycle.
ComfortNet™
Thermostat Only
Message Code
INTERNAL
FAULT
LOCKOUT E0 • Failure to establish fame.
PS1
CLOSED
EE • Manual disconnect switch
E1 • Low stage pressure switch
Possible Causes Corrective Actions Notes & Cautions
OFF, door switch open or 24 volt wir e improperly connected or loose
• Blown fuse or circuit breaker
• Integrated control module has an internal fault
Cause may be no gas to burners, front cover pressure swi t ch st uck open, bad igniter or igniter alignment, improper orifces, or coated/oxidized or improperly connected fame sensor.
• Loss of fame after establishment. Cause may be in te rrupted gas supply, lazy burner fames (improper gas pressure or restriction in fue and/ or combustion air piping), front cover pressure switch opening, or improper induced draft blower performance.
contacts sticking.
• Shorts in pressure switch circuit wiring.
• Assure 115 and 24 volt power to furnace and integrated control module.
• Check integrated control module fuse (3A). Replace if necessary.
• Check for possible shorts in 115 and 24 volt circuits. Repair as necessary.
• Replace bad integrated control module.
• Locate and correct gas interruption.
• Check f r o nt cover pressure switch operation (hose, wiring, contact operation). Correct if necessary.
• Replace or realign igniter.
• Ch eck fame sense signal. Sand sensor if coated and/or oxidized.
• Check fue piping for blockage, proper length, elbows, and termination.
• Verify proper induced draft blower performance.
• Replace low stage pressure switch.
• Repair short in wiring.
• Turn power OFF prior to repair.
• Replace integrated control module fuse with 3A automotive fuse.
• Read precautions in “Electrostatic Discharge” section of manual.
•Replace control with correct replacement part
• Turn power OFF prior to repair.
• Igniter is fragil e, handle with care.
• Sand fame sensor with emery cloth.
• See “Vent/Flue Pipe” section for piping details.
• Turn power OFF prior to repair.
• Replace pressure switch with proper replacement part.
45
TROUBLESHOOTING
Symptoms of Abnormal
Operation (Legacy
& ComfortNet ™
Thermostat)
• Induced draft blower runs continuously with no further furnace operation.
• Integrated control module LED display provides E2 error code.
• ComfortNet™ thermostat “Call for Service” icon illuminated.
• ComfortNet™ thermostat scrolls “Check Furnace” message.
• Circulator blower runs continuously. No furnace operation.
• Integrated control module LED display provides E3 error code .
•ComfortNet™ thermostat “Call for Service” icon illuminated.
•ComfortNet™ thermostat scrolls “Check Furnace” message.
• Induced draft blower and circulator blower runs continuously. No furnace operation.
• Integrated control module LED display provides E4 error code .
•ComfortNet™ thermostat “Call for Service” icon illuminated.
•ComfortNet™ thermostat scrolls “Check Furnace” message.
• No furnace operation.
• Integrated control module LED display provides E5 error code .
•ComfortNet™ thermostat displays “Battery P ower”
• Normal fu rnace operation.
• Integrated control module LED display provides E6 error code .
Diagnostic/ Status LE D
Codes
E2 • Low stage
E3 • Primary limit or
E4 • Flame sen sed
E5 • Open Fuse Not
E6 • Flame sense
Fault Des cription
pressure switch circuit is not closed.
auxiliary limit circuit is open.
• Rollout limit circuit is open.
with no call for heat.
micro amp signal is low
ComfortNet™
Thermostat Only
Message Code
PS1 OPEN E2 • Pressure switch hose
HIGH L I M I T
OPEN
IMPROPER
FLAME
Displayed
WEAK
FLAME
E3 • Insuffcient conditioned
E4 • Short to ground in
Not
Displayed
E6 • Flame sensor is
Possible Causes Corrective Actions Notes & Cautions
blocked pinched, or connected improperly.
• Blocked fue and/or inlet air pipe, blocked drain system or weak induced draft blower.
• Incorrect pressure switch se t poi n t or malfunctioning switch contacts.
• Loose or improperly connected wiring.
air over the heat exchanger . Blocked flters, restrict ive ductwork, improper circulator blower speed, or failed circulator blower motor.
• Flame rollout.
• Misaligned burners, blocked fue and/or air inlet pipe, or failed induced draft blower.
• Loose or improperly connected wiring.
fame sense circuit.
• Lingering burner fame.
• Slow closing gas valve.
• Short in low voltage wiring
coated/oxidized.
•Flame sensor incorrectly positioned in burner fame.
• Lazy burner fame due to improper gas pressure or combustion air.
• Inspect pressure switch hose. Repair/replace if necessary.
• Inspect fue and/or inlet air piping for blockage, proper length, elbows, and termination. Check drain system. Correct as necessary.
• Check induced draft blower performance. Correct as necessary.
• Correct pressure switch set point or contact motion.
• Tighten or correct wiring connection.
• Check flters and ductwork for blockage. Clean flters or remove obstruction.
• Check circulator blower speed and performance. Correct speed or replace blower motor if necessary.
• Check burners for proper alignment.
• Check fue and air inlet piping for blockage, proper length, elbows, and termination. Correct as necessary.
• Check induced draft blower for proper performance. Replace if necessary.
• Tighten or correct wiring connection.
• Correct short at fame sensor or in fame sensor wiring.
• Check for lingering fame.
• V erify proper operation of gas valve.
• Locate and correct short in lo w vol tage wiring
• Sand fame sensor if coated/oxidized.
• Inspect for proper sensor alignment.
• Check inlet air piping for blockage, proper length, elbows, and termination.
• Compare current gas pressure to rating plate. Adjust as needed.
• T urn power OFF prior to repair.
• Replace pressure switch with proper replacement part.
• Replace induced draft blower with proper replacement part.
• Turn power OFF prior to repair.
• See Specifcation Sheet applicable to your model* for allowable rise range and proper circulator speed.
• See "Vent/Flue Pipe" section for piping details.
• Turn power OFF prior to repair.
• Turn power OFF prior to repair.
• Replace fuse with 3-amp automotive type
• Turn power OFF prior to repair.
• Sand fame sensor with emery cloth.
• See "Vent/Flue Pipe" section for piping details.
• See rating plate for proper gas pressure.
46
TROUBLESHOOTING
Symptoms of Abnormal
Operation (Legacy
& Com f ortNet ™
Thermostat)
• Furnace fails to operate.
• Integrated control module LED display provides E7 error code.
•ComfortNet™ thermostat “Call for Service” icon illuminated.
•ComfortNet™ therm o stat scr o l ls “Check Furnace” message.
• Furnace fails to operate on high stage; furnace operates normally on low stage.
• Integrated control module LED display provides E8 error code.
• Furnace fails to operate on high stage; furnace operates normally on low stage.
• Integrated control module LED display provides E9 error code.
• Furnace fails to operate.
• Integrated control module LED display provides EA error code.
• ComfortNet™ therm ostat “Call for Service” icon illuminated.
• ComfortNet™ therm ostat scrol ls “Ch eck Furna ce” message.
• Integrated control module LED display EF error code.
• ComfortNet™ therm ostat “Call for Serv ic e ” .
Diagnostic/ Status LE D
Codes
E7 • Problem with
E8 • High stage
E9 • High stage
EA • Polarity of 115 volt
EF • Aux switch open Aux Alarm
Fault Description
igniter circuit.
pressur e swi tch circu i t is clo se d at start of heating cycle.
• Induced draft blower is operating.
• Furnace is operating on low stage only
pressur e swi tch circuit is not closed.
• Induced draft blower is operating.
• Furnace is operating on low stage only
AC is reversed
PS2 CLOSED E8 • High stage press ure
ComfortNet™
Thermostat Only
Message Code
IGNITER
FAULT
PS2 OPEN E9 • Pressure switch hose
REVERSED
PLTY
Fault
E7 • Improperly connec ted
EA • P olarity of 115 volt AC
EF • High water level in the
Possible Causes Corrective Actions N otes & Cautions
igniter .
• Shorted igniter.
• Poor unit ground.
• Igniter relay fault on integrated control module.
switch contacts sticking.
• Shorts in pressure switch circuit wiring.
blocked pinched, or connected improperly.
• Blocked fue and/or inlet air pipe, blocked drain system or weak induced draft blower.
• Incorrect pressure switch set point or malfunctioning switch contacts.
• Loose or i mproperly connected wiring.
power to furnace or integrated module is revered.
• Poor unit ground
evaporation coil.
• Check and correct wiring from integrated control module to igniter .
• Replace shorted igniter.
• Check and correct unit ground wiring.
• Check igniter output from control. Replace if necessary.
• Replace high stage pressure switch.
• Repair short in w iring
• Inspect pressure switch hose. Repair/replace if necessary.
• Inspect fue and/or inlet air piping for blockage, proper length, elbows, and termination. Check drain system. Correct as necessary.
• Check induced draft blower performance. Correct as necessary.
• Correct pressure switch set point or contact motion.
• Tighten or correct wiring connection.
• Review wiring diagram to correct polarity.
• Verify proper gr ound. Correct if necessary .
• Check and correct wiring.
• Check overfow pan and service.
• Turn power OFF prior to repair.
• Replace igniter with correct replacement part.
• Replace control with correct replacement part.
• Turn power OFF prior to repair.
• Replace pressure switch with proper replacement part.
• Turn power OFF prior to repair.
• Replace pressure switch with proper replacement part.
• Replace induced draft blower with proper replacement part.
• Turn power OFF prior to repair.
• Turn power OFF prior to service.
• Furnace fails to operate.
• Integrated control module LED display provides d0 error code.
• ComfortNet™ therm ostat “Call for Service” icon illuminated.
• ComfortNet™ therm ostat scrol ls “Ch eck Furna ce” message.
d0 • Data not yet on
network.
NO NET
DA TA
d0 • Furnace does not
contain any shared data.
• Populate shared data set using memory card.
• Turn power OFF prior to repair
• Use m emory card for the specifc model.
• Insert memory card BEFORE turning power ON. Memory card may be removed after data is loaded and power is turned off.
• Error code will be cleared once data is
47
TROUBLESHOOTING
Symptoms of Abnormal
Operation (Legacy
& ComfortNet™
Thermostat)
• Operation different than expected or no operation.
• Integrated control module LED display provides d4 error code.
• ComfortNet™ thermostat “Call for Se rvice” icon illuminated.
• ComfortNet™ thermostat scro ll s “ Check Furna ce” message.
• Furnace fails to operate.
• Integrated control module LED display provides b0 error code.
• ComfortNet™ thermostat “Call for Se rvice” icon illuminated.
• ComfortNet™ thermostat scro ll s “ Check Furna ce” message.
• Furnace fails to operate.
• Integrated control module LED display provides b1 error code.
• ComfortNet™ thermostat “Call for Se rvice” icon illuminated.
• ComfortNet™ thermostat scro ll s “ Check Furna ce” message.
• Furnace fails to operate.
• Integrated control module LED display provides b2 error code.
• ComfortNet™ thermostat “Call for Se rvice” icon illuminated.
• ComfortNet™ thermostat scro ll s “ Check Furna ce” message.
• Furnace operates at reduced performance.
• Airfow delivered is less than expected.
• Integrated control module LED display provides b3 error code.
Diagnostic/ Status LED
Fau lt Descrip tion
Codes
d4 • Invalid memory
b0 • Circulator blow er
b1 • Integrated control
b2 • Circulator blow er
b3 • Circulator blow er
card data.
motor is not running when it should be running.
module has lost communic ations with circulator blower motor.
motor horse power in shared data set does not match circulator blower motor horse pow er.
motor is operating in a power, temperature, or speed limiting condition.
ComfortNet™
Thermostat Only
Message Code
INVALID MC
DA TA
MOTOR NOT
RUN
MOTOR
COMM
MOTOR
MISMATCH
MOTOR
LIMITS
Possible Causes Corrective Actions Notes & Cautions
d4 • Shared data set on
memory card has been rejected by integrated control module
b0 • Loose wiring connection
at circulator motor power leads or circulator motor power leads disconnected.
• Open circuit in inductor or loose wiring connection at inductor (3/4 Hp and 1 Hp models only).
• Failed ci r cul at or blower motor.
b1 • Loose wiring connection
at circulator motor control leads.
• Failed ci r cul at or blower motor.
• Failed integrated control module.
b2 • Incorrect circulator
blower motor in furnace.
• Incorrect shared data set in integrated control module.
b3 • Blocked flters.
• Restrictive ductwork.
• Undersized ductwork.
• High ambient temperatures.
• Verify sha r e d data set is correct for the specifc model. Re-popul ate data using correct memory card if required.
• Tighten or correct wiring connection.
• V erify continuous circuit through inductor. Replace if open or short circuit.
• C heck circulator blower motor. Replace if necessary.
• Tighten or correct wiring connection.
• C heck circulator blower motor. Replace if necessary.
• C heck in tegr at e d con t ro l module. Replac e if necessary.
• V erify circulator blower if motor horse power is the same specifed for the specifc furnace model. Replace if nec ess ary.
• Verify sha r e d data set is correct for the specifc model. Re-popul ate data using correct memory card if required.
• C h e ck fl t e r s for blockage. Clean flters or remove obstruction.
• C heck duct wo rk for blockage. Remove obstruction. Verify all registers are fully open.
•Verify ductwork is appropriately sized for system. Resize/ replace ductwork if necessary.
•See "III. Product Description" and "IV. Location R eq u ir ements & Considerations" furnace installation requirements.
• Turn power OFF prio r to repair
• U se memory card for the specifc model.
• Insert memory card BEFORE turning power ON. Memor y card may be remove d after data is load ed and power is tur ned off.
• Error code will be cleared once data is loaded and power is turned off.
• Turn power OFF prio r to repair
• Replace inductor with correct replacement part.
• Rep la ce ci r cul at or motor with correct replacement part.
• Turn power OFF prio r to repair
• Rep la ce ci r cul at or motor with correct replacement part.
• Replace integrated control module with correct replacement part.
• Turn power OFF prio r to repair
•Replace motor with correct replacement part.
• U se memory card for the specifc model
• Insert memory card BEFORE turning power ON. Memor y card may be remove d after data is load ed and power is tur ned off.
• Error code will be cleared once shared data and motor horse power matc h .
• Turn power OFF prio r to repair.
48
TROUBLESHOOTING
Symptoms of Abnormal
Operation (L egacy
& ComfortNet™
Thermostat)
• Furnace fails to operate.
• Integrated control module LED display provides b4 error code.
• ComfortNet™ thermostat “Call for Service” icon illuminated.
• ComfortNet™ thermostat scrol ls “Che ck Furnac e” message.
Diagnostic/ Status LED
Codes
b4
Faul t D es cription
Circulator blower motor senses a loss of rotor control.
• Circulator blo wer motor senses high current.
ComfortNet™
Thermostat Only
Message Code
MOTOR
TRIPS
b4 • Turn power OFF prior
Possible Causes Corrective Actions Notes & Cautions
to repair
• Furnace fails to operate.
• Integrated control module LED display provides b5 error code .
• ComfortNet™ thermostat “Call for Service” icon illuminated.
• ComfortNet™ thermostat scrolls “Check Furnace” message.
• Furnace fails to operate.
• Integrated control module LED display provides b6 error c ode.
• ComfortNet™ thermostat “Call for Serv ice” icon illuminated.
• ComfortNet™ thermostat scrolls “Check Furnace” message.
• Furnace fails to operate.
• Integrated control module LED display provides b7 error c ode.
• ComfortNet™ thermostat “Call for Serv ice” icon illuminated.
• ComfortNet™ thermostat scrolls “Check Furnace” message.
• Circulator blo wer
b5
b6 MOTOR
moto r fa i ls to start 10 consecutive times.
Circulator blower motor shuts down
MOTOR LCKD
ROTOR
VOLTS
for over or under voltage condition.
Circulator blower motor shuts down due to over temperature condition on power module.
b7 MOTOR
Circulator blower motor does not have enough information to operate properly. Motor fails to start
PARAMS
40 consecutive times.
b5 • Turn power OFF prior
b6 • Turn power OFF prior
b7
to repair.
• Replace motor with correct replacement part.
• Replace wheel with correct replacement part.
to repair
• Furnace operates at reduced performance or
operates on low stage when high stage is expected.
• Integrated control
module LED dis play provides b9 error code .
b9 LOW ID
Airflow is lower than demanded.
AIRFLOW
B9 • Blocked filters.
• Restrictive ductwork.
• Undersized ductwork.
• Check filters for blockage. Clean filters or remove obstruction.
• Check ductwork for blockage. Remove obstruction. V erify all registers are fully open.
• V erify ductwork is appropriately sized for syste m. Resize/replace ductwork if necessary.
• Turn power OFF prior to repair.
49
TROUBLESHOOTING
n
O
E0
1
E E2
E3
4
E E5 E6 E7 E8
E9 E A
EF
0
d
4
d
INTERNAL CONTROL FAULT/NO NORMAL OPERATION LO CKOUT DUE TO EXCESSIVERE TRIES LOW STAGE PRESSURE SWITCH STUCK CLOSED AT START OF HEA TING CYCLE LOW STAGE PRESSURE SWITCH STUCK OPEN OPEN HIGH LIMIT FLAME DETECTED WHEN NO FLAME SHOULD BE PRESENT OPE N FU SE LOW FLAME SIGNAL IGNITER F AUL T OR IMP ROPER GROUN DI NG
HIGH STAGE PRESSURE SWITCH STUCK CLO SED AT START O F HEATING CYCLE
HIGH STAGE PRESSU RE SWITCH STUCK
REVERSED 115 VAC POLARITY
AUXILIARY SWITCH OPEN
DATA NOT YET ON NETWORK INVALID M E MORY CARD DATA
SWITCH
POWER
OPEN
BLOWER MO TOR NOT R UN NING
0
b
BLOW ER COMMUNICATION ERROR
b1
BLOW ER HP MIS-M ATCH
b2
BLOW ER MOTOR OPERATING IN PO W ER, TEMPERATURE, OR SPEED LIMIT
b
3
BLOWER MOTOR CURRENT TRIP O R LOST
4
b
BLOWER MOTOR LOCKED ROTOR
b5
OVER/UNDER VOLTAGE TRIP OR OVER TEMPERATURE TRIP
b6
INCOM PLET E PARAMETERS SENT T O
b
7
LOWINDOO RAIRFLOW
b9
LOW STAGE COO L
1
C C2
HI
HIGH ST AG ECO O L LOW STAGE H EAT PUMP H EAT
P1 P2
HIGH STAGE HEAT PUMP
0
L
LOW STAGE G AS
HIGH STAGE GAS HEAT
CONT INUO US FAN
F
HEAT
HEAT
ROTOR
MOTOR
CFM/100; AL TERNA TES WITH
12
50
1
C2
LO
C
, , , ,
P1 P2
,
H
I
F
0140F011 69REV A
SYSTEM OPERATION
ComfortNet™ System
OVERVIEW
The ComfortNet system is a system that includes a ComfortNet compatible furnace and air conditioner or heat pump with a CTK0*** thermostat. A valid ComfortNet sys­tem could also be a compatible furnace, CTK0*** thermo­stat and non-communicating, single stage air conditioner. Any other system configurations are considered invalid ComfortNet systems and must be connected as a tradi­tional (or legacy) system (see Electrical Connections for wiring connections).
A ComfortNet heating/air conditioning system differs from a legacy/traditional system in the manner in which the in­door unit, outdoor unit and thermostat interact with one another. In a traditional system, the thermostat sends commands to the indoor and outdoor units via analog 24 VAC signals. It is a one-way communication path in that the indoor and outdoor units typically do not return informa­tion to the thermostat.
On the other hand, the indoor unit, outdoor unit, and ther­mostat comprising a ComfortNet system “communicate” digitally with one another. It is now a two-way communica­tions path. The thermostat still sends commands to the indoor and outdoor units. However, the thermostat may also request and receive information from both the indoor and outdoor units. This information may be displayed on the ComfortNet thermostat. The indoor and outdoor units also interact with one another. The outdoor unit may send commands to or request information from the indoor unit. This two-way digital communications between the thermo­stat and subsystems (indoor/outdoor unit) and between sub­systems is the key to unlocking the benefits and features of the ComfortNet system.
Two-way digital communications is accomplished using only two wires. The thermostat and subsystem controls are power with 24 VAC. Thus, a maximum of 4 wires be­tween the equipment and thermostat is all that is required to operate the system.
OPERATIONS WITH CTK03AB AND CTK04
1. Humidification Options are ON / OFF with the CTK03AB. When “On” is selected, the humidification relay on the furnace control board will function during a heat call if a humidity demand exists. Selecting “Off” means the humidification relay will not function.
2. If the CTK03AB and CTK04 are set up so the compres­sor off delay is 0 min, it will display a cool / heat call immediately regardless of the delay built into the out­door unit control board. This means the CTK03A* could show COOL ON when the outdoor unit is still in a delay period. The recommendation is to set up the compres­sor delay to at least 3 minutes
3. Dual Fuel – When the CTK03AB and CTK04 call for gas heat, the heat pump will shut off, after a delay of approximately 3 minutes it will then turn on gas heat.
ComfortNet™ System
4. Dehumidification (lowering of CFM to 85%) only happens during low stage cooling operation. The dehumidification feature is not active during high stage cool. The CTK03AB and CTK04 can be set up to overcool the home in order to reach the RH set point.
CTK0*** WIRING
NOTE: Refer to Electrical Connections for 115 volt line
connections to the furnace. NOTE: A removable plug connector is provided with the
control to make thermostat wire connections. This plug may be removed, wire connections made to the plug, and replaced. It is recommended that multiple wires be connected with a wire nut and only one wire be inserted under a screw. Failure to do so may result in intermittent operation.
Typical 18 AWG thermostat wire may be used to wire the system components. However, communications reliability may be improved by using a high quality, shielded, twisted pair cable for the data transmission lines. In either case, 100 feet is the maximum length of wire between indoor unit and outdoor unit, or between indoor unit and thermostat.
FOUR-WIRE INDOOR AND OUTDOOR WIRING
Typical wiring will consist of four wires between the indoor unit and outdoor unit and between the indoor unit and ther­mostat. The required wires are: (a) data lines, 1 and 2; (b) thermostat “R” (24 VAC hot) and “C” (24 VAC common).
C
1
2
12RC
12RC
TWO-WIRE OUTDOOR, FOUR-WIRE INDOOR WIRING
Two wires only may be utilized between the indoor and out­door units. For this wiring scheme, only the data lines, 1 and 2, are required between the indoor and outdoor units. A 40VA, 208/230 VAC to 24VAC transformer must be installed in the outdoor unit to provide 24VAC power to the outdoor unit’s electronic control.
CTK0*** Thermostat
R
ComfortNet Compatible Furnace Integrated Control Module
ComfortNet Compatible AC/HP Integrated Control Module
51
SYSTEM OPERATION
NOTE: Use of an accessory transformer is recommended if
installing a dual fuel system. Failure to use the transformer in the outdoor unit could result in overloading of the furnace transformer.
When using a CTK03A*or CTK04 thermostat, the included transformer must be used.
If your communicating thermostat kit does not include a transformer, an accessory kit is available separately by ordering part TFK01.
ComfortNet™ System
1
2R
12RC
C
C Y
CTK0*** Thermostat
W1 W2 Y1 Y2
G
ComfortNet
O
Non-ComfortNet Compatible Single Stage AC
Compatible Furnace Inte grated Control Module
40V A Transformer
208/230 VAC
1
2R
12RC
12
24 VAC
CTK0***
C
Thermostat
ComfortN et Compatible Furnace Integrated Control Module
ComfortNet Compatible
RC
AC/HP Integrated Control Module
SYSTEM WIRING USING TWO-WIRES BETWEEN FURNACE AND FOUR-WIRES BETWEEN FURNACE AND THERMOSTAT
COMFORTNET FURNACE WITH NON-COMFORTNET A/C S
INGLE STAGE AIR CONDITIONER
Four wires are required between the furnace and thermo­stat. Two wires are required between the furnace control and single stage air conditioner. For this system configura­tion, the “Y1” terminal on the integrated furnace control be­comes an output rather than an input.
SYSTEM WIRING BETWEEN FURNACE AND NON-COMFORTNET COMPATIBLE SINGLE STAGE AIR CONDITIONER
COMFORTNET SYSTEM ADVANCED FEATURES
The ComfortNet system permits access to additional sys­tem information, advanced setup features, and advanced di­agnostic/troubleshooting features. These advanced features are organized into a menu structure.
52
SYSTEM OPERATION
FURNACE ADVANCED FEA TURES MENUS
Submenu Item Indication (for Display Only; not User Modifiable)
Nu mb er of Heat Stages (HT S TG) Displays the number of fur nace heating st ages I n p ut Rate (BTU/ H R) Dis p lays t h e furnace input rate i n kBtu/h r Mot or HP ( 1/2, ¾ , or 1 MTR HP) D isplays the furnace ind oor blow er motor hor s epowe r
Submenu Item Indication/Use r Modifiable Options Comments
Fault 1 (FAULT #1) Most recent furnace fault For display only Fault 2 ( FAULT #2) Ne x t mos t re c ent fur nac e fault For dis play only Fault 3 ( FAULT #3) Ne x t mos t re c ent fur nac e fault For dis play only Fault 4 ( FAULT #4) Ne x t mos t re c ent fur nac e fault For dis play only Fault 5 ( FAULT #5) Ne x t mos t re c ent fur nac e fault For dis play only Fault 6 (FAULT #6) Least recent furnace fault For display only
Clear F ault History (CLEA R) NO or Y ES
NOTE:
Consecutively repeated faults are shown a maximum of 3 times.
ComfortNet™ System
CONFIGURATION
DIAGNOSTICS
Selecti ng “YES” clears th e fault hist or y
IDENTIFICATION
Submenu Item Indication (for Display Only; not User Modifiable)
Model Nu m ber ( M OD NU M ) Displays the furnace m odel n um ber Serial Number ( S E R NUM) Displays the furnace se r ial nu mb er ( Optional) Software (SOFTWARE) Displays the application software revision
SET-UP
Submenu Item User Modifiable Options Comme nts
Heat Airflow Trim (HT TRM) Heat ON Delay (HT ON 5, 10, 15, 20, 25, or 30 seconds,
Heat O FF Delay ( HT OFF) 30, 60, 90 , 12 0, 150, or 180
Heat Airflow (HT ADJ ) 1, 2, 3, or 4 Se lec ts the nominal heat ing airflow (see
-10% to +10% in 2% increments, de fa ul t is 0%
d e f a ul t is 30 se c o nds
seconds, d efault is 150 secon ds
STATUS
Tr im s the hea ting airflow by the se le cted amount. Selects th e i ndoor bl ower heat ON delay
Selects th e i ndoor bl ower heat OFF de lay
Startup Procedure and Adjustment – Circulator Blower Speeds for additional
information)
Submenu Ite m Indication (for Display Only; not User Modifia ble)
Mode (MODE) Displays the current furnace operating mode CFM ( CFM) Display s the airflow for the current operat ing mode
53
SYSTEM OPERATION
NON- C O M M (A P P LI E S ONL Y TO A COM MUNICAT ING COMPATIBL E FURNACE MATCHED
WITH A NON - COM MUNICATING COMPATIBLE SINGL E STAGE AIR CONDITIONER)
Subm e nu Item U s er Mo difiab le Options Co m ments
Cool Air flow (C L CFM) 18, 24, 30, 36, 42, 48, or 60, default
is 18
ComfortNet™ System
Sele c ts the airflow for the non-CT comp atib le sing l e s tag e A C un it
Cool Airflow Trim (CL TRM) -10% to +10% in 2% increments,
d efault is 0%
Cool A ir flow Profile (CL P RFL) A, B , C, or D, default is A Sele c ts the airflow profile for the non-
Cool ON Delay (CL ON) 5, 10, 20, or 30 seconds, default is
5 secon ds
Cool OFF Delay (CL OFF) 30, 60, 90, or 120 seconds, default
is 30 sec o nd s
THERMOSTAT MENU
If this furnace is installed with a ComfortNet compatible heat pump, the system is recognized as a dual fuel system. The balance point temperature should be set via the thermostat advanced menu.
bank of two dipswitches that provide termination functions for the communications transmission lines. Communica­tions errors will result if these switches are not correctly set. The table below indicates the switch position for the bias and termination dipswitches along with the expected
Sele cts the airf low trim amount for the non­communicating compatible s ingle stage AC unit
communicating compatible s ingle stage AC unit Sele c ts t he ind oor blower ON delay for the non - c om m unicat ing c om patible si ngle st age A C unit Sele c ts t he ind oor blower OFF dela y for t he non - c om m unicat ing c om patible si ngle st age A C unit
voltages. Note that the ON position is the correct position
DIAGNOSTICS
Accessing the furnace’s diagnostics menu provides ready access to the last six faults detected by the furnace. Faults are stored most recent to least recent. Any consecutively repeated fault is stored a maximum of three times. Example: A clogged return air filter causes the furnace limit to trip repeatedly. The control will only store this fault the first three
for all bias and termination dipswitches. The ComfortNet system is a fully communicating system,
and thus, constitutes a network. Occasionally the need to troubleshoot the network may arise. The integrated furnace control has some on-board tools that may be used to trouble­shoot the network. These tools are: red communications
LED, green receive (Rx) LED, and learn button. consecutive times the fault occurs. Navigate to the diag­nostics menu as described above in Accessing and Navi- gating the Advanced Features Menus.
Red communications LED – Indicates the status of the network. The table below indicates the LED status and the corresponding potential problem.
NOTE: It is highly recommended that the fault history be cleared when performing maintenance or servicing the furnace.
NETWORK TROUBLESHOOTING
Communications is achieved by taking the difference between two dc signals. The signals and transmission lines are re-
Green receive LED – Indicates network traffic. The table below indicates the LED status and the corre­sponding potential problem.
Learn button – Used to reset the network. Depress the button for approximately 2 seconds to reset the network.
ferred to as “data 1” and “data 2”. Each transmission line is biased to approximately 2.5Vdc. During data reception/trans­mission, the data lines vary between +5V and ground. (When data 1 is increasing towards +5V, data 2 is decreasing to­wards ground and when data 1 is decreasing towards ground, data 2 is increasing towards +5V. Typically, the data 1 line is approximately 2.6Vdc and the data 2 transmission line is approximately 2.3Vdc. The voltage difference between data 1 and data 2 is typically 0.2 to 0.6 Vdc.
The indoor control is equipped with a bank of three dipswitches that provide biasing and termination functions for the communications transmission lines. The outdoor control in the ComfortNet compatible unit is equipped with a
54
SYSTEM OPERATION
ComfortNet™ System
SYSTEM TROUBLESHOOTING
NOTE: Refer to the instructions accompanying the ComfortNet compatible outdoor AC/HP unit for troubleshooting information.
Refer to the Troubleshooting Chart for a listing of possible furnace error codes, possible causes and corrective actions.
LED LED
Status
1 Flash
Red
Communications
LED
2 Flashes
1 Steady
Flash
Green Receive
LED
Rapid
Flashing On Solid
Off
Off
Indication Possible Causes Corrective Action(s) Notes & Cautions
x Normal condition x None x None x None x Communications
Failure
x Out-of-box reset x Control power up
x No power x Communications
error
x No network found x Broken/ disconnected
x Normal network
traffic
x Data 1/ Data 2
miss-wire
x Communications
Failure
x Learn button
depressed
x No power to furnace x Open fuse x Communications error
data wire(s)
x Furnace is installed as
a legacy/ traditional system
x Control is “talking” on
network as expected
x Data 1 and data 2
wires reversed at furnace, thermostat, or CT™ compatible outdoor AC/HP
x Short between data 1
and data 2 wires
x Short between data 1
or data 2 wires and R (24VAC) or C (24VAC common)
x Depress Learn Button x Verify that bus BIAS
and TERM dipswitches are in the ON position.
x None x None
x Check fuses and
circuit breakers; replace/reset
x Replace blown fuse x Check for shorts in
low voltage wiring in furnace/system
x Reset network by
depressing learn button
x Check data 1/ data 2
voltages
x Check
communications wiring (data 1/ data 2 wires)
x Check wire
connections at terminal block
x Verify furnace
installation type (legacy/ traditional or communicating)
x Check data 1/ data 2
voltages
x None x None
x Check
communications wiring (data 1/ data 2 wires)
x Check wire
connections at terminal block
x Check data 1/ data 2
voltages
x Depress once
quickly for a power­up reset
x Depress and hold
for 2 seconds for an out-of-box reset
x Turn power OFF
prior to repair
x Turn power OFF
prior to repair
x Verify wires at
terminal blocks are securely twisted together prior to inserting into terminal block
x Verify data1 and
data voltages as described above
x Turn power OFF
prior to repair
x Verify wires at
terminal blocks are securely twisted together prior to inserting into terminal block
x Verify data1 and
data voltages as described above
55
SYSTEM OPERATION
ComfortNet™ System
TROUBLESHOOTING
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
NOTE: Discharge body’s static electricity before touching
unit. An electrostatic discharge can adversely affect electrical components.
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 away from the control. Any tools held in a person’s hand during grounding will be discharged.
3. Service integrated control module or connecting wiring following the discharge process in step 2. Use cau­tion not to recharge your body with static electricity; (i.e., do not move or shuffle your feet, do not touch un­grounded objects, etc.). If you come in contact with an ungrounded object, repeat step 2 before touching control or wires.
4. Discharge your body to ground before removing a new control from its container . Follow steps 1 through 3 if installing the control on a furnace. Return any old or new controls to their containers before touching any ungrounded object.
FOUR WIRE MOTOR TROUBLESHOOTING
Any manual testing of the 4 wire seriallY communicating motor should only be done with the ULTRACHECK-EZ diag­nostic tool (part # UTT-01). All other methods may not be reliable or cause damage to the 4 wire motor. See section S-16C for additional details.
COMFORTNET SYSTEM TROUBLESHOOTING
At system power-up, the CTK0*** thermostat will begin searching for any connected compatible equipment. The thermostat will scroll "SEARCHING". The thermostat will scroll <equipment> FOUND once it indentifies that piece of equipment. In a typical installation, an indoor unit and outdoor unit will be identified.
Wiring issues may be confirmed (or eliminated) by using the CTK0*** thermostat and sub base, a 4-position connec­tor (included with the kit), and a short section (~ 2ft) of ther­mostat wire. Connect the wire between the connector and thermostat sub base. Connect the thermostat to the indoor unit and apply power. If the thermostat identifies the indoor unit, then a wiring problem exists between the indoor unit and the permanent thermostat location. Repair or replace wiring.
Connect the thermostat to the outdoor unit. If the thermo­stat identifies the outdoor unit, then a wiring problem exists between the indoor and outdoor units. Repair or replace wiring.
NOTE: A 24VAC source will be needed to power the ther­mostat and outdoor unit control.
DIAGNOSTIC CHART
W ARN ING
HIGH VOLTAGE !
TO
AVOID PERSONAL INJURY OR DEATH DUE TO
ELECTRICAL SHOCK, DISCONNECT ELECTRICA L POWER
BEFORE
Refer to the Troubleshooting Chart in the Appendix for as- sistance in determining the source of unit operational prob­lems. The dual 7-segment LED display will display an error code that may contain a letter and number. The error code may be used to assist in troubleshooting the unit.
RESETTING FROM LOCKOUT
Furnace lockout results when a furnace is unable to achieve ignition after three attempts during a single call for heat. It is characterized by a non-functioning furnace and a E code displayed on the dual 7-segment display. If the fur­nace is in “lockout”, it will (or can be) reset in any of the following ways.
1. Automatic reset. The integrated control module will
2. Manual power interruption. Interrupt 115 volt power to
3. Manual thermostat cycle. Lower the thermostat so
PERFORMING ANY SERVICE OR MAINTENANCE
automatically reset itself and attempt to resume normal operations following a one hour lockout period.
the furnace.
that there is no longer a call for heat for 1 -20 seconds then reset to previous setting.
.
0
If the thermostat scrolls "SEARCHING" for several minutes, then it has failed to identify any connected equipment. The thermostat may identify one piece of equipment, but not the other. Broken or improper wiring is the most likely cause for the thermostat to fail to identify any equipment. If an out­door unit is not identified, the thermostat will scroll "CHECK SYSTEM", indicating that no indoor unit was found.
56
NOTE: If the condition which originally caused the lockout still exists, the control will return to lockout. Refer to the Diagnostic Chart for aid in determining the cause.
SERVICING
Some of the electronic boards being used today, with flame rectification, will not function properly and/or at all without polarization of incoming power. Some also require phasing between the primary and secondary sides of step-down transformers.
METER READS 120 VOLTS
VOLT / OHM METER
INCOMING POWER
GND
METER READS 0 VOLTS
GND
VOLT / OHM METER
THIS IS L1 OR THE HOT POWER LEG
These then should be wired to the furnace accordingly.
CHECKING FOR PHASING - PRIMARY TO SECONDARY OF UNMARKED TRANSFORMERS*
D
N
G
METER READS 24 VOLTS
.
.
.
.
.
.
VOLT / OHM METE R
C
R
TRANSFORMER
D
N
G
SECONDARY
LINE VOLTAGE (NEUTRAL)
PRIMARY
LINE VOLTAGE L1 (HOT)
METER READS 120 VOLTS
VOLT / OHM METE R
C
R
VOLT / OHM METE R
READS 96 VOLTS - IN PHASE
D
N
G
C
R
N
L1
N
L1
THIS IS THE COMMON OR NEUTRAL LEG
VOLT / OH M M E TER
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.
D
N
G
C
24 V
R
PHASING SYMBOL
120 V
NEUTRAL
L1
VOLT / OH M M E TER
READS 144 VOLTS - OUT OF PHASE
Some transformers will display phasing symbols as shown in the illustration to the left to assist in determining proper transformer phasing.
57
SERVICING
Seconds for
One
Revolutio n
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
1
One
G AS RA TE -- CUBIC FEET PER HO UR
Size of Test Dial
1/4
cu/ft
90 180 360 720 1800 82 164 327 655 1636 75 150 300 600 1500 69 138 277 555 1385 64 129 257 514 1286 60 120 240 480 1200 56 113 225 450 1125 53 106 212 424 1059 50 100 200 400 1000 47 95 189 379 947 45 90 180 360 900 43 86 171 343 857 41 82 164 327 818 39 78 157 313 783 37 75 150 300 750 36 72 144 288 720 34 69 138 277 692 33 67 133 265 667 32 64 129 257 643 31 62 124 248 621 30 60 120 240 600
28 56 113 225 563
26 53 106 212 529
1/2
cu/ft1cu/ft2cu/ft5cu/ft
-- -- 116 232 581
-- -- 109 218 545
-- -- 103 206 514
CUBIC FEET
Seconds for
One
Revolution
36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
1
Size of Test Dial
1/4
cu/ft
25 50 100 200 500
23 47 95 189 474
22 45 90 180 450
21 43 86 172 429
20 40 80 160 400
19 38 76 153 383
18 36 72 144 360
17 34 -- 136 340
16 32 64 129 321
15 30 60 120 300
1/2
cu/ft1cu/ft2cu/ft5cu/ft
-- -- 97 195 486
-- -- 92 185 462
-- -- -- 176 439
-- -- -- 167 419
-- 41 82 164 409
-- -- 78 157 391
-- -- 75 150 375
-- -- -- 147 367
-- -- -- 141 355
-- -- 69 138 346
-- -- 67 133 333
-- -- -- 131 327
-- -- -- 126 316
-- 31 62 124 310
-- -- -- 122 305
58
SERVICING
Service Problem No Heat Un satisfactory Heat
POSSIB LE CAUSE
DOT S IN ANAL YSIS
GUIDE INDICATE
"POSSIBLE CAUSE"
Power Failure Blown Fuse L o ose Con n ec t i on Shorted or Broken Wires No Low V oltag e Faulty Thermostat Faulty Transformer Poor or High Res istanc e Ground Improper Heat Anticipator Setting Improper Thermostat Location Fa ulty Limit or Roll Out Switch Faul ty Fl am e Senso r F au l ty Ig ni tion C o nt ro l Gas Valve or Gas Supply Shut Off Faul ty In du c e d D r af t Blow e r Faulty Blower Motor (ECM) Broken or Shorted Ignitor Dirty Flame Sensor, Low UA Stuck Gas Valve Faulty Gas Valve Open Auxili ary Li mit Improper Air Flow or Distribution Cycling on Limit Dela y e d I g ni t i o n Flashback Orifice Size Gas Pre ssu r e Cracked Hea t Exchanger Furn ace Undersized Furn ace Oversi z e d Faulty Pressure Switch Blocked or Restricted Flue Open Ro ll Out S witch Bouncin g On Press ur e Sw itc h
SYMPTOM
Burner Won't Ignite
S ys t em Wil l No t St ar t
Burner Ignites-Locks Out
B ur ner Shuts Off prio r to T'Stat being Satisf ied
••
••
•••
••
••
••
••
••
••
••
••
•••
••
Lo ng Cycles
Short Cycles
Too Much Heat
So o t an d /o r Fu m es
Not Enough Heat
•• ••
•• ••
•••
••
Test Voltage S-1 Test Voltage S-4 Check Wiring S-2 Check Wiring S-3A Check Transf ormer S- 4 Che ck Thermostat S-3A Check Transf ormer S-4 Measure Ground Resistance S-17B Adju st Heat An ticip at or Settin g S-3 B Relocate Thermosta t S-316 Test Control S-300 / S-302 Test Flame Sensor S-314 Test Control S-313 Turn Valves to On Position S- 317 Te s t I n du c e d D r af t Mo tor S -3 0 3 Te s t Blo w e r Motor ( & EC M) S-16A,B ,C Test Ignitor S-308 Clean Fl am e Sensor S-314 Replace Gas Valve S- 304 Replace Gas Valve S- 304 Res et Control S-301 Check Duct S tat i c S- 200 Chec k Controls & Temperature Rise S-201 / S -300 Tes t f or D elay ed Igni tion S- 312 Test for Flas hback S-309 / S-311 Check Orifices S-306 / S-311 Che ck Gas Pressure S-307 Check Burner Flames S-305 Replace w ith Proper S ize Furnace S-318 Replace w ith Proper S ize Furnace S-318 Test Pressure Switc h S-310 Check Flue /Dr awdown P r es sure S-310 Tes t Flame Roll Ou t C ontrol S-302 Test Negative Pressure S-310
Test Met hod
Remedy
See Service Procedure Reference
59
SERVICING
SERVICE NUMBERS
S-1 CHECKING VOLT AGE ....................... 61
S-2 CHECKING WIRING .......................... 61
CHECKING THERMOST AT, WIRING
AND ANTICIP ATOR............................ 61
S-3A THERMOST AT AND WIRING ............. 61
S-3B HEATING ANTICIPATOR .................... 61
S-200 CHECKING DUCT STA TIC ................ 65
S-201 CHECKING TEMPERATURE RISE ... 65 S-300 CHECKING PRIMARY
LIMIT CONTROL ................................ 66
S-301 CHECKING AUXILIARY
LIMIT CONTROL ................................ 67
S-302 CHECKING FLAME ROLLOUT
CONTROL ......................................... 67
S-303 INDUCED DRAFT BLOWER Motor ... 68 S-304 CHECKING GAS VAL VE
(REDUNDANT) .................................. 68
S-305 CHECKING MAIN BURNERS............. 69
S-306 CHECKING ORIFICES....................... 69
S-307 CHECKING GAS PRESSURE ........... 69
S-308 CHECKING
HOT SURF ACE IGNITOR .................. 71
S-309 CHECKING FOR FLASHBACK.......... 72
S-310 CHECKING PRESSURE CONTROL. 72 S-311 HIGH ALTITUDE
APPLICA TION (USA).......................... 72
S-312 CHECKING FOR
DELA YED IGNITION........................... 73
S-313 CHECKING INTEGRATED
IGNITION CONTROL BOARDS ........ 73
S-313A MEMORY CHIPS................................ 74
S-314 CHECKING FLAME SENSOR.......... 75
60
SERVICING
S-1 CHECKING VOLTAGE
CHECKING THERMOSTAT, WIRING AND ANTICIPATOR
WARNING
HIGH VOLTAGE D
ISCONNECT ALL POWER BEFORE SERVICI NG OR
CHANGING ANY E LECTRI CAL WI RING. SOURCES MAY BE PRESENT. PROPERTY DAMAGE, PERS ONAL INJURY OR DEATH.
MULTIPLE POWER
FAILURE TO DO SO MAY CAUSE
1. Remove the burner door.
2. Remove cover from the Junction Box and gain access to incoming power lines.
With Power ON:
WARNING
LINE VOLTAGE NOW PRESENT
3. Using a voltmeter, measure the voltage across the hot and neutral connections.
NOTE: To energize the furnace, the Door Interlock Switch must be engaged at this point.
4. No reading - indicates open wiring, open fuse, no power,
or faulty Door Interlock Switch from unit to fused dis­connect service. Repair as needed.
5. With ample voltage at line voltage connectors, energize
the furnace blower motor by jumpering terminals R to G on the integrated ignition control.
6. With the blower motor in operation, the voltage should
be 1 15 volts ± 10 percent.
7. If the reading falls below the minimum voltage, check
the line wire size. Long runs of undersized wire can cause low voltage. If wire size is adequate, notify the local power company of the condition.
8. After completing check and/or repair, replace Junction
Box cover and reinstall the service panel doors.
9. Turn on electrical power and verify proper unit operation.
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
LINE VOLTAGE NOW PRESENT
4. Induced Draft Motor must run and pull in pressure switch.
5. If the hot surface ignitor heats and at the end of the
ignitor warm-up period the gas valve opens and the burn­ers ignite, the trouble is in the thermostat or wiring.
6. With power off, check the continuity of the thermostat
and wiring. Repair or replace as necessary .
If checking the furnace in the air conditioning mode, pro-
ceed as follows.
7. With power off, Jumper terminals R to Y (or Y1 or Y2 for
two-stage models) to G.
8. Turn on the power.
9. If the furnace blower motor starts and the condensing
unit runs, then the trouble is in the thermostat or wiring. Repair or replace as necessary .
10. After completing check and/or repair of wiring and check
and/or replacement of thermostat, reinstall blower com­partment door .
1 1. Turn on electrical power and verify proper unit operation.
S-3B HEATING ANTICIPATOR
On older thermostats, the heating anticipator is a wire wound adjustable heater which is energized during the "ON" cycle to help prevent overheating of the conditioned space.
The anticipator is a part of the thermostat and if it should fail for any reason, the thermostat must be replaced.
The heating anticipator setting for furnaces covered in this manual is 0.70 Amps.
Modern thermostats do not have this type of heat anticipa­tor. Many have a selector switch to adjust the number of cycles per hour
61
SERVICING
S-4 CHECKING TRANSFORMER AND Control CIRCUIT
A step-down transformer 120 volt primary to 24 volt second­ary, 40 VA (Heating and Cooling Models) supplies ample capacity of power for either operation.
WARNING
HIGH VOLTAGE D
ISCO NNECT ALL POWER BEFORE SERVI CING OR
CHANGING ANY ELECTRICAL WIRING. SOURCES MAY BE PRESENT. PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
MULTIPLE POWER
FAILURE TO DO SO MAY CAUSE
ECM Control Connections
ECM control connections are made through the integrated ignition control. No other control connections are needed.
NOTE: An inductor (Factor Power Choke Correction) is re- quired when powering the 3/4 and 1 horsepower motors with 115 volts (inductor pictured below). The operation of this in­ductor is to reduce the line current by storing the electrical energy in a magnetic field, such that the voltage AC wave­form leads the current AC waveform. In other words, the inductor reduces line current which extends the life of the 3/4 and 1 horsepower motors.
1. Remove blower compartment door to gain access to the thermostat low voltage wires located at the furnace inte­grated control module.
2. Remove the thermostat low voltage wires at the furnace integrated control module terminals.
With Power On (and Door Interlock Switch closed):
WARNING
LINE VOLTAGE NOW PRESENT
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 volt-
age 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 operation.
4-Wire ECM Motors Description
These models utilize an Nidec US motors, 4-wire variable speed ECM blower motor. The ECM blower motor provides constant CFM.
The motor is a serially communicating variable speed mo­tor. Only four wires are required to control the motor: +Vdc, Common, Receive, and Transmit.
The +Vdc and Common wires provide power to the motor's low voltage control circuits. Typical supply voltage is 9-15 volts DC.
IMPORTANT: If the inductor fails, there will be no motor operation since this is the "LINE" power supply, black wire, from the integrated ignition control to the motor. To deter­mine if the inductor is at fault, you can bypass by the induc­tor by disconnecting the black wire from the inductor and connecting it directly to the motor. If the motor operates then the inductor will need to be replaced.
Checking ECM Motors ECMmotors connect directly to the AC Line Voltage. DO
NOT insert contactors in series with the ECM Motor AC
Line. The control is powered continuously to insure reliable start-up. The connector plug is polarized, verify and reverify correct connector orientation before applying power. DO NOT force plug into motor and make sure power is off before in­serting power connector. DO NOT apply voltage to termi­nals 1 or 2.
General Checks/Considerations
1. Check power supply to the furnace. Ensure power sup­ply is within the range specified on rating plate. See sec­tion S-1.
2. Check motor power harness. Ensure wires are continu­ous and make good contact when seated in the connec­tors. Repair or replace as needed.
3. Check motor control harness. Ensure wires are continu­ous and make good contact when seated in the connec­tors. Repair or replace as needed.
4. Check thermostat and thermostat wiring. Ensure ther­mostat is providing proper cooling/heating/continuous fan demands. Repair or replace as needed.
5. Check blower wheel. Confirm wheel is properly seated on motor shaft. Set screw must be on shaft flat and torqued to 165 in-lbs minimum. Confirm wheel has no broken or loose blades. Repair or replace as needed.
62
SERVICING
6. Ensure motor and wheel turn freely. Check for interfer­ence between wheel and housing or wheel and motor. Repair or replace as needed.
7. Check housing for cracks and/or corrosion. Repair or replace as needed.
8. Check motor mounting bracket. Ensure mouting bracket is tightly secured to the housing. Ensure bracket is not cracked or broken.
UltraCheck-EZ
The UltraCheck-EZ (part # UTT-01) to diagnose the ECM motor.
HIGH VOLTAGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.
To use the diagnostic tool, perform the following steps:
1. Disconnect power to the furnace.
2. Disconnect the 4-circuit control harness from the motor.
3. Plug the 4-circuit connector from the diagnostic tool into the motor control connector.
4. Connect one alligator clip from the diagnostic tool to a ground source.
5. Connect the other alligator clip to a 24VAC source.
NOTE: The alligator clips are NOT polarized.
NOTE: The UltraCheck-EZTM diagnostic tool is equipped
with a nonreplaceable fuse. Connecting the tool to a source other than 24VAC could damage the tool and cause the fuse to open. Doing so will render the diagnostic tool inop­erable.
6. Turn on power to the furnace.
Line Voltage now present.
TM
Diagnostic Tool
TM
diaganostic tool is the preferred method
WARNING
Replace or repair as needed.
Power Button
OFF OFF
ON B linking Rotating
ON OFF Rotating
O N Blink ing
ON OFF
Green
LED
Motor
Action
Not
Rotating
Not
Rotating
Not
Rotating
Indication(s)
Confirm 24VAC to UltraCheck-EZ
If 24VAC is c on firm ed, diagnost ic tool is inoperable. M otor and cont rol/end bell are funct ioning properly. Replace motor cont rol/end bell. Ch eck mot o r (s e e Motor Chec ks below). Replace motor cont rol/end bell; verify motor (see Motor Check s below).
TM
tool.
9. Depress the orange power button to turn off motor.
10. Disconnect power. Disconnect diagnostic tool.
11. Reconnect the 4-wire harness from control board to motor.
Electrical Checks - High Voltage Power Circuits
HIGH VOLTAGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.
1. Disconnect power to the furnace.
2. Disconnect the 5-circuit power connector to the ECM motor.
3. Turn on power to the furnace.
7. Depress the orange power button on the diagnostic tool to send a run signal to the motor. Allow up to 5 seconds for the motor to start.
NOTE: If the orange power button does not illuminate when depressed, the tool either has an open fuse or is not prop­erly connected to a 24VAC source.
8. The green LED on the diagnostic tool will blink indicating communications between the tool and motor. See table below for indications of tool indicators and motor actions.
WARNING
Line Voltage now present.
4. Measure voltage between pins 4 and 5 on the 5-circuit connector. Measured voltage should be the same as the supply voltage to the furnace.
63
SERVICING
5
AC Line Hot Connection
Motor Control/End Bell Checks
4 3 2 1
5 4 3 2 1
5. Measure voltage between pins 4 and 3. Voltage should be approximately zero.
6. Measure voltage between pins 5 and 3. Voltage should be the same as the supply voltage to the furnace.
7. If no voltage is present, check supply voltage to the fur­nace. See section S-1.
8. Disconnect power to the furnace. Reconnect the 5-cir­cuit power harness disconnected in step 2.
AC Line Neutral Connection Gnd
Lines 1 and 2 will be connected for 120VAC Power Connector
}
applications only
POWER CONNECTOR
(1/2 HP MOTORS)
"Motor Half“
(Viewed from Plug End)
inductor
AC Line Hot Connection
AC Line Neutral Connect ion Gnd
Lines 1 and 2 will be connected for 120VAC Power Connector
}
applications only
POWER CONNECTOR (3/4 & 1 HP MOTORS)
"Motor Half“
(Viewed from Plug End)
HIGH VOLT AGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.
1. Disconnect power to the furnace. NOTE: Motor contains capacitors that can hold a charge
for several minutes after disconnecting power. Wait 5 min­utes after removing power to allow capacitors to discharge.
2. Disconnect the motor control harness and motor power
harness.
3. Remove the blower assembly from the furnace.
4. Remove the (3) screws securing the control/end bell to
the motor. Separate the control/end bell. Disconnect the 3-circuit harness from the control/end bell to remove the control/end bell from the motor.
5. Inspect the NTC thermistor inside the control/end bell
(see figure below). Replace control/end bell if thermistor is cracked or broken.
Electrical Checks - Low Voltage Control Circuits
1. Turn on power to the furnace.
WARNING
Line Voltage now present.
2. Check voltage between pins 1 and 4 on the 4-wire motor control harness between the motor and control board. Voltage should be between 9 and 15 VDC.
3. If no voltage is present, check control board. See sec­tion S-313.
64
6. Inspect the large capacitors inside the control/end bell (see figure below). Replace the control/end bell if any of the capacitors are bulging or swollen.
SERVICING
7. Locate the 3-circuit connector in the control/end bell. Using an ohmmeter, check the resistance between each termi­nal in the connector. If the resistance is 100kΩ or greater, the control/end bell is functioning properly. Replace the control/end bell if the resistance is lower than 100kΩ.
8. Reassemble motor and control/end bell in reverse of dis­assembly. Replace blower assembly into the furnace.
Motor Checks
HIGH VOLTAGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.
Too great of an external static pressure will result in insuffi­cient air that can cause excessive temperature rise, result­ing in limit tripping, etc. Whereas not enough static may result in motor overloading.
To determine proper air movement, proceed as follows:
1. With clean filters in the furnace, use a draft gauge (in­clined manometer) to measure the static pressure of the return duct at the inlet of the furnace. (Negative Pres­sure)
2. Measure the static pressure of the supply duct. (Posi­tive Pressure)
3. Add the two (2) readings together for total external static pressure.
NOTE: Both readings may be taken simultaneously and read directly on the manometer if so desired. If an air condi­tioner coil or Electronic Air Cleaner is used in conjunction with the furnace, the readings must also include theses com­ponents, as shown in the following drawing.
4. Consult proper tables for the quantity of air.
If the total external static pressure exceeds the minimum or maximum allowable statics, check for closed dampers, reg­isters, undersized and/or oversized poorly laid out duct work.
1. Disconnect power to the furnace. NOTE: Motor contains capacitors that can hold a charge
for several minutes after disconnecting power. Wait 5 min­utes after removing power to allow capacitors to discharge.
2. Disassemble motor as described in steps 2 through 4
above.
3. Locate the 3-circuit harness from the motor. Using an
ohmmeter, measure the resistance between each motor phase winding. The resistance levels should be equal. Replace the motor if the resistance levels are unequal, open circuited or short circuited.
4. Measure the resistance between each motor phase wind-
ing and the motor shell. Replace the motor if any phase winding is short circuited to the motor shell.
5. Reassemble motor and control/end bell in reverse of dis-
assembly. Replace blower assembly into the furnace.
S-200 CHECKING DUCT STATIC
The maximum and minimum allowable external static pres­sures are found in the specification section. These tables also show the amount of air being delivered at a given static by a given motor speed or pulley adjustment.
The furnace motor cannot deliver proper air quantities (CFM) against statics other than those listed.
Checking Static Pressure
S-201 CHECKING TEMPERATURE RISE
The more air (CFM) being delivered through a given furnace, the less the rise will be; so the less air (CFM) being deliv­ered, the greater the rise. The temperature rise should be adjusted in accordance to a given furnace specifications and its external static pressure. An incorrect temperature rise
65
SERVICING
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:
PRIMARY LIMIT CONTROL
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
*
*
*
*
2
*
**
Primary Limit Control Location
(90% Upflow Furnace Shown, Counterflow Similar)
The following drawing illustrates the style of limit switches used on the 90% furnaces.
ENCLOSED DISK
RETURN AIR
Temperature Rise Measurement
3. Subtract the return air temperature from the supply air temperature to determine the air temperature rise. Al­low adequate time for thermometer readings to stabi­lize.
4. Adjust temperature rise by adjusting the circulator blower speed. Increase blower speed to reduce temperature rise. Decrease blower speed to increase temperature rise. Refer to Circulator Blower Speed section in the Product Design section of this manual for speed chang­ing details. Temperature rise is related to the BTUH out­put of the furnace and the amount of air (CFM) circu­lated over the heat exchanger. Measure motor current draw to determine that the motor is not overloaded dur­ing adjustments.
S-300 CHECKING PRIMARY LIMIT CONTROL
Primary limit controls are nonadjustable, automatic reset, bi-metal type limit control. Refer to the following drawing for the location of the primary limit.
FRONT VIEW SIDE VIEW
Primary Limit Control Style
(90% Furnaces)
WARNING
HIGH VOLTAGE D
ISCONNECT ALL POWER BEFORE SERV I CING OR
CHANGING A NY ELE CTRI CAL WI RIN G. SOURCES MAY BE PRESENT. PROPERTY DAMAGE, PERS ONAL I NJURY OR DEAT H.
MULTI PLE POWER
FAILURE TO DO SO MAY CAUSE
1. Remove burner compartment door to gain access to the primary limit.
2. Remove low voltage wires at limit control terminals.
3. With an ohmmeter, test between these two terminals as shown in the following drawing. The ohmmeter should read continuous unless heat exchanger temperature is above limit control setting. If not as above, replace the control.
66
SERVICING
Manual or Automatic Reset Auxiliary Limits Located in Blower Side
WARNING
VOLT / OHM ME T E R
COLOR IDENTIFYING TAB
Testing Primary Limit Control
(90% Furnaces)
4. After completing check and/or replacement of primary limit control, reinstall burner compartment door.
5. Turn on electrical power and verify proper unit operation.
To aid in identifying these controls, refer to the Primary Limit Charts in furnace Technical Manual for part number, tem­perature setting and color(s) code.
S-301 CHECKING AUXILIARY LIMIT CONTROL
The auxiliary limit control is designed to prevent furnace op­eration in case of main blower failure in horizontal or coun­terflow installations. It may also open if the power supply is interrupted while the furnace is firing.
The auxiliary limit control is suitable for both horizontal right and horizontal left installations. Regardless of airflow direc­tion, it does not need to be relocated. The (2) two auxiliary limits are located on the blower housing (one on each side), as shown in the following illustration.
AUXILIARY LIMIT CONTROL
BLOWER HOUSING
HIGH VOLTAGE
ISCONNECT ALL POWER BEFORE SERVICING OR
D
INSTALLI NG THIS UNIT. BE PRESENT. DAMAGE, PERS ONAL I NJURY OR D EATH.
MULTIPLE POWER SOURCES MAY
FAILURE TO DO SO MAY CAUSE PROPERTY
1. Remove the wires from the auxiliary limit control termi­nals.
2. Using an ohmmeter, test for continuity across the two terminals (only test when the auxiliary limit is at room temperature).
VOLT / OHM METER
RED RESET BUTTON
COLOR IDENTIFYING TAB
Testing Auxiliary Limit Control
WARNING
T
O AVOID POSSIBLE FIRE, ONLY RESET THE AUXILIARY LIMIT CONTROL
I
ONCE.
F IT SHOULD OPEN A SECOND TIME, A QUALIFIED SERVICER MUST DETERMINE WHY THE AUXILIARY LIMIT OPENED BEFORE RESETTING AGAIN.
S-302 CHECKING FLAME ROLLOUT CONTROL
A temperature activated manual reset control is mounted to the manifold assembly on 90% furnaces, as shown in the following illustration.
Auxiliary Limit Control Location
(Select 90% / 95% Furnaces)
AUXILIARY LIMIT CONTROL
67
SERVICING
FLAME ROLLOUT SWITCHES
*
*
*
*
2
*
**
Flame Rollout Switch Location
(90% Upflow Furnace Shown, Counterflow Similar)
The control is designed to open should a flame roll out oc­cur. An over firing condition or flame impingement on the heat shield may also cause the control to open. If the rollout control opens, the air circulation blower will run continuously.
WARNING
LINE VOLTAGE NOW PRESENT
1. Remove the burner compartment door to gain access to the rollout switch(es) mounted to burner bracket.
2. Reset the manual rollout switch.
3. Remove wires from rollout switch.
4. Using an ohmmeter, check for coninuity across the swtch.
5. if the switch will not close afer manually resetting, it must be replaced.
If a roll out switch has tripped, it is important to find out why. Possible causes could be flame impingement, orifice plate out of position, burners with excessive cross-over slot di­mension, over-firing, improper orifices, improper gas pres­sure, air leaking from around the heat exchanger into the burner compartment, air leaking through the heat exchanger itself.
6. After check and/or replacement of rollout switch, rein­stall burner compartment door and verify proper unit op­eration.
1. Remove burner compartment door to gain access to the induced draft blower motor .
2. Disconnect the motor wire leads from its connection point at the induced draft motor .
3. Using a ohmmeter, test for continuity between each of the motor leads.
4. Touch one probe of the ohmmeter to the motor frame (ground) and the other probe in turn to each lead.
If the windings do not test continuous or a reading is obtained to ground, replace the motor .
5. If the windings have a continuity reading, reconnect wires. Turn power on to the furnace and turn the thermostat on in the heating mode. Check voltage for 115V at the induced draft motor terminals during the trial for ignition. If you have 115V and the motor does not run, replace the induced draft motor.
6. After completing check and/or replacement of induced draft motor, reinst all burner compartment door .
7. Turn on electrical power and verify proper unit operation.
S-304 CHECKING GAS VALVE (REDUNDANT)
A combination redundant operator type gas valve which pro­vides all manual and automatic control functions required for gas fired heating equipment is used.
The valve provides control of main burner gas flow, pressure regulation, and 100 percent safety shut-off.
Two stage gas valves always require 24 volts between com­mon and low fire (main coil) to open. The furnace front cover pressure switch is wired in series with the low (main) sole­noid of the gas valve. In the event of a non-functioning gas valve, always check the front cover pressure switch. Also see section S-307 on Checking Gas Pressure and section S-310 on Checking Pressure Switches.
Low (Main) Common High
S-303 INDUCED DRAFT BLOWER MOTOR
WARNING
HIGH VOLTAGE
ISCONNECT ALL POWER BEFORE SERVICING OR
D
INSTALLI NG THIS UNIT. BE PRESENT. DAMAGE, PERSONAL INJURY OR DEATH.
MULTIPLE POWER SOURCES MAY
FAILURE TO DO SO MAY CAUSE PROPERTY
68
D
ISCONNECT
White-Rodgers 2-Stage Valve
WARNING
ALL
POWER BEFO RE SE RVICING
SERVICING
S-305 CHECKING MAIN BURNERS
The main burners are used to provide complete combustion of various fuels in a limited space, and transfer this heat of the burning process to the heat exchanger.
Proper ignition, combustion, and extinction are primarily due to burner design, orifice sizing, gas pressure, primary and secondary air, vent and proper seating of burners.
B
URNERS
Burners have been redesigned for 34.5" chassis furnaces. Overall length and width dimensions remain the same as 40" model burners. The burners used 34.5" models have burner head insert with larger diameter center hole and a larger number of surrounding holes.
Orifices should be treated with care in order to prevent dam­age. They should be removed and installed with a box-end wrench in order to prevent distortion. In no instance should an orifice be peened over and redrilled. This will change the angle or deflection of the vacuum effect or entraining of pri­mary air, which will make it difficult to adjust the flame prop­erly. This same problem can occur if an orifice spud of a different length is substituted.
WARNING
D
ISCONNECT
1. Check orifice visually for distortion and/or burrs.
2. Check orifice size by the number stamped on the ori­fice.
ALL G
AS AND ELECTRICAL POWER SUPPLY.
A
New 34.5 Burners
WARNING
D
ISCONNECT
In checking main burners, look for signs of rust, oversized and undersized carry over ports restricted with foreign mate­rial, etc., burner cross-over slots should not be altered in size.
ALL G
AS AND ELECTRICAL POWER SUPPLY.
S-306 CHECKING ORIFICES
A/GMVC, A/GCVC model furnaces have factory installed #45 natural gas orifices.
The only time resizing is required is when a reduction in firing rate is required for an increase in altitude or a funace is being converted for use with L.P. gas.
GAS STREAM
B
The length of Dimension "A" determines the angle of Gas Stream "B".
DENT OR BURR
GAS
STREAM
B
A dent or burr will cause a severe deflection of the gas stream.
S-307 CHECKING GAS PRESSURE
Gas Supply Pressure Measurement
CAUTION
T
O PREVENT UNRELIABL E OPERATI ON OR E QUIPMENT DAMAGE, T HE INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING.
Gas inlet and manifold pressures should be checked and adjusted in accordance to the type of fuel being consumed.
The line pressure supplied to the gas valve must be within the range specified below. The supply pressure can be mea­sured at the gas valve inlet pressure tap or at a hose fitting installed in the gas piping drip leg. The supply pressure must be measured with the burners operating. To measure the gas supply pressure, use the following procedure.
69
SERVICING
WARNING
D
ISCONNECT ELECTRICAL POWER AND SHUT OFF GAS SUPPLY.
1. After turning off gas to furnace at the manual gas shutoff valve external to the furnace, remove burner compart­ment door to gain access to the gas valve.
2. Connect a calibrated water manometer (or appropriate gas pressure gauge) at either the gas valve inlet pres­sure tap or the gas piping drip leg as shown in the follow­ing figures.
NOTE: At either location, a hose fitting must be installed prior to making the hose connection.
NOTE: Use adapter kit #0151K00000S to measure gas pres­sure on White-Rodgers 36J54 gas valves.
GAS LINE
GAS SHUTOFF VALVE
GAS LINE TO FURNACE
WARNING
HIGH V OLTAGE
ISCONNECT ALL ELECTRICAL POWER AND SHU T OFF GAS
D
SUPPLY BEFORE SERVICING OR INSTAL LING THIS UNIT.
MULTIP LE POW ER SOURC ES MAY B E PRES ENT. FAILURE TO
DO SO MAY CAUSE P ROPERTY DAMAG E, PERSONAL INJURY O R DEATH.
5. Disconnect manometer after turning off gas at manual shutoff valve. Reinstall plug before turning on gas to fur­nace.
6. Turn OFF any unnecessary gas appliances started in step 3.
7. Turn on gas to furnace and check for leaks. If leaks are found, repair and then reinstall burner compartment door.
8. Turn on electrical power and verify proper unit operation.
WARNING
HIGH V OLTAGE
ISCONNECT ALL ELECTRICAL POWER AND SHU T OFF GAS
D
SUPPLY BEFORE SERVICING OR INSTAL LING THIS UNIT.
MULTIP LE POW ER SOURC ES MAY B E PRES ENT. FAILURE TO
DO SO MAY CAUSE P ROPERTY DAMAG E, PERSONAL INJURY O R DEATH.
OPEN TO ATMOSPHERE
DRIP LEG CAP WITH FITTING
MANOMETER HOSE
MANOMETER
Measuring Inlet Gas Pressure
(Alternate Method)
3. Turn ON the gas and electrical power supply and oper­ate the furnace and all other gas consuming appliances on the same gas supply line.
4. Measure furnace gas supply pressure with burners fir­ing. Supply pressure must be within the range specified in the following table.
INLET GAS SUPPLY PRESSURE
Natural Gas Minimum: 4.5" w.c. Maximum: 10.0" w.c.
Propane Gas Minimum: 11.0" w.c. Maximum: 13.0" w.c.
If supply pressure differs from above, make necessary ad­justments to pressure regulator, gas piping size, etc., and/ or consult with local gas utility.
Gas Manifold Pressure Measurement and Adjust­ment
Natural Gas Adjustments
WARNING
HIGH VOLTAGE D
ISCONNECT
BEFORE SERVICING OR INSTALLING.
NOTE: Use apapter kit #0151K00000S to measure gas pres-
sure on White-Rodgers 36J54 gas valves. Only small variations in gas pressure should be made by
adjusting the gas valve pressure regulator. The manifold pres­sure must be measured with the burners operating. To mea­sure and adjust the manifold pressure, use the following pro­cedure.
1. After turning off gas to furnace at the manual gas shutoff valve external to the furnace, remove burner compart­ment door to gain access to the gas valve.
2. Connect a calibrated water manometer (or appropriate gas pressure gauge) at the gas valve outlet pressure tap. Refer to Measuring Gas Pressure: Two-Stage Valves figure for two-stage gas valve outlet pressure tap con­nections.
ALL
ELECTRICAL POWER AND SHUT OFF GAS SUPPLY
70
SERVICING
WARNING
LINE VOLTAGE NOW PRESENT
3. Turn ON the gas and electrical power supply and oper­ate the furnace.
4. White-Rodgers 36J54 Valves: a. Back outlet pressure test screw (inlet/outlet pressure
boss) out one turn (counterclockwise, not more than one turn).
b. Attach a hose and manometer to the outlet pressure
outlet pressure boss. c. Turn ON the gas supply. d. Turn on power and close thermostat “R” and “W1” con-
tacts to provide a call for low stage heat. e. Measure the gas manifold pressure with burners fir-
ing. Adjust manifold pressure using the Manifold Gas
Pressure table shown on page 86. f. Remove regulator cover screw from the low (LO) out-
let pressure regulator adjust tower and turn screw
clockwise to increase pressure or counterclockwise
to decrease pressure. Replace regulator cover screw. g. Close thermostat “R” and “W2” contacts to provide a
call for high stage heat. h. Remove regulator cover screw from the high (HI) out-
let pressure regulator adjust tower and turn screw
clockwise to increase pressure or counterclockwise
to decrease pressure. Replace regulator cover screw. i. Turn off all electrical power and gas supply to the sys-
tem. j. Remove the manometer hose from the hose barb fit-
ting or outlet pressure boss. k. Turn outlet pressure test screw in to seal pressure
port (clockwise, 7 in-lb minimum).
r
e
n
o
m
t
e
M
a
e
o
s
H
High Fire Regulator
Adjust
Regulator
Vent
WARNING
HIGH VOLTAGE D
ISCONNECT
BEFORE SERVICING OR INSTALLING.
GasRateRangeNominal
Natural Gas
ALL
ELECTRICAL POWER AND SHUT OFF GAS SUPPLY
Manifold Gas Pressure
High Stage 3.2 to 3.8" w.c. 3.5" w.c.
Low Stage 1.6 to 2.2" w.c. 1.9" w.c.
WARNING
HIGH V OLTAGE
ISCONNECT ALL ELECTRICAL POWER AND SHU T OFF GAS
D
SUPPLY BEFORE SERVICING OR INSTAL LING THIS UNIT.
MULTIP LE POW ER SOURC ES MAY B E PRES ENT. FAILURE TO
DO SO MAY CAUSE P ROPERTY DAMAG E, PERSONAL INJURY O R DEATH.
WARNING
HIGH VOLTAG E D
ISCO NNEC T
BEFORE SERVICING OR INSTALLING.
Propane Gas
S-308 CHECKING HOT SURFACE IGNITOR
120V Silicon Nitride Igniter - Amana® Brand and
Goodman® Brand A/GMVC96 and A/GCVC96 furnaces use a 120V silicon nitride igniter for ignition. The normal operat­ing temperature is approximately 2156°F - 2678°F.
ALL
ELECTRICAL POWER AND SHUT OFF GAS SUPPLY
Manifold Gas Pressure
Gas Rate Range Nominal
High Stage 9.7 to 10.3" w.c. 10.0" w.c.
Low Stage 5.7 to 6.3" w.c. 6.0" w.c.
WARNING
o
n
m
M
e
a
t
e
r
Measuring Manifold Gas Pressure
(36J54 Valve)
DISCONNECT ALL POWER BE FORE SERVICING.
1. Remove burner compartment door to gain access to the ignitor.
2. Ignitor cool - approximately 70 - 77°F.
3. Disconnect the ignitor from the Ignition Control.
4. Using an ohmmeter measure the resistance of the igni­tor:
120 Volt Silicon Nitride : 120V Nitride Igniter should read between 37 to 68 ohms.
71
SERVICING
5. Reconnect ignitor.
WARNING
INE VOLTAGE NOW PRESENT
L
6. Place unit in heating cycle, measure current draw of ignitor during preheat cycle.
The steady state current at 120V is 0.37 to 0.68 amps.
7. After checking and/or replacing of hot surface ignitor, reinstall burner compartment door and verify proper unit operation.
S-309 CHECKING FOR FLASHBACK
Flashback will also cause burning in the burner venturi, but is caused by the burning speed being greater than the gas­air flow velocity coming from a burner port.
Flashback may occur at the moment of ignition, after a burner heats up or when the burner turns off. The latter is known as extinction pop.
Since the end results of flashback and delayed ignition can be the same (burning in the burner venturi) a definite at­tempt should be made to determine which has occurred.
If flashback should occur, check for the following:
1. Improper gas pressure - adjust to proper pressure (See S-307 CHECKING GAS PRESSURE)..
2. Check burner for proper alignment and/or replace burner.
3. Improper orifice size - check orifice for obstruction.
S-310 CHECKING PRESSURE CONTROL
The pressure control is a safety device to prevent the com­bustion cycle from occurring with inadequate venting caused by a restricted or blocked vent pipe. In addition to the high fire and low fire pressure switches, A/GMVC96 and A/GCVC model furnaces have a "front cover pressure switch" wired in series with the gas valve. This pressure switch keeps the gas valve from opening in the event of condensate back­ing up in the secondary heat exchanger. This could occur from improperly connected drains or a plugged drain tube.
WARNING
HIGH VOLTAGE
ISCONNECT ALL POWER BEFORE SERVICING OR
D
INSTALLI NG THIS UNIT. BE PRESENT. DAMAGE, PERSONAL INJURY OR DEATH.
1. Remove burner compartment door to gain access to pres­sure switch(es).
2. Remove wires from the pressure switch(es) electrical terminals.
MULTIPLE POWER SOURCES MAY
FAILURE TO DO SO MAY CAUSE PROPERTY
3. Remove the pressure control hose from the control and interconnect with an inclined manometer as shown in the following figure.
4. With an ohm meter connected across the pressure switch terminals and with the inducer running, the switch should close and the ohm meter should show a com­plete circuit across the pressure switch. If the switch is not closed, compare the negative pressure to the clos­ing point specified for the particular switch. Either the switch is defective or the inducer/venting system is in­adequate.
INDUCED DRAFT BLOWER
PRESSURE SWITCH
PRESSURE SWITCH
COIL COVER
PRESSURE SWITCH
*
***
M
1
O F
*
F
23PC
ON
**
INDUCED
DRAFT
BLOWER
HOSE
1/4" TEE
HOSE TO INDUCED DRAFT BLOWER TAP
OPEN TO ATMOSPHERE
INCLINED MANOMETER
Blower Pressure Switch
Negative Pressure Measurement
(90% Upflow Furnace Shown, Counterflow Similar)
S-311 HIGH ALTITUDE APPLICATION (USA)
When furnaces are installed at high altitude, the appropriate High Altitude Orifice or Pressure Switch Kit must be ap­plied. This is required due to the natural reduction in the density of both the gas fuel and combustion air as altitude increases. The High Altitude Orifice Kit will provide the proper design certified input rate within the specified altitude range.
High Altitude Orifice or Pressure Switch Kits are purchased according to the installation altitude and usage of either natu­ral or propane gas. Refer to the Technical Manual or product Specification Sheet for a tabular listing of appropriate alti­tude ranges and corresponding manufacturer's high altitude (Natural or Propane Gas) orifice or pressure switch kits.
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.
72
SERVICING
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.
When the mixture does ignite, it may explode and/or rollout causing burning in the burner venturi.
If delayed ignition should occur, the following should be checked. Furnace design makes this extremely unlikely unless safety controls have been by-passed or tampered with. Never by-pass or alter furnace controls.
1. Improper gas pressure - adjust to proper pressure (See S-307 CHECKING GAS PRESSURE).
2. Improper burner positioning - burners should be in locat­ing slots, level front to rear and left to right.
3. Carry over (lighter tube or cross lighter) obstructed - clean.
4. Main burner orifice(s) deformed, or out of alignment to burner - replace.
S-313 CHECKING INTEGRATED IGNITION
CONTROL BOARDS
NOTE: Failure to earth ground the furnace, reversing the
neutral and hot wire connection to the line (polarity), or a high resistance connection in the neutral line may cause the control to lockout due to failure to sense flame.
WARNING
T
O AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO THE UNIT MUST BE PROPERLY POLARIZED AND GROUNDED. BEFORE PERFORMING SERVICE LISTED BELOW.
D
ISCONNECT POWER
These tests must be completed within a given time frame due to the operation of the ignition control. The trial for igni­tion period is 4 seconds.
The ignition control is capable of diagnosing many furnace failures to help in troubleshooting. The control utilizes a dual, 7-segment LED display to indicate diagnostic codes.
When the control is powered up normally the light will be on continuously. The display wil indicate "ON" when powered and in standby mode. This can be used to test for 120 volts and 24 volts to the control since both must be present for the light to be on. If this step fails, check for 120 volts to the control and check the transformer and its associated wiring. If this step is successful give the control a call for heat and wait five (5) seconds or until the furnace goes into lockout. If the control detects a failure it will now be shown on the diagnostic indicator light/display. Refer to the Abnormal Op- eration section in the Sequence of Operation section of this manual for more detail on failure codes.
1. Check for 120 volts from Line 1 (Hot) to Line 2 (Neutral) at the ignition control. No voltage, check the door switch connections and wire harness for continuity.
2. With the thermostat calling for heat, check for 24 volts from W1 to C terminal on the ignition control. No volt­age. Check transformer, room thermostat, and wiring.
If you have 24 volts coming off the transformer but re­ceive approximately 13 volts on the terminal board be­tween (C) and (R), check for blown fuse.
3. Check for 120 volts to the induced draft blower (low-stage) by measuring voltage between Pin 3 and Pin 4 (on the 5­pin connector) located on circuit board. No voltage, check for loose connection in the 5-pin connector or replace ignition control.
Check for 120 volts to the induced draft blower (high­stage) by measuring voltage between Pin 2 and Pin 4 (on the 5-pin connector) located on circuit board. No volt­age, check for loose connection in the 5-pin connector, no call for high stage heat or replace ignition control.
The ground wire must run from the furnace all the way back to the electrical panel. Proper grounding can be confirmed by disconnecting the electrical power and measuring resis­tance between the neutral (white) connection and the burner closest to the flame sensor. Resistance should be less than 2 ohms.
The ignition control is a combination electronic and electro­mechanical device and is not field repairable. Complete unit must be replaced.
WARNING
INE VOLTAGE NOW PRESENT
L
73
SERVICING
GOODMAN PT# PCBKF104
2 Y2
1
b. The two-stage variable speed furnaces should have
120 Volts at the motor at all times, even without a call for cooling or heating. These motors receive their op­erational signals through the 4-pin wiring harness, connected between the motor and integrated control board. NOTE: For complete troubleshooting informa­tion on units using the ECM blower motors, refer to the servicing section - Checking Air Circulator Blow- ers (S-16B) in this service manual.
S-313A MEMORY CHIPS
Memory chips are a service only item and are not sent out with new equipment. They are used only in the rare occur­rence where communicating equipment shared data needs to be restored.
Memory chips should not be routinely installed at the time of installation. A memory chip is not required when an indi­vidual control board or motor is replaced.
A memory chip is only required when all communicating components have been replaced with service parts contain­ing no shared data. If either an existing control board or ECM motor needed to be replaced, the service part would upload the necessary data from the remaining communicat-
DE
W2
OG Y1CW1R
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ing component. In a fully communicating system, this would include the communicating thermostat and communicating outdoor unit control board as the necessary data is stored in all communicating devices.
4. If voltage is present in Steps 1 through 3 and the in­duced draft blower is operating, check for 120 volts to the ignitor during the preheat cycle. Measure voltage be­tween Pin 1 and Pin 5 (on the 5-pin connector) located on ignition control. No voltage, check low stage and high stage pressure switches or replace the ignition control board.
5. After the ignitor warmup time, begin checking for 24 volts to the gas valve. Voltage will be present for seven sec­onds only if proof of flame has been established.
6. If proof of flame was established voltage will be provided to the air circulation blower following the heat on delay period.
a. BEFORE replacing the ECM motor assembly or the
end bell, first check the motor with a Goodman #UTT­01 UltraCheck-EZTM diaganostic tool . If the motor runs with the diagnostic tool, the motor is good. To check the end bell, see the previous variable speed testing section of this manual before replacing the end bell.
A furnace void of shared data will not function in a legacy or a fully communicating installation. The furnace display would show “d0” indicating that there is no shared data in the fur­nace control board. If it is ever necessary to use a memory chip, the specific memory chip for your furnace number must be used.
To use a memory chip;
1. Power down all HVAC equipment in the system.
2. As when handling any electronic components; discharge any static electricity you may be carrying by touching grounded metal.
74
SERVICING
s
3. Insert the memory card in the slot on the control board.
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1
Memory Card Connector
Dual 7-Segment LED’
4. Power the system back up and allow a few minutes for the network to establish communication between all devices.
5. Furnace control board will display "ON”.
6. Check operation.
7. Memory chip can be left on the control board (recom­mended) or removed once equipment is powered down again.
OG Y1CW1R
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WARNING
HIGH VOLTAGE
ISCONNECT ALL POWER BEFORE SERVICING OR
D
INSTALLI NG THIS UNIT. BE PRESENT. DAMAGE, PERS ONAL I NJURY OR D EATH.
MULTIPLE POWER SOURCES MAY
FAILURE TO DO SO MAY CAUSE PROPERTY
1. Disconnect the flame sensor wire from the sensor.
2. Connect a micro-amp meter in series with this wire and the sensor terminal.
3. Be sure the positive side of the meter is to the flame sensor wire and the negative side of the meter is to sen­sor terminal.
WARNING
INE VOLTAGE NOW PRESENT
L
4. Place the unit into a heating cycle.
5. As soon as flame is established a micro-amp reading should be evident once proof of flame (micro-amp read­ing) is established, the hot surface ignitor will be de­energized.
6. The Integrated Ignition controls will have 1 to 4 micro­amps. If the micro-amp reading is less than the mini­mum specified, check for high resistance wiring con­nections, sensor to burner gap, dirty flame sensor, or poor grounding.
7. If absolutely no reading, check for continuity on all com­ponents and if good - replace ignition control module.
NOTE: Contaminated fuel or combustion air can create a nearly invisible coating on the flame sensor. This coating works as an insulator causing a loss in the flame sense signal. If this situation occurs the flame sensor must be cleaned with steel wool.
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.
75
MAINTENANCE
WARNING
HIGH VOLTAGE
ISCONNECT ALL POWER BEFORE SERVICING OR
D
INSTALLI NG THIS UNIT. BE PRESENT. DAMAGE, PERSONAL INJURY OR DEATH.
MULTIPLE POWER SOURCES MAY
FAILURE TO DO SO MAY CAUSE PROPERTY
CAUTION
IF YOU MUST HANDLE THE ITNITOR, HANDLE WITH CARE. TOUCHING
THE IGNITOR BODY WITH BARE FINGERS, ROUGH HANDLING, OR VIBRATION COULD RESULT IN EARLY IGNITOR FAILURE. QUALIFIED SERVICER SHOULD EVER HANDLE THE IGNITOR.
ONLY A
ANNUAL INSPECTION
The furnace should be inspected by a qualified installer, or service agency at least once per year. This check should be performed at the beginning of the heating season. This will ensure that all furnace components are in proper working order and that the heating system functions appropriately. Pay particular attention to the following items. Repair or service as necessary.
Flue pipe system. Check for blockage and/or leak­age. Check the outside termination and the connec­tions at the furnace.
Combustion air intake pipe system (where applicable). Check for blockage and/or leakage. Check the out­side termination and the connection at the furnace.
Heat exchanger. Check for corrosion and/or buildup within the heat exchanger passageways.
Burners. Check for proper ignition, burner flame, and flame sense.
Drainage system. Check for blockage and/or leakage. Check hose connections at and internal to furnace.
Wiring. Check electrical connections for tightness and/ or corrosion. Check wires for damage.
Filters.
AIR FILTER
WARNING
NEVER OPERATE FURNACE WIHT OUT A FILTER INSTALL ED AS DUST
AND LINT WILL BUILD UP ON INTERNAL PARTS RESULTING IN LOSS OF EFFICIENCY, EQUIPMENT DAMAMGE, AND POSSIBLE FIRE.
Filters must be used with this furnace. Filters do not ship with these furnaces but must be provided by the installer for proper furnace operation.
Remember that dirty filters are the most common cause of inadequate heating or cooling performance.
Maintenance
Improper filter maintenance is the most common cause of inadequate heating or cooling performance. Filters should be cleaned (permanent) or replaced (disposable) every two months or as required. It is the owner's responsibility to keep air filters clean. When replacing a filter, it must be replaced with a filter of the same type and size.
Filter Removal
Depending on the installation, differing filter arrangements can be applied. Filters can be installed in the central return register, the bottom of the blower compartment (upflow only), a side panel external filter rack kit (upflow only), or the duct­work above a counterflow furnace. A media air filter or elec­tronic air cleaner can be used as an alternate filter. The filter sizes given in the Product Design section of this manual or the product Specification Sheet must be followed to ensure proper unit performance. Refer to the following information for removal and installation of filters.
FILTER REMOVAL PROCEDURE Media Air Filter or Electronic Air Cleaner Removal
Follow the manufacturer’s directions for service.
Upright Counterflow Filter Removal
To remove filters from the ductwork above an upright coun­terflow installation:
1. Turn off electrical power to furnace.
2. Remove access door in ductwork above furnace.
3. Remove filters.
4. Remove blower compartment door. Vacuum compart­ment. Replace blower compartment door .
5. Replace filters opposite of removal.
6. Replace access door in ductwork.
Horizontal Unit Filter Removal
Filters in horizontal installations are located in the central return register.
INDUCED DRAFT AND CIRCULATION BLOWERS
The bearings in the induced draft blower and circulator blower motors are permanently lubricated by the manufacturer. No further lubrication is required. Check motor windings for ac­cumulation of dust which may cause overheating. Clean as necessary.
76
MAINTENANCE
CONDENSATE DRAINAGE SYSTEM (QUALIFIED SERVICER ONLY)
The drain tubes, trap, and field supplied drain line must be checked annually and cleaned as often as necessary to ensure proper condensate drainage.
FLAME SENSOR (QUALIFIED SERVICER ONLY)
Under some conditions, the fuel or air supply can create a nearly invisible coating on the flame sensor. This coating acts as an insulator, causing a drop in the flame sensing signal. If this occurs, a qualified servicer must carefully clean the flame sensor with steel wool. After cleaning, the flame sensor output should be as listed on the specification sheet.
BURNERS
WARNING
HIGH VOLTAGE E
LECTRICAL COMPONENT S ARE CONTAINED IN BOTH COMPARTMENTS. DEATH, DO NOT REMOVE ANY INTERN AL COMPARTMENT COVERS OR ATTEMPT ANY ADJUS TMENT. SERVICE AGENT AT ONCE IF AN ABNORM AL FLAME APPEARANCE SHOU LD DEVELOP.
Periodically during the heating season make a visual check of the burner flames. Turn the furnace on at the thermostat. Wait a few minutes since any dislodged dust will alter the normal flame appearance. Flames should be stable, quiet, soft and blue with slightly orange tips. They should not be yellow. They should extend directly outward from the burner ports without curling downward, floating or lifting off the ports.
T
O AVOID ELECTRICAL SHOCK, INJURY OR
CONTACT A QUALIFIED
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
CAUTION
Check the Burner Flames for:
1. Stable, soft and blue.
2. Not curling, floating or lifting off.
Burner Flame
Proper equipment promotes faster, more efficient service and accurate repairs resulting in fewer call backs.
HEATING PERFORMANCE TEST
Before attempting to diagnose an operating fault, run a heat­ing performance test and apply the results to the Service
Problem Analysis Guide.
A
LWAYS CONNECT A MONOMETER TO THE OUTLET TAP AT THE GAS VALVE BEFORE ADJUSTING THE PRESSURE REGULATOR. SHOULD T HE FINAL M ANIFOL D PRESSURE V ARY MOR E THAN PLUS OR MINUS .3 INCH ES WATER CO LUMN FRO M 3.5 INC HES WATER COLUMN FOR NATURAL GAS OR 10 INCHES WATER COLUMN FOR PROPANE GAS.
I
N NO CASE
To adjust the pressure regulator on the gas valve, turn down (clockwise) to increase pressure and input, and out (coun­terclockwise) to decrease pressure and input.
The dissipation of the heat transferred to the heat exchanger is now controlled by the amount of air circulated over its surface.
The amount (CFM) of air circulated is governed by the exter­nal static pressure in inches of water column of duct work, cooling coil, registers, etc., applied externally to the unit versus the motor speed tap (direct drive) or pulley adjust­ments of the motor and blower (belt drive).
A properly operating unit must have the BTU per hour input and CFM of air, within the limits shown to prevent short cy­cling of the equipment. As the external static pressure goes up, the temperature rise will also increase. Consult the proper tables for temperature rise limitation.
77
ACCESSORY WIRING DIAGRAMS
HIGH VOLTA GE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALL ING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
ALL FUEL SYSTEM CONTROL BOARD - AFE1860A
POWER SUPPLY INPUT
FURNACE DEMAND OUTPUT
BLOWER FAN DEMAND OUTPUT
POWER SUPPLY INPUT (COMMON)
SECOND STAGE FURNACE DEMAND OUTPUT
COMPRESSOR OUTPUT
SECOND STAGE COMPRESSOR OUTPUT
REVERSING VALVE OUTPUT
POWER SUPPLY OUT TO THERMOSTAT
CALL FOR REVERSING VALVE
CALL FOR COMPRESSOR
CALL FOR EMERGENCY HEAT
CALL FOR BLOWER FAN
CALL FOR FURNACE HEAT
POWER SUPPLY COMMON OUT TO THER MOSTAT
CALL FOR 2ND STAGE FURNACE HEAT
CALL FOR 2ND STAGE COMPRESSOR
POWER SUPPLY OUT TO HP CONTROL
HP CALL FOR FURNACE (DURING DEFROST)
REVERSING VALVE OUTPUT
COMPRESSOR CONTACTOR OUTPUT
POWER SUPPLY COMMON OUT TO HP C ON TR OL
ODT (OUTDOOR THERMOSTAT)
2ND STAGE COMPRESSOR DEMAND OUTPUT
F U R N A C E
T H E R M O S T A T
H E A T
P U M P
R W1 G C W2 Y Y2 O
R O Y E G W1 C W2 Y2
R W2 O Y
C OT-NO OT-NC OT-C
Y2
P1-8
P1-7
P1-4
P1-6
P1-5
P1-2
P1-3
P1-1
P2-2
P2-1
P2-7
P2-8
P2-5
P2-9
P2-3
P2-4
P2-6
P3-9
P3-8
P3-7
P3-2
P3-6
P3-3
P3-1
P3-4
P3-5
24VAC
24VAC
F1
3A
C
C
24VAC
C
POWER SUPPLY
1.0K
6.8K
6.8K
+5VDC
E/W1
O
Y
+VDC +5VDC
+VDC
K1
K2
Q1
MICROPROCESSOR
24VAC
+VDC
K4
Q2
W1-FURN W2-HP
G-STAT
G-FURN
Y2-HP
Y2-STAT Y2-FURN
Y-ST AT Y-FURN
Y-HP
K3
BREAK FOR ODT
1 2
ALL FUEL SYSTEM CONTROL BOARD - AFE18-60A
This wiring diagram is for reference only. Not all wiring is as shown above.
Refer to the appropriate wiring diagram for the unit being serviced.
(For use with Heat Pumps in conjunction with 80% or 90% Single-Stage or Two-Stage Furnaces)
78
ACCESSORY WIRING DIAGRAMS
HIGH VOLTA GE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALL ING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
INTE GRATED IGNITION CONTROL
DE
2 Y2
1
W2
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WHITE
BLACK
GREEN
DE-HUMIDISTAT
DE-HUMIDISTAT - DEHUM1
This wiring diagram is for reference only. Not all wiring is as shown above.
Refer to the appropriate wiring diagram for the unit being serviced.
80
70
60
50
40
ON
30
79
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