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Home My WebLink AboutMP20-156 TABLE OF CONTENTS I NSTALLATION I NSTRUCTIONSFOR Safety Considerations3 *MVM97 & *CVM97 Shipping Inspection4 ODULATING G AS F URNACE M Electrostatic Discharge (ESD) Precautions4 (Type FSP CATEGORY IV Direct To The Installer5 or Non Direct Vent Air Furnace) Product Description5 These furnaces comply with requirements em- Features5 bodied in the American National Standard / Na- Product Application6 tional Standard of Canada ANSI Z21.47·CSA-2.3 Gas Fired Central Furnaces. Location Requirements & Consideratinos7 Clearances and Accessibility8 Existing Furnace Removal9 Installer: Affix all manuals Thermostat Location9 adjacent to the unit. Combustion & Ventilation Air Requirements9 Installation Positions12 A s a professional installer you have an obligation to know the product better than the customer. This includes all Horizontal Applications & Considerations13 safety precautions and related items. Furnace Suspension13 Prior to actual installation, thoroughly familiarize yourself Front Cover Pressure Switch Tube Location13 with this Instruction Manual. Pay special attention to all safety warnings. Often during installation or repair it is Drain Trap and Lines13 possible to place yourself in a position which is more Leveling13 hazardous than when the unit is in operation. Alternate Electrical and Gas Line Connections14 Remember, it is your responsibility to install the product safely and to know it well enough to be able to instruct a Drain Pan14 customer in its safe use. Freeze Protection14 Safety is a matter of common sense...a matter of thinking Propane Gas/High Altitude Installations14 before acting. Most dealers have a list of specific good safety practices...follow them. Vent/Flue Pipe & Combustion Air Pipe14 Dual Certification: Non-Direct/Direct Vent15 The precautions listed in this Installation Manual are intended as supplemental to existing practices. However, Materials and Joining Methods15 if there is a direct conflict between existing practices and the content of this manual, the precautions listed Proper Vent/Flue here take precedence. and Combustion Air Piping Practices15 RECOGNIZE THIS SYMBOL Termination Locations16 Special Venting Requirements For AS A SAFETY PRECAUTION. *NOTE: Please contact your distributor or our website for the applicable Specification Sheet referred to in this manual. 5151 San Felipe Suite 500 IOG-2007E Houston, TX 77056 9/2016 www.goodmanmfg.com • www.amana-hac.com © 2014 - 2016 Goodman Manufacturing Company, L.P. is a registered trademark of Maytag Corporation or its related companies and is used under license. All rights reserved. TABLE OF CONTENTS Installations In Canada16 Junction Box Relocation28 Standard Furnace Connections18 24 Volt Thermostat Wiring29 Combustion Air Pipe18 Single-Stage Heating Thermostat Application30 Vent/Intake Terminations For Installation 24 Volt Dehumidistat Wiring30 of Multiple Direct Vent Furnaces21 Fossil Fuel Applications30 Concentric Vent Termination22 Line Voltage Accessories Side Wall Vent Kit22 (Electronic Air Cleaner and Humidifier)30 Condensate Drain Lines & Drain Trap22 24 Volt Humidifier31 General Drain Information22 Gas Supply and Piping31 Field Supplied Drain22 High Altitude Derate31 Upflow Model Installed Vertically23 Propane Gas Conversion31 Drain Exiting Right Side23 Gas Piping Connections32 Drain Exiting Left Side23 Propane Gas Tanks and Piping34 Upflow Model Installed Horizontally Circulating Air & Filters35 with Right Side Down23 Duct work - Air Flow35 Upflow Model Installed Horizontally Checking Duct Static35 with Left Side Down24 Bottom Return Air Opening \[Upflow Models\]35 Upflow Model Installed Horizontally Filters - Read This Section With Left Side Down - Alternate24 Before Installing The Return Air Duct work36 Counterflow Model Installed Vertically25 Upright Installations37 Drain Exiting Left Side25 Horizontal Installations38 Drain Exiting Right Side25 Startup Procedure & Adjustment38 Counterflow Model Installed Vertically26 Heating Operation with CTK01 Drain Exiting Left Side26 Thermostat (Communicating)39 Drain Exiting Right Side26 Heating Operation with CTK02**, Counterflow Model Installed Horizontally CTK03** & CTK04** Thermostat with Right Side Down26 (Modulating Communicating)39 Counterflow Model Installed Horizontally Condensate Drain Trap Priming40 with Left Side Down27 Furnace Operation40 Electrical Connections27 Gas Supply Pressure Measurement40 Wiring Harness28 Gas Manifold Pressure Measurement41 115 Volt Line Connections28 WARNING T HEMANUFACTURERWILLNOTBERESPONSIBLEFORANYINJURYORPROPERTYDAMAGEARISINGFROMIMPROPERSERVICEORSERVICEPROCEDURES. I F YOUINSTALLORPERFORMSERVICEONTHISUNIT,YOUASSUMERESPONSIBILITYFORANYPERSONALINJURYORPROPERTYDAMAGEWHICHMAYRESULT. M ANYJURISDICTIONSREQUIREALICENSETOINSTALLORSERVICEHEATINGANDAIRCONDITIONINGEQUIPMENT. 2 TABLE OF CONTENTS Gas Input Rate Measurement (Natural Gas Only)42Diagnostic Chart52 Temperature Rise42Resetting From Lockout52 Circulator Blower Speeds43Maintenance53 Blower Heat Off Delay Timings45Annual Inspection53 Filters53 Overview45Burners53 Airflow Considerations45Induced Draft and Circulator Blowers53 Fossil Fuel Applications46Condensate Trap and Drain System CTK0* Wiring46 (Qualified Servicer Only)53 Flame Sensor (Qualified Servicer Only)54 DIP Switches46Before Leaving an Installation54 Network troubleshooting48Repair and Replacement Parts54 System Troubleshooting49Troubleshooting Codes55 Fault Recall Sequence49Wiring Diagram61 Fault Clear Sequence:49Special Instructions for Products Installed62 Normal Sequence of Operation49in the State of Massachusetts62 Power Up49 Heating Mode49 Cooling Mode50 Fan Only Mode50 Operational Checks50 Safety Circuit Description50 Furnace Control Board51 Primary Limit51 Auxiliary Limit51 Rollout Limit51 Fan Only Mode51 Operational Checks51 Safety Circuit Description51 Furnace Control Board51 Primary Limit51 Auxiliary Limit51 Rollout Limit52 Pressure Switches52 Flame Sensor52 Troubleshooting52 Electrostatic Discharge (ESD) Precautions52 3 S AFETY C ONSIDERATIONS WARNING Adhere to the following warnings and cautions when install- T OPREVENTPERSONALINJURYORDEATHDUETOIMPROPER ing, adjusting, altering, servicing, or operating the furnace. INSTALLATION,ADJUSTMENT,ALTERATION,SERVICEORMAINTENANCE, To ensure proper installation and operation, thoroughly read REFERTOTHISMANUAL. F ORADDITIONALASSISTANCEOR this manual for specifics pertaining to the installation and INFORMATION,CONSULTAQUALIFIEDINSTALLER,SERVICERAGENCYOR application of this product. THEGASSUPPLIER. This furnace is manufactured for use with natural gas. It may be field converted to operate on L.P. gas by using the WARNING appropriate L.P. conversion kit listed in the PROPANE GAS/ I FTHEINFORMATIONINTHESEINSTRUCTIONSISNOTFOLLOWED HIGHALTITUDE INSTALLATIONS section of this manual EXACTLY,AFIREOREXPLOSIONMAYRESULTCAUSINGPROPERTY DAMAGE,PERSONALINJURYORLOSSOFLIFE. Install this furnace only in a location and position as speci- D ONOTSTOREORUSEGASOLINEOROTHERFLAMMABLEVAPORSAND LOCATION REQUIREMENTS & CONSIDERATIONS sec- fied in LIQUIDSINTHEVICINITYOFTHISORANYOTHERAPPLIANCE. tion and INSTALLATION POSITIONS section of this manual. WHAT TO DO IF YOU SMELL GAS: Provide adequate combustion and ventilation air to the fur- D ONOTTRYTOLIGHTANYAPPLIANCE. nace as specified in COMBUSTION & VENTILATIONAIR RE- D ONOTTOUCHANYELECTRICALSWITCH;DONOTUSEANYPHONE QUIREMENTS section of this manual. INYOURBUILDING. I MMEDIATELYCALLYOURGASSUPPLIERFROMANEIGHBOR’S Combustion products must be discharged to the outdoors. PHONE. F OLLOWTHEGASSUPPLIER’SINSTRUCTIONS. Connect this furnace to an approved vent system only, as I FYOUCANNOTREACHYOURGASSUPPLIER,CALLTHEFIRE specified in VENT/FLUE PIPE & COMBUSTION AIR PIPE sec- DEPARTMENT. tion of this manual. I NSTALLATIONANDSERVICEMUSTBEPERFORMEDBYAQUALIFIED INSTALLER,SERVICEAGENCYORTHEGASSUPPLIER. Never test for gas leaks with an open flame. Use a commer- cially available soap solution made specifically for the detec- WARNING tion of leaks to check all connections, as specified in GAS SUPPLYAND PIPING section of this manual. T HISPRODUCTCONTAINSORPRODUCESACHEMICALORCHEMICALS WHICHMAYCAUSESERIOUSILLNESSORDEATHANDWHICHARE KNOWNTOTHE S TATEOF C ALIFORNIATOCAUSECANCER,BIRTH tended temperature-rise range with a duct system which has DEFECTSOROTHERREPRODUCTIVEHARM. external static pressure within the allowable range, as speci- fied on the furnace rating plate and OPERATIONAL CHECKS WARNING section of these instructions. H EATINGUNITSHOULDNOTBEUTILIZEDWITHOUTREASONABLE, When a furnace is installed so that supply ducts carry air ROUTINE,INSPECTION,MAINTENANCEANDSUPERVISION. I FTHE circulated by the furnace to areas outside the space contain- BUILDINGINWHICHANYSUCHDEVICEISLOCATEDWILLBEVACANT, ing the furnace, the return air shall also be handled by duct(s) CARESHOULDBETAKENTHATSUCHDEVICEISROUTINELYINSPECTED, sealed to the furnace casing and terminating outside the MAINTAINEDANDMONITORED.INTHEEVENTTHATTHEBUILDING space containing the furnace. MAYBEEXPOSEDTOFREEZINGTEMPERATURESANDWILLBEVACANT, A gas-fired furnace for installation in a residential garage ALLWATER-BEARINGPIPESSHOULDBEDRAINED,THEBUILDINGSHOULD LOCATION REQUIRE- must be installed as specified in the BEPROPERLYWINTERIZED,ANDTHEWATERSOURCECLOSED.INTHE MENTSAND CONSIDERATIONSsection of this manual. EVENTTHATTHEBUILDINGMAYBEEXPOSEDTOFREEZING TEMPERATURESANDWILLBEVACANT,ANYHYDRONICCOILUNITS This furnace may be used as a construction site heater only SHOULDBEDRAINEDASWELLAND,INSUCHCASE,ALTERNATIVEHEAT if certain conditions are met. These conditions are listed in SOURCESSHOULDBEUTILIZED. the PRODUCTAPPLICATIONsection of this manual. CAUTION WARNING FROZEN AND BURST WATER PIPE HAZARD T OPREVENTPOSSIBLEPROPERTYDAMAGE,PERSONALINJURYOR F AILURETOPROTECTAGAINSTTHERISKOFFREEZINGMAYRESULTIN DEATHDUETOELECTRICALSHOCK,THEFURNACEMUSTBELOCATEDTO PROPERTYDAMAGE. PROTECTTHEELECTRICALCOMPONENTSFROMWATER. S PECIALPRECAUTIONS MUST BEMADEIFINSTALLINGFURNACEINAN AREAWHICHMAYDROPBELOWFREEZING. T HISCANCAUSEIMPROPER Drain trap must be primed at time of installation. Trap is OPERATIONORDAMAGETOEQUIPMENT. I FTHEFURNACE internally partitioned; add water to both inlet ports until wa- ENVIRONMENTHASTHEPOTENTIALOFFREEZING,THEDRAINTRAPAND ter appears at both sides of the outlet opening. Failure to DRAINLINEMUSTBEPROTECTED. T HEUSEOFACCESSORYDRAINTRAP prime trap at time of installation may have a negative ef- HEATERS,ELECTRICHEATTAPEAND/OR RV ANTIFREEZEIS fect on combustion quality and pressure switch action. RECOMMENDEDFORTHESEINSTALLATIONS. 4 MONOXYDE DE CARBONE RISQUE D'EMPOISONNEMENT AU Advertencia especial para la instalación de calentadores ó manejadoras de aire en áreas cerradas como estacionamientos ó cuartos de servicio. Cette ventilation est nécessaire pour éviter le danger d'intoxication Las emisiones de monóxido de carbono pueden circular a través au CO pouvant survenir si un appareil produisant du monoxyde del aparato cuando se opera en cualquier modo. de carbone continue de fonctionner au sein de la zone confinée. El monóxido de carbono puede causar enfermedades severas CO can cause serious illness including permanent brain damage or death.como daño cerebral permanente ó muerte. B10259-216 B10259-216 Le monoxyde de carbone peut causer des maladies graves telles que des dommages permanents au cerveau et meme la mort. B10259-216 WARNING and other discounts or reductions. P OSSIBLEPROPERTYDAMAGE,PERSONALINJURYORDEATHDUETO FIRE,EXPLOSION,SMOKE,SOOT,CONDENSATION,ELECTRICALSHOCK representative at the time damage is reported to ORCARBONMONOXIDEMAYRESULTFROMIMPROPERINSTALLATION,carrier. REPAIROPERATION,ORMAINTENANCEOFTHISPRODUCT. The carrier is responsible for making prompt inspection of damage and for a thorough investigation of each claim. The distributor or manufacturer will not accept claims from deal- WARNING ers for transportation damage. S HOULDOVERHEATINGOCCURORTHEGASSUPPLYFAILTOSHUTOFF, E LECTROSTATIC D ISCHARGE (ESD) P RECAUTIONS TURNOFFTHEMANUALGASSHUTOFFVALVEEXTERNALTOTHE FURNACEBEFORETURNINGOFFTHEELECTRICALSUPPLY. NOTE: Discharge your ing unit. An electrostatic discharge can adversely affect elec- trical components. S HIPPING I NSPECTION Use the following precautions during furnace installation and All units are securely packed in shipping containers tested ac- servicing to protect the integrated control module from dam- cording to International Safe Transit Association specifications. age. By putting the furnace, the control, and the person at The carton must be checked upon arrival for external damage. the same electrostatic potential, these steps will help avoid exposing the integrated control module to electrostatic dis- must be made in writing immediately. charge. This procedure is applicable to both installed and The furnace must be carefully inspected on arrival for damagenon-installed (ungrounded) furnaces. and bolts or screws which may have come loose in transit. In the1.Disconnect all power to the furnace. Do not touch the event of damage the consignee should:integrated control module or any wire connected to 1.Make a notation on delivery receipt of any visible damage to shipment or container.charge to ground. 2.Notify carrier promptly and request an inspection.2.Firmly touch a clean, unpainted, metal surface of the 3.With concealed damage, carrier must be notified hand during grounding will be discharged. as soon as possible - preferably within five days. 4.File the claim with the following support documents within a nine month statute of limitations. indemnity bond. 5 3.Service integrated control module or connecting wiring 8 88 10 following the discharge process in step 2. Use caution 4 7 7 11 5 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 9 an ungrounded object, repeat step 2 before touching 6 control or wires. 12 1 4.Discharge your body to ground before removing a new 14 32 15 control from its container. Follow steps 1 through 3 if 3 31 installing the control on a furnace. Return any old or 16 30 30 new controls to their containers before touching any 29 17 ungrounded object. 13 2 18 22 T O T HE I NSTALLER 19 28 Both Sides 21 Before installing this unit, please read this manual thoroughly 27 to familiarize yourself with specific items which must be ad- 24 hered to, including but not limited to: unit maximum external static pressure, gas pressures, BTU input rating, proper elec- 25 trical connections, circulating air temperature rise, minimum or maximum CFM, and motor speed connections. 20 20 WARNING 26 23 T OPREVENTPROPERTYDAMAGE,PERSONALINJURYORDEATHDUETO UPFLOW / HORIZONTAL MODEL FIRE,DONOTINSTALLTHISFURNACEINAMOBILEHOME,TRAILER,OR Figure 1 RECREATIONALVEHICLE. 5 10 P RODUCT D ESCRIPTION F EATURES 25 The CTK family of thermostat kits allow this furnace to be 11 installed as part of a digitally communicating system. The ComfortNet system provides advanced airflow configuration, 27 enhanced setup features, and enhanced diagnostics. It also 26 reduces the number of thermostat wires to a maximum of 23 four. It may be also installed as part of a non-communicating 13 system using a standard 24 VAC thermostat. 32 15 3 2 This product may be installed with the ComfortNet thermo- 31 17 stat and a non-ComfortNet compatible single stage air condi- 20 tioning unit. However, this reduces the benefits of the 18 ComfortNet system as the enhancements will only apply to 1 16 19 the furnace. 20 2 The modulating furnace operation is based off of nega- 21 6 tive pressure created by the draft inducer. The furnace control board receives commands from the room ther- 12 mostat. The furnace control board then controls the RPM of the (3 phase) inducer by varying the frequency and 7 7 4 9 88 voltage to the inducer. This is known as variable fre- 88 88 quency drive (VFD). The inducer, pressure switches, and COUNTERFLOW/HORIZONTAL gas valve are linked by pneumatic tubing. The gas valve Figure 2 modulates based on this negative pressure. 6 1Gas Valve This product is dual certified. Dual certification means that 2Gas Line Entrance (Alternate) the combustion air inlet pipe is OPTIONAL and the furnace can 3Pressure Switch(es) be vented as a: 4Gas Manifold Non-direct vent (single pipe) central forced air furnace 5Combustion Air Intake Connection in which combustion air is taken from the installation 6Hot Surface Igniter area or from air ducted from the outside or, 7Rollout Limit Direct vent (dual pipe) central forced air furnace in 8Burners which all combustion air supplied directly to the 9Flame Sensor furnace burners through a special air intake system 10Flue Sensor outlined in these instructions. 11Flue Pipe 12Primary Limit This furnace is an ETL dual-certified appliance and is 13Gas Line Entrance appropriate for use with natural or propane gas 14Flue Pipe Connection (Alternate) NK (NOTE:If using propane, a propane conversion kit is 15Rubber Elbow required). 16Variable-Speed Induced Draft Blower 17Electrical Connection Inlets (Alternate) This furnace may be used as a construction site heater 18Coil Front Cover Pressure Tap ONLY if all of the following conditions are met: 19Coil Font Cover Drain Port 20Drian Line Penetrations these installation instructions. 21Drain Trap 22Blower Door Interlock Switch furnace. Fixed jumpers that provide continuous 23Inductor (Not All Models) heating CANNOT be used and can cause long 24Integrated Control Module term equipment damage. Bi-metal thermostats, 2524 Volt Thermostat Connections or any thermostat affected by vibration must 26Transformer (40 VA) not be used during construction. 27ECM Variable Speed Circulator Blower 28Auxiliary Limit furnace. 29Junction Box 30Electrical Connection Inlets (16ºC) and 80ºF (27ºC) is maintained. 31Coil Front Cover replaced daily during construction and upon completion of construction. P RODUCT A PPLICATION per the furnace rating plate. This furnace is primarily designed for residential home-heat- ing applications. It is NOT designed or certified for use in system, using 100% outside air for combustion mobile homes, trailers or recreational vehicles. Neither is it during construction. designed or certified for outdoor applications. The furnace must be installed indoors (i.e., attic space, crawl space, or system, air filters and evaporator coils are garage area provided the garage area is enclosed with an thoroughly cleaned following final construction operating door). clean up by a qualified person. This furnace can be used in the following non-industrial com- ignition, input rate, temperature rise and mercial applications: venting) are verified by a qualified person Schools, Office buildings, Churches, Retail stores, according to these installation instructions. Nursing homes, Hotels/motels, Common or office areas In such applications, the furnace must be installed with the while the furnace is operating in any mode. following stipulations: these requirements is not covered under the provided and per local and national codes. warranty. NOTE: The Commonwealth of Massachusetts requires that on site. the following additional requirements must also be met: free air delivery application. or gas fitter. 7 to and the service area around the unit must haveproposed or existing air distribution system. flooring. the furnace is between 55°F and 100°F when the To ensure proper furnace operation, install, operate and furnace is heating. maintain the furnace in accordance with these instal- lation and operation instructions, all local building codes outdoors through a proper venting system. Special and ordinances. In their absence, follow the latest edi- consideration should be given to vent/flue pipe tion of the National Fuel Gas Code (NFPA 54/ANSI Z223.1), routing and combustion air intake pipe when and/or CAN/CSA B149. 1-15 Installation Codes, local applicable. Refer to Vent/Flue Pipe and Combustion plumbing or waste water codes, and other applicable codes. Air Pipe -Termination Locations for appropriate A copy of the National Fuel Gas Code (NFPA 54/ANSI Z223.1) termination locations and to determine if the can be obtained from any of the following: piping system from furnace to termination can be accomplished within the guidelines given. NOTE: American National Standards Institute The length of flue and/or combustion air piping 25 West 43rd Street, 4th Floor can be a limiting factor in the location of the New York, NY 10036 furnace. National Fire Protection Association downwards to the drain. Do not locate the 1 Batterymarch Park furnace or its condensate drainage system in any Quincy, MA 02169-7471 area subject to below freezing temperatures without proper freeze protection. Refer to CSA International Condensate Drain Lines and Trap for further 8501 East Pleasant Valley details. Independence, OH 44131 the furnace. Improper or insufficient combustion The rated heating capacity of the furnace should be greater air can expose building occupants to gas than or equal to the total heat loss of the area to be heated. combustion products that could include carbon The total heat loss should be calculated by an approved method monoxide. Refer to Combustion and Ventilation Air Requirements. America. condensate drainage. If the floor becomes wet or damp at times, place the furnace above the A copy of the CAN/CSA B149.1-15 Installation Codes can floor on a concrete base sized approximately 1- also be obtained from: 1/2" larger than the base of the furnace. Refer CSA International to the Horizontal Applications and Considerations 178 Rexdale Boulevard for leveling of horizontal furnaces. Etobicoke, Ontario, Canada M9W 1R3 installed directly on carpeting, or any other L OCATION R EQUIREMENTS & C ONSIDERATINOS combustible material. The only combustible material allowed is wood. Follow the instructions listed below and the guidelines provided in the Combustion and Ventilation Air Requirements upright counterflow unit installations over any section when selecting a furnace location. combustible material (including wood). Refer to subbase instructions for installation details. WARNING (NOTE: A subbase will not be required if an air conditioning coil is located beneath the furnace T OPREVENTPOSSIBLEEQUIPMENTDAMAGE,PROPERTYDAMAGE, between the supply air opening and the combustible PERSONALINJURYORDEATH,THEFOLLOWINGBULLETPOINTSMUSTBE floor. OBSERVEDWHENINSTALLINGTHISUNIT. result in safety and performance-related WARNING problems. Do not install the furnace where the combustion air is exposed to the following P OSSIBLEPROPERTYDAMAGE,PERSONALINJURYORDEATHDUETO substances: FIRE,EXPLOSION,SMOKE,SOOT,CONDENSATION,ELECTRICALSHOCK permanent wave solutions ORCARBONMONOXIDEMAYRESULTFROMIMPROPERINSTALLATION, chlorinated waxes or cleaners REPAIROPERATION,ORMAINTENANCEOFTHISPRODUCT. chlorine-based swimming pool chemicals water softening chemicals 8 Counterflow Installation over a combustible floor. deicing salts or chemicals If installation over a combustible floor becomes carbon tetrachloride necessary, use an accessory subbase (see halogen type refrigerants Specification Sheet applicable for your model for cleaning solutions (such as perchloroethylene) details.) A special accessory subbase must be used printing inks for upright counterflow unit installations over any paint removers combustible material including wood. Refer to varnishes subbase instructions for installation details. Follow hydrochloric acid the instructions with the subbase for proper cements and glues installation. Do not install the furnace directly on antistatic fabric softeners for clothes dryers carpeting, tile, or other combustible material masonry acid washing materials other than wood flooring. (NOTE: The subbase will not be required if an air conditioning coil is installed between the supply air opening on the furnace and contaminated by any of the above substances. the floor.) This protects the non-direct vent furnace from C LEARANCESAND A CCESSIBILITY airborne contaminants. To ensure that the enclosed non-directvent furnace has an adequate supply of combustion air, air must be *MVM97* MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS ducted in from a nearby uncontaminated room (INCHES) or from outdoors. Refer to the Combustion and POSITION*FRONTSIDESREARTOPFLUEFLOOR Ventilation Air Requirements for details. Upflow3"0"0"1"0"C HorizontalAlcove6"0"4"0"C unit, install the furnace upstream or in parallel C = If placed on combustible floor, floor MUST be wood only. with the cooling coil. Premature heat exchanger failure will result if the cooling coil is placed NOTES: upstream of the furnace. For vertical (upflow or downflow) applications, greater clearances than the minimum clearances listed above. the minimum cooling coil width shall not be less clearances from the enclosure where accessibility clearances are coil installed above an upflow furnace or under greater. a counterflow furnace may be the same width as the furnace or may be one size larger than *CVM97* MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS the furnace. Example: a “C” width coil may be (INCHES) installed with a “B” width furnace. POSITION*SIDESREARFRONTBOTTOMFLUETOP Counterflow0"0"3"NC0"1" For upflow applications, the front of the coil Horizontal6"0"3"C0"6" and furnace must face the same direction. C = If placed on combustible floor, floor MUST be wood only. NC = For installation on non-combustible floors only. A combustible subbase position the furnace so that the burners and must be used for installations on combustible flooring. ignition source are located not less than 18 inches (457 mm) above the floor. Protect the NOTES: furnace from physical damage by vehicles. greater clearances than the minimum clearances listed above. clearances from the enclosure where accessibility clearances are greater. that serves a separate appliance designed to Installations must adhere to the clearances to combustible burn solid fuel. materials to which this furnace has been design certified. The minimum clearance information for this furnace is pro- conditioning coil must be downstream on the supply (positive) side of the furnace heat permanently maintained. Clearances must also accommo- exchanger. Counterflow Installation over a noncombustible line connections. floor. Before setting the furnace over the plenum opening, ensure the surface around the opening is smooth and level. A tight seal should be made between the furnace base and floor by using a silicone rubber caulking compound or cement grout. 9 NOTE: In addition to the required clearances to combustible 8.If improper venting is observed during any of the above materials, a minimum of 24 inches service clearance must be tests, the venting system must be corrected in accor- available in front of the unit. dance with the National Fuel Gas Code ANSI Z223.1/ NFPA 54 and/or National Gas and Propane Installation Code CSA B149.1-15. TOP TOP 9.After it has been determined that each appliance con- nected to the venting system properly vents when SIDESIDESIDE tested as outlined above, return doors, windows, ex- haust fans, fireplace dampers and any other gas burn- ing appliance to their previous conditions of use. BOTTOM BOTTOM If resizing is required on any portion of the venting system, use the appropriate table in Appendix G in the latest edition UpflowCounterflowHorizontal of the National Fuel Gas Code ANSI Z223.1 and/or Figure 3 CSA B149.1-15 Installation Codes. E XISTING F URNACE R EMOVAL T HERMOSTAT L OCATION NOTE:When an existing furnace is removed from a venting The thermostat should be placed approximately five feet system serving other appliances,the venting system may be from the floor on a vibration-free, inside wall in an area too large to properly vent the remaining attached appliances. having good air circulation. Do not install the thermostat where it may be influenced by any of the following: The following vent testing procedure is reproduced from the American National Standard/National Standard of under cabinets. Canada for Gas-Fired Central Furnaces ANSI Z21.4, CSA- 2.3 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: 1.Seal any unused openings in the venting system; as an outside wall. 2.Inspect the venting system for proper size and hori- Consult the instructions packaged with the thermostat for zontal pitch, as required by the National Fuel Gas Code, mounting instructions and further precautions. ANSI Z223.1 or the Natural Gas and Propane Installa- tion Code, CSA B149.1-15 and these instructions. De- C OMBUSTION & V ENTILATION A IR R EQUIREMENTS termine that there is no blockage or restriction, leak- age, corrosion and other deficiencies which could cause an unsafe condition. WARNING 3.As far as practical, close all building doors and win- T OAVOIDPROPERTYDAMAGE,PERSONALINJURYORDEATH, dows and all doors between the space in which the SUFFICIENTFRESHAIRFORPROPERCOMBUSTIONANDVENTILATIONOF appliance(s) connected to the venting system are lo- FLUEGASESMUSTBESUPPLIED. M OSTHOMESREQUIREOUTSIDEAIRBE cated and other spaces of the building. SUPPLIEDINTOTHEFURNACEAREA. 4.Close fireplace dampers. Improved construction and additional insulation in buildings 5.Turn on clothes dryers and any appliance not connected have reduced heat loss by reducing air infiltration and es- to the venting system. Turn on any exhaust fans, such cape around doors and windows. These changes have helped as range hoods and bathroom exhausts, so they shall in reducing heating/cooling costs but have created a prob- operate at maximum speed. Do not operate a summer lem supplying combustion and ventilation air for gas fired exhaust fan. and other fuel burning appliances. Appliances that pull air 6.Follow the lighting instructions. Place the appliance out of the house (clothes dryers, exhaust fans, fireplaces, being inspected in operation. Adjust thermostat so etc.) increase the problem by starving appliances of air. appliance shall operate continuously. House depressurization can cause back drafting or improper 7.Test for spillage from draft hood appliances at the combustion of gas-fired appliances, thereby exposing build- draft hood relief opening after 5 minutes of main ing occupants to gas combustion products that could include burner operation. Use the flame of a match or candle. carbon monoxide. 10 3 9.3.2.1* Standard Method. The minimum required volume shall be 50 ft When the furnace is installed as a direct vent (2-pipe sys- 3 per 1,000/Btu/hour (4.8m/kW). tem) furnace, no special provisions for air for combustion are required. However, if this furnace is to be installed in 9.3.2.2* Known Air Infiltration Rate Method. Where the air infiltration the same space with other gas appliances, such as a water rate of a structure is known, the minimum required volume shall be deter- heater, ensure there is an adequate supply of combustion mined as follows: and ventilation air for the other appliances. Refer to the (1)For appliances other than fan-assisted, calculate using the following latest edition of the National Fuel Gas Code NFPA 54/ANSI equation: 3 Z223.1 or CAN/CSA B149.1-15 Installation Codes or appli- 21 ftI other Required Volume > _________________ other () cable provisions of the local building codes for determining ACH1000 Btu/hr the combustion air requirements for the appliances. (2)For fan-assisted appliances, calculate using the following equation: Most homes will require outside air be supplied to the fur- 3 15 ftI fan Required Volume > _________________ fan nace area by means of ventilation grilles or ducts connect- ( ) ACH1000 Btu/hr ing directly to the outdoors or spaces open to the outdoors such as attics or crawl spaces. where: I=all appliances other than fan-assisted input in Btu per hour other The following information on air for combustion and ventilation =fan-assisted appliances input in Btu per hour I is reproduced from the National Fuel Gas Code NFPA 54/ANSI fan Z223.1 Section 9.3. ACH=air change per hour (percent of volume of space exchanged 9.3* Air for Combustion and Ventilation. per hour, expressed as a decimal) 9.3.1 General. (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). 9.3.1.1Air for combustion, ventilation, and dilution of flue gases for appli- ances installed in buildings shall be obtained by application of one of the 9.3.2.3 Indoor Opening Size and Location. Openings used to connect methods covered in 9.3.2 through 9.3.6. Where the requirements of 9.3.2 indoor spaces shall be sized and located in accordance with the following: are not met, outdoor air shall be introduced in accordance with methods covered in 9.3.3 through 9.3.6. (1)*Combining spaces on the same story. Each opening shall have a mini- 22 mum free area of 1 in./1000Btu/hr (2200 mm/kW) of the total input 22 Exception No. 1: This provision shall not apply to direct vent appli- rating of all appliances in the space but not less than 100 in. (0.60m). ances. 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 9.3.1.2Appliances of other than natural draft design and other than Cat- enclosure\[see Figure A.9.3.2.3(1)\]. The minimum dimension of air egory 1 vented appliances shall be provided with combustion, ventilation, openings shall be not less than 3 in. (80 mm). and dilution air in accordance with the appliance manufacturer’s instruc- tions. 9.3.1.3 Appliances shall be located so as not to interfere with proper circu- lation of combustion, ventilation, and dilution air. 9.3.1.4Where used, a draft hood or a barometric draft regulator shall be installed in the same room or enclosure as the appliance served so as to prevent any difference in pressure between the hood or regulator and the combustion air supply. 9.3.1.5Makeup 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 require- ments. 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 Figure A.9.2.3.3.(1) All Combustion Air from Adjacent required volume calculated for all appliances located within the space. Rooms Indoor Spaces through Indoor Combustion Air Openings. communicating directly with the space in which the appliances are installed through openings not furnished with doors, and through combustion air open- ings sized and located in accordance with 9.3.2.3, are considered a part of (2)Combining spaces in different stories.The volumes of spaces in dif- the required volume. ferent stories shall be considered as communicating spaces where such spaces are connected by one or more openings in doors or floors having 22 a total minimum free area of 2 in./1000 Btu/hr (4400 mm/kW) of total input rating of all appliances. 11 9.3.3 Outdoor Combustion Air. Outdoor combustion air shall be pro-(2)*Where communicating with the outdoors through horizontal ducts, 2 vided through opening(s) to the outdoors in accordance with the methods ineach opening shall have a minimum free area of 1 in./2000 Btu/hr 2 9.3.3.1 or 9.3.3.2. The minimum dimension of air openings shall not be less(1100 min/kW) of total input rating of all appliances in the enclosure. than 3 in. (80 mm).\[See Figure A.9.3.3.1(2).\] 9.3.3.1 Two Permanent Openings Method. Two permanent openings, one commencing within 12 in. (300 mm) of the top and one commencing within 12 in. (300 mm) of the bottom, of the enclosure shall be provided. The openings shall communicate directly, or by ducts, with the outdoors or spaces that freely communicate with the outdoors, as follows: (1)*Where directly communicating with the outdoors or where communi- cating to the outdoors through vertical ducts, each opening shall have a 22 minimum free area of 1 in./4000 Btu/hr (550 min/kW) of total input rating of all appliances in the enclosure. \[See Figure A.9.3.3.1(1)(a) and Figure A.9.3.3.1(1)(b).\] Figure A.9.3.3.1(2) All Combustion Air From Outdoors through Horizontal Ducts. 9.3.3.2* One Permanent Opening Method. One permanent 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: 22 (1)1 in./3000 Btu/hr (700 mm per kW) of the total input rating of all appliances located in the enclosure, and (2)Not less than the sum of the areas of all vent connectors in the space. Figure A.9.3.3.1(1)(a) All Combustion Air From Outdoors - Inlet Air from Ventilated Crawl Space and Outlet Air to Ventilated Attic. Figure A.9.3.3.2 All Combustion Air From Outdoors through Single Combustion Air Opening. Figure A.9.3.3.1(1)(b) All Combustion Air From Outdoors through Ventilated Attic. 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\]: 12 (1)Indoor Openings: Where used, openings connecting the interior spacesException: Within dwellings units, unobstructed stud and joist spaces shall shall comply with 9.3.2.3.not be prohibited from conveying combustion air, provided that not more (2)Outdoor Opening(s) Location. Outdoor opening(s) shall be located inthan one fireblock is removed. accordance with 9.3.3. (3)Outdoor Opening(s) Size. The outdoor opening(s) size shall be calcu-9.3.8.2Ducts shall terminate in an unobstructed space, allowing free move- lated in accordance with the following:ment of combustion air to the appliances. (a)The ratio of the interior spaces shall be the available volume of all communicating spaces divided by the required volume.9.3.8.3Ducts shall serve a single space. (b)The outdoor size reduction factor shall be 1 minus the ratio of interior spaces.9.3.8.4Ducts shall not serve both upper and lower combustion air openings (c)The minimum size of outdoor opening(s) shall be the full size ofwhere both such openings are used. The separation between ducts servic- outdoor opening(s) calculated in accordance with 9.3.3, multiplieding upper and lower combustion air openings shall be maintained to the source by the reduction factor. The minimum dimension of air openingsof combustion air. shall not be less than 3 in. (80 mm). 9.3.8.5Ducts shall not be screened where terminating in an attic space. 9.3.5 Engineered Installations. Engineered combustion air installations shall provide an adequate supply of combustion, ventilation, and dilution air9.3.8.6Horizontal upper combustion air ducts shall not slope downward and shall be approved by the authority having jurisdiction.toward the source of combustion air. 9.3.6 Mechanical Combustion Air Supply. Where all combustion air is9.3.8.7The remaining space surrounding a chimney liner, gas vent, special provided by a mechanical air supply system, the combustion air shall begas vent, or plastic piping installed within a masonry, metal, or factory built 3 supplied form outdoors at the minimum rate of 0.35 ft/min per 1000 Btu/hrchimney shall not be used to supply combustion air. 3 (0.034 m/min per kW) for all appliances located within the space. 9.3.6.1Where exhaust fans are installed, additional air shall be provided toException: Direct vent appliances designed for installation in a solid replace the exhausted air.fuel-burning fireplace where installed in accordance with the manufacture’s installation instructions. 9.3.6.2Each of the appliances served shall be interlocked to the mechani- cal air supply system to prevent main burner operation where the mechani-9.3.8.8Combustion air intake openings located on the exterior of the build- cal air supply system is not in operation.ing shall have the lowest side of the combustion air intake openings located at least 12 in. (300 mm) vertically from the adjoining grade level. 9.3.6.3Where combustion air is provided by the building’s mechanical ven- tilation system, the system shall provide the specified combustion air rate in I NSTALLATION P OSITIONS addition to the required ventilation air. *MVM97 models may be installed upflow or horizontally 9.3.7 Louvers, Grilles, and Screens. with left or right side down. *CVM97 models may be in- stalled downflow or horizontally with left or right side 9.3.7.1 Louvers and Grilles. The required size of openings for combus- down. tion, 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 Do not install this furnace on its back. For upright upflow is known, it shall be used in calculating the size opening required to provide furnaces, return air ductwork may be attached to the side the free area specified. Where the louver and grille design and free area are panel(s) and/or basepan. For horizontal upflow furnaces, not known, it shall be assumed that wood louvers will have 25 percent free return air ductwork must be attached to the basepan. For area, and metal louvers and grilles will have 75 percent free area. both upright or horizontal counterflow furnaces, return duct- Nonmotorized louvers and grilles shall be fixed in the open position. work must be attached to the basepan (top end of the blower compartment). NOTE: Ductwork must never be attached to 9.3.7.2 Minimum Screen Mesh Size. Screens shall not be smaller than 1/4 in. mesh. 9.3.7.3 Motorized Louvers. Motorized louvers shall be interlocked with ductwork connections, and resulting airflow arrangements. 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 pre- vent 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. 9.3.8.1Ducts shall be constructed of galvanized steel or a material having equivalent corrosion resistance, strength, and rigidity. 13 2"2"3/8"XX ANGLEIRON (3 PLACES) Figure 4A Figure 5 F RONT C OVER P RESSURE S WITCH T UBE L OCATION When a furnace is installed horizontally with left side down, the front cover pressure switch tube must be re-located to the lower port of the collector box cover. 1.Remove tube from front cover pressure switch and collector box cover. Figure 4B 2.Remove rubber plug from bottom collector box port and install on top collector box port. 4.Install one end on front cover pressure switch. 5.Route tube to lower port on collector box cover and cut off excess tubing. D RAIN T RAPAND L INES Figure 4C In horizontal applications the condensate drain trap is se- cured to the furnace side panel, suspending it below the fur- Recommended Installation Positions nace. A minimum clearance of 5 1/2 inches below the fur- H ORIZONTAL A PPLICATIONS & C ONSIDERATIONS nace must be provided for the drain trap. Additionally, the appropriate downward piping slope must be maintained from When installing a furnace horizontally, additional consider- the drain trap to the drain location. Refer to Condensate Drain ation must be given to the following: Trap and Lines for further details. If the drain trap and drain line will be exposed to temperatures near or below freezing, F URNACE S USPENSION adequate measures must be taken to prevent condensate from If suspending the furnace from rafters or joists, use 3/8" freezing. L EVELING lowing diagram. The length of rod will depend on the applica- tion and the clearances necessary. Leveling ensures proper condensate drainage from the heat exchanger. For proper flue pipe drainage, the furnace must If the furnace is installed in a crawl space it must be sus- be level lengthwise from end to end. The furnace should pended from the floor joist or supported by a concrete pad. have a slight tilt from back to front with the access doors Never install the furnace on the ground or allow it to be ex- downhill from the back panel approximately 1/2 to 3/4 posed to water. inches. The slight tilt allows the heat exchanger condensate, generated in the recuperator coil, to flow forward to the recuperator coil front cover. 14 A LTERNATE E LECTRICALAND G AS L INE C ONNECTIONS V ENT/F LUE P IPE & C OMBUSTION A IR P IPE This furnace has provisions allowing for electrical and gas line connections through either side panel. In horizontal ap- WARNING plications the connections can be made either through the F AILURETOFOLLOWTHESEINSTRUCTIONSCANRESULTINBODILY INJURYORDEATH. C AREFULLYREADANDFOLLOWALLINSTRUCTIONS D RAIN P AN GIVENINTHISSECTION. 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). WARNING F REEZE P ROTECTION U PONCOMPLETIONOFTHEFURNACEINSTALLATION,CAREFULLY Refer to Horizontal Applications and Conditions - Drain Trap INSPECTTHEENTIREFLUESYSTEMBOTHINSIDEANDOUTSIDEOFTHE and Lines. FURNACETOASSUREITISPROPERLYSEALED. L EAKSINTHEFLUE SYSTEMCANRESULTINSERIOUSPERSONALINJURYORDEATHDUETO P ROPANE G AS/H IGH A LTITUDE I NSTALLATIONS EXPOSURETOFLUEPRODUCTS,INCLUDINGCARBONMONOXIDE. WARNING A condensing gas furnace achieves its high level of efficiency by extracting almost all of the heat from the products of com- P OSSIBLEPROPERTYDAMAGE,PERSONALINJURYORDEATHMAY bustion and cooling them to the point where condensation OCCURIFTHECORRECTCONVERSIONKITSARENOTINSTALLED. T HE takes place. Because of the relatively low flue gas tempera- APPROPRIATEKITSMUSTBEAPPLIEDTOENSURESAFEANDPROPER ture and water condensation requirements, PVC or ABS pipe FURNACEOPERATION. A LLCONVERSIONSMUSTBEPERFORMEDBYA is typically used as venting material. QUALIFIEDINSTALLERORSERVICEAGENCY. ® In addition to PVC and ABS pipe and fittings, Innoflue by ® Centrotherm Eco Systems and PolyPro by M&G Duravent This furnace is shipped from the factory configured for natu- are also approved vent and combustion air materials for ral gas up to 10,000 ft. altitude. Propane conversions re- installations in the U.S.A. and Canada. Manufacturers In- quire the proper LP kit to compensate for the energy con- stallation instructions for these products must be followed. tent difference between natural and propane gas. These products have specific instructions for installing, Manifold Pressure joining and terminating. Do not mix materials or compo- Pressure nents of one manufacturer with materials or components Low Stage GasAltitudeKitOrificeSwitch High of another manufacturer. (50% firing Change Stage rate) All furnaces are built with 2" vent / intake pipe and con- nectors. For furnaces requiring installation of 3" pipe, the 1 NaturalNone#453.5" w.c.1" w.c.None transition from 2" to 3" should be done as close to the 0-10,000 furnace as practically possible. 2 PropaneLPM-091.25MM10.0" w.c.2.6" w.c.None This furnace must not be connected to Type B, BW, or L vent In Canada, gas furnaces are only certified to 4500 feet. NOTE: or vent connector, and must not be vented into any portion of a factory built or masonry chimney except when used as a For furnaces being converted to LP gas, it is strongly rec- pathway for PVC as described later in this section. Never ommended that a LPLP03 kit also be installed. The use of common vent this appliance with another appliance or use a this kit will prevent the furnace from firing when the LP vent which is used by a solid fuel appliance. gas supply pressure is too low to support proper combus- tion. It is the responsibility of the installer to follow the manufac- The indicated kit must be used to ensure safe and proper ing and connectors are compatible with furnace flue products. furnace operation. All conversions must be performed by a Additionally, it is the responsibility of the installer to ensure qualified installer, or service agency. that all piping and connections possess adequate structural integrity and support to prevent flue pipe separation, shift- ing, or sagging during furnace operation. 15 All 90° elbows must be medium radius (1/4 bend DWV) or long D UAL C ERTIFICATION: N ON-D IRECT/D IRECT V ENT radius (Long sweep 1/4 bend DWV) types conforming to ASTM This furnace is dual certified and may be installed as a non- D3311. A medium radius (1/4 bend DWV) elbow measures 3 1/ direct vent (single pipe) or direct vent (dual pipe) appliance. A non-direct vent installation requires only a vent/flue pipe, while a direct vent installation requires both a vent/flue pipe and a combustion air intake pipe. Refer to the appropriate The use of two short radius 45 degree elbows is permit- section for details concerning piping size, length, number of ted to provide clearance to refrigerant piping above the elbows, furnace connections, and terminations. furnace. P ROPER V ENT/F LUEAND C OMBUSTION A IR P IPING P RACTICES WARNING Adhere to these instructions to ensure safe and proper fur- T OAVOIDBODILYINJURY,FIREOREXPLOSION,SOLVENTCEMENTS nace performance. The length, diameter, and number of el- MUSTBEKEPTAWAYFROMALLIGNITIONSOURCES (I.E.,SPARKS,OPEN bows of the vent/flue pipe and combustion air pipe (when FLAMES,ANDEXCESSIVEHEAT)ASTHEYARECOMBUSTIBLELIQUIDS. applicable) affects the performance of the furnace and must VOIDBREATHINGCEMENTVAPORSORCONTACTWITHSKINAND/OR A be carefully sized. All piping must be installed in accordance EYES. with local codes and these instructions. Piping must be adequately secured and supported to prohibit M ATERIALSAND J OINING M ETHODS sagging, joint separation, and/or detachment from the fur- nace. Horizontal runs of vent/flue and combustion air pip- Two- or three-inch nominal diameter PVC Schedule 40 pipe ing must be properly supported. PVC pipe supports must be meeting ASTM D1785, PVC primer meeting ASTM F656, and no more than 5' apart. For ABS pipe, supports must be no PVC solvent cement meeting ASTM D2564 specifications must more than 3' apart. Horizontal pipe runs must maintain a be used. Fittings must be DWV type fittings meeting ASTM 1/4 inch per foot downward slope, back towards the furnace, D2665 and ASTM D3311. Carefully follow the pipe cementing of PVC. The use of Schedule 40 PVC cellular core DWV meeting ASTM PREFERRED F891-1 or ABS cellular core (Foam Core) plastic pipe is also acceptable as a flue/vent and intake pipe material. PVC primer meeting ASTM F656 and PVC solvent cement meeting ASTM D2564 specifications must be used. Fittings must be DWV type fittings meeting ASTM D2665 and ASTM D3311. Carefully fol- low the manufactures instructions for cutting, cleaning and solvent cementing of PVC. For Canadian installations; all PVC pipe, fittings and join- ing materials must be UL S636 listed. As an alternative to PVC pipe, primer, solvent cement, and fittings, ABS materials which are in compliance with the following specifications may be used: Two-or-three- inch solid wall ABS Schedule 40 pipe must meet ASTM Figure 6 D1527 and, if used in Canada, must be CSA listed or, two- ACCEPTABLE or-three-inch cellular core ABS Schedule 40 pipe must meet ASTM F628 and, if used in Canada, must be CSA listed. Solvent cement for ABS to ABS joints must meet ASTM D2235 and, if used in Canada, must be CSA listed. The solvent cement for the PVC to ABS transition joint must TRANSITION NO LESS meet ASTM D3138. Fittings must be DWV type fittings THAN 45 DEGREES TO meeting ASTM D2661 and ASTM D3311 and, if used in HORIZONTAL PLANE TO Canada, must be CSA listed. Carefully follow the manu- AVOID CREATING A WATER TRAP IN VENT PIPING. cementing PVC and/or ABS. Figure 7 16 application should not terminate in an area which is frequently dusty or dirty. NO TRANSITION ON HORIZONTAL PLANE, NOTE:In Canada, the current edition of CAN/CSA B149.1- THIS CREATES A 15 takes precedence over the preceding termination WATER TRAP AND RESTRICTS FLUE restriction. GASES S PECIAL V ENTING R EQUIREMENTS F OR I NSTALLATIONS I N C ANADA All installations in Canada must conform to the require- ments of CAN/CSA B149.1 -15 code. All vent system com- Figure 8 ponents, including primer and cement, must be listed to ULC S636. The certified pipe and fittings should be clearly Precautions should be taken to prevent condensate from freez- ing inside the vent/flue pipe and/or at the vent/flue pipe cement used must be of the same manufacturer as the termination. All vent/flue piping exposed to temperatures vent system. For Royal Pipe System 636; use GVS-65 Primer below 35°F for extended periods of time must be insulated (Purple) and GVS-65 PVC Solvent Cement. For IPEX Sys- tem 636, use PVC/CPVC Primer, Purple or clear. Use PVC exposed outdoors in excess of the terminations shown in this Solvent Cement (Gray). thick closed cell foam. Inspect piping for leaks prior to in- For Canadian installations, ABS may be used as a combus- stalling insulation. tion air pipe only. ABS is not an approved vent material in Canada. If ABS is used as a combustion air pipe, it must T ERMINATION L OCATIONS NOTE:Refer to Location Requirements and Considerations tions in the use of primer and cement. Do not use primer for combustion air contaminant restrictions. and cement around potential sources of ignition. Do not The following bullets and diagram describe the restrictions use primer or cement beyond its expiration date. concerning the appropriate location of vent/flue pipe and com- The safe operation, as defined by ULC S636, of the vent bustion air intake pipe (when applicable) terminations. Refer system is based on following these installation instruc- to Non-Direct Vent (Single Pipe) Piping and Direct Vent (Dual Pipe) Piping located in this section for specific details on ter- tions, and proper use of primer and cement. It is recom- mination construction. mended under this standard, that the vent system be checked once a year by qualified service personnel. All at least 12 inches above ground level or the fire stops and roof flashings used with this system must anticipated snow level. be UL listed. Acceptability under CAN/CSA B149.1-15 is dependent upon full compliance with all installation in- terminate at least 3 feet above any forced air inlet structions. Consult the authority having jurisdiction (gas located within 10 feet. inspection authority, municipal building department, fire NOTE:This provision does not apply to the department, etc.) before installation to determine the need combustion air intake termination of a direct vent to obtain a permit. *IPEX System 636™ is a trademark of application. IPEX Inc. direct vent application must terminate at least 12 inches from any opening through ting, cleaning, and solvent cementing PVC and/or ABS. which flue gases may enter a building (door, window, or gravity air inlet). The vent can be run through an existing unused chimney pro- running vertically through a vided the space between the vent pipe and the chimney is roof must terminate at least 12 inches above the insulated and closed with a weather-tight, corrosion-resistant roof line (or the anticipated snow level) and be at flashing. least 12 inches from any vertical wall (including any anticipated snow build up). 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. 17 V X v DIRECT VENT TERMINAL CLEARANCES 12 12 Canadian InstallationsU.S. Installations Canadian InstallationsU.S. Installations I=Clearance to service3 ft. (91 cm).* A=Clearance above grade,12 in. (30 cm)12 in. (30 cm) regulator vent outlet. veranda, porch, deck or balcony. (See 1.24.6-i(9)b.) J=Clearance to nonmechanical air 6 in. (15 cm) for appliances 10,0006 in. (15 cm) for appliances 10,000 supply inlet to building or the Btuh (3 kW), 12 in. (30 cm) for Btuh (3 kW), 9 in. (23 cm) for B=Clearance to window or6 in. (15 cm) for appliances6 in. (15 cm) for appliances combustion air inlet to any other appliances > 10,000 Btuh (3kW) and appliances > 10,000 Btuh (3kW) and 10,000 Btuh (3 kW), 9 in. (23 cm) for door that may be opened.10,000 Btuh (3 kW), 12 in. (30 cm) for appliance.100,000 Btuh (30 kW), 36 in. (91 cm) 50,000 Btuh (15 kW), 12 in. (30 cm) for appliances > 10,000 Btuh (3 kW) and appliances > 10,000 Btuh (3 kW) and for appliances > 100,000 Btuh (30 kW).appliances > 50,000 Btuh (15 kW). 100,000 Btuh (30 kW), 36 in. (91 cm) 50,000 Btuh (15 kW), 12 in. (30 cm) for for appliances > 100,000 Btuh (30 appliances > 500,000 Btuh (15 kW). kW). K=Clearance to a mechanical6 ft. (1.83 m)3 ft. (91 cm) above if within air supply inlet.10 ft. (3 m) horizontally. C=Clearance to permanently** closed window. L=Clearance above paved sidewalk or7 ft. (2.13m) †* D=Vertical clearance to ventilated soffit**paved driveway located on public located above the terminal within a property. horizontal distance of 2 feet (61 cm) M=Clearance under veranda, porch,12 in. (30 cm) ‡* from the center line of the terminal. deck or balcony. E=Clearance to unventilated soffit.** 1In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code. F=Clearance to outside corner.** 2In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code. G=Clearance to inside corner.** H=Clearance to each side of center3 ft. (91 cm) within a height 15 ft.* †A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves line extended above meter/regulator (4.5 m) above the meter/regulator both dwellings. assembly.assembly. ‡Permitted only if veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor. *For clearances not specified in ANSI Z223.1/NFPA 54 or CSA B149.1, the following statement shall be included: “Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer’s installation instruction.” OTHER THAN DIRECT VENT TERMINAL CLEARANCES 12 12 Canadian InstallationsU.S. Installations Canadian InstallationsU.S. Installations I=Clearance to sevice3 ft. (91 cm).* A=Clearance above grade,12 in. (30 cm)12 in. (30 cm) regulator vent outlet. veranda, porch, deck or balcony. (See 1.24.6-i(9)b.) J=Clearance to nonmechanical air 6 in. (15 cm) for appliances 10,0004 ft. (1.2 m) below or to side of supply inlet to building or the Btuh (3 kW), 12 in. (30 cm) for opening; 1 ft. (300 m) above opening. B=Clearance to window or6 in. (15 cm) for appliances4 ft. (1.2 m) below or to side of combustion air inlet to any other appliances > 10,000 Btuh (3kW) and door that may be opened.10,000 Btuh (3 kW), 12 in. (30 cm) for opening; 1 ft. (300 m) above opening. appliance.100,000 Btuh (30 kW), 36 in. (91 cm) appliances > 10,000 Btuh (3 kW) and for appliances > 100,000 Btuh (30 kW). 100,000 Btuh (30 kW), 36 in. (91 cm) for appliances > 100,000 Btuh (30 kW). K=Clearance to a mechanical6 ft. (1.83 m)3 ft. (91 cm) above if within air supply inlet.10 ft. (3 m) horizontally. C=Clearance to permanently** L=Clearance above paved sidewalk or7 ft. (2.13m) †7 ft. (2.13m) closed window. paved driveway located on public D=Vertical clearance to ventilated soffit** property. located above the terminal within a horizontal distance of 2 feet (61 cm) M=Clearance under veranda, porch,12 in. (30 cm) ‡* from the center line of the terminal. deck or balcony. E=Clearance to unventilated soffit.** 1In accordance with the current CSA B149.1-15, Natural Gas and Propane Installation Code. F=Clearance to outside corner.** 2In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code. G=Clearance to inside corner.** H=Clearance to each side of center3 ft. (91 cm) within a height 15 ft.* †A vent shall not terminate directly above a sidewalk or paveable driveway that is located between two single family dwellings and serves both dwelling. line extended above meter/regulator (4.5 m) above the meter/regulator assembly.assembly. ‡Permitted only if veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor. *For clearances not specified in ANSI Z223.1/NFPA 54 or CSA B149.1, the following statement shall be included: “Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer’s installation instruction.” 18 piping internal to the furnace blower compartment. The com- S TANDARD F URNACE C ONNECTIONS bustion air intake pipe can also be secured directly to the counterflow unit air intake pipe coupling. It is the responsibility of the installer to ensure that the piping connections to the furnace are secure, airtight, and adequately COMBUSTION AIR INTAKE OPTION: The RF000142 coupling supported. can be secured directly to the furnace intake coupling if V ENT P IPE C ONNECTION condensation is a concern. If the RF000142 is used on the combustion air inlet, it must be installed with the arrow pointing up. It should be noted, the combustion air will flue pipe directly into the furnace fitting with the appropri- actually be moving in a direction opposite of the arrow on ate glue. Alternately, a small section of 2" pipe may be glued the RF000142 coupling. It must have a field supplied, in the furnace socket and a rubber coupling installed to allow trapped drain tube free-draining to proper condensate dis- removal for future service. Combustion Air and Vent piping posal location. A loop in the drain tube can serve as a should be routed in a manner to avoid contact with refrigerant trap. The unused RF000142 drain fitting should be capped. lines, metering devices, condensate drain lines, etc. If neces- N ON-D IRECT V ENT I NSTALLATIONS sary, clearances may be increased by creating an offset us- ing two 45 degree elbows. This joint can be rotated on the A minimum of one 90° elbow should be installed on the com- fitting to establish maximum clearance between refrigerant lines, metering devices, and condensate drain lines, etc. This joint is blockage. the equivalent of one 90 deg. elbow when considering elbow count. WARNING E DGESOFSHEETMETALHOLESMAYBESHARP. U SEGLOVESASA PRECAUTIONWHENREMOVINGHOLEPLUGS. A LTERNATE V ENT/F LUE L OCATION 45 DEGREE The alternate vent/flue location is the large hole directlyin ELBOWS line with the induced draft blower outlet. To use the alter- nate vent/flue location on an upflow / horizontal model, This feature is not currently available on counterflow models. Increased Clearance NOTE: In the horizontal left installation position, a means Figure 9A of condensate collection must be provided to keep vent VENT-DRAIN pipe condensate from entering the draft inducer housing. If the vent-drain elbow is eliminated from the installation; an RF000142 kit must be used. R000142F Figure 9B C OMBUSTION A IR P IPE D IRECT V ENT I NSTALLATIONS On upflow units secure the combustion air intake pipe to the air intake coupling by using a take apart rubber coupling supplied with the furnace or a plastic coupling. Also, the intake cou- pling may be inverted to allow the intake pipe to be glued directly to it. After inverting the coupling, secure it to the furnace top with screws. On counterflow units secure the com- bustion air intake pipe to the air intake coupling using the rubber coupling and worm gear hose clamps provided with the unit. The Figure 10 counterflow rubber coupling allows service removal of air intake 19 A LTERNATE C OMBUSTION A IR P ROVISION (Upflow / Horizontal models only) When using the alternate venting location, either in a horizontal left side down installation or a vertical instal- opening can used. A locating dimple is located on the right side of the furnace cabinet. The locating dimple is 1 7/8" measured from the front edge of the cabinet in line with the knock out. To use the alternate combustion air Vent/Flue Pipe Cuts Figure 11 location: 1.Remove screws and combustion air flange from cabinet. 1.Remove screws from vent flange. 2.Insert cabinet plug in unused combustion air hole. 2.Remove internal elbow and vent pipe. 3.Drill a pilot hole at the cabinet dimple (size dictated by knockout tool used). 4.Remove cabinet plug adjacent to inducer outlet and 4.Use a knockout tool to create a 3" diameter hole install an original cabinet vent hole. 5.Install combustion air flange and secure with screws 5.Install RF000142 coupling on inducer outlet. removed in step one. 6.Install flanged vent section removed in step 2 & secure with clamps. V ENT/F LUE P IPE L ENGTHSAND D IAMETERS 7.Secure flange to cabinet using screws removed in step 1. venting. Refer to the following table for applicable length, elbows, and pipe diameter for construction of the vent/flue pipe system. The tee used in the vent/flue termination must be counted as an elbow when determining the number of elbows in the piping system. DOWN VENTING UPFLOW MODEL FURNACES ONLY Figure 12 Use alternate vent & combination air locations 6’ MAX. Vent Pipe Combustion Air Pipe Both Pipes Terminated Outside Structure Field Supplied Drain Tee on Vent Pipe 1/4” per foot min. slope Condensate trapped to prevent flue gas from escaping and routed to field supplied condensate disposal All piping and fittings must be joined per material manufacturer’s specifications to prevent separation and flue gas leaks. 20 (6) TEE(OPTIONAL) Direct Vent (2 - Pipe) and Non-Direct Vent (1- Pipe) Number of Elbows Pipe Model Size COMBUSTIONAIR INTAKE 12345678 12”MIN (OPTIONAL) HEIGHTDIFFERENCE 11511010510095908580 2 or 2 1/2 BETWEEN *Notrequiredfor *MVM970603BNA* singlepipeinstallation INTAKEANDVENT 1371301231161091029588 3 2 or 2 1/211511010510095908580 *MVM970803BNA* 314714013312611911210598 2 or 2 1/26055504540353025 *MVM970804CNA* 31201131069992857871 403530252015105 2 or 2 1/2 *MVM971005CNA* 14413713012311610910295 3 403530252015105 2 or 2 1/2 *MVM971205DNA* 12”MINTOROOFORHIGHEST 14413713012311610910295 3 ANTICIPATEDSNOWLEVEL 2 or 2 1/29590858075706560 *CVM970603BNA* 314413713012311610910295 Figure 13 2 or 2 1/29590858075706560 *CVM970803BNA* 314413713012311610910295 6055504540353025 2 or 2 1/2 *CVM970804CNA* 1201131069992857871 3 403530252015105 2 or 2 1/2 *CVM971005CNA* ELBOWS 10396898275686154 3 STRAIGHT 1)Maximum allowable limits listed on individual lengths for inlet and flue and NOT a combination. Figure 14 2)Minimum requirement for each vent pipe is five (5) feet in length and one elbow/tee. 12" MIN. 3)Tee used in the vent/flue termination must be included when determin- ing the number of elbows in the piping system. VENT/FLUE TEE (OPTIONAL) or 45° ELBOW TURNED DOWN or 5)Increased Clearance Configurations using (2) 45 deg. elbows should be 90° ELBOW TURNED considered equivalent to one 90 deg. elbow.DOWN 6)One 90° elbow should be secured to the combustion air intake connec- tion. 12" MIN. ABOVE HIGHEST ANTICIPATED SNOW LEVEL V ENT/F LUE P IPE T ERMINATIONS NOTE: If either a 90 degree or 45 degree elbow is used for termination, it must be pointed downward. Horizontal Termination (Single Pipe) Above Highest Anticipated Snow Level The vent/flue pipe may terminate vertically, as through a Figure 15 roof, or horizontally, as through an outside wall. V ENT/F LUE & C OMBUSTION A IR P IPE L ENGTHS & D IAMETERS Vertical vent/flue pipe terminations should be as shown in the following figure. Refer to Vent/Flue Pipe and Combustion If there is a difference between the vent and combustion Air Pipe - Termination Locations for details concerning loca- air pipes, count the pipe with the most fittings. Elbows tion restrictions. The penetration of the vent through the and/or tees used in the terminations must be included when roof must be sealed tight with proper flashing such as is used determining the number of elbows in the piping systems. with a plastic plumbing vent. If the combustion air intake pipe is to be installed above a Horizontal vent/flue pipe terminations should be as shown in finished ceiling or other area where dripping of condensate the following figure. Refer to Vent/Flue Pipe and Combustion will be objectionable, insulation of the combustion air pipe Air Pipe - Termination Locations for details concerning loca- tion restrictions. The wall penetration should be sealed with silicone caulking material. NOTE: Terminate both pipes in the same pressure zone (same side of roof, no major obstacles between pipes, etc.). 21 90° ELBOWS 6”MAX 4”MIN 3”-24”BETWEENPIPES 90ºOR45° ELBOW 12"MIN.ABOVE HIGHESTANTICIPATED 12"MIN.TOGRADEOR SNOWLEVEL HIGHESTANTICIPATED SNOWLEVEL CombustionAir Intakemayalsobesnorkeledtoobtain12”mingroundclearance. AlternateVentTerminationAboveAnticipatedSnowLevel StandardHorizontalTerminations(DualPipe) (DualPipe) Figure 16 Figure 18 Vent & Combustion Air Intake Measurements for Stan- V ENT/I NTAKE T ERMINATIONS F OR I NSTALLATIONOF M ULTIPLE dard Horizontal Terminations (Dual Pipe) D IRECT V ENT F URNACES If more than one direct vent furnace is to be installed verti- cally through a common roof top, maintain the same mini- mum 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. Vent and intake clearance to ground If more than one direct vent furnace is to be installed horizon- tally 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. 90° ELBOWS 3”-24” 3”MIN 24”MAX 12”MINSEPARATION 3”MIN 12"MIN. ABOVE HIGHESTANTICIPATED SNOWLEVEL AlternateHorizontalVentTermination(DualPipe) Figure 17 12”MINTOGRADEORHIGHEST ANTICIPATEDSNOWLEVEL TerminationofMultipleDirectVentFurnaces Figure 19 22 C ONCENTRIC V ENT T ERMINATION a common drain may be used. An open tee must be Refer to the directions provided with the Concentric Vent Kit installed in the drain line, near the cooling coil, to (DCVK) for installation specifications. This is necessary to prohibit any interference with the S IDE W ALL V ENT K IT G ENERAL D RAIN I NFORMATION All furnace models come with a factory installed drain trap. For vertical installations, the trap will remain in Horizontal Installation the factory position except for a counterflow when the installer desires the drain to exit the right side. All fur- nace models installed horizontally require the trap to be will provide a cabinet seal when installed. See following Vertical Installation instructions for your model and installation position. Figure 20 NOTE: Both sides of the drain trap must be primed prior to initial furnace start up. This F IELD S UPPLIED D RAIN vent kit must terminate outside the structure and may be installed with the intake and exhaust pipes located side-by- Drain the furnace and air conditioning coil if applicable, in side or with one pipe above the other. These kits are NOT compliance with code requirements. In horizontal or intended for use with single pipe (indirect vent) installations. counterflow installations, a field installed rubber coupling Refer to the directions furnished with the Side Wall Vent will allow the drain trap to be removed for cleaning. The Kit (p/n 0170K00000S or 0170K00001S) for installation drain trap must be primed before initial furnace start up. specifications. When an air conditioning coil drain is connected to the field supplied furnace drain, it must be vented. C ONDENSATE D RAIN L INES & D RAIN T RAP 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 #2 #1 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 sys- tem. Refer to the following sections for specific details con- #5 cerning furnace drain trap installation and drain hose hook #4 ups. used. must be primed at time of #8 #7 installation. must meet local and nation codes. #9 must maintain a 1/4 inch per foot downward slope #10 Coupling toward the drain. at the drain trap supplied with the furnace. 100 Degree Elbow #11 may see temperatures near or below freezing, precautions must be taken to prevent condensate from freezing within the drain line. Figure 21 NOTE:Drain components shown for information purposes only. 23 U PFLOW M ODEL I NSTALLED V ERTICALLY D RAIN E XITING R IGHT S IDE 1.Locate and Install the 45º pipe / hose drain coupling The trap and factory installed hoses remain as shipped. from the outside of the cabinet (barbed end goes in The furnace drain may exit either the right or left side of the cabinet) through hole in the right side of the cabinet the furnace cabinet. Both sides of the cabinet have two and secure with two field supplied #8 self-tapping screws (see Figure 23). for drain and low voltage wiring purposes. If a higher drain 3.Install large end of hose #3 to trap outlet and secure area shown in Figure 22. Any unused cabinet opening with 1.25" clamp. must be sealed. Do not allow drain hose to sag or trap 4.Install smaller end of hose #3 on 45º elbow and secure water. with 1" clamp. 5.Refer to Field Supplied Drain section for instructions on field supplied / installed drain on outlet of furnace trap. D RAIN E XITING L EFT S IDE 1.Install the 45 degree pipe / hose drain coupling from Acceptable the outside of the cabinet (barbed end goes in the areafor cabinet) through the hole in the left side of the cabinet drain hole. and secure with two field supplied #8 self-tapping screws. (see Figure 23). Side Cut-Out 12” 3.Install large end of hose #3 to trap outlet and secure Right side shown. 3” 4.Install smaller end of hose #3 on 45° elbow and 5.Refer to Field Supplied Drain section for instructions Figure 22 on field supplied / installed drain on outlet of furnace trap. U PFLOW M ODEL I NSTALLED H ORIZONTALLYWITH R IGHT S IDE D OWN Minimum 5 1/2" clearance is required for the drain trap beneath the furnace. Hose #1 Hose #2 45 degree 45 degree barb-pipe barb-pipe adapter adapter Hose #2 Hose #11 Installer selects right or left side drain Figure 24 and installs this hose accordingly. Figure 23 24 1.Remove the clamps from both ends of the drain hoses.1.Remove the clamps from the two drain tubes on the trap. 2.Remove the two screws holding the drain trap to the2.Remove the two screws holding the drain trap to the blower deck.blower deck. 3.Remove the trap and two hoses from the blower3.Remove the trap and hoses from the blower deck . deck 4.Remove the two plugs from the left side of the cabinet 4.Remove the two plugs from the right side of theand install them in the blower deck. cabinet and install them in the blower deck. 5.(Draining the Vent Elbow) Locate hose #6. Measuring 5.(Draining the Vent Elbow ) Locate hose #2 (factory discard the 45 degree section. Insert hose #2 and from outside the cabinet through the cabinet drain hole nearest the top, secure it to the barbed fitting in the elbow with a red clamp. and secure with a silver clamp . 6.(Draining the Collector Box) Install the non-grommet 7.Unused vent-drain elbow drip leg port must be end of hose #11 from outside the cabinet in the sealed to prevent flue gases from escaping. Insert bottom drain hole. Install on collector box and the rubber plug removed in step 6 into the unused secure with a silver clamp. elbow drain port. Inserting a blunt tool such as a 7.Use two silver clamps and secure the hoses to drain 3/16’’Allen wrench into the center of the rubber trap. The trap outlet faces the front of the furnace.plug will stretch the plug and allow complete Secure the trap to the cabinet using two screws insertion. removed in step 2 byinserting the two screws through the large set of holes in the top Discard the section without the grommet. mounting tabs of the trap into the two predrilled 9.Insert the cut end of tube #5 through the lower cabinet holes in the side of the cabinet. drain hole. 8.Refer to Field Supplied Drain section for instructions 10.Connect hose #6 & hose #5 using 100º elbow and secure on field supplied / installed drain on outlet of with two red clamps furnace trap. 11.(Draining the Collector Box) Remove cap from left side collector box drain port (bottom in horizontal left U PFLOW M ODEL I NSTALLED H ORIZONTALLYWITH L EFT S IDE position) and install it on right side (top) collector D OWN box drain port. 12.Install the non-grommet end of hose #11 from outside Minimum 5 1/2" clearance is required for the drain trap the cabinet in the upper drain hole. Install on collector beneath the furnace. box and secure with a silver clamp. *Also see Front Cover Pressure Switch Tube Location on page 13.Use two silver clamps and secure the hoses to drain 14. trap. The trap outlet faces the front of the furnace. Secure the trap to the cabinet using two screws removed in step 2 by inserting the two screws through the large set of holes in the top mounting tabs of the trap into the two predrilled holes in the side of the cabinet. \[Removed: Place cap on vent...\] 14.Refer to Field Supplied Drain section for instructions on field supplied / installed drain on outlet of furnace trap. Hose #6 Hose #11 Hose #5 Figure 25 25 U PFLOW M ODEL I NSTALLED H ORIZONTALLY W ITH L EFT S IDE C OUNTERFLOW M ODEL I NSTALLED V ERTICALLY D OWN - A LTERNATE *Also see Front Cover Pressure Switch Tube Location page 14. R000142F Hose #4 x 3 Hose #5 Figure 27 The furnace drain may exit the right or left side of the fur- nace cabinet (left side preferred) Trap and factory installed hoses remain as shipped if the drain will exit the left side of Figure 26 the cabinet. Draining from the right side requires re-loca- tion of the trap to outside the cabinet. 1.(Draining the RF000142 Coupling) Locate hose #2 D RAIN E XITING L EFT S IDE (factory installed). Cut off and discard the 45°radius end. 1.Install a field supplied rubber coupling secured with 2.Install 90°radius end of hose #2 on RF000142 drain future cleaning. Alternately, a PVC fitting may be outlet and secure with a red clamp. glued on the trap outlet. 3. Insert coupling in hose #2 and secure with a red 2.Install drain per local and National codes. clamp. D RAIN E XITING R IGHT S IDE end. Discard the section without the grommet. 5.Insert the cut end of tube #5 through the lower cabinet drain hole. 6.Insert 100 degree elbow in the cut end of hose #5. 7.Locate hose #6. Using red clamps, connect between the coupling and 100 degree elbow, cutting off excess tubing. 8. (Draining the Collector Box) Remove cap from left side collector box drain port (bottom in horizontal left position) and install it on right side (top) collector box drain port. 9. Install the non-grommet end of hose #11 from outside the cabinet in the upper drain hole. Install on collector box and secure with a silver clamp. 10. Use two silver clamps and secure the hoses to drain trap. The trap outlet faces the front of the furnace. Secure the trap to the cabinet using two screws removed in step 2 by inserting the two screws Figure 28 through the large set of holes in the top mounting 1.Remove hose clamps and hoses from trap tabs of the trap into the two predrilled holes in the 2.Remove trap. side of the cabinet. 3.(Draining the Vent Elbow) Insert the non-grommet end hose #10 into the cabinet back drain hole. Insert a coupling into the drip leg of the vent-drain elbow and 26 secure with a silver clamp. Secure hose #10 on vent -drain hole and secure to collector box drain port using a drain elbow barb fitting with a silver clamp.silver clamp. 4.(Draining the Collector Box) Insert non-grommet end4.(Draining the Vent Elbow) Insert the straight barbed of hose #9 into the cabinet front drain hole andcoupling into the vent - drain elbow drip leg and secure secure on collector box drain port with a silverwith a red clamp. clamp. 5.From outside the cabinet, insert te non-grommet end of 5.Mate the drain trap inlets to the hoses and securehose #8 into the front cabinet drain hole and secure on with silver clamps.the vent - drain elbow barb fitting using a red clamp. 6.Line up the trap mounting holes with the pre-drilled6.Place the drain hoses on the trap inlets and secure holes in the furnace and secure with 2 screwswith silver clamps. The outlet of the trap must face removed in step 2.the original botom of furnace. 7.Refer to Field Supplied Drain section for instructions7.Using the two sheet metal screws provided in the cabinet, on field supplied / installed drain on outlet ofsecure the trap to the furnace. furnace trap. 8.Refer to Field Supplied Drain section for instructions on 8. (Draining the Collector Box) Remove cap from leftfield supplied/installed drain on outlet of furnace trap. side collector box drain port (bottom in horizontal C OUNTERFLOW M ODEL I NSTALLED H ORIZONTALLYWITH L EFT left position) and install it on right side (top) S IDE D OWN collector box drain port. 9. Install the non-grommet end of hose #11 from outside Minimum 5 1/2" clearance is required for the drain trap the cabinet in the upper drain hole. Install on beneath the furnace. collector box and secure with a silver clamp. *Also see Front Cover Pressure Switch Tube Location on 10. Use two silver clamps and secure the hoses to drain page 14. trap. The trap outlet faces the front of the furnace. Secure the trap to the cabinet using two screws Hose #4 removed in step 2 by inserting the two screws through the large set of holes in the top mounting tabs of the trap into the two predrilled holes in the side of the cabinet. C OUNTERFLOW M ODEL I NSTALLED H ORIZONTALLYWITH R IGHT S IDE D OWN Minimum 5 1/2” clearance is required for the drain trap beneath the furnace. Hose #4 Hose #5 Hose #2 Figure 30 1.Remove the factory installed drain trap and hose assemblies. Leave the 100°elbow inserted and clamped in the vent drain elbow. 3.(Draining the Collector Box) Remove the cap from the left side of the collector box drain port (bottom Hose #8Hose #7 Hose #7Hose #7 in horizontal left position) and install it on right Figure 29 side drain port. 4. Place radius end of hose #4 (factory installed) on the collector box drain port and secure with a silver clamp. 1.Remove the drain trap and factory installed drain tube 5. Insert hose #2 from outside the cabinet in the front assemblies. drain hole. 6. Connect hose #4 & hose #2 together using a straight 3.(Draining the Collector Box) From outside the cabinet, barbed coupling and two gold clamps (factory installed). insert the non-grommet end hose #7 into the back 27 7. (Draining the Vent Elbow) Remove rubber plug fromas supplied with the furnace must be replaced, it must be re- placed with wiring material having a temperature rating of at least 105° C. Any replacement wiring must be a copper conduc- 8.The unused vent-drain elbow drip leg port must be tor. plugged to prevent flue gases from escaping. Insert rubber plug removed in step 7 into the 100° elbow.. 115 V OLT L INE C ONNECTIONS into the center of the rubber plug will stretch the plug Before proceeding with electrical connections, ensure that and allow complete insertion) the supply voltage, frequency, and phase correspond to that specified on the unit rating plate. Power supply to the fur- drain elbow and secure with a gold clamp. nace must be NEC Class 1, and must comply with all appli- cable codes. The furnace must be electrically grounded in accordance with local codes or, in their absence, with the hose #4 and secure with a gold clamp. latest edition of The National Electric Code, ANSI NFPA 70 11. Insert the non-grommet end of hose #5 (factory and/or The Canadian Electric Code CSA C22.1. installed) from outside the cabinet in the back drain hole. Use a separate fused branch electrical circuit containing prop- 12. Insert 100º elbow in hose #5 and secure with a red erly sized wire, and fuse or circuit breaker. The fuse or clamp. circuit breaker must be sized in accordance with the maxi- mum overcurrent protection specified on the unit rating plate. and discard the radius end. An electrical disconnect must be provided at the furnace location. elbow and the PVC pipe and secure with red clamps. Connect hot, neutral, and ground wires as shown in the wir- 15. Connect the hoses to the trap inlets and secure with silver clamps, drain trap outlet must point to the vent applications, the cabinet opening to the junction box original bottom of the furnace. must be sealed air tight using either an UL approved bushing 16. Using the two sheet metal screws provided in the such as Heyco Liquid Tight or by applying non-reactive UL cabinet, secure the trap to the furnace. approved sealant to bushing. 17.Refer to Field Supplied Drain section for instructions Line polarity must be observed when making field connec- on field supplied / installed drain on outlet of tions. Line voltage connections can be made through either furnace trap. the right or left side panel. The furnace is shipped config- ured for a right side (left side for counterflows) electrical E LECTRICAL C ONNECTIONS connection with the junction box located inside the burner compartment. To make electrical connections through the WARNING opposite side of the furnace, the junction box must be relo- HIGH VOLTAGE ! cated to the other side of the burner compartment prior to T OAVOIDTHERISKOFELECTRICALSHOCK,WIRINGTO making electrical connections. To relocate the junction box, THEUNITMUSTBEPOLARIZEDANDGROUNDED. follow the steps shown below. NOTE:Wire routing must not interfere with circulator blower WARNING operation, filter removal, or routine maintenance. HIGH VOLTAGE ! T OAVOIDPERSONALINJURYORDEATHDUETO ELECTRICALSHOCK,DISCONNECTELECTRICALPOWER BEFORESERVICINGORCHANGINGANYELECTRICAL WIRING. CAUTION L ABELALLWIRESPRIORTODISCONNECTIONWHENSERVICING CONTROLS. W IRINGERRORSCANCAUSEIMPROPERANDDANGEROUS OPERATION. V ERIFYPROPEROPERATIONAFTERSERVICING. W IRING H ARNESS The wiring harness is an integral part of this furnace. Wires are color coded for identification purposes. Refer to the wiring diagram for wire routings. If any of the original wire 28 J UNCTION B OX R ELOCATION 24 V OLT T HERMOSTAT W IRING WARNING W IREROUTINGMUSTNOTINTERFEREWITHCIRCULATORBLOWER E DGESOFSHEETMETALHOLESMAYBESHARP. U SEGLOVESASA OPERATION,FILTERREMOVALORROUTINEMAINTENANCE. PRECAUTIONWHENREMOVINGHOLEPLUGS. A REMOVABLEPLUGCONNECTORISPROVIDEDWITHTHEFURNACE CONTROLTOMAKETHERMOSTATWIRECONNECTIONS. T HISPLUGMAY WARNING BEREMOVED,WIRECONNECTIONSMADETOTHEPLUG,AND REPLACED. I TIS STRONGLY RECOMMENDEDTHATMULTIPLEWIRES T OPREVENTPERSONALINJURYORDEATHDUETOELECTRICSHOCK, BEJOINEDWITHAWIRENUTANDASINGLECONDUCTORBEINSERTED DISCONNECTELECTRICALPOWERBEFOREINSTALLINGORSERVICINGTHIS UNDERTHETERMINALSCREW. F AILURETODOSOMAYRESULTIN UNIT. INTERMITTENTOPERATION. WARNING IMPORTANT NOTE HIGH VOLTAGE ! HEAT SET-UP DIP SWITCH - DIP SWITCH #13 MUST BESETTO T OAVOIDTHERISKOFINJURY,ELECTRICALSHOCKOR MATCHTHERMOSTATTYPE. T OUSETHE CTK01 COMMUNICATING DEATH,THEFURNACEMUSTBEELECTRICALLY THERMOSTAT, DIP SWITCH #13 MUSTBESETTO ON POSITION. T HISIS GROUNDEDINACCORDANCEWITHLOCALCODESORIN ALSOTHECORRECTSETTINGFORANON-COMMUNICATING 2-STAGE THEIRABSENCE,WITHTHELATESTEDITIONOFTHE THERMOSTAT. T OUSE CTK02**, CTK03** OR CTK04** ATIONAL E LECTRIC C ODE. US: National Electrical N MODULATINGTHERMOSTAT,CHECKTOMAKESURE DIP SWITCH #13 IS Code (NEC) ANSI/NFPA 70-2011. In CANADA: INTHE OFF POSITION (FACTORYPOSITION). T HISISALSOTHECORRECT Canadian Electrical Code CSA C22.1. POSITIONWHENUSINGANON-COMMUNICATINGSINGLE-STAGE THERMOSTAT. Line voltage connections can be made through either the right When installed with a non-communicating thermostat, the or left side panel. The furnace is shipped configured for a right furnace integrated control module provides terminals for both side electrical connection. To make electrical connections through the opposite side of the furnace, the junction box must This allows the furnace to support the following system appli- be relocated to the left side prior to making electrical connec- tions. To relocate the junction box, perform the following steps. 1.Remove the burner compartment door. 2.Remove and save the two screws securing the junction tions to the integrated control module. box to the side panel. 3.Relocate junction box and associated plugs and Low voltage connections can be made through either the right grommets to opposite side panel. Secure with screws or left side panel. Thermostat wiring entrance holes are lo- removed in step 2. cated in the blower compartment. The following figure shows WARNING This furnace is equipped with a 40 VA transformer to facilitate use with most cooling equipment. Consult the wiring dia- T OAVOIDTHERISKOFINJURY,ELECTRICALSHOCKORDEATH,THE gram, located on the blower compartment door, for further FURNACEMUSTBEELECTRICALLYGROUNDEDINACCORDANCEWITH details of 115 Volt and 24 Volt wiring. LOCALCODESOR,INTHEIRABSENCE,WITHTHELATESTEDITIONOFTHE NATIONAL E LECTRICAL C ODE. NOTE:Use of cooling ramping profiles and dehum feature requires a jumper between Y1 and O when a straight cool- ing unit is used. To ensure proper unit grounding, an earth ground wire must be connected between the furnace ground screw located inside the furnace junction box and the electrical IMPORTANT NOTE service panel. NOTE:Do not use gas piping as an electrical ground. To confirm proper unit grounding, turn off the elec- T HERMOSTAT “R” REQUIREDIFOUTDOORUNITISEQUIPPEDWITHA trical power and perform the following check. C OMFORT A LERT™MODULEORIFTHEOUTDOORUNITISAPARTOF 1.Measure resistance between the neutral (white) THE C OMFORT N ET™FAMILYOFEQUIPMENT. connection and one of the burners. 2.Resistance should measure 10 ohms or less. This furnace is equipped with a blower door interlock switch which interrupts unit voltage when the blower door is opened for ser- vicing. Do not defeat this switch. 29 Y2 W1W2 Furnace Integrated Y2 W1W2 Control Module Field installed jumper to enable cooling ramping profile when using a straight NEU 24 V THERMOSTAT CONNECTIONSAUX cooling unit. Y2 Dehumidistat \[Optional\] Low Voltage Connections with Auxiliary Terminals Remote Condensing Unit Figure 31 (Two-Stage Cooling) Thermostat - Two-Stage Heating with Two-Stage Cooling The auxiliary contacts are shipped with a factory installed Figure 34 jumper. As an option, the auxiliary contacts may be wired to a normally closed float switch. In the event of open contacts, the gas heat and cooling will be disabled until IMPORTANT NOTE (COOLING SETUP) the condition is corrected. These are 24 volt terminals powered internally, do not apply another voltage source S ET DIP SWITCH #14 TO ON POSITIONWHENUSINGA 2-STAGE to these terminals. COOLINGTHERMOSTAT. THERMOSTAT R S INGLE-S TAGE H EATING T HERMOSTAT A PPLICATION A single-stage thermostat with only one heating stage may be used to control this furnace. Furnace Integrated R Control Module To use a single-stage thermostat, turn off power to the fur- nace, move the thermostat selection DIP switch to the OFF NEU position. Turn power back on. Refer to the DIP switch chart YC Dehumidistat in this manual. \[Optional\] Remote Condensing Unit 24 V OLT D EHUMIDISTAT W IRING (Single-Stage Cooling) Thermostat - Single-Stage Heatingwith Single-Stage Cooling circulator blower to operate at a slightly lower speed (85% of Figure 32 desired speed) during a combined thermostat call for cooling and dehumidistat call for dehumidification. This can be done IMPORTANT NOTE T OUSEASINGLE-STAGE H EAT T HERMOSTAT, DIP SWITCH #13 ONTHE DEHUM terminal (if available). This lower blower speed en- FURNACECONTROLBOARDMUSTBESETTOTHE OFF POSITION. hances dehumidification of the conditioned air as it passes through the AC coil. For proper function, a dehumidistat ap- plied to this furnace must operate on 24 VAC and utilize a THERMOSTAT switch which opens on humidity rise. R To install/connect a dehumidistat: 1.Turn OFF power to furnace. Furnace Integrated 2.Secure the dehumidistat neutral wire (typically the white R Control Module integrated control module. NEU YC 3.Secure the dehumidistat hot wire (typically the black Dehumidistat \[Optional\] Remote integrated control module. Condensing Unit (Single-Stage Cooling) 4.Secure the dehumidistat ground wire (typically the green lead) to the ground screw on the furnace junction box. Thermostat - Two-Stage Heating with Single-Stage Cooling Figure 33 NOTE: Ground wire may not be present on all dehumidistats. 5.If the condenser is a straight cooling unit, install a jumper from Y1 to 0 on the furnace board. 6.Turn ON power to furnace. To enable the dehumidify function on the integrated control mod- ule, set the dehumidification ENABLE DIP switch from OFF to ON. 30 Once the switch is set, the dehumidify function is enabled during a combination call for cooling (T-Stat) and dehumidification (DEHUM-Stat). Refer to the DIP switch chart in the back sec- tion of this manual. NEUTRAL L1 F OSSIL F UEL A PPLICATIONS This furnace can be used in conjunction with a heat pump in a fossil fuel application. A fossil fuel application refers to a combined gas furnace and heat pump installation which uses an outdoor temperature sensor to determine the most cost AUX OUT AUX IN efficient means of heating (heat pump or gas furnace). Strictly follow the wiring guidelines in the fossil fuel kit in- stallation instructions. All furnace connections must be made to the furnace control board Accessories Wiring on the fossil fuel control board. Figure 35 L INE V OLTAGE A CCESSORIES (E LECTRONIC A IR C LEANERAND If it is necessary for the installer to supply additional line voltage H UMIDIFIER) wiring to the inside of the furnace, the wiring must conform to all local codes, and have a minimum temperature rating of 105°C. The furnace control board is equipped with line voltage ac- All line voltage wire splices must be made inside the furnace cessory terminals for controlling power to an electronic air junction box. cleaner. The furnace control board HUM (dry contacts) are closed when- WARNING ever the inducer is energized in a non-communicating in- HIGH VOLTAGE ! stallation. When used with a CTK02**, CTK03 or CTK04 com- T OAVOIDPERSONALINJURYORDEATHDUETO municating thermostat, the HUM terminals are closed when- ELECTRICALSHOCK,DISCONNECTELECTRICALPOWER ever there is a call for humidity when this feature is enabled BEFORESERVICINGORCHANGINGANYELECTRICAL in the communicating thermostat. In the CTK03AB & CTK04** WIRING. humidity must be enabled in he main menu, se up in the Installer menu & ComfortNet user menu. The integrated con- The accessory load specifications are as follows. (The fur- trol module electronic air cleaner terminals (EAC) are energized nace control board also has a set of dry contacts for hu- with 115 volts whenever the circulator blower is energized. midifier connection.) 24 V OLT H UMIDIFIER Humidifier1.0 Amp maximum at 120 VAC A 24 volt humidifier can be powered by feeding one of the Electronic Air Cleaner1.0 Amp maximum at 120 VAC HUM terminals with a field installed wire from the R ter- minal. Turn OFF power to the furnace before installing any accesso- G AS S UPPLYAND P IPING structions for locating, mounting, grounding, and controlling these accessories. Accessory wiring connections are to be The furnace rating plate includes the approved furnace gas made through the 1/4" quick connect terminals provided on input rating and gas types. The furnace must be equipped to the furnace integrated control module. The Electronic air operate on the type of gas applied. This includes any conver- cleaner hot terminal is identified as EAC. It is necessary sion kits required for alternate fuels and/or high altitude. to remove the protective tab on the board cover to access the EAC Terminal. The EAC neutral terminal is identified as NEUTRAL. A line voltage humidifier may be connected CAUTION between one of the HUM contacts and NEUTRAL. The other T OPREVENTUNRELIABLEOPERATIONOREQUIPMENTDAMAGE,THE HUM contact must be fed from the L1 terminal. INLETGASSUPPLYPRESSUREMUSTBEASSPECIFIEDONTHEUNIT All field wiring must conform to applicable codes. Connections RATINGPLATEWITHALLOTHERHOUSEHOLDGASFIREDAPPLIANCES should be made as shown in Figure 35. OPERATING. Inlet gas supply pressures must be maintained within the ranges specified in the following table. The supply pressure must be constant and available with all other household gas fired appli- ances operating. The minimum gas supply pressure must be maintained to prevent unreliable ignition. The maximum must not be exceeded to prevent unit overfiring. 31 The gas piping supplying the furnace must be properly sized based Inlet Gas Supply Pressure on the gas flow required, specific gravity of the gas, and length Natural GasMinimum: 4.5" w.c.Maximum: 10.0" w.c. of the run. The gas line installation must comply with local codes, Propane GasMinimum: 11.0" w.c.Maximum: 13.0" w.c. or in their absence, with the latest edition of the National Fuel Gas Code, NFPA 54/ANSI Z223.1 or CAN/CSA B149.1-15 in A heat pump thermostat with three stages of heat is required Canada. to properly use a two-stage furnace in conjunction with a heat pump. Refer to the fossil fuel kit (AFE18-60A) installa- Natural Gas Capacity of Pipe In Cubic Feet of Gas Per Hour (CFH) tion instructions for additional thermostat requirements. Pipe Size (in.) Nominal ½¾11¼1½22½ H IGH A LTITUDE D ERATE Actual ID: 0.6220.8241.0491.3801.6102.0672.469 Capacity in Cubic Feet of Gas per Hour In some areas the gas supplier may artificially derate the gas Length (ft) 101703606781390209040206400 in an effort to compensate for the effects of altitude. If the 20118247466957143027604400 gas is artificially derated, the appropriate orifice size must be 3 3095199374768115022203530 determined based upon the BTU/ft content of the derated gas 408117032065798519003020 and the altitude. Refer to the National Fuel Gas Code, NFPA 54/ 507215128458387316802680 ANSI Z223.1 or CAN/CSA B149.1-15 in Canada, and informa- 606513725752879115202430 tion provided by the gas supplier to determine the proper orifice 706012623748672814002230 size. 805611722045267713002080 905211020742463512201950 P ROPANE G AS C ONVERSION 1005010419540060011601840 125449217335553210201630 WARNING 15040831573224829281480 P OSSIBLEPROPERTYDAMAGE,PERSONALINJURYORDEATHMAY 17537771442964438541360 OCCURIFTHECORRECTCONVERSIONKITSARENOTINSTALLED. T HE 20034711342754127941270 25030631192443667041120 APPROPRIATEKITSMUSTBEAPPLIEDTOENSURESAFEANDPROPER FURNACEOPERATION. A LLCONVERSIONSMUSTBEPERFORMEDBYA This chart refers to natural gas with an inlet pressure of less than 2 psi and a pressure drop of 0.5" W.C. Specific gravity is 0.60. QUALIFIEDINSTALLERORSERVICEAGENCY. CFH =BTUH Furnace Input Heating Valve of Gas (BTU/Cubic Foot) As shipped, this unit is configured for natural gas. The LPM-09 is required to convert this furnace to operate on LP gas. The correct kit must be used to insure safe and proper furnacestaller must supply a ground joint union, drip leg, manual operation. All conversions must be performed by a qualifiedshutoff valve, and line and fittings to connect to gas valve. In installer, or service agency.some cases, the installer may also need to supply a transition piece from 1/2" pipe to a larger pipe size. G AS V ALVE The following stipulations apply when connecting gas piping. This unit is equipped with a 24 volt gas valve which modu- Refer to Gas Piping Connections figure for typical gas line lates by pneumatic linkage to the combustion air blower. connections to the furnace. Taps for measuring the gas supply pressure and manifold pres- Gas piping must be supported external to the furnace sure are provided on the valve. This is a non-convertible, cabinet so that the weight of the gas line does not non-adjustable gas valve equipped for natural gas. distort the burner rack, manifold or gas valve. The gas valve has a manual ON/OFF control located on the Use black iron or steel pipe and fittings for building piping. Where possible, use new pipe that is properly chamfered, reamed, and free of burrs and chips. If old Startup Procedure & Adjustment section of this manual for pipe is used, be sure it is clean and free of rust, scale, use of this control during start up and shut down periods. burrs, chips, and old pipe joint compound. G AS P IPING C ONNECTIONS Use pipe joint compound on male threads ONLY. Always use pipe joint compound (pipe dope) that is APPROVED FOR ALL GASES. DO NOT apply compound to the first WARNING two threads. T OAVOIDPOSSIBLEUNSATISFACTORYOPERATIONOFEQUIPMENT Use ground joint unions. DAMAGEDUETOUNDERFIRINGOREQUIPMENT,USETHEPROPERSIZE OFNATURAL/PROPANEGASPIPINGNEEDEDWHENRUNNINGPIPEFROM THEMETER/TANKTOTHEFURNACE. 32 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. A line pressure test port is provided on the gas valve. If desired, install a 1/8" NPT pipe plug fitting, accessible for test gage connection, immediately upstream of the gas supply connection to the furnace. Always use a back-up wrench when making the 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. Maximum torque for the gas valve connection is 375 in-lbs; excessive over-tightening may damage the gas valve. 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. Tighten all joints securely. Connection method must be in compliance with all local and national codes. US: National Fuel Gas Code (NFGC) NFPA 54-2012/ANSI Z223.1-2012 and the Installation Standards, Warm Air Heating and Air Conditioning Systems ANSI/NFPA 90B. In Canada, CANADA: National Standard of Canada, Natural Gas and Propane Installation Code (NSCNGPIC) CSA B149.1-15. Connect the furnace to the building piping by one of the following methods: Rigid metallic pipe and fittings. Semi-rigid metallic tubing and metallic fittings. Aluminum alloy tubing must not be used in exterior locations. In order to seal the grommet cabinet penetration, rigid pipe must be used to reach the outside of the cabinet. A semi-rigid connector to the gas piping may be used from there. Use listed gas appliance connectors in accordance with their instructions. Connectors must be fully in the same room as the furnace. Protect connectors and semirigid tubing against physical and thermal damage when installed. Ensure aluminum- alloy tubing and connectors are coated to protect against external corrosion when in contact with masonry, plaster, or insulation, or subjected to repeated wetting by liquids such as water (except rain water), detergents, or sewage. 33 Gas Piping Connections Manual Shut Off Valve (upstream from ground joint pipe union) Manual Shut Off Valve Alternate Burners Manifold (upstream from Gas Line ground joint Location pipe union) Gas Valve *Ground Joint *Ground Pipe Joint Union Pipe Union Drip Leg Grommet in Standard Gas Line Hole *NOTE: Union may be inside furnace cabinet where allowed by local codes. UPFLOW Figure 36 When gas line is in the alternate location, swap the position of Manual Shut Off Valve the plug and grommet. (upstream from ground joint pipe union) UPFLOW - HORIZONTAL LEFT Alternate Figure 38 Gas Line Location Manual Shut Off Valve (upstream from Alternate ground joint pipe union) *Ground *Ground Union Joint Joint Location Pipe Union Pipe Union Grommet Plug in in Standard Drip Leg Alternate Grommet in Gas Line Gas Line Plug in Alternate Gas Line Hole Standard Gas Line Hole Hole Hole Drip Leg Gas Valve Burners Burners *NOTE: Union may be inside furnace cabinet where allowed by local codes. COUNTERFLOW Figure 37 Plug in Main Gas Line Hole Gas Manifold Valve Drain Trap Drip leg may terminate with a 1/2” x 1/8” pipe plug to accommodate line gas pressure measurement. COUNTERFLOW - HORIZONTAL RIGHT Figure 39 34 A gas detecting warning system is the only reliable way to detect WARNING a propane gas leak. Rust can reduce the level of odorant in pro- pane gas. Do not rely on your sense of smell. Contact a local E DGESOFSHEETMETALHOLESMAYBESHARP. U SEGLOVESASA propane gas supplier about installing a gas detecting warning PRECAUTIONWHENREMOVINGHOLEPLUGS. system. If the presence of gas is suspected, follow the instruc- tions listed in the SafetyConsiderations section of this manual. The gas piping may enter the left or right side of the furnace cabinet. The installer must supply rigid pipe long enough to reach All propane gas equipment must conform to the safety standards the outside of the cabinet to seal the grommet cabinet penetra- of the National Board of Fire Underwriters, NBFU Manual 58. tion. A semi-rigid connector to the gas piping can be used out- CANADA: National Standard of Canada, Natural Gas and Pro- side the cabinet per local codes. long nipple is required. For models with a hook shaped mani- WC the furnace manifold with all gas appliances in operation. Maintaining proper gas pressure depends on three From the elbow, the length of pipe and the fittings required main factors: will vary by the side chosen, location of union and cabinet 1.Vaporization rate, depending on temperature of the width. The union may be placed inside or outside of the cabinet. containers. G AS P IPING C HECKS 2.Proper pressure regulation. (Two-stage regulation is recommended for both cost and efficiency). Before placing unit in operation, leak test the unit and gas 3.Pressure drop in lines between regulators, and between connections. second stage regulator and the appliance. Pipe size will depend on length of pipe run and total load of all appliances. WARNING Complete information regarding tank sizing for vaporization, recommended regulator settings, and pipe sizing is available T OAVOIDTHEPOSSIBILITYOFEXPLOSIONORFIRE,NEVERUSEAMATCH from most regulator manufacturers and propane gas suppli- OROPENFLAMETOTESTFORLEAKS. ers. Check for leaks using an approved chloride-free soap and water Since propane gas will quickly dissolve white lead and most solution, an electronic combustible gas detector, or other ap- standard commercial compounds, special pipe dope must be proved testing methods. used. Pipe dope used on propane gas installations must be approved for use with propane gas. NOTE: Never exceed specified pressures for testing. Higher pressure may damage the gas valve and cause subsequent Refer to the Figure 40 for typical propane gas installations overfiring, resulting in heat exchanger failure. and piping. Disconnect this unit and shutoff valve from the gas supply 5 to 15 PSIG piping system before pressure testing the supply piping sys-First Stage (20 PSIG Max.) Regulator Continuous tem with pressures in excess of 1/2 psig (3.48 kPa). 11" W.C. Isolate this unit from the gas supply piping system by closing 200 PSIG its external manual gas shutoff valve before pressure testing Second Stage Maximum Regulator supply piping system with test pressures equal to or less than 1/2 psig (3.48 kPA). P ROPANE G AS T ANKSAND P IPING WARNING Propane Gas Installation (Typ.) I FTHEGASFURNACEISINSTALLEDINABASEMENT,ANEXCAVATED Figure 40 AREAORCONFINEDSPACE,ITISSTRONGLYRECOMMENDEDTO CONTACTAPROPANESUPPLIERTOINSTALLAGASDETECTINGWARNING DEVICEINCASEOFAGASLEAK. •S INCEPROPANEGASISHEAVIERTHANAIR,ANYLEAKINGGASCAN SETTLEINANYLOWAREASORCONFINEDSPACES. •ROPANEGASODORANTMAYFADE,MAKINGTHEGASUNDETECTABLE P EXCEPTWITHAWARNINGDEVICE. 35 Example: C IRCULATING A IR & F ILTERS static reading from return duct = -0.1" W.C. D UCTWORK - A IR F LOW static reading from supply duct = +0.3" W.C. Duct systems and register sizes must be properly designed for the CFM and external static pressure rating of the furnace. total external static pressure on this system = 0.4" W.C. Design the ductwork in accordance with the recommended NOTE:Both readings may be taken simultaneously and D. read directly on the manometer if so desired. If an air conditioner coil or Electronic Air Cleaner is used in con- Install the duct system in accordance with Standards of the junction with the furnace, the readings must also include National Board of Fire Underwriters for the Installation of Air these components, as shown in the following drawing. Conditioning, Warm Air Heating and Ventilating Systems. Pam- phlets No. 90A and 90B. 4.Consult proper tables for the quantity of air. A closed return duct system must be used, with the return If the total external static pressure exceeds the maxi- duct connected to the furnace. NOTE: Ductwork must never mum listed on the furnace rating plate, check for closed be attached to the back of the furnace. For upflow installa- dampers, registers, undersized and/or oversized poorly tions requiring 1800 CFM or more, use either two side returns laid out duct work. or bottom return or a combination of side and bottom. Flex- The temperature rise of the furnace must be within the ible joints may be used for supply and return connections to temperature rise range listed on the furnace rating plate. reduce noise transmission. To prevent the blower from inter- fering with combustion air or draft when a central return is used, a connecting duct must be installed between the unit and the utility room wall. Never use a room, closet, or alcove as a return air chamber. C HECKING D UCT S TATIC Refer to your furnace rating plate for the maximum ESP (ex- ternal duct static) rating. Total external static refers to everything external to the furnace cabinet. Cooling coils, filters, ducts, grilles, reg- isters must all be considered when reading your total ex- ternal static pressure. The supply duct pressure must be read between the furnace and the cooling coil. This read- plate from the end on the coil; drilling a test hole in it and reinstalling the block off plate. Take a duct static reading at the test hole. Tape up the test hole after your test is complete. The negative pressure must be read between the filter and the furnace blower. Checking Static Pressure Excessive external static pressure will result in insuffi- Figure 41 cient air which can cause excessive temperature rise. This can cause limit switch tripping and heat exchanger fail- B OTTOM R ETURN A IR O PENING \[U PFLOW M ODELS\] ure. The bottom return air opening on upflow models utilizes a To determine total external duct static pressure, proceed as follows; opening in the base pan. To remove, simply press out the lanced sections by hand to expose the metal strips retaining 1.With clean filters in the furnace, use a draft gauge the sheet metal over the duct opening. Using tin snips, cut (inclined manometer) to measure the static pressure the metal strips and remove the sheet metal covering the of the return duct at the inlet of the furnace. (Nega- duct opening. In the corners of the opening, cut the sheet tive Pressure) metal along the scribe lines to free the duct flanges. Using 2.Measure the static pressure of the supply duct. (Posi- the scribe line along the duct flange as a guide, bend the duct tive Pressure) flanges around the perimeter of the opening using a pair of seamer pliers or seamer tongs. 3.The difference between the two numbers is your total NOTE: Airflow area will be reduced by approximately 18% if external static pressure. duct flanges are not folded open. This could cause perfor- mance issues and noise issues. 36 ter with a MERV rating of 8 (minimum) will often provide WARNING better filtration to protect equipment and the air distribu- tion system than a standard 1" filter and often has lower E DGESOFSHEETMETALHOLESMAYBESHARP. U SEGLOVESASA static pressure loss than a 1" filter. Also a deep-pleated filter PRECAUTIONWHENREMOVINGSHEETMETALFROMRETURNAIR will typically require less frequent replacement intervals. Avoid OPENINGS. using highly restrictive 1" filters which produce static pres- sure loss greater than .25" W.C. In some installations the CUT USING TIN SNIPS minimum filter size required (consult filter sizing chart) will not lend itself to a filter installation on the side of the fur- PRESS OUT BY HAND nace. The installation of a centrally installed air cleaner cabi- net or a return duct filter installation may offer more practi- cality. media filters and are available in the following configura- CUT FOUR CORNERS AFTER REMOVING SHEET tions. Consult your distributor for information on our com- METAL SCRIBE LINES OUTLINING DUCT FLANGES Duct Flange Cut Outs Figure 42 Filter Sizing Chart When the furnace is used in connection with a cooling unit, the furnace should be installed in parallel with or on the upstream ModelMinimum Recommended Filter Size^ side of the cooling unit to avoid condensation in the heating element. With a parallel flow arrangement, the dampers or other *MVM970603BN*1 - 16 X 25 Side or Bottom means used to control the flow of air must be adequate to pre- *MVM970803BN*1 - 16 X 25 Side or Bottom vent chilled air from entering the furnace and, if manually oper- *MVM970804CN*1 - 16 X 25 Side or Bottom ated, must be equipped with means to prevent operation of ei- *MVM971005CN*1 - 20 X 25 Bottom / 2 - 16 X 25 Side Return ther unit unless the damper is in the full heat or cool position. *MVM971205DN*1 - 20 X 25 Bottom / 2 - 16 X 25 Side Return When the furnace is installed without a cooling coil, it is recom- *CVM970603BN*2 - 10 X 20 or 1 - 16 X 25 Top Return mended that a removable access panel be provided in the supply *CVM970803BN*2 - 10 X 20 or 1 - 16 X 25 Top Return air plenum. This opening shall be accessible when the furnace is *CVM970804CN*2 - 10 X 20 or 1 - 16 X 25 Top Return installed and shall be of such a size that the heat exchanger can *CVM971005CN*2 - 14 X 20 or 1 - 20 X 25 Top Return be viewed for visual light inspection or such that a sampling ^ Larger filters may be used; filters may also be centrally located. probe can be inserted into the airstream. The access panel must be sealed to prevent air leaks when the furnace is in operation. When the furnace is heating, the temperature of the return air entering the furnace must be between 55°F and 100°F. F ILTERS - R EAD T HIS S ECTION B EFORE I NSTALLING T HE R ETURN A IR D UCTWORK Filters must be used with this furnace. Discuss filter mainte- nance with the building owner. Filters do not ship with this furnace, but must be provided, sized and installed externally by the installer. Filters must comply with UL900 or CAN/ ULCS111 standards. Damage or repairs due to the installa- tion of the furnace without filters are not covered under the warranty. Consider installing an air cleaner with deep-pleated media filter at the time of furnace installation. A deep-pleated fil- 37 Air Air cleaner installation locationMaximum Heating AirflowFilter (Media) DimensionsPart NumberCleaner Family Side or bottom return1200 CFM16 in X 20 in x 5¼"AM11-1620-5 Side or bottom return1600 CFM16 in X 25 in x 5¼"AM11-1625-5 AM11-5 Side or bottom return1600 CFM20 in X 20 in x 5¼"AM11-2020-5 Side or bottom return2000 CFM20 in X 25 in x 5¼"AM11-2025-5 Side return 2 X 1600 CFM2, 16 in X 25 in x 5¼"AM11-3225-5AM11-3225 (for 2 separate returns) Side return (Right angle)2000 CFM20 in X 25 in x 5¼"AM11-2025-5RAAM11-5RA Bottom return (platform)2000 CFM20 in X 25 in x 5¼"AM11-2832-5PP AM11-5PP Bottom return (platform)2000 CFM20 in X 25 in x 5¼"AM11-2843-5PP AM11-5AM11-5RAAM11-5PP FamilyFamilyFamily On upflow units, guide dimples locate the side return cutout AIR FLOW locations. Use a straight edge to scribe lines connecting the CENTRAL dimples. Cut out the opening on these lines. NOTE: An under- RETURN GRILLE sized opening will cause reduced airflow. SIDE RETURN Refer to the Filter Sizing Chart to determine filter area re- EXTERNAL FILTER quirements. RACK KIT FILTER (EITHER SIDE) Change filters before occupants take ownership of a new home! U PRIGHT I NSTALLATIONS FILTER Depending on the installation and/or customer preference, differing filter arrangements can be applied. Filters can be installed in the central return register or a side panel exter- nal filter rack kit (upflows). As an alternative a media air filter or electronic air cleaner can be used as the requested Possible Upright Upflow Filter Locations filter. Figure 43 38 Call for heat, thermostat energizes W1 on the furnace con- FILTER trol board (W2 input is ignored). ACCESS DOOR After a successful Light Off Sequence and expiration of the Ignition Stabilization Period: RETURN 35% (low fire rate). CENTRAL DUCT RETURN GRILLE increases the firing rate to 57% at a rate of 1% FILTER SUPPORT per second. BRACKET (Field Supplied) increases the firing rate to 78% at a rate of 1% per second. increases to 100% at a rate of 1% per second for the remainder of the call for heat. CFM, corresponding to the current firing rate. AIR FLOW Possible Upright Counterflow Filter Locations Figure 44 IGNITION (80%) H ORIZONTAL I NSTALLATIONS 70% Filters must be installed in either the central return register 10 MINS. 60% or in the return air duct work. 8 MINS. 50% S TARTUP P ROCEDURE & A DJUSTMENT 2 MINS. Furnace must have a 115 VAC power supply properly connected MIN. and grounded. Proper polarity must be maintained for correct operation. In addition to the following start-up and adjust- ment items, refer to further information in Operational Checks section. Operation with Conventional 2-Stage Thermostat (DIP switch selects 2-stage heat) UNIT CALL FOR HEAT ENDS Figure 46 100% IGNITION Call for 1st-Stage Heat - Thermostat contacts close R to W1. (80%) 10 MINS. 78% After a successful Light Off Sequence and expiration of the Ignition Stabilization Period: 8 MINS. 57% rate. 2 MINS. increases the firing rate to 50% for the next 8 MIN. minutes. the firing rate 10%, at a rate of 1% per second, Operation with Conventional 1-Stage Thermostat every 10 minutes for the remainder of the call for (DIP switch selects 1-Stage heat) heat (See above figure). Figure 45 CFM, corresponding to the current firing rate. 39 Call for 2nd-Stage Heat satisfied; Call for 1st-Stage Heat 10 MINS. remains. 90% 8 MINS. IGNITION firing rate until the 1st-Stage call for heat is (80%) satisfied. 70% H EATING O PERATIONWITH CTK01 T HERMOSTAT (C OMMU- 60% NICATING) 50% set to 2-Stage heat, the furnace control board operation will be compatible with a CTK01 2 MINS. MIN. communicating thermostat. through the Light Off Sequence, at which time the Heat Current Demand Status will still show Operation with Conventional 2-Stage Thermostat 0%. After the successful Light Off Sequence and (DIP switch selects 2-stage heat) expiration of the Ignition Stabilization Period: Figure 47 Call for 2nd-Stage Heat - Thermostat contacts close R to W1 rate. and W2. the specific heat requested demand. After a successful Light Off Sequence and expiration of the Ignition Stabilization Period: the furnace control board will follow the conventional 2-Stage algorithm, equivalent to a rate of 35%. W1 request and be reflected in the heat current demand status %. increases the firing rate to 80%. the furnace control board will follow the by 10%, at a rate of 1% per second, every 10 conventional 2-Stage algorithm, equivalent to a minutes for the remainder of the call for heat. W2 request and be reflected in the heat current demand status %. CFM, corresponding to the current firing rate. profile. Call for 2nd-Stage Heat with 1st-Stage call for heat call in progress, with conventional 2-Stage Thermostat. H EATING O PERATIONWITH CTK02**, CTK03** & CTK04** T HERMOSTAT (M ODULATING C OMMUNICATING) to 100% at a rate of 1% per second for the remainder of the W2 call. set to 1-Stage heat, the furnace control board operation will be compatible with a modulating corresponding to the current firing rate. communicating thermostat (CTK02**, CTK03 or CTK04). UNIT CALL FOR HEAT ENDS 100% through the Light Off Sequence, at which time IGNITION the Heat Current Demand Status will still show (80%) 0%. After the successful Light Off Sequence and 78% expiration of the Ignition Stabilization Period: rate. 50% CALL FOR 2ND STAGE HEAT the specific Heat Requested Demand. 2 MINS. MIN. current demand status will show 50%. Figure 48 40 2.Remove the burner compartment door and move the degrees, the heat current demand status willfurnace gas valve manual control to the OFF position. track the specific heat requested demand. 3.Close the manual gas shutoff valve external to the furnace. profile. 4.Replace the burner compartment door. C ONDENSATE D RAIN T RAP P RIMING G AS S UPPLY P RESSURE M EASUREMENT The drain trap MUST be primed prior to furnace startup. To CAUTION prime, fill the drain trap with water. This ensures proper furnace drainage upon startup and eliminates the possibility T OPREVENTUNRELIABLEOPERATIONOREQUIPMENTDAMAGE,THE of flue gases escaping through the drain system. Please see INLETGASSUPPLYPRESSUREMUSTBEASSPECIFIEDONTHEUNIT requirements in Condensate Drain Lines & Drain Trap sec- RATINGPLATEWITHALLOTHERHOUSEHOLDGASFIREDAPPLIANCES tion. OPERATING. F URNACE O PERATION Before placing a gas furnace or any gas appliance in op- Purge gas lines of air prior to startup. Be sure not to purge eration, verify that the gas piping, gas fittings and all gas lines into an enclosed burner compartment. Follow NFPA 54, components are safe and free of leaks by means of an National Fuel gas Code 8.3 for proper purging methods. In electronic combustible gas indicator and a gas meter dial Canada, follow approved purging methods in B149.1-15. test. Combustible gas indicators must be calibrated and Check for leaks using an approved chloride-free soap and wa- verified at intervals prescribed by the instrument manu- ter solution, an electronic combustible gas detector, or other facturer. approved method. Verify that all required kits (propane gas, The line pressure supplied to the gas valve must be within the etc.) have been appropriately installed. range specified in the Inlet Gas Supply Pressure table. The F URNACE S TARTUP supply pressure can be measured at the gas valve inlet pres- sure tap or at a hose fitting installed in the gas piping drip 1.Close the manual gas shutoff valve external to the leg. The supply pressure must be measured with the burners furnace. operating. To measure the gas supply pressure, use the fol- 2.Turn off the electrical power to the furnace. lowing procedure: 3.Set the room thermostat to the lowest possible setting. PRESSURE 4.Remove the burner compartment door. ATMOSPHERE SWITCH PORT CONNECTION NOTE:This furnace is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand. FLOW 5.Move the furnace gas valve manual control to the DIRECTION OFF position. 6.Wait five minutes then smell for gas. Be sure to check near the floor as propane is heavier than air, 7.If you smell gas after five minutes, immediately Honeywell Model VR9205R follow the Safety Considerations on page 3 of this Figure 49 manual. If you do not smell gas after five minutes, move the furnace gas valve manual control to the 2-PIN ON position. POWER OpetoMnometer na 8.Replace the burner compartment door. CONNECTOR re ospheose AtmH 9.Open the manual gas shutoff valve external to the furnace. 10.Turn on the electrical power to the furnace. 11.Adjust the thermostat to a setting above room i temperature. 12. After the burners are lit, set the thermostat to Inlet Pressure desired temperature. Tap 1/8 NPT F URNACE S HUTDOWN Manometer 1.Set the thermostat to the lowest setting. Figure 50A The integrated control will close the gas valve and extinguish flame. After the blower off delay expires, the circulator blower de-energizes. 41 Gas Line Outlet Gas Shutoff Pressure Valve Tap 1/8 NPT Gas Line To Furnace Open To Atmosphere Drip Leg Cap With Fitting Figure 50B Manometer Hose Honeywell Model VR9205R Connected to Manometer 1.Turn OFF gas to furnace at the manual gas shutoff valve Manometer external to the furnace. Measuring Inlet Gas Pressure (Alt. Method) 2.Connect a calibrated water manometer (or appropriate Figure 51 gas pressure gauge) at either the gas valve inlet pressure tap or the gas piping drip leg. See Honeywell G AS M ANIFOLD P RESSURE M EASUREMENT VR9205R gas valve figure for location of inlet pressure tap. CAUTION T OPREVENTUNRELIABLEOPERATIONOREQUIPMENTDAMAGE,THE NOTE: If measuring gas pressure at the drip leg or Honeywell VR9205R gas valve, a field-supplied hose barb fitting must be INLETGASSUPPLYPRESSUREMUSTBEASSPECIFIEDONTHEUNIT installed prior to making the hose connection. RATINGPLATEWITHALLOTHERHOUSEHOLDGASFIREDAPPLIANCES OPERATING. 3.Turn ON the gas supply, check for leaks and operate the furnace and all other gas consuming appliances on the same gas supply line.The manifold pressure must be measured with the burners operating. To measure the manifold pressure, use the fol- NOTE:To bring furnace up to High Fire, see lowing procedure: instructions for field test mode in GAS MANIFOLD 1.Turn OFF gas to furnace at the manual gas shutoff valve PRESSURE MEASUREMENT section. external to the furnace. 2.Turn off all electrical power to the system. 4.Measure furnace gas supply pressure with burners firing. Supply pressure must be within the range specified in 3.Outlet pressure tap connections: Remove the outlet the Inlet Gas Supply Pressure table. pressure tap plug. Install an 1/8" NPT hose barb fitting into the outlet pressure tap. Refer to gas valve Inlet Gas Supply Pressure diagram on preceding page. Natural GasMinimum: 4.5" w.c.Maximum: 10.0" w.c. 4.Attach a hose and manometer to the outlet pressure Propane GasMinimum: 11.0" w.c.Maximum: 13.0" w.c. barb fitting. If supply pressure differs from table, make the necessary ad- 5.Turn ON the gas supply. justments to pressure regulator, gas piping size, etc., and/or consult with local gas utility. contacts to provide a call for low stage heat. 5.Turn OFF gas to furnace at the manual shutoff valve 7.Modulating furnaces light at 80% of max input. For and disconnect manometer. Reinstall threaded plug natural gas, the expected manifold pressure at before turning on gas to furnace. 6.Turn OFF any unnecessary gas appliances stated in step 3. NOTE: Measure the gas manifold pressure with the burners firing. After every time the main power is turned off and back on, the furnace will enter a calibration routine on the next call for heat The inducer will ramp up and down during the calibration routine. After calibration, the furnace will proceed to ignition cycle. 42 8.Field Test Mode is intended to help a service person 3.If the 1/2 cu. ft. dial was used, multiply your troubleshoot and check out an installed appliance number x 2. by bringing the furnace up to High fire (100% input), EXAMPLE: If it took 23 seconds to complete by-passing the normal modulating routing. one revolution of the 1/2 ft. dial. To enter Field Test Mode the Fault Recall Push- This tells us that at this rate, it would take 46 Button must be pressed twice within a 5 second seconds to consume one cu. ft. of gas. 23 x 2 = period at any time during a heating cycle, at which seonds per cu. ft. 3600 (secs in 1 hour) / 46 = 78 Recall Push-Button for 3 seconds will enable the field This tells us that in one hour, the furnace would test mode and override the normal firing rate consume 78 cu. ft. of gas. sequence at a rate of 100% for 5 minutes or until the end of the call for heat. The display will show The typical caloric range for 1 cu. ft. of natural gas is around 1000 BTU. Check with your gas utility, if If the Fault Recall Push-Button has not been pressed possible. In this example, the furnace is consum- ing 78,000 BTUH. revert back to normal. NOTE: The final manifold pressure cannot NOTE: Gas valve is factory set and does NOT require for Natural and any field adjustment. Do NOT attempt to adjust from the specified setting. valve. Consult your local gas supplier if additional 9.Turn off all electrical power and gas supply to the input rate adjustment is required. system. 4.Turn ON gas to and relight all other appliances 10.Remove the manometer hose from the hose barb fitting. turned off in step 1. Be certain that all 11.Remove the 1/8" NPT hose barb fitting from the outlet appliances are functioning properly and that all pressure tap. Replace the outlet pressure tap plug and pilot burners are operating. seal with a high quality thread sealer. T EMPERATURE R ISE 12.Turn on electrical power and gas supply to the system. Temperature rise must be within the range speci- energize the valve. fied on the unit rating plate. An incorrect tempera- ture rise may result in condensing in or overheat- Using an approved liquid gas leak detector solution, check ing of the heat exchanger. An airflow and tempera- for leaks at outlet pressure tap plug. Bubbles forming indi- ture rise table is provided in the Specification Sheet cate a leak. SHUT OFF GAS AND REPAIR ALL LEAKS IMMEDI- applicable to your model. Determine and adjust ATELY! temperature rise as follows: 1.Operate furnace with burners firing for Manifold Gas Pressure approximately ten minutes. Ensure all registers are open and all duct dampers are GasRangeNominal in their final (fully or partially open) position. NaturalHigh Stage3.2 - 3.8" w.c.3.5" w.c. 2.Place thermometers in the return and supply PropaneHigh Stage9.5 - 10.5" w.c.10.0" w.c. ducts as close to the furnace as possible. Thermometers must not be influenced by G AS I NPUT R ATE M EASUREMENT (N ATURAL G AS O NLY) exchanger. The actual gas input rate to the furnace must never be greater 3.Subtract the return air temperature from the than that specified on the unit rating plate. To measure natu- supply air temperature to determine the air ral gas input using the gas meter, use the following proce- temperature rise. Allow adequate time for dure. thermometer readings to stabilize. 1.Turn OFF the gas supply to all other gas-burning appliances except the furnace. 4.Adjust temperature rise by adjusting the 2.While the furnace is operating at high fire rate, time circulator blower speed. Increase blower and record one complete revolution of the gas meter speed to reduce temperature rise. Decrease dial measuring the smallest quantity, usually the blower speed to increase temperature rise. dial that indicates 1/2 cu. ft. per revolution. You Refer to Startup Procedure and Adjustment - will use this number to calculate the quantity of Circulator Blower Speeds for speed changing gas in cubic ft. if the furnace would consume if it details. ran steadily for one hour (3600 seconds). 43 Use the dual 7-segment LED display adjacent to the DIP switches TEMPERATURE RISE to obtain the approximate airflow quantity. The airflow quan- ModelHI / LO tity is displayed as a number on the display, rounded to the nearest 100 CFM. The display alternates airflow delivery indi- *MVM970603BNAA20-50/25-55 cation and the operating mode indication. *MVM970803BNAA30-60/25-55 Example: The airflow being delivered is 1225 CFM. The *MVM970804CNAA25-55/25-55 display indicates 12. If the airflow being delivered is 1275, *MVM971005CNAA35-65/25-55 the display indicates 13. 1.Determine the tonnage of the cooling system installed *MVM971205DNAA35-65/30-60 with the furnace. If the cooling capacity is in BTU/hr *CVM970603BNAA35-65/30-60 divide it by 12,000 to convert capacity to TONs. *CVM970803BNAA35-65/35-65 Example:Cooling Capacity of 30,000 BTU/hr. 30,000/12,000 = 2.5 Tons *CVM970804CNAA35-65/35-65 2.Determine the proper air flow for the cooling system. *CVM971005CNAA35-65/30-60 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 SUPPLY AIR checked for required air flow. Any electronic air cleaners or other devices may require specific quantity of air, consult installation instructions of those devices for requirements. 3.Knowing the furnace model, locate the high stage cooling air flow table. Look up the cooling air flow determined in step 2 and find the required cooling speed and adjustment setting. Example:A DM97MC0603BN** furnace installed with a 2.5 ton air conditioning system. The air RETURN flow needed is 1000 CFM. Looking at the AIR cooling speed chart for DM97MC0603BN**, find the air flow closest to 1000 CFM. A Temperature Rise Measurement cooling airflow of 1000 CFM can be Figure 52 attained by selecting the cooling speed C IRCULATOR B LOWER S PEEDS WARNING T OAVOIDPERSONALINJURYORDEATHDUETOELECTRICALSHOCK, TURN OFF POWERTOTHEFURNACEBEFORECHANGINGSPEEDTAPS. This furnace is equipped with an ECM circulator blower. The blower speed setting is adjusted by the installer to match the installation require- ments so as to provide the correct heating temperature rise and correct cooling CFM. 44 Profile A provides only an OFF delay of one (1) minute at Low100%Low heat High Stage 100% of the cooling demand airflow. ModelTapStageHeatCFM for Cool Cool*CFM2 stage A 398599953667 100% CFM100% CFM OFFOFF B 5578171059740 *MVM970603BN* C 69610071158808 1 min D 81012121260881 A 4036291202855 B 5408061316923 Figure 53A *MVM970803BN* C 705102313891033 D 819123013961063 Profile B ramps up to full cooling demand airflow by A 5137891228867 first stepping up to 50% of the full demand for 30 B 6609671337939 *MVM970804CN* C 791118214301016 seconds. The motor then ramps to 100% of the required D 913137515161077 airflow. A one (1) minute OFF delay at 100% of the A 56482018181256 cooling airflow is provided. B 784113318701292 *MVM971005CN* C 982146419101316 D 1259173619571358 100% CFM 100% CFM A 54786718911329 50% CFM OFF B 831116019401362 OFF *MVM971205DN* 1/2 min1 min C 1020146719681390 D 1278191020281440 A 433656938687 B 541790950751 *CVM970603BN C 686972986814 Figure 53B D 8061195992874 A4056241057758 Profile C ramps up to 85% of the full cooling demand B5498081146815 *CVM970803BN airflow and operates there for approximately 7 1/2 C6789941256882 minutes. The otor then steps up to the full demand D78411771349946 5568371234889 A airflow. Profile C also has a one (1) minute 100% OFF B 71410221325944 delay. *CVM970804CN* C 838120614421019 D 991147515281068 100% CFM A 52478417591209 OFF OFF B 744107817971249 *CVM971005CN* C 927138818401277 D 1185176618811300 *100% CFM shown. CFM will vary proportionally with the gas valve BTU/H input. Figure 53C Profile D ramps up to 50% of the demand for 1/2 minute, 4.Continuous fan speed is selectable at 25%, 50%, 75% then ramps to 85% of the full cooling demand airflow or 100% of and operates there for approximately 7 1/2 minutes. Example: The motor then steps up to the full demand airflow. is 2000 CFM, the continuous fan speed at Profile D has a 1/2 minute at 50% airflow OFF delay. 25% will be 0.25 x 2000 or 500 CFM. 5.Locate the blower speed selection DIP switches on the OFF OFF speed tap by positioning switches 1 and 2 appropriately. 9 and 10 appropriately. Refer to the DIP switch chart for switch positions and their corresponding taps. Verify Figure 53D Airflow Tables CFM by noting the number displayed on the dual 7- segment LED display. 7.Select the heating speed for your model from the heating 6.The multi-speed circulator blower also offers several speed table in this manual. custom ON/OFF ramping profiles for cooling. These (already established by the cooling speed selection) profiles may be used to enhance cooling performance determines which set of speeds are available. The and increase comfort level. The ramping profiles selected speed must provide a temperature rise within are selected using DIP switches 7 and 8. Refer to the rise range listed with the particular model. the bullet points below for a description of each ramping profile. Verify CFM by noting the number switches 3 and 4 appropriately. Refer to the airflow displayed on the dual 7-segment LED display. table. Verify CFM by noting the number displayed on the dual 7-segment LED display. 45 In general, lower heating speeds will reduce electrical consump- Two-way digital communications is accomplished using only two tion, lower operating sound levels of the blower, and increase the wires. The thermostat and subsystem controls are powered with outlet air temperature delivered to the home. The speeds avail- 24 VAC. Thus, a maximum of 4 wires between the equipment able allow the blower performance to be optimized for the par- and thermostat is all that is required to operate the system. ticular needs of the installation. A IRFLOW C ONSIDERATIONS B LOWER H EAT O FF D ELAY T IMINGS A irflow demands are managed differently in a communi- The integrated control module provides a selectable heat offcating system than they are in a non-communicating wired delay function. The heat off delay period may be set to 90,system. The system operating mode (as determined by 120, 150, 180 seconds using the DIP switches or jumper pro-the thermostat) determines which unit calculates the sys- vided on the control module. The delay is factory shipped attem airflow demand. If the furnace is responsible for 150 seconds but may be changed to suit the installation re-determining the airflow demand, it calculates the demand quirements and/or homeowner preference. Refer to the DIPand sends it to the ECM motor. If the outdoor unit or switch chart in the back section of this manual for switchthermostat is responsible for determining the demand, it positions and corresponding delay times.calculates the demand and transmits the demand along with a fan request to the indoor unit. The furnace then C OMFORT N ET™ S YSTEM sends the demand to the ECM motor. The following table lists the various ComfortNet systems, the operating O VERVIEW mode, and airflow demand source. NOTE: DIP switch #13 MUST be set to match thermostat System Operating SystemAirflow Demand Source type. To use the CTK01 communicating thermostat, DIP Mode switch #13 must be set to ON position. This is also the CoolingAir Conditioner correct setting for a non-communicating 2-stage thermo- stat. To use the CTK02**, CTK03** or CTK04** modulating Air Conditioner + thermostat, check to make sure DIP switch #13 is in the HeatingFurnace Furnace OFF position (factory position). This is also the correct position when using a non-communicating single stage Continuous FanThermostat thermostat. The ComfortNet system is a system that includes a ComfortNet CoolingHeat Pump compatible furnace and air conditioner or heat pump with a Heat Pump Heating CTK0* thermostat. A valid ComfortNet system could also be a Heat Pump Only Heat Pump + compatible furnace, CTK0* thermostat and non-compatible, Furnace single stage air conditioner. Any other system configurations Auxiliary HeatingFurnace are considered invalid ComfortNet systems and must be con- nected as a traditional (or non-communicating) system (see Continuous FanThermostat Electrical Connections for wiring connections). A ComfortNet heating/air conditioning system differs from a CoolingFurnace non-communicating/traditional system in the manner in which Furnace + Non- the indoor unit, outdoor unit and thermostat interact with Comm 1stg Air HeatingFurnace one another. In a traditional system, the thermostat sends Conditioner commands to the indoor and outdoor units via analog 24 VAC Continuous FanThermostat signals. It is a one-way communication path in that the in- door and outdoor units typically do not return information to For example, assume the system is an air conditioner the thermostat. matched with a furnace. With a call for low stage cool- The indoor unit, outdoor unit and thermostat comprising a stage cooling airflow demand. The air conditioner will creating a two-way communications path. The thermostat then send a fan request along with the low stage cooling still sends commands to the indoor and outdoor units. How- airflow demand to the furnace. Once received, the fur- ever, the thermostat may also request and receive informa- nace will send the low stage cooling airflow demand to tion from both the indoor and outdoor units. This information the ECM motor. The ECM motor then delivers the low may be displayed on the ComfortNet thermostat. The indoor stage cooling airflow. See the applicable ComfortNet air and outdoor units also interact with one another. The out- conditioner or heat pump installation manual for the air- door unit may send commands to or request information from flow delivered during cooling or heat pump heating. the indoor unit. This two-way digital communications be- tween the thermostat and subsystems (indoor/outdoor unit) is the key to unlocking the benefits and features of the ComfortNet system. 46 In continuous fan mode, the CTK0* thermostat provides2, are needed between the indoor and outdoor units. A 40VA, the airflow demand. The thermostat may be configured208/230 VAC to 24VAC transformer must be installed in the out- for one of three continuous fan speed settings allow for control. The transformer is included in selected communicat- airflow capability. During continuous fan operation, theing thermostat kits. See kit instructions for mounting and wir- thermostat sends a fan request along with the continuousing instructions. Four wires are required between the indoor fan demand to the furnace. The furnace, in turn, sendsunit and thermostat. If using a communicating thermostat the demand to the ECM motor. The ECM motor deliverskit that does not include a transformer in a dual fuel system, the requested continuous fan airflow. The control boardthe accessory transformer kit TFK01 should be used. also has the capability of providing constant fan by supply- NOTE: Use of the accessory transformer is recommended if ing 24 VAC input to G terminal while using a communicat- installing a dual fuel/fossil fuel system. Failure to use the ing thermostat (CTK0*). This will allow the furnace fan to transformer in the outdoor unit could result in over loading of support ERV/HRV and other accessories while using a the furnace transformer. communicating thermostat. The continuous fan speed can be adjusted on switch bank S5, DIP switch 3 & 4. Connec- C OMFORT N ET™ C OMPATIBLE F URNACEWITH N ON-C OMFORT N ET tion to the G terminal can be made by using two four pin COMPATIBLE S INGLE-S TAGE A IR C ONDITIONER terminal blocks (similar to using a Y1 input) or by using the 9 pin connector that ships on the control board. Remove Four wires are required between the furnace and thermostat. the red keying tabs from the on-board connector block to Two wires are required between the furnace control and single use either method. terminal on the integrated furnace control becomes an output rather than an input. F OSSIL F UEL A PPLICATIONS unit is made using both of the 4-position thermostat connec- This furnace can be used in conjunction with a tors in the CTK0* kit. Remove the red keying tabs from the compatible heat pump in a fossil fuel application. A fossil on-board connector block and position both 4-position con- fuel application refers to a combined gas furnace and heat pump installation which uses an outdoor temperature sensor filled. to determine the most cost efficient means of heating (heat pump or gas furnace). The balance point temperature may C OMFORT N ET™ S YSTEM A DVANCED F EATURES be adjusted via the CTK0* thermostat advanced user menus (see CTK0* instructions for additional information). The ComfortNet system permits access to additional system in- formation, advanced setup features, and advanced diagnostic/ CTK0* W IRING troubleshooting features. These advanced features are orga- nized into a menu structure. The menus are accessed and navi- NOTE: Refer to Electrical Connections for 115 volt line connections gated as described in the instructions provided with the com- to the furnace. municating control. NOTE:A removable plug connector is provided with the control to make thermostat wire connections. This plug may A 24 VAC input may be applied to the G terminal of the modu- be removed, wire connections made to the plug, and replaced. lating furnace control board to operate the indoor blower to It is strongly recommended that multiple wires into a single support and HRV/ERV. The 24 VAC source must originate from terminal be twisted together prior to inserting into the plug the R terminal of furnace. connector. Failure to do so may result in intermittent operation. Typical 18 AWG thermostat wire may be used to wire the system components. One hundred (100) feet is the maximum CTK0* Thermostat length of wire between indoor unit and outdoor unit, or be- 12RC tween indoor unit and thermostat. Wire runs over (100) 4-Pin (X2), 7 Pin, or 9 Pin Connector feet require larger gauge wire. Furnace Integrated F OUR-W IRE I NDOORAND O UTDOOR W IRING 12RCG W1W2Y1Y2ODEHUM Control Module Typical wiring will consist of four wires be- 24 vac "G" input to Furnace Integrated Control module From tween the indoor unit and outdoor unit and between the in- ERV / HRV or Similar Devices door unit and thermostat. The required wires are: (a) data Diagram 1 VAC common). T WO-W IRE O UTDOOR, F OUR-W IRE I NDOOR W IRING As few as two wires can be utilized between the indoor and outdoor units. For this wiring scheme, only the data lines, 1 and 47 DIP S WITCHES ------ ON ------------ ON ------------------ ON ------------------------ OFF --------------- OFF ------------------ OFF ------------------------ OFFON ------------------------------ DIP SwitchOFFOFF ------------------------------------ OFFOFF * or CTK02, CTK03, CTK04** or CTK01 ------------------------------------------ ONOFF ------------------------------------------------ ONOFF 123456789101112131415161718 ------------------------------------------------------------------------------ON ONON age AOFFOFF------------------------------------------------BONOFF------------------------------------------------COFFON------------------------------------------------DA------OFFOFF---------------------- --------------------B------C------OFFON------------------------------------------D------ONON------------------------------------------A------------OFFOFF------------------------------------B--------- ---C------------OFFON------------------------------------D------------ONON------------------------------------A------------------B------------------ONOFF------------------------------C--------------- ---OFFON------------------------------D------------------ONON------------------------------ tage SSt -- 12 Enabled------------------------------------------ONEnabled---------------------------------------------Enabled------------------------------------------------Enabled---------------------------------- ----------------- Plus 10%------------------------ONOFF------------------------Disabled------------------------------------------Disabled---------------------------------------------OFFDisabled------------------------ ------------------------OFFDisabled---------------------------------------------------OFF Minus 10%------------------------OFFON------------------------ 90 Seconds------------------------------OFFOFF------------------ CompressorCompressor 120 Seconds------------------------------ONOFF------------------150 Seconds------------------------------180 Seconds------------------------------ONON------------------ 1 Stage Stat*------------------------------------ 0 Trim Adjust------------------------0 Trim Adjust------------------------ONON------------------------2 Stage Stat**------------------------------------ON--------------- Fan TapTapBias Taps Delay SpeedSpeed AdjustDehum Pull Up Cooling Cooling Heating PurposeFunction Ramping Heat Off Pull Down Speed Tap ContinuousT-Stat Heat Compressor Not applicable(Indicates factory setting) 123 --- Bank Switch Communicating thermostats are used only with Bias, Pull Up, Pull Down dip switches. 48 CTK0* CTKO* 1 & 2 12RC Thermostat Thermostat 12RC ComfortNet Compatible ComfortNet Compatible Furnace 12RC Furnace Integrated 12RC Integrated Control Module Control Module 40VA Transformer ComfortNet Compatible (included in CTK01 kit) RC 12 AC/HP Integrated ComfortNet Compatible AC/HP Control Module 12RC Integrated Control Module 24 VAC 208/230 VAC System Wiring using Four-Wires System Wiring using Two-Wires between Furnace and AC/HP and Four-Wires between Furnace and Thermostat CTK0* 4-Position Connectors Thermostat from CTK0* Thermostat Kit 12RC ComfortNet Compatible W1W2Y1Y2 O Furnace Integrated 12RCG Control Module Non- CompatibleComfortNet CY Single Stage AC System Wiring between Furnace and Non- Communicating Compatible Single Stage Air Conditioner D IAGNOSTICS data 1 line is approximately 2.8 VDC and the data 2 trans- mission line is approximately 2.2 VDC. The voltage differ- ence between data 1 and data 2 must be 0.6 VDC. cess to the last ten faults detected by the furnace. Faults are stored most recent to least recent. Any consecutively repeated fault is stored a maximum of three times. Ex- thus, constitutes a network. Occasionally the need to trouble- ample: A clogged return air filter causes the furnace limit to shoot the network may arise. The furnace control board has trip repeatedly. The control will only store this fault the some on-board tools that may be used to troubleshoot the net- first three consecutive times the fault occurs. work. These tools are: red communications LED, green receive (Rx) LED, and learn button. NOTE: It is highly recommended that the fault history be cleared when performing maintenance or servicing the fur- nace.the network. The following table indicates the LED status and the corresponding potential problem. N ETWORKTROUBLESHOOTING The indoor control is equipped with a bank of three DIP table below indicates the LED status and the switches that provide biasing and termination functions for corresponding potential problem. the communications transmission lines. The outdoor con- trol in the communicating compatible unit is equipped with the button for approximately 2 seconds to reset the a bank of two DIP switches that provide termination func- network. tions for the communications transmission lines. Commu- nications errors will result if these switches are not cor- rectly set. Note that the ON position is the correct position for furnace control board bias and pull up/pull down DIP switches. Communications is achieved by the difference between two DC signals. The signals and transmission 49 LEDLED StatusIndicationPossible CausesCorrective Action(s)Notes & Cautions None Red Control power up None Communications LED Learn button depressed None network as expected Data 1/ Data 2 miss- Data 1 and data 2 wires reversedCheck communicationsTurn power OFF prior to wire at furnace, thermostat or wiring (data 1/ data 2 repair. communicating compatible wires). outdoor AC/HP Green Short between data 1 andCheck wire connections at Verify wires at terminal Receive data 2 wires. terminal block blocks are securely twisted LED together prior to inserting into terminal block. Short between data 1 orCheck data 1/ data 2Verify data 1 and data data 2 wires and R voltages. voltages as described above (24VAC) or C (24VAC common). S YSTEM T ROUBLESHOOTING N ORMAL S EQUENCEOF O PERATION NOTE: Refer to the instructions accompanying the ComfortNet P OWER U P compatible outdoor AC/HP unit for troubleshooting information. The normal power up sequence is as follows: Refer to the Troubleshooting Codes for a listing of possible 115 VAC power applied to furnace. furnace error codes, possible causes and corrective actions. Integrated control module performs internal checks. F AULT R ECALL S EQUENCE Integrated control module monitors safety circuits continuously. showing ON. Furnace awaits call from thermostat. Dual 7-segment display is blank) and then release.P while awaiting call from thermostat. H EATING M ODE displaying faults stored in history. The normal operational sequence in heating mode is as fol- to least recent. lows: Thermostat contacts close, initiating a call for heat. type will be logged. Integrated control module performs safety circuit checks. screen for 1 second in between. Induced draft blower is energized on high speed for a 15-second prepurge. returns to ON. Induced draft blower steps to low speed following F AULT C LEAR S EQUENCE: prepurge. Low stage pressure switch contacts are closed. showing ON. 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. and display returns to ON. Integrated control module monitors flame presence. Gas valve will remain open only if flame is detected. the display will return to ON and the faults will not be cleared. 50 The percentage of heating demand is sent from theFurnace circulator blower and outdoor cooling unit run their furnace control board to determine what RPM theappropriate speeds, integrated control module monitors draft inducer should run at. A higher percentagesafety circuits continuously. demand will drive the inducer RPM higher. This will R and Y1/G or Y2/G thermostat contacts open, cause the gas valve to modulate higher. The burner completing the call for cool. will modulate based on the inducer speed Outdoor fan and compressor are de-energized. Circulator blower is energized on heat speed following Circulator blower continues running during a cool off a thirty (30) second blower on delay. The circulator delay period. The OFF delay time and airflow level are blower CFM will increase or decrease with gas valve determined by the selected ramping profile. modulation. Electronic air cleaner terminal is energized with circulator blower. are de-energized. Furnace is now operating on the specified stage called Furnace awaits next call from thermostat. for by the thermostat. Furnace runs, integrated control module monitors safety F AN O NLY M ODE circuits continuously. The normal operational sequence in fan only mode is as fol- If the two-stage thermostat changes the call from low lows: heat to high heat, the integrated control module will R and G thermostat contacts close, initiating a call for immediately switch the induced draft blower, gas valve, fan. and circulator blower to their high stage settings. Integrated control module performs safety circuit The thermostat contacts open, completing the call for checks. heat. Circulator blower is energized on continuous fan speed Gas valve closes, extinguishing flame. (25%, 50%, 75% or 100% DIP switch selectable when Induced draft blower is de-energized following a fifteen using a conventional thermostat). Electronic air second post purge. Humidifier contacts open. cleaner terminal is energized. Circulator blower continues running for the selected The furnace control board HUM dry contacts close. heat off delay period (90, 120, 150 or 180 seconds). Circulator blower runs, integrated control module The speed run during this period depends on the last monitors safety circuits continuously. heat call provided by the thermostat. R and G thermostat contacts open, completing the call If the last call for heat was a call for high heat, the air for fan. circulating motor will run on the high heating speed for Circulator blower is de-energized. Electronic air cleaner thirty (30) seconds and then switch to the low heating speed for the balance of the heat off delay period (60, terminal is de-energized. 90, 120 or 150 seconds). Furnace awaits next call from thermostat. Circulator blower and electronic air cleaner terminal is de-energized. O PERATIONAL C HECKS Circulator blower ramps down to OFF during the 30 The burner flames should be inspected with the burner com- seconds following the heat off delay period. partment door installed. Flames should be stable, quiet, soft, Furnace awaits next call from thermostat. and blue (dust may cause orange tips but they must not be yellow). Flames should extend directly outward from the burn- C OOLING M ODE ers without curling, floating, or lifting off. Flames must not impinge on the sides of the heat exchanger firing tubes. The normal operational sequence in cooling mode is as fol- lows: R and Y1/G or Y2/G thermostat contacts close, S AFETY C IRCUIT D ESCRIPTION initiating a call for cool. A number of safety circuits are employed to ensure safe and Integrated control module performs safety circuit proper furnace operation. These circuits serve to control any checks. potential safety hazards and serve as inputs in the monitoring Outdoor fan and compressor are energized to their and diagnosis of abnormal function. These circuits are con- appropriate speed. tinuously monitored during furnace operation by the integrated Circulator blower is energized on the appropriate cool control module. speed at the level and time determined by the selected ramping profile. Electronic air cleaner terminal is energized with circulator blower. 51 F URNACE C ONTROL B OARD R and G thermostat contacts open, completing the call for fan. The furnace control board is an electronic device which, if a Circulator blower is de-energized. Electronic air cleaner potential safety concern is detected, will take the necessary precautions and provide diagnostic information through an terminal is de-energized. LED display. Furnace awaits next call from thermostat. P RIMARY L IMIT O PERATIONAL C HECKS The primary limit control is located on the partition panel and monitors heat exchanger compartment temperatures. It is a The burner flames should be inspected with the burner com- normally-closed (electrically), automatic reset, temperature- partment door installed. Flames should be stable, quiet, soft, activated sensor. The limit guards against overheating as a and blue (dust may cause orange tips but they must not be result of insufficient conditioned air passing over the heat yellow). Flames should extend directly outward from the burn- exchanger. ers without curling, floating, or lifting off. Flames must not impinge on the sides of the heat exchanger firing tubes. A UXILIARY L IMIT The auxiliary limit controls are located on or near the circula- tor blower and monitors blower compartment temperatures. They are a normally-closed (electrically), auto-reset sensors. These limits guard against overheating as a result of insuffi- Check the cient conditioned air passing over the heat exchanger. Burner Flames for: 1. Stable, soft and blue. R OLLOUT L IMIT 2. Not curling, floating or lifting off. The rollout limit controls are mounted on the burner/mani- fold assembly and monitor the burner flame. They are nor- mally-closed (electrically), manual-reset sensors. These lim- Burner Flame its guard against burner flames not being properly drawn into Figure 54 the heat exchanger. S AFETY C IRCUIT D ESCRIPTION Furnace circulator blower and outdoor cooling unit run their appropriate speeds, integrated control module A number of safety circuits are employed to ensure safe and monitors safety circuits continuously. proper furnace operation. These circuits serve to control any R and Y1/G or Y2/G thermostat contacts open, potential safety hazards and serve as inputs in the monitoring completing the call for cool. and diagnosis of abnormal function. These circuits are con- Outdoor fan and compressor are de-energized. tinuously monitored during furnace operation by the integrated control module. Circulator blower continues running during a cool off delay period. The OFF delay time and airflow level are F URNACE C ONTROL B OARD determined by the selected ramping profile. The furnace control board is an electronic device which, if a potential safety concern is detected, will take the necessary are de-energized. precautions and provide diagnostic information through an Furnace awaits next call from thermostat. LED display. P RIMARY L IMIT F AN O NLY M ODE The primary limit control is located on the partition panel and The normal operational sequence in fan only mode is as fol- monitors heat exchanger compartment temperatures. It is a lows: normally-closed (electrically), automatic reset, temperature- R and G thermostat contacts close, initiating a call for activated sensor. The limit guards against overheating as a fan. result of insufficient conditioned air passing over the heat Integrated control module performs safety circuit exchanger. checks. A UXILIARY L IMIT Circulator blower is energized on continuous fan speed The auxiliary limit controls are located on or near the circula- (25%, 50%, 75% or 100% DIP switch selectable when tor blower and monitors blower compartment temperatures. using a conventional thermostat). Electronic air They are a normally-closed (electrically), auto-reset sensors. cleaner terminal is energized. These limits guard against overheating as a result of insuffi- The furnace control board HUM dry contacts close. cient conditioned air passing over the heat exchanger. Circulator blower runs, integrated control module monitors safety circuits continuously. 52 R OLLOUT L IMIT D IAGNOSTIC C HART The rollout limit controls are mounted on the burner/manifold assembly and monitor the burner flame. They are normally- WARNING closed (electrically), manual-reset sensors. These limits guard against burner flames not being properly drawn into the heat HIGH VOLTAGE ! exchanger. T OAVOIDPERSONALINJURYORDEATHDUETO ELECTRICALSHOCK,DISCONNECTELECTRICALPOWER P RESSURE S WITCHES BEFORE PERFORMINGANYSERVICEORMAINTENANCE. The pressure switches are normally-open (closed during opera- tion) negative air pressure-activated switches. They monitor Refer to the Troubleshooting Codes for assistance in deter- the airflow (combustion air and flue products) through the heat mining the source of unit operational problems. The dual 7- exchanger via pressure taps located on the induced draft blower segment LED display will display an error code that may con- and the coil front cover. These switches guard against insuffi- tain a letter and number. The error code may be used to assist cient airflow (combustion air and flue products) through the heat in troubleshooting the unit. exchanger and/or blocked condensate drain conditions. F LAME S ENSOR R ESETTING F ROM L OCKOUT The flame sensor is a probe mounted to the burner/manifold Furnace lockout results when a furnace is unable to achieve assembly which uses the principle of flame rectification to ignition after three attempts during a single call for heat. It determine the presence or absence of flame. is characterized by a non-functioning furnace and a E0 code displayed on the dual 7-segment display. If the furnace is in T ROUBLESHOOTING ways. E LECTROSTATIC D ISCHARGE (ESD) P RECAUTIONS 1.Automatic reset. The integrated control module will NOTE: automatically reset itself and attempt to resume normal An electrostatic discharge can adversely affect electrical operations following a one hour lockout period. components. 2.Manual power interruption. Interrupt 115 volt power Use the following precautions during furnace installation and to the furnace. servicing to protect the integrated control module from dam- 3.Manual thermostat cycle. Lower the thermostat so age. By putting the furnace, the control, and the person at that there is no longer a call for heat for 1 -20 seconds the same electrostatic potential, these steps will help avoid then reset to previous setting. exposing the integrated control module to electrostatic dis- charge. This procedure is applicable to both installed and NOTE: If the condition which originally caused the lockout uninstalled (ungrounded) furnaces. still exists, the control will return to lockout. Refer to the 1.Disconnect all power to the furnace. Do not touch the Troubleshooting Codes for aid in determining the cause. integrated control module or any wire connected to charge to ground. 2.Firmly touch a clean, unpainted, metal surface of the furnace away from the control. Any tools held in a 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. 53 F ILTER R EMOVAL M AINTENANCE Depending on the installation, differing filter arrangements can WARNING be applied. Filters can be installed in either the central return T OAVOIDELECTRICALSHOCK,INJURYORDEATH,register or a side panel external filter rack (upflow only). A me- dia air filter or electronic air cleaner can be used as an alternate DISCONNECTELECTRICALPOWERBEFOREPERFORMINGANY filter. Follow the filter sizes given in the Recommended Mini- MAINTENANCE. I FYOUMUSTHANDLETHEIGNITER, mum Filter size table to ensure proper unit performance. HANDLEWITHCARE. T OUCHINGTHEIGNITERELEMENT WITHBAREFINGERS,ROUGHHANDLINGORVIBRATION To remove filters from an external filter rack in an upright upflow COULDDAMAGETHEIGNITERRESULTINGINPREMATURE installation, follow the directions provided with external filter FAILURE. O NLYAQUALIFIEDSERVICERSHOULDEVER rack kit. HANDLETHEIGNITER. H ORIZONTAL U NIT F ILTER R EMOVAL A NNUAL I NSPECTION Filters in horizontal installations are located in the central The furnace should be inspected by a qualified installer, or return register or the ductwork near the furnace. service agency at least once per year. This check should be To remove: performed at the beginning of the heating season. This will 1.Turn OFF electrical power to furnace. ensure that all furnace components are in proper working 2.Remove filter(s) from the central return register or order and that the heating system functions appropriately. ductwork. Pay particular attention to the following items. Repair or 3.Replace filter(s) by reversing the procedure for removal. service as necessary. 4.Turn ON electrical power to furnace. Check the outside termination and the connections M EDIA A IR F ILTEROR E LECTRONIC A IR C LEANER R EMOVAL at and internal to the furnace. within the heat exchanger passageways. B URNERS and flame signal. Visually inspect the burner flames periodically during the heat- ing season. Turn on the furnace at the thermostat and allow Check hose connections at and internal to furnace.several minutes for flames to stabilize, since any dislodged dust will alter the flames normal appearance. Flames should be stable, quiet, soft, and blue (dust may cause orange tips and/or corrosion. Check wires for damage. but they must not be yellow). They should extend directly outward from the burners without curling, floating, or lifting level after 2 off. Flames must not impinge on the sides of the heat ex- 5 minutes of run time. changer firing tubes. F ILTERS I NDUCED D RAFTAND C IRCULATOR B LOWERS CAUTION The bearings in the induced draft blower and circulator blower motors are permanently lubricated by the manufacturer. No T OENSUREPROPERUNITPERFORMANCE,ADHERETOTHEFILTERSIZES further lubrication is required. Check openings on motor GIVENINTHERECOMMENDED M INIMUM F ILTER S IZE T ABLEOR housing for accumulation of dust which may cause overheat- PECIFICATION S HEETAPPLICABLETOYOURMODEL. S ing. Clean as necessary. C ONDENSATE T RAPAND D RAIN S YSTEM (Q UALIFIED S ERVICER F ILTER M AINTENANCE O NLY) Improper filter maintenance is the most common cause of Annually inspect the drain tubes, drain trap, and field-sup- inadequate heating or cooling performance. Filters should be plied drain line for proper condensate drainage. Check drain cleaned (permanent) or replaced (disposable) every two months system for hose connection tightness, blockage, and leaks. or as required. When replacing a filter, it must be replaced Clean or repair as necessary. with a filter of the same type and size. 54 F LAME S ENSOR (Q UALIFIED S ERVICER O NLY) R EPAIRAND R EPLACEMENT P ARTS When ordering any of the listed functional parts, be Under some conditions, the fuel or air supply can create a nearly sure to provide the furnace model, manufacturing, and invisible coating on the flame sensor. This coating acts as an serial numbers with the order. insulator causing a drop in the flame sense signal. If the flame sense signal drops too low the furnace will not sense flame and Although only functional parts are shown in the parts will lock out. The flame sensor should be carefully cleaned by a list, all sheet metal parts, doors, etc. may be ordered qualified servicer using emery cloth or steel wool. Following by description. cleaning, the flame sense signal should be as indicated in the Parts are available from your distributor. Specifications Sheet. Functional Parts List- Gas ValveBlower Motor Gas ManifoldBlower Wheel B EFORE L EAVINGAN I NSTALLATION Natural Gas OrificeBlower Mounting Bracket Cycle the furnace with the thermostat at least three Propane Gas OrificeBlower Cutoff times. Verify cooling and fan only operation. IgniterBlower Housing Flame SensorInductor discuss proper furnace operation and maintenance. Rollout Limit SwitchHeat Exchanger with Primary Limit SwitchRecuperator Coil Leave literature packet near furnace. Auxiliary Limit SwitchCoil Front Cover Pressure SwitchIntegrated Control Module Induced Draft BlowerTransformer Door Switch 55 T ROUBLESHOOTING C ODES Turn power OFF prior to repair.Read precautions in “Electrostatic Discharge” section of manual.Replace integrated control module with current replacement parts.Turn power OFF prior to repair.Igniter is fragile, handle with care.Clean flame rod with steel wool.See “Vent/Flue Pipe” section for piping details.Turn power OFF prior to repair.Replace pressure switch with correct replacement part.Turn power OFF prior to repair.Replace pressure switch with correct replacement part.Replace induced draft blower with correct replacement part.Take care to assemble/install H fitting in factory configuration.Turn power OFF prior to repair.See Specification Sheet applicable to your model for allowable rise range and proper circulator speed. ••••••••••••••• Assure proper wiring to furnace and integrated control module.Verify power to the furnace and integrated control module is stable and within specifications.Replace bad integrated control module.Locate and correct gas interruption.Check front cover pressure switch operation (hose, wiring, contact operation). Correct if necessary. Make sure furnace is draining properly.Replace or realign igniter.Check flame sense signal. Sand sensor if coated and/or oxidized.Check flue piping for blockage, proper length, elbows, and termination.Verify proper induced draft blower performance.Replace low stage pressure switch.Repair short in wiring.Inspect pressure switch hose. Repair/replace if necessary.Inspect flue 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.Clean H fitting.Check filters and ductwork for blockage. Clean filters or remove obstruction.Check circulator blower speed and performance. Correct speed or replace blower motor if necessary.Tighten or correct wiring connection. ••••••••••••••••••••• Possible CausesCorrective ActionsNotes & Cautions Improper wiring to the furnace or integrated control module. Normal operation•None•Normal operationFailure to establish flame. Cause may be no gas to burners, front cover pressure switch stuck open, bad igniter or igniter alignment, improper orifices, or coated/oxidized or improperly connected flame sensor.Loss of flame after establishment. Cause may be interrupted gas supply, lazy burner flames (improper gas pressure or restriction in flue and/or combustion air piping), front cover pressure switch opening, or improper induced draft blower performance.Low stage pressure switch contacts sticking.Shorts in pressure switch circuit wiring.Pressure switch hose blocked pinched, or connected improperly.Blocked flue and/or inlet air pipe, blocked drain system or weak induced draft blower.Incorrect pressure switch set point or malfunctioning switch contacts.Loose or improperly connected wiring.Inducer not running.H fitting atmospheric port blocked.Insufficient conditioned air over the heat exchanger. Blocked filters, restrictive ductwork, improper circulator blower speed, or failed circulator blower motor.Loose or improperly connected wiring. ••••••••• E1• E2•E3• EE• ComfortNet PS1 PS1 HIGH LIMIT OPENOPEN Thermostat Only FAULT CLOSED MessageCode INTERNAL LOCKOUTE0• Fault Description control module has an internal faultdue to an excessive number of ignition “retries” or flame “recycles” (3 total).pressure switch circuit is closed at start ofheating cycle.pressure switch circuit is not closed. •Normal operationNoneNone •Integrated•Furnace lockout •Low stage •Low stage •Primary limit. IF E0E1E2E3 On & Status Diagnostic LED Codes n O error code.error code.error code. error code. E0 E1 E2 E3 (Non-communicating & ComfortNet™ Thermostat) Furnace fails to operateIntegrated control module LED display provides IF error code.ComfortNet thermostat “Call for Service” icon illuminatedComfortNet thermostat scrolls“Check Furnace” messageLED display indicates Furnace fails to operateIntegrated control module LEDdisplay provides ComfortNet thermostat “Call for Service” icon illuminated.ComfortNet thermostat scrolls“Check Furnace” message.Furnace fails to operate.Integrated control module LEDdisplay provides ComfortNet thermostat “Call for Service” icon illuminated.ComfortNet thermostat scrolls“Check Furnace” message.Induced draft blower runs continuously with no furtherfurnace operation.Integrated control module LEDdisplay provides ComfortNet thermostat “Call for Service” icon illuminated.ComfortNet thermostat scrolls“Check Furnace” message.Circulator blower runs continuously. No furnace operation.Integrated control module LEDdisplay provides ComfortNet thermostat “Call for Service” icon illuminated.ComfortNet thermostat scrolls “Check Furnace” message. • Symptoms of Abnormal Operation •••••••••••••••••••• 56 T ROUBLESHOOTING C ODES Turn power OFF prior to repair.Replace fuse with 3- amp automotive typeTurn power OFF prior to repair.Clean flame sensor with steel wool.See "Vent/Flue Pipe" section for piping details.See rating plate for proper gas pressure.Turn power OFF prior to repair.Replace pressure switch with correct replacement part.Replace control with correct replacement part. •Turn power OFF prior to repair.•Turn power OFF prior to repair.•Turn power OFF prior to repair.•••••••••• Correct short at flame sensor or in flame sensor wiring.Check for lingering flame.Verify proper operation of gasvalve. Replace if necessary.Reset system power and verifyinducer is running properly.Replace inducer or integratedcontrol module, if necessary.Line up orifice plate.Remove Blockage from heatexchanger.Line up burners.Check for flame disturbance onroll out when blower comes on.Install jumper.Inspect float switch.low voltage wiring.Clean flame sensor if coated/oxidized.Inspect for proper sensor alignment.Check inlet air piping for blockage, proper length, elbows, and termination.Compare current gas pressure to rating plate. Adjust as needed.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. ••••••••••••••••••• Possible CausesCorrective ActionsNotes & Cautions Short to ground in flame sense circuit.Lingering burner flame.Slow closing gas valve.Lingering Inducer motor overcurrent detected.Orifice plate out of position.Blocked heat exchanger.Burners out of alignment.Defective heat exchanger.Open circuit between aux in or aux out.Missing jumper.Open float switch.Flame sensor is coated/oxidized.Flame sensor incorrectly positioned in burner flame.Lazy burner flame due to improper gas pressure or combustion air.Improperly connected igniter.Shorted igniter.Poor unit ground.Igniter relay fault onintegrated control module. •Short in low voltage wiring•Locate and correct short in •••••••••••• d E4•Ed•Not E6•E7• EC•EF• Code Displaye e T R ER OR RY ComfortNet OPENWEAK FAULT FLAMEFLAME INDUCEINDUCET OPENAUXILIADisplayed MessagLOCKOUROLLOUIGNITER Thermostat OnlyIMPROPR FAULT n Fault Descriptio when it should not be present.overcurrent fault.rollout switch is open.input.micro ampsignal is low.igniter circuit. •Flame sensed •Inducer motor •Manual reset •Open auxiliary •Open Fuse.Not •Flame sense •Problem with i c E4EdEFE5E6E7 EC LED agnost & Status Di error code.error code.error code.error code. E4 Ed E5 E6 error code. thermostat "Callthermostat scolls E7 (Non-communicating & ComfortNet™ Thermostat) Induced draft blower and circulator blower runs continuously. Nofurnace operation.Integrated control module LEDdisplay provides ComfortNet thermostat “Call for Service” icon illuminated.ComfortNet thermostat scrolls“Check Furnace” message.Furnace fails to operateIntegrated control module LEDdisplay provides EC error code.ComfortNet thermostat “Call for Service” icon illuminated.ComfortNet thermostat scrolls“Check Furnace” message.No furnace operation.Integrated control module LEDdisplay provides No furnace operation.Integrated control module LEDdisplay provides Ef error code.No furnace operation.Integrated control module LEDdisplay provides ComfortNet thermostat displays “Battery Power”.Normal furnace operation.Integrated control module LEDdisplay provides Furnace fails to operate.Integrated control module LED display provides ComfortNetfor Service" icon illuminated.ComfortNet"Check Furnace" message. Symptoms of Abnormal Operation ••••••••••••••••••••• 57 T ROUBLESHOOTING C ODES Turn power OFF prior to repair.Replace pressure switch with correct replacement part.Turn power OFF prior to repair.Replace pressure switch with correct replacement part.Replace induced draft blower with correct replacement part.Turn power OFF prior to repair.Use memory card for the specific model.Insert memory card BEFORE turning power ON. Memory card may be removed after data is loaded.Turn power OFF before removing memory card.Error code will be cleared once data is loaded.Turn power OFF prior to repairUse memory card for the specific model.Insert memory card BEFORE turning power ON. Memory card may be removed after data is loaded.Turn power OFF before removing memory card.Error code will be cleared once data is loaded. ••••••Turn power OFF prior to repair.•••••••••• Replace high stage pressure switch.Repair short in wiringInspect pressure switch hose. Repair/replace if necessary.Inspect flue 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 ground. Correct if necessary.Check and correct wiring.memory card.Verify shared data set is correct for the specific model. Re-populatedata using correct memory card if required. •••••••••••Populate shared data set using • Possible CausesCorrective ActionsNotes & Cautions High stage pressure switch contacts sticking.Shorts in pressure switch circuit wiring.Pressure switch hose blocked pinched, or connected improperly.Blocked flue and/or inlet air pipe, blocked drain system or weak induced draft blower.Incorrect pressure switch set point or malfunctioning switch contacts.Loose or improperly connected wiring.Polarity of 115 volt AC power to furnace or integrated module is reversed.Reversed unit ground.Furnace does not contain any shared data.Shared data set on memory card has been rejected by integrated control module ••••• E8•E9•d0•d4• EA• ComfortNet PS2 PS2 PLTY DATADATA OPEN Thermostat Only NO NET CLOSED MessageCode REVERSED INVALID MC Fault Description High stage pressure switch circuit is closed at start ofheating cycle.Induced draft blower is operating.Furnace is operating onlow stage onlyHigh stage pressure switch circuit is not closed.Induced draft blower is operating.Furnace is operating onlow stage only115 volt AC is reversedon network.Invalid memory card data. •••••••Polarity of•Data not yet• E8E9d0d4 EA & Status Diagnostic LED Codes error code. error code.error code. error code.error code. E8 E9 EA d0 d4 (Non-communicating & ComfortNet™ Thermostat) Furnace fails to operate on highstage; furnace operates normally on low stage.Integrated control module LEDdisplay provides Furnace fails to operate on highstage; furnace operates normally on low stage.Integrated control module LEDdisplay provides Furnace fails to operate.Integrated control module LEDdisplay provides ComfortNet thermostat “Call for Service” icon illuminated.ComfortNet thermostat scrolls“Check Furnace” message.Furnace fails to operate.Integrated control module LEDdisplay provides ComfortNet thermostat “Call for Service” icon illuminated.ComfortNet thermostat scrolls“Check Furnace” message.Operation different than expected or no operation.Integrated control module LEDdisplay provides ComfortNet thermostat “Call for Service” icon illuminated.ComfortNet thermostat scrolls“Check Furnace” message. Symptoms of Abnormal Operation •••••••••••••••• 58 T ROUBLESHOOTING C ODES 59 T ROUBLESHOOTING C ODES Turn power OFF prior to repairReplace motor with correct replacement part.Replace wheel with correct replacement part.Turn power OFF prior to repair.Replace with correct replacement part(s).Use memory card for the specific model. ••••Turn power OFF prior to repair.••••Turn power OFF prior to repair. and for furnace "Product Description" Check circulator blower for obstructions. Remove and repair/replace wheel/motor if necessary.Check circulator blower motor shaft rotation and motor. Replace motor if necessary.Check power to furnace. Verify line voltage to furnace is within the range specified on the furnace rating plate.See "Location Requirements & Considerations" installation requirements.Check integrated control module.Verify control is populated withcorrect shared data set. See dataerrors above for details.Check for locked rotor condition(see error code above for details).Check filters for blockage. Clean filters or remove obstruction.Check ductwork for blockage. Remove obstruction. Verify all registers are fully open.Verify ductwork is appropriately sized for system. Resize/replace ductwork if necessary. ••••••••• Possible CausesCorrective ActionsNotes & Cautions Obstruction in circulator blower housing.Seized circulator blower motor bearings.Failed circulator blower motor.High AC line voltage to furnace.Low AC line voltage to furnace.High ambient temperatures.Error with integrated control module.Motor has a locked rotor condition.Blocked filters.Restrictive ductwork.Undersized ductwork. ••••••••••• b5b6b7b9 ComfortNet Thermostat Only VOLTS ROTORLOW ID MOTOR MOTOR MessageCodePARAMS AIRFLOW MTR LCKD Fault Description Circulator blower motor fails to start 10 consecutive times.Circulator blower motor shuts down for over or under voltage condition.Circulator blower motor shuts down due toover temperature condition on power module.Circulator blower motor does not have enough information to operate properly.Motor fails to start 40 consecutive times.Airflow is lower than demanded. •••••• b5b6b7b9 & Status Diagnostic LED Codes error code.error code.error code.error code. b5 b6 b7 b9 (Non-communicating & ComfortNet™ Thermostat) Furnace fails to operate.Integrated control module LEDdisplay provides ComfortNet thermostat “Call for Service” icon illuminated.ComfortNet thermostat scrolls“Check Furnace” message.Furnace fails to operate.Integrated control module LEDdisplay provides ComfortNet thermostat “Call for Service” icon illuminated.ComfortNet thermostat scrolls“Check Furnace” message.Furnace fails to operate. Integrated control module LED display provides ComfortNet thermostat “Call for Service” icon illuminated.ComfortNet thermostat scrolls“Check Furnace” message.Furnace operates at reduced performance.Integrated control module LEDdisplay provides Symptoms of Abnormal Operation •••••••••••••• 60 S TATUS C ODES NO POWER NORMAL OPERATION On INDICATES AIRFLOW, FOLLOWED BY CFM A BLOWER MOTOR NOT RUNNING b0 BLOWER COMMUNICATION ERROR b1 BLOWER HP MIS-MATCH b2 BLOWER MOTOR OPERATING IN POWER, TEMPERATURE, OR SPEED LIMIT b3 BLOWER MOTOR CURRENT TRIP OR LOST ROTOR b4 BLOWER MOTOR LOCKED ROTOR b5 BLOWER OVER/UNDER VOLTAGE TRIP OR OVER TEMPERATURE TRIP b6 INCOMPLETE PARAMETERS SENT TO MOTOR b7 LOW INDOOR AIRFLOW b9 CONVENTIONAL COMPRESSOR COOLING WHEN 1-STAGE COMPRESSOR IS SET UP C LOW STAGE COOL C1 HIGH STAGE COOL C2 CONVENTIONAL COMPRESSOR COOLING WITH DEHUMIDIFICATION WHEN 1-STAGE COMPRESSOR IS SET UP d DATA NOT YET ON NETWORK d0 CONVENTIONAL 1-STAGE COMPRESSOR COOLING WITH DEHUMIDIFICATION WHEN 2-STAGE COMPRESSOR IS SET UP d1 CONVENTIONAL 2-STAGE COMPRESSOR COOLING WITH DEHUMIDIFICATION WHEN 2-STAGE COMPRESSOR IS SET UP d2 INVALID MEMORY CARD DATA d4 DEFROST DEMAND dF LOCKOUT DUE TO EXCESSIVE RETRIES OR RECYCLES E0 LOW STAGE PRESSURE SWITCH STUCK CLOSED AT START OF HEATING CYCLE E1 LOW STAGE PRESSURE SWITCH STUCK OPEN E2 OPEN HIGH LIMIT SWITCH E3 FLAME DETECTED WHEN NO FLAME SHOULD BE PRESENT E4 OPEN FUSE E5 LOW FLAME SIGNAL E6 IGNITER FAULT OR IMPROPER GROUNDING E7 HIGH STAGE PRESSURE SWITCH STUCK CLOSED AT START OF HEATING CYCLE E8 HIGH STAGE PRESSURE SWITCH STUCK OPEN E9 REVERSED 115 VAC POLARITY EA INDUCER MOTOR OVERCURRENT FAULT EC ROLLOUT SWITCH OPEN Ed AUXILIARY INPUT OPEN EF CONTINUOUS FAN OR FURNACE PROVIDING AIR FOR COMMUNICATING OUTDOOR UNIT F FIELD TEST MODE Ft INDICATES GAS HEAT, FOLLOWED BY PERCENTAGE OF DEMAND H HIGH HEAT = 100% HI INTERNAL FAULT IF CONVENTIONAL COMPRESSOR HEATING WHEN 1-STAGE COMPRESSOR IS SET UP P CONVENTIONAL 1-STAGE COMPRESSOR HEATING WHEN 2-STAGE COMPESSOR IS SET UP P1 CONVENTIONAL 2-STAGE COMPRESSOR HEATING WHEN 2-STAGE COMPESSOR IS SET UP P2 % OF HIGH HEAT 50 CFM x 100, ALTERNATES WITH THERMOSTAT CALL & GAS HEAT OPERATING PERCENTAGE. 12 61 W IRING D IAGRAM *MVM97_A*, *CVM97_A* TO GND GR 115VAC/1/60 HZ POWERSUPPLYWITH OVERCURR ENT IDBLOWERMODULATINGPRESSURE HOT PROTECTION SWITCHASSEMBLY SURFACEL DEVICE GND IGNITER BK WARNING:DISCONNECT HIGHFIRE OR POWERBEFORESERVICING PRESSURE LOWFIRE N WIRING.TOUNITMUSTBE C SWITCH C PRESSUREWH PROPERLYPOLARIZED NO NO SWITCH ANDGROUNDED. DISCONNECT YL 2CIRCUIT 21 CONNECTOR TO115VAC/1/60HZPOWERSUPPLYWITH OVERCURRENTPROTECTIONDEVICE OR GND LN MODULATING WARNING: 2 PM BR GASVALVE TOUNITMUSTBE FLAME DISCONNECTPOWER (HONEYWELL) C SENSOR BEFORESERVICING 1 GY CGY WIRINGTOUNIT NO FRONTCOVER MUSTBEPROPERLY PRESSURESWITCH POLARIZEDAND DISCONNECT GROUNDED. MANUALRESETROLLOUTLIMITCONTROLS (SINGLECONTROLON40kBTU) PU PK DOOR SWITCH JUNCTION BOX OR AUTORESETPRIMARY LIMITCONTROL INDUCTOR COIL OR PU (ON SOME MODELS) GND INDOOR INDUCED AIR 3 WH CIRCULATOR DRAFT BLWR 2 RD BLOWER 1 BK GND LINENEUTRAL BURNERCOMPARTMENT GND INTEGRATED CONTROL MODULE EACINTEGRATED CONTROL MODULE NEUTRAL ELECTRONIC BLOWERCO MPARTMENT P U AIR CLEANER AUTORESET OPTIONAL AUXILIARY YL 3 LIMITCONTROL 2 BLWR 1 NEUTRAL HUM HUMIDIFIER CONNECTORID BLOWER NEUTRAL 1 OPTIONAL IGN NEUTRAL 2 HOT SURFACE IGNITER 3 FS SENSORFLAME LINE FLAME SENSOR 115NEUTRAL LINE DIAGNOSTIC VAC 24V THERMOSTAT CONNECTIONS N.E.C. CLASS 2 WIRE HSI 40 VA COOL TAPS HEAT TAPS FAN TAPS EAC FUSE 3A TRANSFORMER TR (5) HUM R 24 VAC AUTO RESET PRIMARY AUTO RESET AUXILIARY LIMIT LIMIT CONTROL TO+VDC CONTROLS (3) 124 3 Y1 HEAT OFF RAMPING ADJUST DELAY (6) DIP SWITCHES 24 LOW FIRE VAC 10 1 7 PRESS. W1 (12) SWITCH 115 NO COOL SETUP HEAT SETUP 11 C PULL DOWN8 54 2 VAC W2 PULL UP DEHUM (2) NO 12 3 69 BIAS TO C HIGH FIRE Y2 MICRO PRESS. SWITCH MANUAL RESET ROLLOUT G LIMIT CONTROLS WH (11) O FUSE DEHUM 24VTHERMOSTATCONNECTIONSAUX (7) 24V HUM. 24V3A N.E.C.CLASS2WIRE PM (8) NO C C ECMMTR C FRONT COVER (10) GAS PRESS. BK HARNESS BL VALVE SWITCH GND (4) RDWH GY TR (9)GND BK TO GND (4) R 5 BK + VDC (1) 4 WH INDOOR 3 GR AIR RX (2) 2 GND PK CIRCULATOR 1 TO BLOWER TX (3) BLWR MICRO COMPARTMENT DOORSWITCH (OPENWHEN INTEGRATED CONTROL DOOROPEN) CIRCULATORBLOWER INDUCTORCOIL MODULE (ON SOME MODELS) NOTES: LOWVOLTAGEFIELDEQUIPMENTGND COLORCODES: 1.SETHEATANTICIPATORONROOMTHERMOSTATAT0.7AMPS. PKPINK 2.MANUFACTURERSPECIFIEDREPLACEMENTPARTSMUSTBE LOWVOLTAGE(24V) FIELDGND BRBROWN USEDWHENSERVICING. WHWHITE 3.IFANYOFTHEORIGINALWIREASSUPPLIEDWITHTHE HIVOLTAGE(115V) BLBLUE FIELDSPLICE FURNACEMUSTBEREPLACED,ITMUSTBEREPLACEDWITH GYGRAY WIRINGMATERIALHAVINGATEMPERATURERATINGOFAT HIVOLTAGEFIELD RDRED LEAST105C.USECOPPERCONDUCTORSONLY. SWITCH(TEMP) YLYELLOW 4.UNITMUSTBEPERMANENTLYGROUNDEDANDCONFORMTO ORORANGE JUNCTION N.E.C.ANDLOCALCODES. IGNITER PUPURPLE 5.TORECALLTHELAST10FAULTS,MOSTRECENTTOLEAST TERMINAL GR GREEN RECENT,DEPRESSSWITCHFORMORETHAN2SECONDS BKBLACK INTERNALTOSWITCHPRESSURE WHILEINSTANDBY(NOTHERMOSTATINPUTS) INTEGRATED CONTROL OVERCURRENT PLUGCONNECTION PROT.DEVICE 0140F02013-A 62 S PECIAL I NSTRUCTIONSFOR P RODUCTS I NSTALLED THE S TATEOF M ASSACHUSETTS IN For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the VENT/FLUE Commonwealth and where the side wall exhaust vent termination TEE is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the follow- ing requirements shall be satisfied: DISTANCE BETWEEN COMBUSTION 1.INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time VENT AND GRADE AIR INTAKE. of installation of the side wall horizontal vented gas fueled DISTANCE BETWEEN equipment, the installing plumber or gasfitter shall observe COMBUSTION AIR that a hard wired carbon monoxide detector with an alarm INTAKE AND GRADE and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors a.In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level. b.In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed. 2.APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified. 3.SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”. 4.INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4. EXEMPTIONS The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4: adopted by the Board; and 2.Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes. (c)MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include: 1.Detailed instructions for the installation of the venting system design or the venting system components; and 2.A complete parts list for the venting system design or venting system. (d)MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but ons; and rts list and detailed installation instructions. (e)A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation. 63 NOTE: SPECIFICATIONS AND PERFORMANCE DATA LISTED HEREIN ARE SUBJECT TO CHANGE WITHOUT NOTICE. Goodman Manufacturing Company, L.P. 5151 San Felipe Suite 500 Houston, TX 77056 www.goodmanmfg.com • www.amana-hac.com © 2014 - 2016 Goodman Manufacturing Company, L.P. 64 Service Instructions TM 34.5" Chassis ACVC96/AMVC96 GCVC96/GMVC96 Gas Furnaces This manual is to be used by qualified, professionally trained HVAC technicians only. Goodman does RS6612010 not assume any responsibility for property damage or personal injury due to improper service August 2014 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. Copyright © 2014 Goodman Company, L.P. TABLE OF CONTENTS TROUBLESHOOTING...........................................45 - 50 IMPORTANT INFORMATION.....................................2 - 5 PRODUCT IDENITIFICATION..................................6 - 10 SYSTEM OPERATION COMFORTNET™............ 51 - 56 ACCESSORIES....................................................11 - 13 SERVICING..........................................................57 - 75 INSTALLATION CONSIDERATIONS......................14 - 39 MAINTENANCE................................................... 76 - 77 SYSTEM OPERATION..........................................40 - 44 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 MATERIALS OR USE GASOLINE OR OTHER FLAMMABLE LIQUIDS OR VAPORS IN THE VICINITY OF THIS APPLIANCE. 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 WHICH M MAY RESULT. ANY JURISDICTIONS REQUIRE A LICENSE TO INSTALL OR SERVICE HEATING AND AIR CONDITIONING EQUIPMENT. WARNING HIGHVOLTAGE D ISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. M ULTIPLE POWER SOURCES MAY BE PRESENT. F AILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. 2 IMPORTANT INFORMATION Special Warning for Installation of Furnace or Air Handling Units in Enclosed Areas such as Garages, Utility Rooms or Parking Areas Carbon monoxide producing devices (such as an automobile, space heater, gas water heater, etc.) should not be operated in enclosed areas such as unventilated garages, utility rooms or parking areas because of the danger of carbon monoxide (CO) poisoning resulting from the exhaust emissions. If a furnace or air handler is installed in an enclosed area 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)circulated throughout the structure if the furnace or air handler is operating in any mode. CO can cause serious illness including permanent brain damage or death. 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 CONSUMER INFORMATION LINE ® ® AMANABRAND PRODUCTS GOODMAN BRAND PRODUCTS TOLL FREE TOLL FREE 1-877-254-4729 (U.S. only) 1-877-254-4729 (U.S. only) email us at: email us at: hac.consumer.affairs@amanahvac.com customerservice@goodmanmfg.com fax us at: (731) 856-1821 fax us at: (731) 856-1821 (Not a technical assistance line for dealers.) (Not a technical assistance line for dealers.) Outside the U.S., call 1-713-861-2500. (Not a technical assistance line for dealers.) Your telephone company will bill you for the call. 3 IMPORTANT INFORMATION FOR YOUR SAFETY READ BEFORE OPERATING WARNING:Improper If you do not follow these instructions exactly, alteration, service or a fire or explosion may result causing property maintenance can damage, personal injury or loss of life. cause injury or property damage. If you cannot reach your gas supplier, A. This appliance does not have a pilot. It Refer to the user's call the fire department. is equipped with an ignition device which information manual automatically lights the burners. Donot provided with this C. Use only your hand to move the gas try to light the burners by hand. control switch or knob. Never use B. BEFORE OPERATING smell around tools. If the gas control switch or knob consult a qualified the appliance area for gas. Be sure to will not operate, don't try to repair it, smell next to the floor because some gas call a qualified service technician. or the gas supplier. is heavier than air and will settle on the Force or attempted repair may result in floor. a fire or explosion. WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance. D. Do not use this appliance if any part This furnace must be has been under water. Immediately call Do not touch any electric switch; a qualified service technician to inspect do not use any telephone in your the appliance and to replace any part of building. instructions and local the control system and any gas control codes. In the absence Immediately call your supplier which has been under water. of local codes, follow from a neighbor's phone. Follow the National Fuel Gas the gas suppliers instructions. Code, ANSI Z223.1. OPERATING INSTRUCTIONS For indoor installation. 1. STOP! Read the safety information7. Wait five (5) minutes to clear out any above on this label.gas. If you then smell gas, STOP! Follow "B" in the safety information PGB & PGJ 2. Set the thermostat to lowest setting. above on this label. If you don't smell For outdoor gas, go to the next step. 3. Turn off all electric power to the installation only. appliance. 8. Move the gas control switch or knob to "ON". 4. This appliance is equipped with an automatic ignition system which 9. Replace control access panel. WARNING:If not automatically lights the burners. Donot installed, operated 10. Turn on all electric power to the try to light the burners by hand. and maintained in appliance. accordance with the 5. Remove control access panel. manufacturer's 11. Set the thermostat to the desired 6. Move the gas control switch or knob setting. instructions, this to "OFF". product could expose 12. If the appliance will not operate, you to substances follow the instructions "To Turn Off Gas in fuel combustion To Appliance" and call your service which can cause technician or gas supplier. death or serious illness and which are known to the State of California to cause cancer, birth GAS CONTROL SWITCH SHOWN defects or other IN "ON" POSITION reproductive harm. This product contains fiberglass insulation. TO TURN OFF GAS TO APPLIANCE Fiberglass insulation contains a chemical 1. Set the thermostat to its lowest setting.4. Move the gas control switch or knob to "OFF". Do not force. 2. Turn off all electric power to the California to cause appliance if service is to be performed.5. Replace control access panel. cancer. 3. Remove control access panel. Do not store or use gasoline or FOR YOUR SAFETY other flammable vapors and liquids in the vicinity of this or any other appliance. 0140F00001P 4 IMPORTANT INFORMATION CONSIGNES DE SECURITE - LIREINSTRUCTIONS DE SERVICE 1. UN INSTANT! Lisez d'abord les consignes AVANT D'ALLUMER L'APPAREIL de securite ci-dessus. 2. Reglez le thermostat a son point le plus bas. AVERTISSEMENT: Le non-respect des instructions qui suivent peut 3. Coupez l'alimentation electrique de l'appareil. ^ entrainer un risque d'incendie ou d'explosion causant des dommages, 4. Cet appareil est muni d'un mecanisme qui ^ des blessures ou la mort. allume automatiquement le bruleur. Ne tentez ^ pas d'allumer le bruleur manuellement. A. Cet appareil comporte pas de veilleuse. Il est muni d'un mecanisme qui allume 5. Retirez le panneau d'acces de la commande. ^^ automatiquement le bruleur.N'allumez paz le bruleur manuellement. 6. Mettez la commande de gaz a la position ^ ARRET ("OFF"). B. Sentir tout autour de l'appariel AVANT D'ALLUMER afin de deceler toute fuite de gaz. 7. Attendez cinq (5) minutes afin de permettre a Assurez-vous de sentir tout pres du plancher car certains gaz sont plus lourds que l'air ^ tout gaz present d'etre evacue. Si vous sentez ^ et se deposeront sur le plancher. une odeur de gaz a ce moment, ARRETEZ! et suivez les consignes de securite donnees au SI VOUS SENTEZ UNE ODEUR DE GAZ: paragraphe B ci-dessus. Si vous ne sentez pasCommande de gaz en position de gaz, passez a l'etape suivante. Ne tentez d'allumer aucun appariel. "MARCHE" Ne touchez pas aux interrupteurs electriques; n'utiliser aucun telephone8. Mettez la commande de gaz a la position MARCHE ("ON"). dans l'edifice ou vous vous trouvez. 9. Remettez la panneau d'acces de la commande Appelez immediatement votre fournisseur de gaz en utilisant le telephone en place. d'un voisin et suivez les instructions du fournisseur. 10. Retablissez l'alimenation electrique de l'appareil. Appelez les pompiers si vous ne parvenez pas a rejoindre votre fournisseur 11. Reglez le thermostat a le temperature desiree. de gaz. 12. Si l'appareil ne fonctionne pas, suivez les ^ instructions intitulees "Arret du gaz" et appelez un C. N'utiliser que votre main pour pousser ou tourner le commande du gaz. N'utilisez reparateur qualifie ou votre fournisseur de gaz. jamais d'outils. Si vous ne parvenez pas a pousser ou a tourner la commande, ne tentez pas de la reparer; appelez un reparateur qualifie. Forcer la commande ou essayer de la ^ ^ ARRET DU GAZ reparer peut entrainer un risque d'incendie ou d'explosion. 1. Reglez le thermostat a son point le plus bas. D. N'utilisez pas cet appareil si l'une de ses parties a ete dans l'eau. Si cela se produit, 2. Coupez l'alimentation electrique de l'appareil si vous devez effectuer un entretien. demandez immediatement a un reparateur qualifie d'inspecter l'appareil et de remplacer 3. Retirez le panneau d'acces de la commande. ^ toute piece du systeme de controle et toute commande de gaz ayant ete dans l'eau. ^ 4. Mettez la commande de gaz a la position ARRET ("OFF"). 5. Remettez le panneau d'acces de la commande en place. 0140F00002P 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. GMVC960804CNAA PRODUCT FURNACE TYPE: MAJOR REVISION TYPE G: Goodman A: Initial Release E: Two-Stage/ CABINET A: Amana® X-13 Motor WIDTH Brand S: Single-Stage/ A: 14" D: Amana® Multi-Speed B: 17-1/2" Distinctions™ V: Two Stage/ C: 21" Brand Variable- D: 24-1/2" MINOR REVISION Speed A: Initial Release H: Two Stage NOMINAL INPUT Gas Valve - 040: 40,000 Btuh Multi-Speed 060: 60,000 Btuh 080: 80,000 Btuh 100: 100,000 Btuh ADDITIONAL 120: 120,000 Btuh FEATURES SUPPLY TYPE N: Natural Gas M: Upflow/Horizontal X: Low NOx D: Decidated Downflow C: Downflow/Horizontal H: High Air Flow AFUE 8: 80% AIRFLOW 9: 90% CAPABILITY 95: 95% @ 0.5" ESP 3: 1200 4: 1600 COMMUNICATION FEATURE 5: 2000 C: 4-Wire Communication Ready 6 PRODUCT IDENTIFICATION MODEL: GMVC96 REV AA MODEL: GCVC96 REV AA Equipment TypeGoodman Brand Residential Gas Furnace Equipment TypeGoodman Brand Residential Gas Furnace Heating StagesTwo Heating StagesTwo Cooling StagesTwo Cooling StagesTwo Control TypeClimateTalk ™ or Conventional 24 Volt Control TypeClimateTalk ™ or Conventional 24 Volt Blower Motor Type4 Wire Variable Speed ECM Blower Motor Type4 Wire Variable Speed ECM 0403BN0603BN0803BN0804CN1005CN1205DN GMVC96 0403BN0603BN0803BN0804CN1005CN1205DN GCVC96 Installation Positions UF, Hor L/RUF, Hor L/RUF, Hor L/RUF, Hor L/RUF, Hor L/RUF, Hor L/R Installation PositionsCF, Hor L/RCF, Hor L/RCF, Hor L/RCF, Hor L/RCF, Hor L/RCF, Hor L/R BTUH Input Low Fire (X 1000) 304560607590 BTUH Input Low Fire (X 1000)304560607590 BTUH Input High Fire (X 1000) 40608080100120 BTUH Input High Fire (X 1000)40608080100120 A/C Capable Tons 1.5 - 31.5 - 31.5 - 32 - 41.5 - 52 - 5 A/C Capable Tons 1.5 - 31.5 - 32 - 42 - 42 - 52 - 5 Cabinet Hight " 34.534.534.534.534.534.5 Cabinet Hight "34.534.534.534.534.5 Cabinet Width " 17.517.517.5212124.5 Cabinet Width "17.517.5212124.5 Heating CFM @ 100% Firing Rate 55310591316133718701940 Heating CFM @ 100% Firing Rate10599501146132517971827 Draft Inducer Two Speed Two Speed Draft Inducer Two Stage Gas Valve Two Stage Gas Valve W1 / W2 24 VAC Heating Inputs W1 / W2 24 VAC Heating Inputs Y1 / Y2 24 VAC Cooling Inputs Y1 / Y2 24 VAC Cooling Inputs Aluminized Steel Primary Heat Exchanger Aluminized Steel Primary Heat Exchanger EAC terminal, Field Powered HUM IN / HUM OUT terminals, Single Hum terminal EAC terminal, Field Powered HUM IN / HUM OUT terminals, Single Hum terminal Accessory Terminals powered simultaneously with draft inducer, AUX circuit Accessory Terminals powered simultaneously with draft inducer, AUX circuit Left or Right Gas Line Entry Left or Right Gas Line Entry First revision of 34.5" two stage communicating capable up flow furnace Revision Attributes First revision of 34.5" modulating counter flow furnace Revision Attributes MODEL: AMVC96 REV AA MODEL: ACVC96 REV AA Equipment TypeAmana Brand Residential Gas Furnace Equipment TypeAmana Brand Residential Gas Furnace Heating StagesTwo Heating StagesTwo Cooling StagesTwo Cooling StagesTwo Control TypeClimateTalk ™ or Conventional 24 Volt Control TypeClimateTalk ™ or Conventional 24 Volt Blower Motor Type4 Wire Variable Speed ECM Blower Motor Type4 Wire Variable Speed ECM 0403BN0603BN0803BN0804CN1005CN1205DN ACVC96 0403BN0603BN0803BN0804CN1005CN1205DN AMVC96 Installation PositionsCF, Hor L/RCF, Hor L/RCF, Hor L/RCF, Hor L/RCF, Hor L/RCF, Hor L/R Installation Positions UF, Hor L/RUF, Hor L/RUF, Hor L/RUF, Hor L/RUF, Hor L/RUF, Hor L/R BTUH Input Low Fire (X 1000)304560607590 BTUH Input Low Fire (X 1000) 304560607590 BTUH Input High Fire (X 1000)40608080100120 BTUH Input High Fire (X 1000) 40608080100120 A/C Capable Tons 1.5 - 31.5 - 32 - 42 - 42 - 52 - 5 A/C Capable Tons 1.5 - 31.5 - 31.5 - 32 - 41.5 - 52 - 5 Cabinet Hight "34.534.534.534.534.5 Cabinet Hight " 34.534.534.534.534.534.5 Cabinet Width "17.517.5212124.5 Cabinet Width " 17.517.517.5212124.5 Heating CFM @ 100% Firing Rate10599501146132517971827 Heating CFM @ 100% Firing Rate 55310591316133718701940 Two Speed Draft Inducer Draft Inducer Two Speed Two Stage Gas Valve Two Stage Gas Valve W1 / W2 24 VAC Heating Inputs W1 / W2 24 VAC Heating Inputs Y1 / Y2 24 VAC Cooling Inputs Y1 / Y2 24 VAC Cooling Inputs Stainless Steel Primary Heat Exchanger Stainless Steel Primary Heat Exchanger EAC terminal, Field Powered HUM IN / HUM OUT terminals, Single Hum terminal EAC terminal, Field Powered HUM IN / HUM OUT terminals, Single Hum terminal Accessory Terminals powered simultaneously with draft inducer, AUX circuit Accessory Terminals powered simultaneously with draft inducer, AUX circuit Left or Right Gas Line Entry Left or Right Gas Line Entry First revision of 34.5" modulating counter flow furnace Revision Attributes First revision of 34.5" two stage communicating capable up flow furnace Revision Attributes 7 PRODUCT IDENTIFICATION MODEL # MFG #DESCRIPTION The AFE18-60A control is designed for use where the indoor coil is located Fossil Fuel Kit. above/downstream of a gas or fossil fuel furnace when used with a heat pump. It will operate with single and two stage heat pumps and single and two stage furnaces. The AFE18-60A AFE18-60A N/A control will turn the heat pump unit off when the furnace is turned on. An anti-short cycle feature initiates a 3 minute timed off delay when the compressor goes off. AMU1620 For use with current architectural grey Goodman® and Amana® Brand Media Air Cleaner. P1251305F AMU1625 furnace models. The Amana (AMU*) and Goodman (GMU*) Media Air Cleaner is a high P1251306F AMU2020 efficiency air filtration device designed to remove dirt, dust, pollen and other microscopic P1251307F AMU2025 particles from the air passing through it. Flexible performance range up to 2,000 CFM P1251308F capacity. The air cleaner should be installed in the system so that all the system air is GMU1620 circulated through the air cleaner. The air cleaner will only remove the airborne contaminants GMU1625 delivered to it. Maximum performance is obtained when the system blower is set for GMU2020 N/A continuous operation. Carbon filters (optional) are available. GMU2025 For use with current architectural grey Goodman® and Amana® Electronic Air Cleaner. ASAS-10 P1251301F Brand furnace models. The High-Efficiency Electronic Air Cleaner is designed to remove air P1251302F ASAS-11 contaminants down to .01 microns. Carbon filters (optional) remove odors. Dual indicator P1251303F ASAS-12 lights show unit operation at a glance. Electronic proving switch cycles the air cleaner On/Off P1251304F ASAS-18 with the system fan. Durable powder-coat paint finish resists corrosion. For use with select Goodman® and Amana® Brand 34.5" furnace Counterflow Subbase Kit. models ACVC9 and GCVC9. These kits are available for the following furnace widths: 17.5" wide (CFSB17), 21" wide (CFSB21) and 24" wide (CFSB24). The kits must be used to prevent CFSB17 N/A excessive temperature from reaching combustible materials, if the furnace is installed on a CFSB21 combustible floor. This subbase effectively separated the furnace base and plenum from CFSB24 combustible materials. To ensure safe installation, do not install the counterflow floor base directly on carpeting, tile, or other combustible material other than wood flooring. Digitally communicating touchscreen thermostat. Designed Communicating Thermostat Kit- for use with compatible Amana® Brand or Goodman® Brand Air Handlers or Furnaces and outdoor split AC or Heat Pump units. This thermostat supports up to three stages of heat, two stages of cooling, dual fuel applications, dehumidification, filter maintenance reminders, CTK01AA CTK01AA outdoor temperature display and advanced menus including diagnostics. The CTK01AA kit includes a communicating touchscreen thermostat and sub base, 230V-24V 40va transformer, terminal blocks(2), wire jumpers, mounting screws, installation manual and homeowner guide. Digitally communicating touchscreen thermostat. Designed Communicating Thermostat Kit- for use with compatible Amana® Brand or Goodman® Brand Air Handlers or Furnaces and outdoor split AC or Heat Pump units. This thermostat supports up to three stages of heat, two CTK01BA stages of cooling, dual fuel applications, dehumidification, filter maintenance reminders, CTK01BA outdoor temperature display and advanced menus including diagnostics. The CTK01BA kit includes a communicating touchscreen thermostat and sub base, terminal blocks(2), installation manual and homeowner guide. 8 PRODUCT IDENTIFICATION MODEL # MFG #DESCRIPTION Digitally communicating thermostat. Designed for Communicating Thermostat Kit- use with compatible Amana® Brand or Goodman® Brand Air Handlers or Furnaces and outdoor split AC or Heat Pump units. The CTK02** thermostat features a full color high definition display, advanced programming options including humidification control CTK02** CTK02** & heat and cool maximum temperature settings, a USB plug allowing dealers the ability to insert pre-programmed operating parameters and dealer information by use of an online data entry system. Digitally communicating touchscreen thermostat Communicating Thermostat Kit- from Honeywell. Designed for use with compatible Amana® Brand or Goodman® CTK03AA Brand Air Handlers or Furnaces and outdoor split AC or Heat Pump units. The CTK03AA CTK03AA thermostat features full color high definition display and can be used with RedLINK wireless accessories. Digitally communicating touchscreen thermostat Communicating Thermostat Kit- from Honeywell. Designed for use with compatible Amana® Brand or Goodman® Brand Air Handlers or Furnaces and outdoor split AC or Heat Pump units. The CTK03AB CTK03AB CTK03AB thermostat features full color high definition display and can be used with RedLINK wireless accessories and added capabilty to control the HUM IN - HUM OUT relay. Digitally communicating touchscreen thermostat Communicating Thermostat Kit- from Honeywell. Designed for use with compatible Amana® Brand or Goodman® Brand Air Handlers or Furnaces and outdoor split AC or Heat Pump units. The CTK04 CTK04AA CTK04 thermostat features full color high definition display and can be used with RedLINK wireless accessories and added capabilty to control the HUM IN - HUM OUT relay. Split system inverter capable. For use with Amana® Brand 90% furnace models. This kit is Concentric Vent Kit. DCVK-20 designed to allow terminations of a direct vent furnace to be "concentrically" vented (CVENT-2) through a wall or roof. This kit allows a single penetration to support terminations for N/A both the vent/flue and the combustion air intake pipe. The DCVK-20 (2") and DCVK-30 DCVK-30 (3") kits are certified for models listed above. See specification sheets on future (CVENT-3) models for use of the vent kit. . For use with 90% furnace models.This kit is to be Side Wall Only Concentric Vent Kit used with 2" - 3" vent systems. The vent kit must terminate outside the structure. This N/A 0170K00000S kit is NOT intended for use with single pipe (indirect vent) installations. . For use with 90% furnace models.This kit is to be Side Wall Only Concentric Vent Kit N/A used only with 2" vent systems. The vent kit must terminate outside the structure. This 0170K00001S kit is NOT intended for use with single pipe (indirect vent) installations. For use with Goodman® and Amana® Brand two-stage variable speed Dehumidistat. furnace models. Wall mounted, 24 volt humidity control available as a Dehumidistat used to reduce the airflow in the air conditioning mode when necessary to lower the humidity in an occupied home to prevent dew build-up associated with high humidity P1227801F DEHUM1 levels. This control features a moisture-sensitive nylon element and also provides positive ON-OFF settings for manual operation. The control is a normally closed switch that opens on humidity rise causing the blower to switch to a lower speed to control the humidity within the structure. 9 PRODUCT IDENTIFICATION MODEL # MFG #DESCRIPTION For use with Goodman® and Amana® Brand 90% upflow variable External Filter Rack Kit. speed gas furnace models. This kit is intended to provide a location, external to the furnace N/A casing, for installation of a permanent filter. The rack is mounted over the indoor air blower EFR02 compartment area of either side panel, and provide filter retention as well as a location for attaching return air ductwork. Used on selected Goodman® Brand and Amana® Brand 90% two High Altitude Natural Gas Kit. stage furnace models. These kits are required when installing the furnaces above their N/A maximum rated altitude. The orifices in the kit have been selected as a result of testing with the HASFK-1 American Gas Association. They will provide appropriate derating at the altitude listed in the High Altitude Charts as shown in the installations of the kit. Designed for application on Goodman® and Amana® Brand's gas LP Gas Low Pressure Kit. furnace products installed on LP gas listed in this manual. This kit includes harness adaptors to N/A LPLP03 work with White-Rodgers single & two stage gas valves,Honeywell single and two-stage gas valves, as well as modulating gas valves. For use with Goodman® and Amana® Brand 34.5" 2-stage variable speed LP Conversion Kit. N/A models using a White-Rodgers 36J54,, 2-stage gas valve kit. Includes regulator springs, LPM-08 1.25mm orifices, instructions and a label to show the furnace has been converted to L.P. 10 ACCESSORIES 96% Com Furnace Accessories Model AFE180-60AAMU / GMUEFR02ASAS / GSASCFSB17CFSB21CFSB24RF000142 Number FossilExternalElectronicDownflow Downflow Downflow Drain Media Air DescriptionFuelFilterAirSubbaseSubbaseSubbaseCoupling Cleaners KitRackCleaner17.5"21"24.5"Kit *MVC960403BN**XXXXX *MVC960603BN**XXXXX *MVC960803BN**XXXXX *MVC960804CN**XXXXX *MVC961005CN**XXXXX *MVC961205DN**XXXXX *CVC960403BN**XXXXX *CVC960603BN**XXXXX *CVC960804CN**XXXXX *CVC961005CN**XXXXX *CVC961205DN**XXXXX ModelDCVK-20DCVK-30 CTK01*CTK02*CTK03*CTK04*0170K00000S0170K00001S Number(CVENT-2)(CVENT-3) Com Com Com Com.ThermostatThermostaThermostatConcentric Concentric Concentric Concentric DescriptionThermostatKit KitKitSide WallSide Wall Vent Kit (2")Vent Kit (3") KitModulating, Modulating, Modulating, Vent Kit (3")Vent Kit (2") High DefHigh DefHigh Def *MVC960403BN**XXXXXXXX *MVC960603BN**XXXXXXXX *MVC960803BN**XXXXXXXX *MVC960804CN**XXXXXXXX *MVC961005CN**XXXXXXXX *MVC961205DN**XXXXXXXX *CVC960403BN**XXXXXXXX *CVC960603BN**XXXXXXXX *CVC960804CN**XXXXXXXX *CVC961005CN**XXXXXXXX *CVC961205DN**XXXXXXXX Model DEHUM1LPM-08LPLP03HASFK-1 Number Low LP High Altitude DescriptionDehumidistatL.P. KitTank Kit Protection *MVC960403BN**XXXX *MVC960603BN**XXXX *MVC960803BN**XXXX *MVC960804CN**XXXX *MVC961005CN**XXXX *MVC961205DN**XXXX *CVC960403BN**XXXX *CVC960603BN**XXXX 11 ACCESSORIES SLOTS IN FILTER CLEAR SCREWS EXTERNAL FILTER RACK (EFR02) ON UNIT BLOWER DECK SCREWS 96% Upflow Model Furnaces UNIT SIDE PANEL FRONT OF UNIT FILTER RACK ASSEMBLY (FACE FILTER OPENING BASE TOWARDS FRONT OF UNIT OF UNIT) RETURN AIR CUTOUT AREA LOWER EDGE SCREW 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-by- side or with one pipe above the other. See the section in this manual under "Vent Flue and Combustion Air Pipe Terminations" for more information or consult the Installation Instructions (IO-635). 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 Vertical Installation 12 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 24" above roof. Combustion Air Combustion Air Strap Roof Boot/Flashing (Field Supplied) Vent (Field Supplied) Vent Support (Field Supplied) Flush to 1" maximum 45 Elbow 45 Elbow (Field Supplied) Combustion Air (Field Supplied) Vent Combustion Air DCVK (Vertical Installation) DCVK (Horizontal Installation) LPLP03 Low LP Gas Pressure Shut-off Kit AFE18-60A Dual Fuel Accessory Installation of the LPLP03 kit is recommended on every L.P. When installing the communicating capable furnace with a converted furnace to protect the furnace against low L.P. heat pump, the preferred installation would include a com- gas supply pressure. Low L.P. supply pressure can cause municating thermostat. A communicating thermostat pro- poor combustion and carbon in the heat exchanger. The vides control of gas heat and heat pump operation and elimi- LPLP03 kit will open the electrical circuit to the gas valve in nates the need for a separate dual fuel control. A legacy the event of low supply pressure. The kit contains a pres- dual fuel thermostat could also be used with 24 volt wiring to sure switch, gas fittings and electrical harness to connect control the gas furnace and heat pump. If a communicating the switch in series with the gas valve. thermostat or legacy dual fuel thermostat are not used, the AFE18-60A kit must be added to provide control of the equip- LPM-08 LP Conversion Kit ment. This control is mounted indoors near the furnace and provides terminals for thermostat, furnace, and heat pump This furnace is factory equipped to operate on Natural Gas wiring. The AFE18-60A may be used with or without a sepa- but may be field converted to operate on L.P. gas. To con- rate outdoor thermostat. vert a *MVC96 or *CVC96 furnace to operate on L.P. gas, the LPM-08 conversion kit must be used. The LPM-08 kit CFSB17, 21, 24 Counter Flow Base contains a set of 1.25 mm orifices to replace the factory installed natural gas orifices and a set of springs to convert The CFSB base must be used when installing a *CVC96 the gas valve to L.P. gas. furnace in the vertical position on a combustible floor with- out a coil under the furnace. OT18-60A Outdoor Thermostat For use in a legacy dual fuel installation to lock-out the heat pump at a selected temperature. 13 INSTALLATION CONSIDERATIONS Safety Product Application Please adhere to the following warnings and cautions when This product is designed for use as a residential home gas installing, adjusting, altering, servicing, or operating the fur- furnace. It is not designed or certified for use in mobile home, nace. trailer, or recreational vehicle applications. This furnace can be used in the following non-industrial commercial applications: Schools, Office buildings, Churches, WARNING Retail stores, Nursing homes, Hotels/motels, Common or office areas. In such applications, the furnace must be installed T O PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION, with the installation instructions. ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE, REFER TO THIS MANUAL. OR ADDITIONAL ASSISTANCE OR INFORMATION, CONSULT A Goodman® Brand and Amana® Brand 90% furnaces are F QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER. ETL certified appliances and are appropriate for use with natural or propane gas. (NOTE:If using propane gas, a pro- pane conversion kit is required). Dual certification means that the combustion air inlet pipe is WARNING optional and the furnace can be vented as a: HIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS WHICH T Non-direct vent (single pipe) central forced air furnace MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE KNOWN TO THE in which combustion air is taken from the installation S TATE OF C ALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER area or from air ducted from the outside or, REPRODUCTIVE HARM. Direct vent (dual pipe) central forced air furnace in which all combustion air supplied directly to the furnace burn- ers through a special air intake system outlined in WARNING this manual and the installation instructions. To ensure proper installation, operation and servicing, thor- T O PREVENT POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, THE FURNACE MUST BE LOCATED TO PROTECT oughly read the installation and service manuals for specif- THE ELECTRICAL COMPONENTS FROM WATER. ics pertaining to the installation, servicing and application of this product. Charge (ESD) Precautions NOTE:Discharge body’s static electricity before touching WARNING unit. An electrostatic discharge can adversely affect electri- cal components. P OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE, Use the following precautions during furnace installation and EXPLOSION, SMOKE, SOOT, CONDENSTAION, ELECTRICAL SHOCK OR CARBON servicing to protect the integrated control module from dam- MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION, REPAIR, OPERATION, OR MAINTENANCE OF THIS PRODUCT. age. By putting the furnace, the control, and the person at the same electrostatic potential, these steps will help avoid exposing the integrated control module to electrostatic dis- charge. This procedure is applicable to both installed and WARNING uninstalled (ungrounded) furnaces. T 1.Disconnect all power to the furnace. Do not touch the O PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE, DO NOT INSTALL THIS FURNACE IN A MOBILE HOME, TRAILER, OR RECREATIONAL integrated control module or any wire connected to the VEHICLE. control prior to discharging your body’s electrostatic charge to ground. To ensure proper furnace operation, install, operate, main- 2.Firmly touch a clean, unpainted, metal surface of the tain and service the furnace in accordance with the installa- furnace near the control. Any tools held in a person’s tion, operation and service instructions, all local building hand during grounding will be discharged. codes and ordinances. In their absence, follow the latest 3.Service integrated control module or connecting wiring edition of the National Fuel Gas Code (NFPA 54/ANSI following the discharge process in Step 2. Use caution Z223.1), and/or CAN/CGA B149 Installation Codes, local not to recharge your body with static electricity; (i.e., do plumbing or waste water codes, and other applicable codes. not move or shuffle your feet, do not touch ungrounded A copy of the National Fuel Gas Code (NFPA 54/ANSI objects, etc.). If you come in contact with an ungrounded Z223.1) can be obtained from any of the following: object, repeat Step 2 before touching control or wires. American National Standards Institute 4.Discharge any static electricity from your body to ground 1430 Broadway before removing a new control from its container. Follow New York, NY 10018 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. 14 INSTALLATION CONSIDERATIONS National Fire Protection Association•Set the 90% furnace on a level floor to enable proper condensate drainage. If the floor becomes wet or damp 1 Batterymarch Park at times, place the furnace above the floor on a con- Quincy, MA 02269 crete base sized approximately 1-1/2" larger than the base of the furnace. Refer to the Horizontal Applica- The rated heating capacity of the furnace should be greater tions and Considerations section in this manual or than or equal to the total heat loss of the area to be heated. the installation instructions for leveling of horizontal The total heat loss should be calculated by an approved furnaces. method or in accordance with “ASHRAE Guide” or “Manual •Ensure upflow or horizontal furnaces are not installed J-Load Calculations” published by the Air Conditioning Con- directly on carpeting, or any other combustible mate- tractors of America. rial. The only combustible material allowed is wood. •A special accessory subbase must be used for up- Location Requirements and Considerations right counterflow unit installations over any combus- tible material (including wood). Refer to subbase in- WARNING structions for installation details. (NOTE: A subbase will not be required if an air conditioning coil is located T O PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE, PERSONAL beneath the furnace between the supply air opening INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE OBSERVED and the combustible floor. WHEN INSTALLING THE UNIT. •Exposure to contaminated combustion air will result Follow the instructions listed below when selecting a fur- in safety and performance-related problems. Do not nace location. Refer also to the guidelines provided in the install the furnace where the combustion air is ex- Combustion and Ventilation Air Requirements section in this posed to the following substances: manual or the installation instructions for details. chlorinated waxes or cleaners •Centrally locate the furnace with respect to the pro- chlorine-based swimming pool chemicals posed or existing air distribution system. water softening chemicals •Ensure the temperature of the return air entering the deicing salts or chemicals furnace is between 55°F and 100°F when the furnace carbon tetrachloride is heating. halogen type refrigerants •If the furnace is installed in an application where the typical operating sound level of a furnace is deemed cleaning solutions (such as perchloroethylene) objectionable, an optional sound reduction kit is avail- printing inks able. Consult your local distributor for more details. paint removers •Provide provisions for venting combustion products varnishes outdoors through a proper venting system. Special hydrochloric acid consideration should be given to vent/flue pipe routing cements and glues and combustion air intake pipe when applicable. antistatic fabric softeners for clothes dryers 90% Furnaces: Refer tothe Vent/Flue Pipe and Com- bustion Air Pipe -Termination Locations section in thisand masonry acid washing materials manual or the installation instructions for appropriate •Isolate a non-direct furnace from an area contaminated termination locations. Also for 90% furnaces, refer to by any of the above substances. This protects the theVent/Flue Pipe and Combustion Air Pipe -Termi- non-direct vent furnace from airborne contaminants. nation Locations section in this manual or the instal- To ensure that the enclosed non-directvent furnace lation instructions to determine if the piping system has an adequate supply of combustion air, vent from from furnace to termination can be accomplished a nearby uncontaminated room or from outdoors. Re- within the guidelines given. NOTE: The length of flue fer to the Combustion and Ventilation Air Require- and/or combustion air piping can be a limiting factor ments section in this manual or the installation in- in the location of the furnace. structions for details. •Locate the 90% furnaceso that the condensate can •If the furnace is used in connection with a cooling be piped at a downward slope away from the furnace unit, install the furnace upstream or in parallel with to the drain. Do not locate the furnace or its conden- the cooling unit coil. Premature heat exchanger fail- sate drainage system in any area subject to below ure will result if the cooling unit coil is placed in the freezing temperatures without proper freeze protec- return air of the furnace. tion. Refer tothe Condensate Drain Lines and Trap section in this manual or the installation instructions for further details. 15 INSTALLATION CONSIDERATIONS PROVIDE8"MINIMUMCLEARANCEBETWEEN •If the furnace is installed in a residential garage, posi- CENTERRODANDFURNACECABINET TOALLOWFORCIRCULATORBLOWERREMOVAL. tion the furnace so that the burners and ignition source ASSURE FURNACE IS LEVEL FROM ALTERNATE 3/8"DIAMETER are located not less than 18 inches (457 mm) above END TO END. GASPIPING THREADEDROD ON 90% FURNACES MAKE SURE the floor. Protect the furnace from physical damage (6PLACES) THE UNIT HAS A SLIGHT by vehicles. FORWARD TILT WITH THE FRONT OF THE FURNACE 0"-3/4" HOLDDOWN •If the furnace is installed horizontally, the furnace ac- BELOW THE BACK OF THE FURNACE. NUTS cess doors must be vertical so that the burners fire SUPPORT NUTS 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. CONDENSATE DRAIN GASPIPING Clearances and Accessibility 2"X 2"X 1/8"ANGLEIRON Installations must adhere to the clearances to combustible TILTOUTWARDTOALLOWFOR (3PLACES) POSITIONASCLOSEASPOSSIBLE DOORANDCIRCULATORBLOWER materials to which this furnace has been design certified. TOBLOWERDECKTOALLOWFOR REMOVAL. CIRCULATORBLOWERREMOVAL. The minimum clearance information for this furnace is pro- vided on the unit’s clearance label. These clearances must 90% Suspended Furnace Shown be permanently maintained. Refer to Specification Sheet for E XISTING F URNACE R EMOVAL minimum clearances to combustible materials. Clearances must also accommodate an installation’s gas, electrical, NOTE:When an existing furnace is removed from a venting and drain trap and drain line connections. If the alternate system serving other appliances,the venting system may combustion air intake or vent/flue connections are used on be too large to properly vent the remaining attached appli- a 90% furnace, additional clearances must be provided to ances. accommodate these connections. Refer to Vent Flue Pipe The following vent testing procedure is reproduced from the and Combustion Air Pipe section in this manual or the in- American National Standard/National Standard of Canada for stallation instructions for details. NOTE: In addition to the Gas-Fired Central Furnaces ANSI Z21.47, latest edition, required clearances to combustible materials, a minimum CSA-2.3b, latest edition Section 1.23.1. of 24 inches service clearance must be available in front of The following steps shall be followed with each appliance connected to the unit. the venting system placed in operation, while any other appliances A furnace installed in a confined space (i.e., a closet or connected to the venting system are not in operation: utility room) must have two ventilation openings with a total a.Seal any unused openings in the venting system; minimum free area of 0.25 square inches per 1,000 BTU/hr b.Inspect the venting system for proper size and horizontal pitch, of furnace input rating. One of the ventilation openings must as required by the National Fuel Gas Code, ANSI Z223.1 or the be within 12 inches of the top; the other opening must be CSA B149 Installation Codes and these instructions. Determine within 12 inches of the bottom of the confined space. In a that there is no blockage or restriction, leakage, corrosion and other typical construction, the clearance between the door and deficiencies which could cause an unsafe condition; door frame is usually adequate to satisfy this ventilation re- c.In so far as practical, close all building doors and windows and all quirement. doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building. Furnace Suspension Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods If suspending the furnace from rafters or joist, use 3/8" and bathroom exhausts, so they shall operate at maximum speed. threaded rod and 2”x2”x1/8” angle iron as shown in the fol- Do not operate a summer exhaust fan. Close fireplace dampers; lowing figure. If the furnace is installed in a crawl space it d.Follow the lighting instructions. Place the appliance being in- must also be suspended from the floor joist or supported by spected in operation. Adjust thermostat so appliance shall oper- a concrete pad. Never install the furnace on the ground or ate continuously; allow it to be exposed to water. The length of rod will depend e.Test for draft hood equipped spillage at the draft hood relief on the application and the clearances necessary. opening after 5 minutes of main burner operation. Use the flame of a match or candle; f.After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous conditions of use; g.If improper venting is observed during any of the above tests, the common venting system must be corrected. Corrections must be in accordance with the latest edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1 and/or CSA B149 Installation Codes. 16 INSTALLATION CONSIDERATIONS whichopens on humidity rise. Refer to Electrical Connec- If resizing is required on any portion of the venting system, tions - 24 Volt Dehumidistat Wiring section in this manual use the appropriate table in Appendix G in the latest edition or the installation instructions for correct installation proce- of the National Fuel Gas Code ANSI Z223.1 and/or CSA B149 dure. Installation Codes. Thermostat Requirements Thermostat and Dehumidistat Location The optional CTK0*** thermostat kit may be used with In an area having good air circulation, locate the thermostat ComfortNet™ compatable furnaces (ACVC, AMVC, GCVC, and dehumidistat (if applicable) about five feet high on a vi- GMVC models). Refer to System Operation - ComfortNet™ bration-free inside wall. Do not install the thermostat or de- System for details. humidistat where it may be influenced by any of the follow- ing: NOTE: A single-stage thermostat with only one heating stage can be used to control a two-stage furnace. The ap- •Drafts, or dead spots behind doors, in corners, or un- plication of a single-stage thermostat does not offer "true" der cabinets. thermostat driven two-stage operation, but provides a timed •Hot or cold air from registers. transition from low to high fire. The furnace will run on low •Radiant heat from the sun. stage for a fixed period of time before stepping up to high •Light fixtures or other appliances. stage to satisfy the thermostat's call for heat. The delay period prior to stepping up can be set at either 5 or 10 min- •Radiant heat from a fireplace. utes through the DIP switch adjacent to the Heat Off delay •Concealed hot or cold water pipes, or chimneys. DIP switches on the integrated control module. To use a •Unconditioned areas behind the thermostat and de- single-stage thermostat, turn off power to the furnace, move humidistat, such as an outside wall. the thermostat selection jumper on the integrated contro module from the "two-stage" position to the "single-stage" Consult the instructions packaged with the thermostat and position, turn power back on. Refer to DIP switch charts on dehumidistat for mounting instructions and further precau- pages 41 & 42. tions. NOTE: A single-stage thermostat with only one heating stage COMBUSTION AND VENTILATION AIR may be used to control ComfortNet™ compatible furnaces REQUIREMENTS (ACVC, AMVC, GCVC, GMVC models). The application of a single-stage thermostat does not offer “true” thermostat- driven two-stage operation, but provides a timed transition WARNING 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 sat- P OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR isfy the thermostat’s call for heat. The delay period prior to IF THE FURNACE IS NOT PROVIDED WITH ENOUGH FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF FLUE GASES. MOST HOMES REQUIRE stepping up can be set at either a fixed 5 minute time delay OUTSIDE AIR BE SUPPLIED TO THE FURNACE AREA. or a load based variable time between 1 and 12 minutes (AUTO mode). If the AUTOmode is selected, the control Improved construction and additional insulation in buildings averages the cycle times of the previous three cycles and have reduced heat loss by reducing air infiltration and es- uses the average to determine the time to transition from cape around doors and windows. These changes have helped low stage to high stage. in reducing heating/cooling costs but have created a prob- To use a single-stage thermostat, turn off power to the fur- lem supplying combustion and ventilation air for gas fired nace, move the thermostat selection DIP switch to the OFF and other fuel burning appliances. Appliances that pull air position. Set the desired transition time by setting the tran- out of the house (clothes dryers, exhaust fans, fireplaces, sition delay DIP switch to the desired ON/OFF position. Turn etc.) increase the problem by starving appliances for air. power back on. Refer to DIP switch charts on pages 41 & When the furnace is installed as a direct vent (2-pipe) fur- 42. nace, no special provisions for air for combustion are re- quired. However, if this furnace is to be installed in the same Dehumidistat Requirements space with other gas appliances, such as a water heater, A dehumidistat can be used in conjunction with the two- ensure there is an adequate supply of combustion and ven- stage variable speed furnace to lower the humidity in the tilation air for the other appliances. Refer to the latest edi- conditioned space. The dehumidistat will improve dehumidi- tion of the National Fuel Gas Code NFPA 54/ANSI Z223.1 fication of the conditioned air by prompting the furnace to (Section 9.3), or CAN/CGA B149 Installation Codes (Sec- reduce the speed of the circulator blower during operation in tions 7.2, 7.3, or 7.4), or applicable provisions of the local the cooling mode. To be compatible with these furnaces, a building codes for determining the combustion air require- dehumidistat must operate on 24 VAC and utilize a switch ments for the appliances. 17 INSTALLATION CONSIDERATIONS Most homes will require outside air be supplied to the fur- (2)For fan-assisted appliances, calculate using the following equation: 3 nace area by means of ventilation grilles or ducts connect- 15 ftI fan Required Volume > _________________ fan ing directly to the outdoors or spaces open to the outdoors ACH1000 Btu/hr such as attics or crawl spaces. () where: I=all appliances other than fan-assisted input in Btu per other The following information on air for combustion and ventilation hour is reproduced from the National Fuel Gas Code NFPA 54/ANSI I=fan-assisted appliances input in Btu per hour fan Z223.1 Section 9.3. ACH=air change per hour (percent of volume of space exchanged 9.3* Air for Combustion and Ventilation. per hour, expressed as a decimal) 9.3.1 General. (3)For purposes of this calculation, an infiltration rate greater than 0.60ACH shall not be used in the equations in 9.3.2.2(1) and 9.3.1.1Air for combustion, ventilation, and dilution of flue gases for 9.3.2.2(2). 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 9.3.2.3 Indoor Opening Size and Location. Openings used to connect of 9.3.2 are not met, outdoor air shall be introduced in accordance with indoor spaces shall be sized and located in accordance with the follow- methods covered in 9.3.3 through 9.3.6. ing: Exception No. 1: This provision shall not apply to direct vent appliances. (1)*Combining spaces on the same story. Each opening shall have a 22 minimum free area of 1 in./1000Btu/hr (2200 mm/kW) of the total 9.3.1.2Appliances of other than natural draft design and other than 2 input rating of all appliances in the space but not less than 100 in. Category 1 vented appliances shall be provided with combustion, ven- 2 (0.60m). One opening shall commence within 12 in. (300 mm) of tilation, and dilution air in accordance with the appliance manufacturer’s the top, and one opening shall commence within 12 in. (300 mm) of instructions. 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). 9.3.1.3 Appliances shall be located so as not to interfere with proper circulation of combustion, ventilation, and dilution air. Chimney or Gas Vent NOTE: Each opening must have 9.3.1.4Where used, a draft hood or a barometric draft regulator shall be a free area of not less than one installed in the same room or enclosure as the appliance served so as to square inch per 1000 BTU of the total input rating of all equip- prevent any difference in pressure between the hood or regulator and the ment in the enclosure, but not combustion air supply. less than 100 square inches. 9.3.1.5Makeup air requirements for the operation of exhaust fans, kitchen Opening ventilation systems, clothes dryers, and fireplaces shall be considered in determining the adequacy of a space to provide combustion air require- Water ments. Heater Furnace 9.3.2 Indoor Combustion Air. The required volume of indoor air shall Opening be determined in accordance with the method in 9.3.2.1 or 9.3.2.2 ex- cept 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 Figure A.9.2.3.3.(1) All Combustion Air from Adjacent located within the space. Rooms communicating directly with the space Indoor Spaces through Indoor Combustion Air Openings. in which the appliances are installed through openings not furnished with doors, and through combustion air openings sized and located in (2)Combining spaces in different stories.The volumes of spaces in accordance with 9.3.2.3, are considered a part of the required volume. different stories shall be considered as communicating spaces where such spaces are connected by one or more openings in doors or 9.3.2.1* Standard Method. The minimum required volume shall be 50 2 /1000 Btu/hr (4400 floors having a total minimum free area of 2 in. 33 ft per 1,000/Btu/hour (4.8m/kW). 2 mm/kW) of total input rating of all appliances. 9.3.2.2* Known Air Infiltration Rate Method. Where the air infiltra- 9.3.3 Outdoor Combustion Air. Outdoor combustion air shall be pro- tion rate of a structure is known, the minimum required volume shall be vided through opening(s) to the outdoors in accordance with the meth- determined as follows: ods 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). (1)For appliances other than fan-assisted, calculate using the following equation: 9.3.3.1 Two Permanent Openings Method. Two permanent open- 3 21 ftI other Required Volume > _________________ ings, one commencing within 12 in. (300 mm) of the top and one com- other ACH1000 Btu/hr mencing 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 INSTALLATION CONSIDERATIONS Chimney or Gas Vent (1)*Where directly communicating with the outdoors or where commu- nicating to the outdoors through vertical ducts, each opening shall 22 have a minimum free area of 1 in./4000 Btu/hr (550 min/kW) of NOTE: The air duct openings total input rating of all appliances in the enclosure. \[See Figure must have a free area of not less than one square inch per A.9.3.3.1(1)(a) and Figure A.9.3.3.1(1)(b).\] 2000 BTU of the total input rating of all equipment in the enclosure*. Outlet air duct Chimney or Gas Vent Ventilation louvers Water Heater (each end of attic) Furnace NOTE: The inlet and outlet air Inlet air duct 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. Figure A.9.3.3.1(2) All Combustion Air From Outdoors Outlet Air through Horizontal Ducts. Water 9.3.3.2* One Permanent Opening Method. One permanent open- Heater Furnace Inlet Air ings, commencing within 12 in. (300 mm) of the top of the enclosure, Alternate shall be provided. The appliance shall have clearances of at least 1 in. (25 air inlet 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 Ventilation louvers for or spaces that freely communicate with the outdoors (see Figure unheated crawl space A.9.3.3.2)and shall have a minimum free area of the following: 22 (1)1 in./3000 Btu/hr (700 mm per kW) of the total input rating of all Figure A.9.3.3.1(1)(a) All Combustion Air From Outdoors - appliances located in the enclosure, and Inlet Air from Ventilated Crawl Space and Outlet Air (2)Not less than the sum of the areas of all vent connectors in the to Ventilated Attic. space. Chimney or Gas Vent NOTE: The single opening must have Ventilation louvers Chimney or Gas Vent a free area of not less than one (each end of attic) square inch per 3000 BTU of the total input rating of all equip- NOTE: The inlet and outlet air ment in the enclosure, but not less than openings must each have a free the sum of the areas of all vent area of not less than one square connectors in the confined space. inch per 4000 BTU of the total input rating of all equipment in the enclosure. Outlet Air Opening Water Alternate Heater Water Furnace Inlet air ductOpening Heater \[ends 1 ft (300 mm)Location Furnace above floor\] Figure A.9.3.3.1(1)(b) All Combustion Air From Outdoors through Ventilated Attic. Figure A.9.3.3.2 All Combustion Air From Outdoors through Single Combustion Air Opening. (2)*Where communicating with the outdoors through horizontal ducts, 2 each opening shall have a minimum free area of 1 in./2000 Btu/hr 9.3.4 Combination Indoor and Outdoor Combustion Air. The use of 2 (1100 min/kW) of total input rating of all appliances in the enclo- a combination of indoor and outdoor combustion air shall be in accor- sure.\[See Figure A.9.3.3.1(2).\] dance 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 INSTALLATION CONSIDERATIONS 9.3.8.4Ducts shall not serve both upper and lower combustion air (c)The minimum size of outdoor opening(s) shall be the full size openings where both such openings are used. The separation between of outdoor opening(s) calculated in accordance with 9.3.3, ducts servicing upper and lower combustion air openings shall be main- multiplied by the reduction factor. The minimum dimension tained to the source of combustion air. of air openings shall not be less than 3 in. (80 mm). 9.3.8.5Ducts shall not be screened where terminating in an attic space. 9.3.5 Engineered Installations. Engineered combustion air installa- tions shall provide an adequate supply of combustion, ventilation, and 9.3.8.6Horizontal upper combustion air ducts shall not slope down- dilution air and shall be approved by the authority having jurisdiction. ward toward the source of combustion air. 9.3.6 Mechanical Combustion Air Supply. Where all combustion air 9.3.8.7The remaining space surrounding a chimney liner, gas vent, spe- is provided by a mechanical air supply system, the combustion air shall 3 cial gas vent, or plastic piping installed within a masonry, metal, or be supplied form outdoors at the minimum rate of 0.35 ft/min per 1000 3 factory built chimney shall not be used to supply combustion air. Btu/hr (0.034 m/min per kW) for all appliances located within the space. Exception: Direct vent appliances designed for installation in a solid fuel-burning fireplace where installed in accordance with the 9.3.6.1Where exhaust fans are installed, additional air shall be provided manufacture’s installation instructions. to replace the exhausted air. 9.3.8.8Combustion air intake openings located on the exterior of the 9.3.6.2Each of the appliances served shall be interlocked to the me- building shall have the lowest side of the combustion air intake openings chanical air supply system to prevent main burner operation where the located at least 12 in. (300 mm) vertically from the adjoining grade level. mechanical air supply system is not in operation. 9.3.6.3Where combustion air is provided by the building’s mechanical Horizontal Applications and Considerations ventilation system, the system shall provide the specified combustion Horizontal applications, in particular, may dictate many of air rate in addition to the required ventilation air. the installation’s specifics such as airflow direction, duct- work connections, flue and/or combustion air pipe connec- 9.3.7 Louvers, Grilles, and Screens. tions, etc. The basic application of this furnace as a hori- zontal furnace differs only slightly from an upright installa- 9.3.7.1 Louvers and Grilles. The required size of openings for com- tion. When installing a furnace horizontally, additional con- bustion, ventilation, and dilution air shall be based on the net free area of sideration must be given to the following: each opening. Where the free area through a design of louver or grille or screen is known, it shall be used in calculating the size opening required to provide the free area specified. Where the louver and grille design and free area are not known, it shall be assumed that wood louvers will have 25 percent free area, and metal louvers and grilles will have 75 percent free area. Nonmotorized louvers and grilles shall be fixed in the open position. 9.3.7.2 Minimum Scree Mesh Size. Screens shall not be smaller than 1/4 in. mesh. 9.3.7.3 Motorized Louvers. Motorized louvers shall be interlocked with the appliance so they are proven in the full open position prior to main burner ignition and during main burner operation. Means shall be provided to prevent the main burner form igniting should the louver fail to open during burner startup and to shut down the main burner if the louvers close during burner operation. 9.3.8 Combustion Air Ducts. Combustion air ducts shall comply with 9.3.8.1 through 9.3.8.8. 9.3.8.1Ducts shall be constructed of galvanized steel or a material hav- 90% Horizontal Furnace Shown ing 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. 9.3.8.2Ducts shall terminate in an unobstructed space, allowing free movement of combustion air to the appliances. 9.3.8.3Ducts shall serve a single space. 20 INSTALLATION CONSIDERATIONS 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 Vent/Flue Pipe Cuts front of the furnace. When installing a *MVM97 horizontally with the left side 1.Remove screws from vent flange. down, there are two options for connecting the vent pipe to 2.Remove internal elbow and vent pipe. the furnace. 3.Cut pipe 2 1/2” from flange. 1.Venting may be connected to the furnace vent pipe fit- 4.Remove cabinet plug adjacent to inducer outlet and in- ting on the original top (now the end) of the furnace stall an original cabinet vent hole. 2.The internal vent pipe and elbow may be removed from 5.Install RF000142 coupling on inducer outlet. the furnace to permit the vent to exit the top (original side) of the furnace. If this option is used, an RF000142 6.Install flanged vent section removed in step 2 & secure Vent-Drain coupling must be used to keep condensate with clamps. from collecting in the inducer assembly. 7.Secure flange to cabinet using screws removed in step Refer to the following instructions and illustration. 1. Insert flange. Cut 2 ½” long. R000142F 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 connec- tions 21 INSTALLATION CONSIDERATIONS Alternate Electrical and Gas Line Connections WARNING The furnaces have provisions allowing for electrical and gas line connections through either side panel. In horizontal ap- U PON COMPLETION OF THE FURNACE INSTALLATION, CAREFULLY INSPECT THE plications the connections can be made either through the ENTIRE FLUE SYSTEM BOTH INSIDE AND OUTSIDE THE FURNACE TO ASSURE IT “top” or “bottom” of the furnace. IS PROPERLY SEALED. L EAKS IN THE FLUE SYSTEM CAN RESULT IN SERIOUS PERSONAL INJURY OR DEATH DUE TO EXPOSURE TO FLUE PRODUCTS, Drain Pan INCLUDING CARBON MONOXIDE. A drain pan must be provided if the furnace is installed above A condensing gas furnace achieves its high level of efficiency a conditioned area. The drain pan must cover the entire area by extracting almost all of the heat from the products of under the furnace (and air conditioning coil if applicable). combustion and cooling them to the point where condensa- tion takes place. Because of the relatively low flue gas tem- Freeze Protection perature and water condensation requirements, PVC pipe is If the drain trap and drain line will be exposed to tempera- used as venting material. tures near or below freezing, adequate measures must be taken to prevent condensate from freezing. NOTE:The use This furnace must not be connected to Type B, BW, or L of insulation and/or heat tape is recommended. Failure to vent or vent connector, and must not be vented into any provide proper condensate drainage can result in property portion of a factory built or masonry chimney except when damage. used as a pathway for PVC as described later in this sec- tion.Never common vent this appliance with another appli- ance or use a vent which is used by a solid fuel appliance. Propane Gas and/or High Altitude Installations It is the responsibility of the installer to follow the manufac- turers’ recommendations and to verify that all vent/flue pip- WARNING ing and connectors are compatible with furnace flue prod- ucts. Additionally, it is the responsibility of the installer to P OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR IF T HE APPROPRIATE KITS THE CORRECT CONVERSION KITS ARE NOT INSTALLED. ensure that all piping and connections possess adequate A LL MUST BE APPLIED TO INSURE SAFE AND PROPER FURNACE OPERATION. structural integrity and support to prevent flue pipe separa- CONVERSIONS MUST BE PERFORMED BY A QUALIFIED INSTALLER OR SERVICE tion, shifting, or sagging during furnace operation. AGENCY. Materials and Joining Methods This furnace is shipped from the factory configured for natu- ral gas at standard altitude. Propane gas installations re- WARNING quire an orifice change to compensate for the energy con- tent difference between natural and propane gas. T O AVOID BODILY INJURY, FIRE OR EXPLOSION, SOLVENT CEMENTS MUST BE High altitude installations may require both a pressure switch KEPT AWAY FROM ALL IGNITION SOURCES (I.E., SPARKS, OPEN FLAMES, AND A EXCESSIVE HEAT) AS THEY ARE COMBUSTIBLE LIQUIDS. VOID BREATHING and an orifice change. These changes are necessary to com- CEMENT VAPORS OR CONTACT WITH SKIN AND/OR EYES. pensate for the natural reduction in the density of both the gas fuel and the combustion air at higher altitude. Precautions should be taken to prevent condensate from Refer to the Accessories Charts in this manual or product freezing inside the vent/flue pipe and/or at the vent/flue pipe Specification Sheet for a tabular listing of appropriate termination. It is our recommendation that all vent/flue piping manufacturer’s kits for propane gas and/or high altitude in- exposed to temperatures below 35°F for extended periods stallations. The indicated kits must be used to insure safe of time should be insulated with 1/2” thick closed cell foam. and proper furnace operation. All conversions must be per- Also all vent/flue piping exposed outdoors in excess of the formed by a qualified installer, or service agency. terminations shown in this manual (or in unheated areas) should be insulated with 1/2” thick closed cell foam. Inspect VENT/FLUE PIPE AND COMBUSTION AIR PIPE piping for leaks prior to installing insulation. The following bullets and diagram describe the restrictions WARNING concerning the appropriate location of vent/flue pipe and com- bustion air intake pipe (when applicable) terminations. Re- F AILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN BODILY INJURY OR fer to the installation instructions for specific details on ter- DEATH. C AREFULLY READ AND FOLLOW ALL INSTRUCTIONS GIVEN IN THIS mination construction. SECTION. •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 INSTALLATION CONSIDERATIONS NOTE: This provision does not apply to the combus- Non-Direct Vent Installations tion air intake termination of a direct vent application. A minimum of one 90° elbow must be installed on the com- bustion air intake “coupling” to guard against inadvertent •The vent termination of a non-directvent application blockage. must terminate at least 4 feet below, 4 feet horizon- tally 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 WARNING a roof must terminate at least 12 inches above the roof line (or the anticipated snow level) and be at least HE RUBBER ELBOW IS NOT DESIGNED TO SUPPORAT A LOAD. HEN THE TW 12 inches from any vertical wall (including any antici- RUBBER ELBOW IS MOUNTED EXTERNALLY TO THE FURNACE CABINET, pated snow build up). EXTREME CARE MUST BE TAKEN TO ADEQUATELY SUPPORT FIELD-SUPPLIED VENT/FLUE PIPING, AS DAMAGE CAN RESULT IN LEAKS CAUSING BODILY •A vent termination shall not terminate over public walk- INJURY OR DEATH DUE TO EXPOSURE TO FLUE GASES, INCLUDING CARBON ways or over an area where condensate or vapor could MONOXIDE. create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves, or other Vent/Flue Pipe Lengths (Non-Direct Vent) and Diam- equipment. eters •The combustion air intake termination of a direct vent Refer to the following table for applicable length, elbows, application should not terminate in an area which is and pipe diameter for construction of the vent/flue pipe sys- frequently dusty or dirty. tem of a non-direct vent installation. In addition to the vent/ NOTE: In Canada, CAN B149.1 Fuel Gas Code takes pre- flue pipe, a single 90° elbow must be secured to the com- cedence over the preceding termination restrictions. bustion air intake to prevent inadvertent blockage. The tee or elbows used in the vent/flue termination must be included OTHER THAN COMBUSTION AIR when determining the number of elbows in the piping sys- TERMINATION INTAKE tem. NON-DIRECT VENT VENT/FLUE TERMINATION Vent/Flue and Combustion Air Pipe Lengths and Diam- eters NO TERMINATIONS ABOVE WALKWAY Refer to the following table for applicable length, elbows, 10' and pipe diameter for construction of the vent/flue and com- 4' 12" bustion air intake pipe systems of a non-direct vent (single 3" 4' pipe) installation. The number of elbows tabulated repre- 12" sents the number of elbows and/or tees in each (Vent/Flue & Combustion Air Intake) pipe. Elbows and/or tees used in GRADE OR HIGHEST 12" ANTICIPATED the terminations must be included when determining the num- SNOW LEVEL 12" ber of elbows in the piping systems. FORCED AIR NON-DIRECT VENT INLET VENT/FLUE TERMINATION If the combustion air intake pipe is to be installed above a DIRECT VENT VENT/FLUE TERMINATION 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 90% Furnace Vent Termination Clearances such as Armaflex or Insultube where required. Direct Vent Installations Onupflowunits secure the combustion air intake pipe di- Vent/Flue Pipe Terminations rectly to the air intake coupling. On counterflow units se- The vent/flue pipe may terminate vertically, as through a roof, cure the combustion air intake pipe to the air intake cou- or horizontally, as through an outside wall. pling using the rubber coupling and worm gear hose clamps Vertical vent/flue pipe termination should be as shown in the provided with the unit. The counterflow rubber coupling al- following figures. Refer to Vent/Flue Pipe and Combustion lows service removal of air intake piping internal to the fur- Air Pipe - Termination Locations section in this manual or nace blower compartment. The combustion air intake pipe the installation instructions for details concerning location can also be secured directly to the counterflow unit air in- restrictions. The penetration of the vent through the roof must take pipe coupling. be sealed tight with proper flashing such as is used with a plastic plumbing vent. 23 INSTALLATION CONSIDERATIONS Horizontal vent/flue pipe terminations should be as shown in 12" MINIMUM the following figure. Refer to Vent/Flue Pipe and Combus- tion Air Pipe - Termination Locations section in this manual VENT/FLUE TEE or the installation instructions for details concerning loca- OR tion restrictions. A 2 3/8" diameter wall penetration is re- 90° ELBOW TURNED quired for 2" diameter pipe while a 3 1/2" diameter hole is DOWN 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 12" MINIMUM ABOVE solvent cemented to a length of pipe connecting the two HIGHEST ANTICIPATED couplings. The length of pipe should be the wall thickness SNOW LEVEL 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 be- tween joist spaces. If the vent pipe must go below a joist and then up into the last joist space to penetrate the header, 90% Furnace Horizontal Termination (Single Pipe) two 45° elbows should be used to reach the header rather Above Highest Anticipated Snow Level than two 90° elbows. NOTE:Terminate both pipes in the same pressure zone Direct Vent (Dual Pipe) Piping (same side of roof, no major obstacle between pipes, etc). Direct vent installations require both a combustion air in- take and a vent/flue pipe. The pipes may be run horizontally and exit through the side of the building or run vertically and TEE (OPTIONAL) 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 chim- COMBUSTION AIR INTAKE 12” MIN (OPTIONAL) HEIGHT DIFFERENCE ney. The space between the pipes and the chimney must BETWEEN *Not required for be closed with a weather tight, corrosion resistant flashing. single pipe installation INTAKE AND VENT Both the combustion air intake and a vent/flue pipe termina- tions must be in the same atmospheric pressure zone. Re- fer to Vent/Flue and Combustion Air Pipe - Termination Lo- INTAKE cations or Concentric Vent Termination section in this manual SCREEN OPTIONAL or the installation instructions for specific details on termi- nation construction. (6) 12” MIN TO ROOF OR HIGHEST *MVC96/*CVC96 Direct Vent (2 - Pipe) and Non-Direct Vent (1- Pipe) ANTICIPATED SNOW LEVEL Maximum Allowable Length of Vent/Flue Pipe (1) (2) & Combustion Air Pipe (ft) (3) (5) Number of Elbows Pipe Size Unit Input (4) (Btu) (in.) 12345678 2 ELBOWS 40,000120115110105100959085 or 2 1/2 STRAIGHT 2 60,0009590858075706560 or 2 1/2 80,000 "B"2 or 2 1/27570656055504540 80,000 "B"3200193186179172165158151 80,000 "C"2 or 2 1/2252015105N/AN/AN/A 80,000 "C"3200193186179172165158151 100,0002 or 2 1/2252015105N/AN/AN/A 100,0003200193186179172165158151 120,0002 or 2 1/24540353025201510 120,00039590858075706560 24 INSTALLATION CONSIDERATIONS 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 90° one elbow/tee. ELBOWS 3)Tee used in the vent/flue termination must be included when deter- mining 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. 3” - 24” 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 con- nection. AIR INTAKE Vent/Flue and Combustion Air Pipe Terminations SCREEN (OPTIONAL) V ENT/F LUEAND C OMBUSTION A IR P IPE T ERMINATIONS The vent/flue and combustion air pipes may terminate verti- 12" MIN. ABOVE HIGHEST ANTICIPATED cally, as through a roof, or horizontally, as through an out- SNOW LEVEL side wall. Vertical pipe terminations should be as shown in the follow- ing figure.Refer to Section IX, Vent/Flue Pipe and Com- 90% Alternate Horizontal Vent Termination (Dual Pipe) 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. 10”- 24” Horizontal terminations should be as shown in the following figure. Refer to Vent/Flue Pipe and Combustion Pipe - Ter- 6” MAX 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" 4” MIN 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 90º OR 45° ELBOW the wall and solvent cemented to a pipe connecting the two couplings. The pipe length should be the wall thickness SCREEN (OPTIONAL) plus the depth of the socket fittings to be installed on the inside and outside of the wall. The wall penetration should 12" MIN. TO GRADE OR be sealed with silicone caulking material. HIGHEST ANTICIPATED SNOW LEVEL Standard Horizontal Terminiations (Dual Pipe) Vent & Combustion Air Intake Measurements for Stan- dard Horizontal Terminations (Dual Pipe) Center to center = 10” min / 24” max. Vertical separation: 0” - 24” Vent termination from wall = 8” min / 12” max. Combustion air intake from wall = 6” max. Vent and intake clearance to ground or anticipated snow level = 12” min. 25 INSTALLATION CONSIDERATIONS Condensate Drain Lines and Drain Trap 90° ELBOWS 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 appropri- ate drain location in compliance with local and national codes. Follow the bullets listed below when installing the drain system. 3”-24” BETWEEN PIPES Refer to the following sections for specific details concerning AIR furnace drain trap installation and drain hose hook ups. INTAKE SCREEN •The drain trap supplied with the furnace must be used. (OPTIONAL) •The drain trap must be primed at time of installation. 12" MIN. ABOVE •The drain line between furnace and drain location must HIGHEST ANTICIPATED SNOW LEVEL 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 Combustion Air Intake may also be snorkeled to obtain 12” drain. min ground clearance. •Do not trap the drain line in any other location than at the 90% Furnace Alternate Vent Termination drain trap supplied with the furnace. Above Anticipated Snow Level (Dual Pipe) •If the drain line is routed through an area which may see temperatures near or below freezing, precautions must In a basement installation, the pipes may be run between be taken to prevent condensate from freezing within the the joist spaces. If the pipes must go below the joist and drain line. then up into the last joist space to penetrate the header, two 45° elbows should be used to reach the header rather than •If an air conditioning coil is installed with the furnace, a two 90° elbows. common drain may be used. An open tee must be in- stalled in the drain line, near the cooling coil, to relieve V ENT/I NTAKE T ERMINATIONS F OR I NSTALLATIONOF M ULTIPLE positive air pressure from the coil’s plenum. This is nec- D IRECT V ENT F URNACES essary to prohibit any interference with the function of the If more than one direct vent furnace is to be installed verti- furnace’s drain trap. cally through a common roof top, maintain the same mini- mum clearances between the exhaust vent and air intake terminations of adjacent units as with the exhaust vent and WARNING air intake terminations of a single unit. I N UPRIGHT UPFLOW INSTALLATIONS, THE DRAIN TRAP MUST BE MOUNTED ON If more than one direct vent furnace is to be installed hori- THE OPPOSITE SIDE OF THE UNIT FROM THE JUNCTION BOX. T HIS WILL zontally through a common side wall, maintain the clear- REDUCE THE RISK OF WATER REACHING THE JUNCTION BOX IN THE EVENT OF ap.rt ances as in the following figure. Always terminate all ex- A BLOCKED DRAIN CONDITION. F AILURE TO FOLLOW THESE INSTRUCTIONS haust vent outlets at the same elevation and always termi- CAN RESULT IN POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH nate all air intakes at the same elevation. DUE TO ELECTRICAL SHOCK. 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 con- version kits required for alternate fuels and/or high altitude. 3” - 24” 12” MIN SEPARATION CAUTION 3” MIN T O PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING. OPTIONAL INTAKE SCREENS 12” MIN TO GRADE OR HIGHEST ANTICIPATED SNOW LEVEL 90% Furance Horizontal Venting of Multiple Units (Dual Pipe) 26 INSTALLATION CONSIDERATIONS Inlet gas supply pressures must be maintained within the ranges specified below. The supply pressure must be con- stant and available with all other household gas fired appli- ances 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 MANIFOLD Natural GasMinimum: 4.5" w.c.Maximum: 10.0" w.c. Propane GasMinimum: 11.0" w.c.Maximum: 13.0" w.c. HIGH ALTITUDE DERATE DESCRIPTION: This kit is designed for gas-fired units con- When this furnace is installed at high altitude, the appropri- verted to propane gas use. The Propane Low Pressure ate High Altitude orifice kit must be applied. This is required (LPLP03) Kit monitors the gas line pressure with a pressure due to the natural reduction in the density of both the gas switch and disables the unit's gas valve if the line pressure fuel and combustion air as altitude increases. The kit will drops below acceptable levels. provide the proper design certified input rate within the speci- fied altitude range. GAS VALVE High altitude kits are purchased according to the installa- This unit is equipped with a 24 volt gas valve controlled dur- tion altitude and usage of either natural or propane gas. ing furnace operation by the integrated control module. As Refer to the product Specification Sheet or Technical Manual shipped, the valve is configured for natural gas. The valve is for a tabular listing of appropriate altitude ranges and corre- field convertible for use with propane gas by using the ap- sponding manufacturer’s high altitude (Natural, Propane gas, propriate propane gas conversion kit. Taps for measuring and/or Pressure Switch) kits. the gas supply pressure and manifold pressure are provided on the valve. Donot derate the furnace by adjusting the manifold pres- sure to a lower pressure than specified on the furnace rat- ing 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 yel- Low (Main) low tipping. Common In some areas the gas supplier may artificially derate the High gas in an effort to compensate for the effects of altitude. If the gas is artificially derated, the appropriate orifice size 3 must be determined based upon the BTU/ft content of the derated gas and the altitude. Refer to the National Fuel Gas Code, NFPA 54/ANSI Z223.1, and information provided by the gas supplier to determine the proper orifice size. A different pressure switch may be required at high altitude 3 regardless of the BTU/ft content of the fuel used. Refer to the product Specification Sheet or Technical Manual for a tabular listing of appropriate altitude ranges and correspond- White-Rodgers 2-Stage Valve ing manufacturer’s pressure switch kits. NOTE: The gas supply pressure on White-Rodger "J" PROPANE GAS CONVERSION model gas valve, used on single and two stage fur- naces, can be checked with a gas pressure test kit (Part WARNING #0151K00000S) available through our authorized dis- tributors. P OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INSTALLED. T HE APPROPRIATE KITS MUST BE APPLIED TO INSURE SAFE AND PROPER FURNACE OPERATION. LL A CONVERSIONS MUST BE PERFORMED BY A QUALIFIED INSTALLER OR SERVICE AGENCY. 27 INSTALLATION CONSIDERATIONS 4.Install a drip leg to trap dirt and moisture before it can GAS PIPING CONNECTIONS enter the gas valve. The drip leg must be a minimum of three inches long. CAUTION 5.Install a 1/8" NPT pipe plug fitting, accessible for test gage connection, immediately upstream of the gas T O AVOID POSSIBLE UNSATISFACTORY OPERATION OR EQUIPMENT DAMAGE supply connection to the furnace. DUE TO UNDERFIRING OF EQUIPMENT, USE THE PROPER SIZE OF NATURAL/PROPANE GAS PIPING NEEDED WHEN RUNNING PIPE FROM THE 6.Use two pipe wrenches when making connection to METER/TANK TO THE FURNACE. the gas valve to keep it from turning. The orientation of the gas valve on the manifold must be maintained The gas piping supplying the furnace must be properly sized as shipped from the factory. based on the gas flow required, specific gravity of the gas, 7.Install a manual shutoff valve between the gas meter and length of the run. The gas line installation must comply and unit within six feet of the unit. If a union is in- with local codes, or in their absence, with the latest edition of stalled, the union must be downstream of the manual the National Fuel Gas Code, NFPA 54/ANSI Z223.1. shutoff valve, between the shutoff valve and the fur- nace. Natural Gas Capacity of Pipe 8.Tighten all joints securely. In Cubic Feet of Gas Per Hour (CFH) Length ofNominal Black Pipe Size Pipe in Feet1/2"3/4"1"1 1/4"1 1/2" 1013227852010501600 20921903507301100 3073152285590980 4063130245500760 5056115215440670 6050105195400610 704696180370560 804390170350530 904084160320490 1003879150305460 (Pressure 0.5 psig or less and pressure drop of 0.3" W.C.; Based on 0.60 Specific Gravity Gas) BTUH Furnace Input CFH = Heating Value of Gas (BTU/Cubic Foot) To connect the furnace to the building’s gas piping, the in- staller 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 transi- tion 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 INSTALLATION CONSIDERATIONS GAS PIPING CHECKS All propane gas equipment must conform to the safety stan- dards of the National Board of Fire Underwriters, NBFU Before placing unit in operation, leak test the unit and gas Manual 58. connections. For satisfactory operation, propane gas pressure must be 10 inch WC at the furnace manifold with all gas appliances WARNING in operation. Maintaining proper gas pressure depends on three main factors: T O AVOID THE POSSIBLITY OF EXPLOSION OR FIRE, NEVER USE A MATCH OR OPEN FLAME TO TEST FOR LEAKS. 1.Vaporization rate, depending on temperature of the liq- uid, and “wetted surface” area of the container or con- Check for leaks using an approved chloride-free soap and tainers. water solution, an electronic combustible gas detector, or 2.Proper pressure regulation. (Two-stage regulation is rec- other approved testing methods. ommended for both cost and efficiency). NOTE: Never exceed specified pressures for testing. Higher 3.Pressure drop in lines between regulators, and between pressure may damage the gas valve and cause subsequent second stage regulator and the appliance. Pipe size will overfiring, resulting in heat exchanger failure. Disconnect this depend on length of pipe run and total load of all appli- unit and shutoff valve from the gas supply piping system ances. before pressure testing the supply piping system with pres- Complete information regarding tank sizing for vaporization, sures in excess of 1/2 psig (3.48 kPa). Isolate this unit from recommended regulator settings, and pipe sizing is avail- the gas supply piping system by closing its external manual able from most regulator manufacturers and propane gas gas shutoff valve before pressure testing supply piping sys- suppliers. tem with test pressures equal to or less than 1/2 psig (3.48 Use pipe dope approved for use with L.P. gas. kPa). Refer to the following illustration for typical propane gas in- stallations and piping. PROPANE GAS TANKS AND PIPING 5 to 15 PSIG First Stage WARNING (20 PSIG Max.) Regulator Continuous 11" W.C. P ROPANE GAS IS HEAVIER THAN AIR AND ANY LEAKING GAS CAN SETTLE IN T O PREVENT PROPERTY DAMAGE, ANY LOW AREAS OR CONFINED SPACES. PERSONAL INJURY, OR DEATH DUE TO FIRE OR EXPLOSION CAUSED BY A 200 PSIG Second Stage Maximum Regulator PROPANE GAS LEAK, INSTALL A GAS DETECTION WARNING DEVICE. 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 Typical Propane Gas Installation suspected, adhere to the instructions in the following warn- ing. WARNING WARNING I F THE GAS FURNACE IS INSTALLED IN A BASEMENT, AN EXCAVATED AREA OR A CONFINED SPACE, IT IS STRONGLY RECOMMENDED TO F THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A I CONTACT A PROPANE SUPPLIER TO INSTALL A GAS DETECTING FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL WARNING DEVICE IN CASE OF A GAS LEAK. INJURY OR LOSS OF LIFE. •S INCE PROPANE GAS IS HEAVIER THAN AIR, ANY LEAKING GAS CAN –O NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND D SETTLE IN ANY LOW AREAS OR CONFINED SPACES. LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE. •P ROPANE GAS ODORANT MAY FADE, MAKING THE GAS UNDETECTABLE –: EXCEPT WITH A WARNING DEVICE. WHATTODOIFYOUSMELLGAS • D O NOT TRY TO LIGHT ANY APPLIANCE. • O NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY D PHONE IN YOUR BUILDING. WARNING • I MMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR’S PHONE. OLLOW THE GAS SUPPLIER’S INSTRUCTIONS. F A N UNDETECTED GAS LEAK WILL CREATE A DANGER OF EXPLOSION • I F YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE OR FIRE. I F THE PRESENCE OF GAS IS SUSPECTED, FOLLOW THE DEPARTMENT. F AILURE TO DO SO INSTRUCTIONS ON THE COVER OF THIS MANUAL. –NSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER, I COULD RESULT IN SERIOUSPERSONALINJURYORDEATH. SERVICE AGENCY OR THE GAS SUPPLIER. 29 INSTALLATION CONSIDERATIONS When installing a propane storage tank, the contractor must WARNING consider proper tank sizing, safety, efficiency, ground char- acteristics and aesthetics. For a residential customer, the F THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A I size may range from 100-1,000 gallons, depending on house- FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL hold use. Typically, a 500 gallon tank is ample for an aver- INJURY OR LOSS OF LIFE. age four-bedroom home. However, it is best to consult your –O NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND D local propane supplier to ensure the proper sizing for pro- LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE. pane storage requirements. Determining the correct tank –: WHATTODOIFYOUSMELLGAS size for each household is a function of demand, economy, • O NOT TRY TO LIGHT ANY APPLIANCE. D efficiency and convenience. It is a process that requires • O NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY D cooperation between the propane supplier and customer. PHONE IN YOUR BUILDING. • MMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR’S I ELECTRICAL CONNECTIONS PHONE. F OLLOW THE GAS SUPPLIER’S INSTRUCTIONS. • F YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE I DEPARTMENT. WARNING – I NSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER. T O AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO THE UNIT MUST BE PROPERLY POLARIZED AND GROUNDED. Sizing Between First and Second Stage Regulator* Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting. Capacities in 1,000 BTU/hour. Pipe or WARNING Nominal Pipe Size TubingTubing Size, O.D. Type L Schedule 40 Length HIGHVOLTAGE Feet 3/8"1/2"5/8"3/4"7/8"1/2"3/4" D ISCONNECT ALL POWER BEFORE SERVICING OR 107301,7003,2005,3008,3003,2007,500 INSTALLING THIS UNIT. M ULTIPLE POWER SOURCES MAY 205001,1002203,7005,8002,2004,200 F AILURE TO DO SO MAY CAUSE PROPERTY BE PRESENT. 304009202,0002,9004,7001,8004,000 DAMAGE, PERSONAL INJURY OR DEATH. 403708501,7002,7004,1001,6003,700 503307701,5002,4003,7001,5003,400 603007001,3002,2003,3001,3003,100 802606101,2001,9002,9001,2002,600 1002205401,0001,7002,6001,0002,300 CAUTION 1252004909001,4002,3009002,100 1501904308301,3002,1008301,900 L ABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. 1751704007801,2001,9007701,700 W IRING ERRORS CAN COUSE IMPROPER AND DANGEROUS OPERATION. 2001603807301,1001,8007201,500 V ERIFY PROPER OPERATION AFTER SERVICING. To convert to capacities at 15 psig settings - multiply by 1.130 To convert to capacities at 5 psig settings - multiply by 0.879 WIRING HARNESS Sizing Between Second or Second Stage Regulator & Appliance* The wiring harness is an integral part of this furnace. Field Maximum Propane Capacities listed are based on 1/2" W.C. pressure drop at 11" W.C. setting. Capacities in 1,000 BTU/hour. alteration to comply with electrical codes should not be required. Wires are color coded for identification purposes. Pipe or Nominal Pipe Size TubingTubing Size, O.D. Type L Refer to the wiring diagram for wire routings. If any of the Schedule 40 Length original wire as supplied with the furnace must be replaced, Feet 3/8"1/2"5/8"3/4"7/8"1/2"3/4"1"1-1/4"1-1/2" 1039921993295012755671,0712,2053,307 it must be replaced with wiring material having a tempera- 2026621312163461893937321,4962,299 ture rating of at least 105° C. Any replacement wiring must 3021501071812771523155901,2121,858 be copper conductor. 401941901452331292675041,0391,559 501837791311981142374489131,417 601635721,2111871032174098341,275 115 VOLT LINE CONNECTIONS 80132962104155891853467241,066 Before proceeding with electrical connections, ensure that 1001126559013878162307630976 1251024488112269146275567866 the supply voltage, frequency, and phase correspond to 150921437210963132252511787 that specified on the unit rating plate. Power supply to the 200819396610054112209439665 furnace must be N.E.C. Class 1, and must comply with all 25081736609348100185390590 *Data in accordance with NFPA pamphlet No. 54 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 Propane Gas Piping Charts 70 and/or The Canadian Electric Code CSA C22.1. 30 INSTALLATION CONSIDERATIONS Use a separate fused branch electrical circuit containing prop- Accessory Load Specifications erly sized wire, and fuse or circuit breaker. The fuse or cir- Humidifier1.0 Amp maximum at 120 VAC cuit breaker must be sized in accordance with the maxi- Electronic Air Cleaner1.0 Amp maximum at 120 VAC mum overcurrent protection specified on the unit rating plate. An electrical disconnect must be provided at the furnace Turn OFF power to the furnace before installing any acces- location. sories. Follow the humidifier or air cleaner manufacturers’ NOTE: Line polarity must be observed when making field instructions for locating, mounting, grounding, and control- connections. ling these accessories. HUMIDIFIER CONNECTION OPTIONS NING WAR 24 volt thermostat I N 90% FURNACE UPRIGHT UPFLOW INSTALLATIONS, THE DRAIN TRAP MUST Option 1:Use the single HUM terminal to supply 115 VAC BE MOUNTED ON THE OPPOSITE SIDE OF THE UNIT FROM THE JUNCTION to a humidifier transformer. This terminal is pow- BOX. T HIS WILL REDUCE THE RISK OF WATER REACHING THE JUNCTION ered anytime there is a call for heat. BOX IN THE EVENT OF A BLOCKED DRAIN CONDITION. Option 2:Use the brown wire coming off the common side of the pressure switch to supply 24 VAC to hu- Connect hot, neutral, and ground wires as shown in the wir- midifier ing diagram located on the unit’s blower door. Line polarity Option 3:The HUM IN / HUM OUT terminals are dry con- must be observed when making field connections. Line volt- tacts that will close during a call for heat. To age connections can be made through either the right or left power a humidifier with these contacts The HUM side panel. IN contact can be fed with 24vac from the R ter- minal 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 con- trolled by a separate humidistat. The recommended wiring NOTE: Wire routing must not interfere with circulator blower is one of the methods shown with a 24 volt thermostat. operation, filter removal, or routine maintenance. CTK02is capable of generating a call for humidity. See dia- gram for wiring. The user is now provided with 3 modes of WARNING operations which can be selected within the thermostat user menu. T O AVOID THE RISK OF ELECTRICAL SHOCK, INJURY, OR DEATH, THE FURNACE MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH LOCAL 1. ON: Humidifier is turned on with a heat demand. CODES OR, IN THEIR ABSENCE, WITH THE LATEST EDITION OF THE 2. OFF: Humidifier remains off (relay never closes). N ATIONAL E LECTRIC C ODE. 3. IND: Humidifier will cycle with humidification demand, in- dependent of heat demand. This mode allows the user to select one of 4 fan speeds (25, 50, 75, and 100%). 115 VOLT LINE CONNECTION OF ACCESSORIES (HUMIDIFIER AND ELECTRONIC AIR CLEANER) 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 WARNING provide a line voltage output when the inducer is running. HIGHVOLTAGE ISCONNECT POWER BEFORE SERVICING OR DALL CTK03AB and CTK04, can provide a humidity call to the CHANGING ANY ELECTRICAL WIRING. M ULTIPLE POWER SOURCES MAY BE PRESENT. F AILURE TO DO SO MAY CAUSE PCBKF103 or PCBKF104 control board relay and operate PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. the HUM IN - HUM OUT dry contacts. HUMIDIFIER WIRING All communicating furnaces have an integrated igni- Accessory wiring connections are to be made through the tion control that is equipped with line voltage acces- 1/4" quick connect terminals provided on the furnace inte- sory terminals for controlling power to an optional field- grated control module.The Humidifier and Electronic Air supplied humidifier and/or electronic air cleaner. Cleaner hot and neutral terminals are identified as HUM and EAC. All field wiring must conform to applicable codes. Con- nections should be made as shown in OPTIONAL ACCES- SORIES, Accessories Wiring figure. 31 INSTALLATION CONSIDERATIONS NEUTRAL 24 V OLT H UMIDIFIER 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. A UXILIARY A LARM S WITCH: The control is equipped with a 24VAC Auxiliary Alarm Input Accessories Wiring (12 inch purple / white wire attached to pin 6 of 15 pin con- If it is necessary for the installer to supply additional line voltage nector) which can be utilized with communicating mode set- wiring to the inside of the furnace, the wiring must conform to all ups (typically used for condensate switch wiring but could local codes, and have a minimum temperature rating of 105°C. sensors or Fire Alarms). be used with compatible C0 2 All line voltage wire splices must be made inside the furnace Legacy mode use junction box. In a legacy system (Non-communicating), this auxiliary alarm The integrated control module humidifier terminal (HUM) is ener- input is not operational. Any auxiliary alarm switch must be gized with 115 volts whenever the induced draft blower is ener- used to interrupt Y1 signal either to IFC or to UC. gized. The integrated control module electronic air cleaner ter- Communication mode use minals (EAC) are energized with 115 volts whenever the circula- This feature can be activated or deactivated through the ther- tor blower is energized. mostat user menus. By default, an AUX switch is normally In addition, the control is equipped with a dedicated humidi- closed and opens when the water level in the evaporator coil fication relay which is available through ¼ inch terminals base pan reaches a particular level. The control will respond HUM-IN and HUM-OUT. Similar to the HUM terminal, when by turning off the outdoor compressor and display the proper utilizing legacy connections, this relay will be closed during fault codes. If the AUX switch is detected closed for 30 sec- normal heating operation (115VAC must be present on the onds, normal operation resumes and error messages are no HUM-IN terminal to take advantage of HUM-OUT). How- longer displayed. Installer must wire control voltage (24VAC) ever, the control can provide additional humidification fea- to AUX switch to ensure the Auxiliary Alarm Input has 24VAC tures when wired to a communicating thermostat (1, 2, R, C during normal operation. connections). If the communicating thermostat is not ca- pable of providing a humidification call, this dedicated relay 24 VOLT THERMOSTAT WIRING will function exactly as mentioned above with a legacy setup. NOTE: Low voltage connections can be made through ei- If the communicating thermostat is capable of providing a ther the right or left side panel. Wire routing must not inter- humidification call the user is now provided with 3 modes of fere with circulator blower operation, filter removal, or routine operations which can be selected within the thermostat user maintenance. menu. A 40 V.A. transformer and an integrated electronic control 1.ON: Humidifier is turned on during a call for heat along are built into the furnace to allow use with most cooling equip- with a call for humidity ment. Consult the wiring diagram, located in the Technical 2.OFF: Humidifier remains off (relay never closes). Manual or on the blower door for further details of 115 Volt 3.IND: Humidifier will cycle with humidification demand, and 24 Volt wiring. independent of heat demand. This mode allows the user to select one of 4 fan speeds (25, 50, 75, and 100%). 32 INSTALLATION CONSIDERATIONS Thermostat Wiring - Two-Stage Variable Speed In a Non-Dual Fuel Thermostat ComfortNet™ Furnaces Application, Place Jumper Two-Stage Heating Between Y1 and O For with As a two-stage non-communicating furnace, the furnace Proper Dehumidification Single-Stage Cooling Y Operation and Proper integrated control module provides terminals for both “W1” Ramping Profile Operation and “W2”, and “Y1” and “Y2” thermostat connections. This R allows the furnace to support the following system applica- tions: ‘Two-Stage Heating Only’, ‘Two-Stage Heating with Furnace Integrated R Single Stage Cooling’, and ‘Two-Stage Heating with Two-Control Module Stage Cooling’. Refer to the following figures for proper NEU connections to the integrated control module. YC Dehumidistat Low voltage connections can be made through either the \[Optional\] Remote right or left side panel. Thermostat wiring entrance holes Condensing Unit (Single-Stage Cooling) are located in the blower compartment. The following figure shows connections for a “heat/cool system”. Two-Stage Heating with Single-Stage Cooling This furnace is equipped with a 40 VA transformer to facili- tate use with most cooling equipment. Consult the wiring diagram, located on the blower compartment door, for fur- ther details of 115 Volt and 24 Volt wiring. In a Non-Dual Fuel Thermostat W2 Y2 Application, Place Jumper Two-Stage Heating NOTE: For single stage cooling applications, a jumper may Between Y1 and O For with Proper Dehumidification () Two-Stage Cooling W1 Operation and Proper be required between Y1 and Y2 at the furnace control in Ramping Profile Operation 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 Furnace Integrated stage (Y1 input) or high stage (Y2 input). Additionally, use Y2 W1W2 Control Module of ramping profile features require a jumper between Y1 and O when used with a straight cooling unit. NEU Y2 Dehumidistat NOTE:Thermostat “R” required if outdoor unit is equipped \[Optional\] with a Comfort Alert™ module or if the out door unit is a Remote Condensing Unit part of the ComfortNet family of equipment AND is wired as (Two-Stage Cooling) a legacy system. Two-Stage Heating with Two-Stage Cooling In a Non-Dual Fuel Application, Place Jumper Thermostat Thermostat Wiring Diagrams Between Y1 and O For Single Stage Heating with Proper Dehumidification Single Stage Cooling Operation and Proper Y Ramping Profile Operation R Furnace Integrated R Control Module NEU Dehumidistat YC \[Optional\] Remote Condensing Unit (Single-Stage Cooling) Single Stage Heating with Single Stage Cooling NOTE:To apply a single-stage Heating Thermostat, the thermostat selector switch on the Integrated Control Module be set on must single-stage. 33 INSTALLATION CONSIDERATIONS CFM CHART LowHighLowHigh ModelTapStageStageStageStage CoolCoolHeatHeat A 403596422494 B 527796471553 *MVC960403BN* C 675974521601 D 8031192574676 A 398599667953 B 5578177401059 *MVC960603BN* C 69610078081158 D 81012128811260 A 4036298551202 B 5408069231316 *MVC960803BN* C 705102310331389 D 819123010631396 A 5137898671228 B 6609679391337 *MVC960804CN* C 791118210161430 D 913137510771516 A 56482012561818 B 784113312921870 *MVC961005CN* C 982146413161910 D 1259173613581957 A 54786713291891 B 831116013621940 *MVC961205DN* C 1020146713901968 D 1278191014402028 A 449655682957 B 5698077501059 *CVC960403BN* C 7169988201155 D 85412078881251 A 433656687938 B 541790751950 *CVC960603BN C 686972814986 D 8061195874992 A4056247581057 B5498088151146 *CVC960803BN C6789948821256 D78411779461349 A 5568378891234 B 71410229441325 *CVC960804CN* C 838120610191442 D 991147510681528 A 52478412091759 B 744107812491797 *CVC961005CN* C 927138812771840 D 1185176613001881 A 54085412841744 B 870112313101827 *CVC961205DN* C 1000139913501860 D 1235180413881918 AIRFLOW TABLE 34 INSTALLATION CONSIDERATIONS DIP SWITCHES - FURNACES EQUIPPED WITH PCBKF103 / PCBKF104 Dip Switch Switch BankPurposeFunction 1234 90OffOff 120 OnOff Heating Off Delay 150OffOn 180OnOn S1 2 Stage Stat OnOn Thermostat 2 Stage StatOnOff Setup1 Stg Stat 5 min delayOffOff 1 Stg Stat auto delayOffOn AOffOff BOnOff Cooling Airflow COffOn D OnOn S3 Add 5% OffOff Minus 5%OnOff Trim Add 10%OffOn Minus 10%OnOn A OffOff BOnOff Ramping Profile COffOn DOnOn S4 AOffOff B OnOff Heating Airflow COffOn DOnOn Disabled Off Dehum EnabledOn Disabled Off Trim EnabledOn S5 25%OffOff 50% OnOff Continuous Fan 75%OffOn 100%OnOn * = Factory Setting 35 INSTALLATION CONSIDERATIONS For a furnace equipped with a PCBKF103 or PCBKF104 Single-Stage Thermostat Application control board, select preferences on S5 #1 DIP switch. A single-stage thermostat with only one heating stage may be used to control this furnace. The application of a single- Fossil Fuel Applications stage thermostat does not offer “true” thermostat-driven two- stage operation, but provides a timed transition from low to This function is automatically configured and controlled when high fire. The furnace will run on low stage for a fixed period using a communicating thermostat. of time before stepping up to high stage to satisfy the Furnaces can be used in conjunction with a heat pump in a thermostat’s call for heat. The delay period prior to stepping fossil fuel application. A fossil fuel application is where an up can be set at either a fixed 5 minute time delay or a load outdoor temperature sensor determines the most cost effi- based variable time between 1 and 12 minutes (AUTO mode). cient means of heating (heat pump, gas furnace, or both). If the AUTOmode is selected, the control averages the cycle times of the previous three cycles and uses the average to A heat pump thermostat with two stages of heat is required determine the time to transition from low stage to high stage. to properly use the single-stage furnace with a heat pump. A heat pump thermostat with three stages of heat is re- To use a single-stage thermostat, turn off power to the fur- quired to properly use the two-stage furnace with a heat nace, move the thermostat selection DIP switch to the OFF pump. Refer to dual fuel, AFE-18-60A installation manual position. Set the desired transition time by setting the tran- (IO-627) for additional wiring instructions. sition delay DIP switch to the desired ON/OFF position. Turn power back on. Select preferences on S1 #3 and #4 DIP switches. CONTINUOUS FAN OPERATION Continuous fan speed is selectable from a communicating thermostat or by DIP switches when using a conventional 24 Volt Dehumidistat Wiring (Not needed if a thermostat. ---------------------------- communicating thermostat is used) The optional usage of a dehumidistat allows the furnace’s CIRCULATOR BLOWER SPEED ADJUSTMENT circulator blower to operate at a slightly lower speed (85% of desired speed) during a combined thermostat call for cool- ing and dehumidistat call for dehumidification. This can be WARNING done through an independent dehumidistat or through a HIGHVOLTAGE thermostat’s DEHUM terminal (if available). This lower blower ISCONNECT ALL POWER BEFOR CHANGING SPEED TAPS. D speed enhances dehumidification of the conditioned air as it ULTIPLE POWER SOURCES MAY BE PRESENT. AILURE TO DO MF passes through the AC coil. For proper function, a dehumi- SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. distat applied to this furnace must operate on 24 VAC and utilize a switch which opens on humidity rise. Blower set up is automatically configured in a fully commu- To install/connect a dehumidistat: nicating system. Adjustments can also be made at the communicating thermostat. Set up blower speeds with DIP 1.Turn OFF power to furnace. switches when using a conventional thermostat. 2.Secure the dehumidistat neutral wire (typically the white This furnace is equipped with a multi-speed circulator blower. lead) to the terminal marked “DEHUM” on the furnace This blower provides ease in adjusting blower speeds. The integrated control module. heating blower speed is shipped set at “B”, and the cooling 3.Secure the dehumidistat hot wire (typically the black blower speed is set at “D”. These blower speeds should be lead) to the terminal marked “R” on the furnace integrated adjusted by the installer to match the installation require- control module. ments so as to provide the correct heating temperature rise 4.Secure the dehumidistat ground wire (typically the green and correct cooling CFM. lead) to the ground screw on the furnace junction box. Use the dual 7-segment LED display adjacent to the NOTE: Ground wire may not be present on all dehumi- dipswitches to obtain the approximate airflow quantity. The distats. airflow quantity is displayed as a number on the display, 5.Turn ON power to furnace. rounded to the nearest 100 CFM. The display alternates To enable the dehumidify function on the integrated control airflow delivery indication and the operating mode indica- module, set the dehumidification ENABLE dipswitch from tion. OFF to ON. COOLING CFM Once the switch is set, the dehumidify function is enabled Example:The airflow being delivered is 1225 CFM. The during a combination call for cooling (T-Stat) and dehumidi- display indicates 12. If the airflow being delivered is 1275, fication (DEHUM-Stat). the display indicates 13. For a furnace equpped with aPCBKF101 or PCBKF102 con- 1.Determine the tonnage of the cooling system installed trol board, select preferences on S5 #9 DIP switch. with the furnace. If the cooling capacity is in BTU/hr divide it by 12,000 to convert capacity to TONs. 36 INSTALLATION CONSIDERATIONS Example:Cooling Capacity of 30,000 BTU/hr. 100% CFM 30,000/12,000 = 2.5 Tons OFF OFF 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 manufactur- ers recommend an air flow of about 400 CFM per ton. •Profile D ramps up to 50% of the demand for 1/2 minute, Example: 2.5 tons X 400 CFM per ton = 1000 CFM then ramps to 85% of the full cooling demand airflow The cooling system manufacturer’s instructions must be and operates there for approximately 7 1/2 minutes. The checked for required air flow. Any electronic air cleaners or motor then steps up to the full demand airflow. Profile D other devices may require specific air flows, consult instal- has a 1/2 minute at 50% airflow OFF delay. lation instructions of those devices for requirements. 3.Knowing the furnace model, locate the high stage cool- OFF OFF ing 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 adjust- ment setting. ----------------------------------- HEATING SPEED 4. Locate the blower speed selection DIP switches on the1.Select the heating speed for your model from the heating integrated control module. Select the desired “cooling”speed chart in the Specification Sheet. The adjust setting speed tap by positioning switches S3 1 and 2 appropri-(already established by the cooling speed selection) deter- ately. ------------------------------------------mines which set of speeds are available. NOTE:Trim function must also be inabled on S5 #2 DIPThe selected speed must provide a temperature rise within switch.the rise range listed with the particular model. RAMPING PROFILESelect Heating Speed preferences on S4 #7 & #8 DIP Switches. Verify CFM by noting the number displayed 5.The multi-speed circulator blower also offers several cus- on the dual 7-segment LED display. tom ON/OFF ramping profiles. These profiles may be used to enhance cooling performance and increase com- In general lower heating speeds will: reduce electrical con- fort level. ------------------------------------ sumption, lower operating sound levels of the blower, and increase the outlet air temperature delivered to the home. Refer to the bullet points below for a description of each The speeds available allow the blower performance to be ramping profile. Verify CFM by noting the number dis- optimized for the particular homeowner’s needs. played on the dual 7-segment LED display. CIRCULATING AIR AND FILTERS •Profile A provides only an OFF delay of one (1) minute DUCTWORK - AIR FLOW at 100% of the cooling demand airflow. Duct systems and register sizes must be properly designed for the C.F.M. and external static pressure rating of the fur- 100% CFM100% CFM nace. Ductwork should be designed in accordance with the OFFOFF recommended methods of "Air Conditioning Contractors of 1 min America" manual D. A duct system should be installed in accordance with Stan- •Profile B ramps up to full cooling demand airflow by dards of the National Board of Fire Underwriters for the In- first stepping up to 50% of the full demand for 30 sec- stallation of Air Conditioning, Warm Air Heating and Venti- onds. The motor then ramps to 100% of the required lating Systems, Pamphlets No. 90A and 90B. airflow. A one (1) minute OFF delay at 100% of the A return air filter is not supplied with the furnace. The in- cooling airflow is provided. staller must supply a means of filtering all of the return air. Filter(s) shall comply with UL900 or CAN/ULC-S111 Stan- dards. If the furnace is installed without filters, the warranty 100% CFM 100% CFM 50% CFM OFF will be voided. OFF 1/2 min 1 min The following two charts show the bottom and side return filter sizes available for each size furnace. Larger sizes are also acceptable. •Profile C ramps up to 85% of the full cooling demand airflow and operates there for approximately 7 1/2 min- utes. The motor then steps up to the full demand air- flow. Profile C also has a one (1) minute 100% OFF delay. 37 INSTALLATION CONSIDERATIONS Upflow furnaces with air delivery of less than 1800 CFM: SIDE RETURNBOTTOM RETURN CabinetNominal Approx.CabinetNominal Approx. Use one side return or one bottom return ductwork connec- WidthFilterFlow AreaWidthFilterFlow Area tion. (In.)Size (In.)(In.)(In.)Size (In.)(In.) Upflow furnaces with air delivery of 1800 CFM or higher: All16x25x140014"14X25X1350 Use two side returns or one side return and one bottom 17-1/214X25X1350 return connection. 2116x25x1400 Guide dimples locate the side and bottom return cutout lo- 24-1/220X25X1500 cations. Use a straight edge to scribe lines connecting the dimples. Cut out the opening on these lines. An undersized Refer to Minimum Filter Area tables to determine filter area opening will cause reduced airflow. For bottom return con- requirement.NOTE: Filters can also be installed elsewhere nection, remove the bottom of the cabinet before setting the in the duct system such as a central return. 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 Filter Sizing Chart be attached to the back of the furnace. Supply and return ModelMinimum Filter Size connections to the furnace may be made with flexible joints *MVC960403BN**20 X 24 to reduce noise transmission, if desired. If a central return is *MVC960603BN**20 X 25 used, a connecting duct must be installed between the unit and the utility room wall so the blower will not interfere with *MVC960803BN**18 X 36 combustion air or draft. The room, closet, or alcove must *MVC960804CN**24 x 30 not be used as a return air chamber. *MVC961005CN**24 X 36 When the furnace is used in connection with a cooling unit, *MVC961205DN**2 (20 X 25) the furnace should be installed in parallel with or on the up- stream side of the cooling unit to avoid condensation in the *CVC960403BN**20 X 24 heating element. With a parallel flow arrangement, the damp- *CVC960603BN**20 X 25 ers or other means used to control the flow of air must be adequate to prevent chilled air from entering the furnace and, *CVC960804CN**18 X 36 if manually operated, must be equipped with means to pre- *CVC961005CN**24 x 30 vent operation of either unit unless the damper is in the full *CVC961205DN**2 (20 X 25) 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. One inch throwaway filters should be sized for a face veloc- ity of 300 feet per minute or less (14x25x1 throwaway = 730 UPRIGHT FILTER INSTALLATIONS CFM maximum, 16x25x1 throwaway = 830 CFM maximum, Depending on the installation and/or customer preference, 18x25x1 throwaway = 940 CFM maximum, 20x25x1 throw- differing filter arrangements can be applied. Filters can be away = 1040 CFM maximum) All other filters should be sized installed in the central return register and a side panel exter- according to their manufacturer's instructions. nal filter rack kit (upflow filter kit # EFR01). As an alternative 2 To find the miminum filter requirement (in) for either perma- a media air filter or electronic air cleaner can be used as the nent or disposable filters divide the required airflow (CFM) requested filter. Refer to the following minimum filter require- by the rated velocity of the filter, either 300ft/min for dispos- ment charts for determination of the minimum filter area to able filter or 600ft/min for permanent filter. Multiply the num- ensure proper unit performance. The following figures show 22 ber by 144 in. to obtain the minimum filter requirement (in). possible filter locations. NOTE: A ductwork access door must be used in counterflow applications to allow filter removal. If EXAMPLE: the filter rack is used, the side of the plenum must be at least as tall as dimension "A" shown in the following illustra- 2 1400 CFM x 144 in tion. For dimension of "A" refer to the following chart. 2 Filter Size (in) = 600 ft./min. (Permanent) 2 1400 CFM x 144 in 2 Filter Size (in) = 300 (Disposable) ft./min. 2 Disposable Filter Size = 672in 2 Filter Size = 336in Permanent 38 INSTALLATION CONSIDERATIONS COUNTERFLOW FILTER INSTALLATION Electronic Air Cleaner (ASAS and GSAS) or Media This furnace has provisions for the installation of return air Air Cleaner (AMU and GMU) filters at the counterflow top return. The furnace will accom- The electronic air cleaner and media air cleaner are multi- modate the following filter sizes depending on cabinet size: positional 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 Return Air air cleaner, consider the application. The electronic air cleaner must be readily accessible for periodic inspection and clean- Optional ing of the pre-filters and electronic cells while the media air Access "A" cleaner must be readily accessible for periodic inspection Door Min 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. Refer to Minimum Filter Area tables to determine filter area requirement.NOTE: Filters can also be installed elsewhere in the duct system such as a central return. Horizontal Installations Filter(s) must be installed external to the furnace casing for horizontal installations. For most installations it is prefer- able 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 perma- nent 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 stage settings. The circulator blower will remain on high heating speed for thirty (30) seconds before P OWER U P switching to the low heat circulating speed. The normal power up sequence is as follows: •R and W1 (or R and W1/W2) thermostat contacts •115 VAC power applied to furnace. open, completing the call for heat. •Integrated control module performs internal checks. •Gas valve closes, extinguishing flame. •Integrated control module displays 8 8 on dual 7-seg- •Induced draft blower is de-energized following a fif- ment display LED’s. teen second post purge. Humidifier terminals are de- •Integrated control module monitors safety circuits con- energized. tinuously. •Circulator blower continues running for the selected •Furnace awaits call from thermostat. Dual 7-segment heat off delay period (90, 120, 150 or 180 seconds). LED’s display ON while awaiting call from thermo- The speed run during this period depends on the last stat. heat call provided by the thermostat. H EATING M ODE If the last call for heat was a call for low heat, the air The normal operational sequence in heating mode is as fol- circulator motor will run on low heat speed for the du- lows: ration of the heat off delay period (90, 120, 150 or 180 •R and W1 (or R and W1/W2) thermostat contacts seconds). close, initiating a call for heat. If the last call for heat was a call for high heat, the air •Integrated control module performs safety circuit circulating motor will run on the high heating speed checks. for thirty (30) seconds and then switch to the low heat- ing speed for the balanceof the heat off delay period •Induced draft blower is energized on high speed for a (60, 90, 120 or 150 seconds). 15-second prepurge. Humidifier terminal is energized with induced draft blower. •Circulator blower and electronic air cleaner terminal is de-energized. •Induced draft blower steps to low speed following prepurge. Low stage pressure switch contacts are •Circulator blower ramps down to OFF during the 30 closed. seconds following the heat off delay period. •Igniter warm up begins upon step to low speed and •Furnace awaits next call from thermostat. presence of closed low stage pressure switch con- C OOLING M ODE tacts. The normal operational sequence in cooling mode is as fol- •Gas valve opens at end of igniter warm up period, de- lows: livering gas to burners and establishing flame. •R and Y1/G or Y2/G thermostat contacts close, initi- •Integrated control module monitors flame presence. ating a call for cool. Gas valve will remain open only if flame is detected. •Integrated control module performs safety circuit •If the thermostat call is for low heat, gas valve and checks. induced draft blower will continue on low stage. If the •Outdoor fan and compressor are energized to their call is for high heat, the gas valve and induced draft appropriate speed. blower will change to high stage. •Circulator blower is energized on the appropriate cool •Circulator blower is energized on heat speed follow- speed at the level and time determined by the se- ing a thirty (30) second blower on delay. The circula- lected ramping profile. Electronic air cleaner terminal tor blower requires thirty seconds to ramp up to full is energized with circulator blower. speed. Electronic air cleaner terminal is energized with •Furnace circulator blower and outdoor cooling unit run circulator blower. their appropriate speeds, integrated control module •Furnace is now operating on the specified stage called monitors safety circuits continuously. for by the two-stage thermostat. •R and Y1/G or Y2/G thermostat contacts open, com- •Furnace runs, integrated control module monitors pleting the call for cool. safety circuits continuously. •Outdoor fan and compressor are de-energized. •If the two-stage thermostat changes the call from low •Circulator blower continues running during a cool off heat to high heat, the integrated control module will delay period. The OFF delay time and airflow level immediately switch the induced draft blower, gas valve, are determined by the selected ramping profile. and circulator blower to their high stage settings. •Electronic air cleaner terminal and circulator blower •If the two-stage thermostat changes the call from high are de-energized. heat to low heat, the control will immediately switch the induced draft blower and gas valve to their low •Furnace awaits next call from thermostat. 40 SYSTEM OPERATION F AN O NLY M ODE play. Next, refer to the Troubleshooting Chart - ComfortNet™ on the following pages for an interpretation of the code dis- The normal operational sequence in fan only mode is as played on the LED's for a description of the problem. follows: •R and G thermostat contacts close, initiating a call for fan. NOTE: Use caution when reading the diagnostic codes from the furnace control's dual, 7-segment LED's. The position •Integrated control module performs safety circuit of the control within the furnace can lead to a misinterpreta- checks. tion of the error codes. With the control in an orienation as •Circulator blower is energized on continuous fan speed shown below, codes on the dual, 7-segment LED's are read following a five (5) second delay. Electronic air cleaner left to right. terminal is energized. •Circulator blower runs, integrated control module moni- tors 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. D EHUMIDIFICATION M ODE 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 ap- propriate 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 en- ergized with circulator blower. 5.Furnace circulator blower and outdoor cooling unit run their appropriate speed, integrated control module moni- tors safety circuits continuously. 6.Dehumidistat opens on humidity rise allowing the fur- DE W2 12RCG W1 Y1Y2O HUM nace circulator blower to operate at 85% of the cooling speed during combined thermostat call for cooling and Memory Card Connector dehumidistat call for dehumidification. Dual 7-Segment LED’s 7.Humidistat opens on humidity fall allowing furnace cir- culator blower to switch back to normal cooling speed. 1.Internal Control Failure with Integrated Ignition 8.R and Y1/G or Y1+Y2/G thermostat contacts open, com- Control.Check for voltage to the furnace and low volt- pleting the call for cool. age at the control board. Check for blown fuse on the 9.Outdoor fan and compressor are de-energized. control board. If the control determines it has an internal 10. Circulator blower continues running during a cool off de- fault, it enters a locked-out state. Any of the situations lay period. The OFF delay time and airflow level are de- mentioned will cause the dual, 7-segment LED's to be termined by the selected ramping profile. off.The control board should only be replaced only after all other checks from the Troubleshooting Chart - 11.Electronic air cleaner terminals and circulator blower ComfortNet™ have been verified. are de-energized. 2.System Lockout. If a flame is not sensed during the 12. Furnace awaits next call from thermostat. first seven (4) seconds after the gas valve is energized, the control turns off the gas. There will then be a 30 HEATING - A BNORMAL O PERATION second delay while the induced draft blower is energized The following presents the probable causes of questionable to purge the heat exchanger. The ignitor will again be furnace operation and how to fix them. Look through the energized and preheated for an additional (1) second. observation window in the blower access door and make a The gas valve will then be energized. If flame is not sensed note of the error code displayed on the dual 7-segment dis- 41 SYSTEM OPERATION the gas valve will be de-energized and another purge will8.Low Flame Sense Signal. If the furnace continues to occur and a third ignitor warm up for an additional (2)operate and the micro-amp signal from the flame sensor seconds will occur. The control will cycle the gas valve afalls below specified level. The diagnostic error code for total of three (3) times before it determines it cannotthis problem is E6. The probable cause is either a coated/ establish measurable combustion and enters a lockedoxidized sensor, incorrectly positioned senser in burner out state. The diagnostic error code for this problem isflame or lazy burner flame due to improper gas pressure E0. The control can be reset and brought out of lockoutor combustion air. mode by turning the thermostat off for more than (5) sec- 9.Check Igniter or No Ground Condition. Check for onds and less then (20) seconds and then back on. It broken or improperly connected igniter. Check for proper can also be reset by turning off the electrical disconnect ground and correct. The diagnostic error code for this switch to the furnace for a minimum of 5 seconds. problem is E7. NOTE: The control board will automatically reset one hour 10.High Stage Pressure Switch Stuck Closed. If the con- after lockout occurs. If the furnace frequently has to be re- trol fails to operate at high stage heat when commanded set, it means that a problem exists that should be corrected. to do so, the high stage pressure switch is stuck closed. Refer to Troubleshooting Chart - ComfortNet™ on the fol- For this condition, the furnace will operate at low stage lowing pages for aid in determining the cause. only, regardless of the thermostat demand. The diag- 3.Low Stage Pressure Switch Stuck Closed. If the con-nostic error code for this condition is E8. The probable trol senses the low stage pressure switch is closed whencause is sticking high stage pressure switch contacts the induced draft blower is off, it waits until the fault isor a short in the high stage pressure switch wiring. corrected. The diagnostic error code for this problem is 11.High Stage Pressure Switch Stuck Open. This con- E1. The probable cause is either a faulty pressure switch dition can occur if the pressure switch hose is blocked or wiring. or pinched. Check for blocked flue and/or inlet air pipe. 4.Low Stage Pressure Switch Stuck Open. If, after theBlocked drain, weak induced draft blower and malfunc- induced draft blower is energized, the low stage pres-tioning pressure switch are possible. The diagnostic sure switch does not close within 5 minutes, the controlerror code for this problem is E9followed by a pause. will go into a 1-hour lockout. The control will automati- 12.Reversed Polarity. If the 115V or 24V AC power leads cally reset fro lockout and restart the ignition sequance. are reversed, the furnace will fail to operate. The diag- The diagnostic error code for this problem is E2. The nostic error code for this problem is EA. The probable probable causes are either disconnected hose to the cause is either the 115V AC power to furnace or inte- pressure switch, faulty pressure switch or wiring, re- grated control module is reversed, the 24V AC wires to stricted air intake or flue piping. transformer are reversed, or poor unit ground. 5.Open Primary, Auxiliary, or Rollout Limit. If the limit 13.No Shared Data. The control does not contain any control opens, the air circulator blower and induced draft shared data. Shared data sets contain all the informa- blower will be turned on until the limit closes. The diag- tion required to drive the variable speed motor as well as nostic error code for this problem is E3. The probable calculate airflow demands. The furnace cannot function cause is either low conditioned air flow due to dirty filter without the approriate shared data set. The diagnostic or resistance in duct work, faulty limit, faulty blower, error code for the this condition is d0. A memory card blower speed set to low, misaligned burners, faulty in- must be used to populate shared data to the control. duced draft blower, or blocked flue. Contact your distributor to obtain the appropriate memory card for your particular furnace model. 6.Flame Sensed with No Call for Heat. If the control senses a flame when the gas valve is de-energized, it NOTE: Turn off power to the furnace prior to inserting memory will run the air circulation blower and the induced draft card onto the control. With memory card inserted onto con- blower continuously with no further furnace operation. trol, turn power to furnace on. Control has accepted memory The diagnostic error code for this condition is E4. The card data once control displays ON on the dual, 7-segment probable causes are either a short to ground in flame display. Memory card may be left on control or removed sense circuit, miswiring, lingering burner flame or a slow and used on another furnace of the same model. Turn power closing gas valve. off to furnace prior to removing memory card. 7.Open Fuse. If the control detects an open fuse, it will 14.Invalid Memory Card Data. This condition occurs if inhibit all furnace operation, except the display of the the control rejects the shared data set on a memory error code. The diagnostic error code for this condition card. Memory cards are model specific. If a memory isE5. The probable cause is a short in the low voltage card for a different model is used to populate data to a wiring, either internal to the furnace or external to the specific furnace, if will be rejected by the control. If us- furnace. ing 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 Temperature Limit. In attempting to deliver the airflow NOTE: Turn off power to the furnace prior to inserting memory demand, the motor may exceed its temperature limit. card onto the control. With memory card inserted onto con- The motor will reduce its output in an attempt to reduce trol, turn power to furnace on. Control has accepted memory its temperature. This will result in lower than demanded card data once control displays ON on the dual, 7-segment airflow. A high ambient temperatue at a high loading display. Memory card may be left on control or removed condition is the most probable cause. Reduce the am- and used on another furnace of the same model. Turn power bient temperature and/or motor loading/demand. off to furnace prior to removing memory card. 19.Motor Trips. This condition occurs if the ECM motor 15.ECM Blower Motor Not Running. This condition oc- senses a loss of control or becomes overloaded. The curs if the control fails to detect the ECM blower motor furnace may halt operation if the motor shuts down for a running when it should be running. The furnace will not trip condition. The diagnostic error code for this condi- operate if the control detects the blower motor is not tion is b4. running when it should be running. The diagnostic error code for this condition is b0. The probable cause looseLoss of Control (Lost Rotor Trip). This occurs if a sud- or disconnected wiring between the motor and control,den change in speed or torque is detected. The motor an open inductor (3/4 Hp and 1 Hp motors only), or awill shut down and restart if this condition is encoun- failed ECM blower motor (see section S-16C in Servic-tered. Possible causes are abnormal loading conditions ing).due to sudden blockages of the duct system or sudden high increases in the loading on the motor. 16.ECM Motor Communciations Lost. This condition oc- curs if the furnace control cannot communicate with theOverload (Current Trip). This occurs if the motor be- ECM blower motor. The furnace will not operate if thecomes overloaded due to high loading conditions. The control cannot communicate with the blower motor. Themotor will shut down and restart if this condition is en- diagnostic error code for this condition is b1. The prob-countered. High loading conditions could be due to able cause loose or disconnected wiring between theblocked/clogged filters, blocked or restrictive ductwork, motor and control, a failed ECM blower motor (see sec-or undersized ductwork. tion S-16C in Servicing), or a failed control. 20.Motor Locked Rotor. This condition occurs if the mo- 17.Motor Horsepower Mismatch. This condition occurstor fails to start after (10) consecutive attempts. The if the horsepower of the motor connected to the controlfurnace will not operate if the ECM blower motor fails to does not match the motor horsepower specified in thestart. The diagnostic error code for this condition is b5. shared data set. The furnace will not operate is there isThe probable cause is an obstruction in the blower hous- a motor horsepower mismatch. The diagnostic erroring or wheel, siezed motor bearings, or a failed blower code for this condition is b2.motor. Verify that the installed motor is the correct motor for21.Motor Volts. This condition occurs if the line voltage is the furnace model. Obtain the correct motor for the fur-too low or too high, or if the motors power module gets nace model. Verify the shared data set is correct for thetoo hot. The ECM motor will shut down while the abnor- furnace. The shared data set may be corrected usingmal condition is present. If the abnormal condition is the appropriate memory card. Contact your distributorcleared, the motor will restart. The furnace will be inop- for the correct memory card. See 13 and 14 above forerable while the motor is off. additional memory card information. Over Voltage. If the line voltage exceeds 140VAC, the 18.ECM Motor Operating in a Limiting Condition. Thismotor will shut down due to an over voltage condition. condition will occur if the ECM operates in a power,Verify the line voltage to the furnace is within the range speed, or temperature limiting condition. The furnacespecified on the rating plate. will continue operating at reduced performance. The di- Under Voltage. If the line voltage is less than 70VAC, agnostic error code for the this condition is b3. the motor will shut down due to an under voltage condi- Power Limit. In attempting to deliver the airflow demand,tion. Verify the line voltage to the furnace is within the the motor may exceed its rated output power. The mo-range specified on the rating plate. tor will reduce its output to prevent exceeding its power Over Temperature. A high ambient temperatue or a high limit. This will result in lower than demanded airflow. loading condition is the most probable cause. Reduce This will occur under high loading conditions. High load- the ambient temperature and/or motor loading/demand. ing 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 air- flow. A blocked inlet, lightly loaded or no load condi- tions could cause high motor speeds. 43 SYSTEM OPERATION 22.Motor Parameters. This condition occurs if the motor the shared data set. If the airflow falls below the calcu- does not receive all the information is requires to operate lated minimum, the furnace will continue to operate with or an event occurs that prevents the motor from running, the reduce airflow. If the furnace was operating at high or the motor fails to start for (40) consecutive attempts. stage, it will stage back to low in an effort to remedy the The diagnostic error code for the this condition is b7. condition. The furnace will halt operation if the airflow Probable causes are intermittent wiring connection be- falls to 0 CFM. tween the control and motor, an error with the furnace The diagnostic error code for the this condition is b9. control, or any of the conditions described in 19, 20, or Probable causes are blocked/clogged filters, blocked 21 above. or restrictive ductwork, or undersized ductwork. 23.Low Indoor Airflow. This condition occurs if the indoor airflow falls below a calculated minimum value. The mini- mum airflow value is calculated from factors defined in 44 TROUBLESHOOTING ComfortNet™ Symptoms of Abnormal Diagnostic/ Thermostat Only Operation (Legacy & Status LED Fault DescriptionPossible CausesCorrective ActionsNotes & Cautions ComfortNet™ Thermostat)Codes MessageCode •Furnace fails to operateNone•No 115 power to INTERNAL EE•Manual disconnect switch •Assure 115 and 24 •Turn power OFF prior furnace or no 24 volt FAULTOFF, door switch open or volt power to furnace to repair. •Integrated control module power to integrated 24 volt wire improperly and integrated control LED display provides no •Replace integrated control moduleconnected or loosemodule. control module fuse signal. •Blown fuse or circuit •Blown fuse or circuit •Check integrated control with 3A automotive •ComfortNet™ thermostat breakerbreakermodule fuse (3A). fuse. “Call for Service” icon Replace if necessary. illuminated•Integrated control •Integrated control module •Read precautions module has an has an internal fault•Check for possible in “Electrostatic •ComfortNet™ thermostat internal faultshorts in 115 and 24 Discharge” section of scrolls “Check Furnace” volt circuits. Repair as manual. message necessary. •Replace control with •Replace bad integrated correct replacement control module.part •LED display indicates OnOn•Normal operationNoneNone•Normal operation•None•Normal operation •Furnace fails to operateE0•Furnace lockout LOCKOUTE0•Failure to establish fame. •Locate and correct gas •Turn power OFF prior due to an excessive Cause may be no gas interruption.to repair. •Integrated control module number of ignition to burners, front cover LED display provides E0 •Check front cover •Igniter is fragile, “retries” (3 total)pressure switch stuck error code. pressure switch operation handle with care. open, bad igniter or igniter (hose, wiring, contact •ComfortNet™ thermostat •Sand fame sensor alignment, improper operation). Correct if “Call for Service” icon with emery cloth. orifces, or coated/oxidized necessary. illuminated. •See “Vent/Flue Pipe” or improperly connected •Replace or realign igniter. •ComfortNet™ thermostat section for piping fame sensor. scrolls “Check Furnace” •Check fame sense details. •Loss of fame after message.signal. Sand sensor if establishment. Cause coated and/or oxidized. may be interrupted gas •Check fue piping for supply, lazy burner fames blockage, proper length, (improper gas pressure elbows, and termination. or restriction in fue and/ •Verify proper induced or combustion air piping), draft blower performance. front cover pressure switch opening, or improper induced draft blower performance. •Furnace fails to operate.E1•Low stage pressure PS1E1•Low stage pressure switch •Replace low stage •Turn power OFF prior switch circuit is CLOSEDcontacts sticking.pressure switch.to repair. •Integrated control module closed at start of LED display provides E1 •Shorts in pressure switch •Repair short in wiring.•Replace pressure heating cycle. error code.circuit wiring.switch with proper replacement part. •ComfortNet™ thermostat “Call for Service” icon illuminated. •ComfortNet™ thermostat scrolls “Check Furnace” message. 45 TROUBLESHOOTING Symptoms of Abnormal ComfortNet™ Diagnostic/ Operation (Legacy Thermostat Only Status LED Fault DescriptionPossible CausesCorrective ActionsNotes & Cautions & ComfortNet™ Codes MessageCode Thermostat) •Induced draft blower E2•Low stage PS1 OPENE2•Pressure switch hose •Inspect pressure switch •Turn power OFF prior runs continuously with no pressure switch blocked pinched, or hose. Repair/replace if to repair. further furnace operation.circuit is not connected improperly.necessary. •Replace pressure closed. •Integrated control module •Blocked fue and/or inlet •Inspect fue and/or inlet switch with proper LED display provides E2 air pipe, blocked drain air piping for blockage, replacement part. error code.system or weak induced proper length, elbows, •Replace induced draft draft blower.and termination. Check •ComfortNet™ thermostat blower with proper drain system. Correct as “Call for Service” icon •Incorrect pressure replacement part. necessary. illuminated.switch set point or malfunctioning switch •Check induced draft •ComfortNet™ thermostat contacts.blower performance. scrolls “Check Furnace” Correct as necessary. message.•Loose or improperly connected wiring.•Correct pressure switch set point or contact motion. •Tighten or correct wiring connection. •Circulator blower E3•Primary limit or HIGH LIMIT E3•Insuffcient conditioned •Check flters and •Turn power OFF runs continuously. No auxiliary limit OPENair over the heat ductwork for blockage. prior to repair. furnace operation.circuit is open.exchanger. Blocked Clean flters or remove •See Specifcation flters, restrictive obstruction. •Integrated control •Rollout limit Sheet applicable ductwork, improper module LED display circuit is open.•Check circulator to your model* for circulator blower provides E3 error code.blower speed and allowable rise range speed, or failed performance. Correct and proper circulator •ComfortNet™ circulator blower motor. speed or replace blower speed. thermostat “Call •Flame rollout.motor if necessary. for Service” icon •See "Vent/Flue Pipe" illuminated.•Misaligned burners, •Check burners for section for piping blocked fue and/or proper alignment.details. •ComfortNet™ air inlet pipe, or failed thermostat scrolls •Check fue and air inlet induced draft blower. “Check Furnace” piping for blockage, message.•Loose or improperly proper length, elbows, connected wiring. and termination. Correct as necessary. •Check induced draft blower for proper performance. Replace if necessary. •Tighten or correct wiring connection. •Induced draft blower E4•Flame sensed IMPROPER E4•Short to ground in •Correct short at fame •Turn power OFF and circulator blower with no call for FLAMEfame sense circuit.sensor or in fame prior to repair. runs continuously. No heat.sensor wiring. •Lingering burner fame. furnace operation. •Check for lingering •Slow closing gas valve. •Integrated control fame. module LED display •Verify proper operation provides E4 error code. of gas valve. •ComfortNet™ thermostat “Call for Service” icon illuminated. •ComfortNet™ thermostat scrolls “Check Furnace” message. •No furnace operation.E5•Open FuseNot Not •Short in low voltage •Locate and correct •Turn power OFF DisplayedDisplayedwiringshort in low voltage prior to repair. •Integrated control wiring module LED display •Replace fuse with provides E5 error code.3-amp automotive type •ComfortNet™ thermostat displays “Battery Power” •Normal furnace E6•Flame sense WEAK E6•Flame sensor is •Sand fame sensor if •Turn power OFF operation. micro amp signal FLAMEcoated/oxidized.coated/oxidized.prior to repair. is low •Flame sensor •Inspect for proper •Sand fame sensor •Integrated control module LED display incorrectly positioned sensor alignment.with emery cloth. in burner fame. provides E6 error code. •Check inlet air piping •See "Vent/Flue Pipe" •Lazy burner fame for blockage, proper section for piping due to improper gas length, elbows, and details. pressure or combustion termination. •See rating plate for air. •Compare current gas proper gas pressure. pressure to rating plate. Adjust as needed. 46 TROUBLESHOOTING ComfortNet™ Symptoms of Abnormal Diagnostic/ Thermostat Only Operation (Legacy Status LED Fault DescriptionPossible CausesCorrective ActionsNotes & Cautions & ComfortNet™ Codes MessageCode Thermostat) •Furnace fails to operate.E7•Problem with IGNITER E7•Improperly connected •Check and correct •Turn power OFF igniter circuit.FAULTigniter.wiring from integrated prior to repair. •Integrated control control module to •Shorted igniter.•Replace igniter with module LED display igniter. provides E7 error code.correct replacement •Poor unit ground. •Replace shorted igniter.part. •ComfortNet™ •Igniter relay fault on thermostat “Call •Check and correct unit •Replace control with integrated control for Service” icon ground wiring.correct replacement module. illuminated.part. •Check igniter output •ComfortNet™ from control. Replace if thermostat scrolls necessary. “Check Furnace” message. •Furnace fails to operate E8•High stage PS2 CLOSEDE8•High stage pressure •Replace high stage •Turn power OFF prior on high stage; furnace pressure switch switch contacts sticking.pressure switch.to repair. operates normally on low circuit is closed •Shorts in pressure •Repair short in wiring•Replace pressure stage.at start of heating switch circuit wiring.switch with proper cycle. •Integrated control module replacement part. LED display provides E8 •Induced draft error code.blower is operating. •Furnace is operating on low stage only •Furnace fails to operate E9•High stage PS2 OPENE9•Pressure switch hose •Inspect pressure switch •Turn power OFF prior blocked pinched, or hose. Repair/replace if to repair. on high stage; furnace pressure switch operates normally on low circuit is not connected improperly.necessary. •Replace pressure stage.closed. •Blocked fue and/or inlet •Inspect fue and/or inlet switch with proper •Integrated control module •Induced draft air pipe, blocked drain air piping for blockage, replacement part. blower is system or weak induced LED display provides E9 proper length, elbows, •Replace induced draft error code.operating.draft blower. and termination. Check blower with proper drain system. Correct as •Furnace is •Incorrect pressure replacement part. necessary. operating on low switch set point or stage onlymalfunctioning switch •Check induced draft contacts.blower performance. Correct as necessary. •Loose or improperly connected wiring.•Correct pressure switch set point or contact motion. •Tighten or correct wiring connection. •Furnace fails to operate.EA•Polarity of 115 volt REVERSED EA•Polarity of 115 volt AC •Review wiring diagram to •Turn power OFF prior AC is reversedPLTYpower to furnace or correct polarity.to repair. •Integrated control module integrated module is LED display provides EA •Verify proper ground. revered. error code.Correct if necessary. •Poor unit ground •ComfortNet™ thermostat •Check and correct “Call for Service” icon wiring. illuminated. •ComfortNet™ thermostat scrolls “Check Furnace” message. •Integrated control EF•Aux switch openAux Alarm EF•High water level in the •Check overfow pan and •Turn power OFF prior module LED display EF Faultevaporation coil.service.to service. error code. •ComfortNet™ thermostat “Call for Service” . •Furnace fails to operate.d0•Data not yet on NO NET d0•Furnace does not •Populate shared data •Turn power OFF prior network.DATAcontain any shared data.set using memory card.to repair •Integrated control module LED display provides d0 •Use memory card for error code.the specifc model. •ComfortNet™ thermostat •Insert memory card “Call for Service” icon BEFORE turning illuminated.power ON. Memory card may be removed •ComfortNet™ thermostat after data is loaded scrolls “Check Furnace” and power is turned message. off. •Error code will be cleared once data is 47 TROUBLESHOOTING ComfortNet™ Symptoms of Abnormal Diagnostic/ Thermostat Only Operation (Legacy Status LED Fault DescriptionPossible CausesCorrective ActionsNotes & Cautions & ComfortNet™ Codes MessageCode Thermostat) •Operation different than d4•Invalid memory INVALID MC d4•Shared data set on •Verify shared data set is •Turn power OFF prior expected or no operation.card data.DATAmemory card has been correct for the specifc to repair rejected by integrated model. Re-populate data •Integrated control •Use memory card for control moduleusing correct memory module LED display the specifc model. card if required. provides d4 error code. •Insert memory card •ComfortNet™ thermostat BEFORE turning “Call for Service” icon power ON. Memory illuminated.card may be removed after data is loaded •ComfortNet™ thermostat and power is turned scrolls “Check Furnace” off. message. •Error code will be cleared once data is loaded and power is turned off. •Furnace fails to operate.b0•Circulator blower MOTOR NOT b0•Loose wiring connection •Tighten or correct wiring •Turn power OFF prior motor is not RUNat circulator motor connection. to repair •Integrated control running when it power leads or module LED display •Verify continuous •Replace inductor with should be running.circulator motor power provides b0 error code. circuit through inductor. correct replacement leads disconnected. Replace if open or short part. •ComfortNet™ thermostat •Open circuit in inductor circuit. “Call for Service” icon •Replace circulator or loose wiring illuminated.•Check circulator blower motor with correct connection at inductor motor. Replace if replacement part. •ComfortNet™ thermostat (3/4 Hp and 1 Hp necessary. scrolls “Check Furnace” models only). message. •Failed circulator blower motor. •Furnace fails to operate.b1•Integrated control MOTOR b1•Loose wiring connection •Tighten or correct wiring •Turn power OFF prior module has lost COMMat circulator motor connection.to repair •Integrated control communications control leads. module LED display •Check circulator blower •Replace circulator with circulator provides b1 error code.•Failed circulator blower motor. Replace if motor with correct blower motor. motor.necessary.replacement part. •ComfortNet™ thermostat “Call for Service” icon •Check integrated control •Replace integrated •Failed integrated control illuminated.module.module. Replace if control module with necessary.correct replacement •ComfortNet™ thermostat part. scrolls “Check Furnace” message. •Furnace fails to operate.b2•Circulator blower MOTOR b2•Incorrect circulator •Verify circulator blower if •Turn power OFF prior motor horse MISMATCHblower motor in furnace.motor horse power is the to repair •Integrated control power in shared same specifed for the module LED display •Incorrect shared data •Replace motor with data set does not specifc furnace model. provides b2 error code.set in integrated control correct replacement match circulator Replace if necessary. module.part. •ComfortNet™ thermostat blower motor •Verify shared data set is “Call for Service” icon •Use memory card for horse power. correct for the specifc illuminated.the specifc model model. Re-populate data •ComfortNet™ thermostat •Insert memory card using correct memory scrolls “Check Furnace” BEFORE turning card if required. message.power ON. Memory card may be removed after data is loaded and power is turned off. •Error code will be cleared once shared data and motor horse power match. •Furnace operates at b3•Circulator blower MOTOR b3•Blocked flters.•Check flters for •Turn power OFF prior reduced performance.motor is operating LIMITSblockage. Clean flters to repair. •Restrictive ductwork. in a power, or remove obstruction. •Airfow delivered is less •Undersized ductwork. temperature, or than expected.•Check ductwork for •High ambient speed limiting blockage. Remove •Integrated control temperatures. condition. obstruction. Verify all module LED display registers are fully open. provides b3 error code. •Verify ductwork is appropriately sized for system. Resize/replace ductwork if necessary. •See "III. Product Description" and "IV. Location Requirements & Considerations" furnace installation requirements. 48 TROUBLESHOOTING ComfortNet™ Symptoms of Abnormal Diagnostic/ Thermostat Only Operation (Legacy Status LED Fault DescriptionPossible CausesCorrective ActionsNotes & Cautions & ComfortNet™ Codes MessageCode Thermostat) • Circulator blower MOTOR b4b4•Turn power OFF prior •Furnace fails to operate. motor senses TRIPSto repair •Integrated control a loss of rotor module LED display control. provides b4 error code. •Circulator blower •ComfortNet™ thermostat motor senses “Call for Service” icon high current. illuminated. •ComfortNet™ thermostat scrolls “Check Furnace” message. MOTOR LCKDb5•Turn power OFF prior •Furnace fails to operate. •Circulator blower b5 ROTOR to repair. motor fails to start •Integrated control •Replace motor with 10 consecutive module LED display correct replacement provides b5 error code.times. part. •ComfortNet™ thermostat • •Replace wheel with “Call for Service” icon correct replacement illuminated. part. •ComfortNet™ thermostat scrolls “Check Furnace” message. •Furnace fails to operate.b6MOTOR b6•Turn power OFF prior • Circulator blower VOLTSto repair •Integrated control motor shuts down • module LED display for over or under provides b6 error code. voltage condition. • •ComfortNet™ thermostat • Circulator blower • “Call for Service” icon motor shuts illuminated. down due to •ComfortNet™ thermostat over temperature scrolls “Check Furnace” condition on message.power module. • •Furnace fails to operate.b7MOTOR b7 Circulator blower PARAMS motor does not •Integrated control • have enough • module LED display information to provides b7 error code. • operate properly. •ComfortNet™ thermostat Motor fails to start “Call for Service” icon 40 consecutive illuminated. times. •ComfortNet™ thermostat scrolls “Check Furnace” message. • •Furnace operates at b9LOW IDB9•Blocked filters.•Check filters for •Turn power OFF prior Airflow is lower AIRFLOW blockage. Clean filters to repair. reduced performance orthan demanded. •Restrictive ductwork. or remove obstruction. operates on low stage •Undersized ductwork. when high stage is •Check ductwork for expected. blockage. Remove •Integrated control obstruction. Verify all module LED display registers are fully open. provides b9 error code. •Verify ductwork is appropriately sized for system. Resize/replace ductwork if necessary. 49 TROUBLESHOOTING POWER INTERNAL CONTROL FAULT/NO n NORMALOPERATION O LOCKOUT DUE TO EXCESSIVERETRIES E0 LOW STAGE PRESSURE SWITCH STUCK CLOSED AT START OF HEATINGCYCLE 1 E LOW STAGE PRESSURE SWITCH STUCKOPEN E2 SWITCH OPEN HIGH LIMIT E3 4 FLAME DETECTED WHEN NO FLAME SHOULD BEPRESENT E OPENFUSE E5 LOW FLAMESIGNAL E6 IGNITER FAULT OR IMPROPERGROUNDING E7 HIGH STAGE PRESSURE SWITCH STUCK CLOSED AT START OF HEATINGCYCLE E8 OPEN HIGH STAGE PRESSURE SWITCH STUCK E9 REVERSED 115 VACPOLARITY E A AUXILIARY SWITCHOPEN EF DATA NOT YET ONNETWORK 0 d 4 INVALID MEMORY CARD DATA d BLOWER MOTOR NOTRUNNING 0 b BLOWER COMMUNICATIONERROR b1 BLOWER HPMIS-MATCH b2 BLOWER MOTOR OPERATING IN POWER, TEMPERATURE, OR SPEEDLIMIT b 3 ROTOR BLOWER MOTOR CURRENT TRIP OR LOST 4 b BLOWER MOTOR LOCKEDROTOR b5 OVER/UNDER VOLTAGE TRIP OR OVER TEMPERATURETRIP b6 INCOMPLETE PARAMETERS SENT TO MOTOR b 7 LOWINDOORAIRFLOW b9 LOW STAGECOOL 1 C HIGH STAGECOOL C2 LOW STAGE HEAT PUMPHEAT P1 HEAT P2 HIGH STAGE HEAT PUMP 0 L LOW STAGE GAS HEAT HIGH STAGE GASHEAT HI F CONTINUOUS FAN CFM/100; ALTERNATESWITH 12HF C2 CLOI 1 , , ,, P1P2 ,0140F01169REV A 50 SYSTEM OPERATION ComfortNet™ System 4.Dehumidification (lowering of CFM to 85%) only happens ComfortNet™ System during low stage cooling operation. The dehumidification O VERVIEW feature is not active during high stage cool. The CTK03AB The ComfortNet system is a system that includes a and CTK04 can be set up to overcool the home in order ComfortNet compatible furnace and air conditioner or heat to reach the RH set point. pump with a CTK0*** thermostat. A valid ComfortNet sys- tem could also be a compatible furnace, CTK0*** thermo- CTK0*** W IRING stat and non-communicating, single stage air conditioner. Any other system configurations are considered invalid NOTE:Refer to Electrical Connections for 115 volt line ComfortNet systems and must be connected as a tradi- connections to the furnace. tional (or legacy) system (see Electrical Connections for wiring connections). NOTE:A removable plug connector is provided with the control to make thermostat wire connections. This plug may A ComfortNet heating/air conditioning system differs from be removed, wire connections made to the plug, and replaced. a legacy/traditional system in the manner in which the in- It is recommended that multiple wires be connected with a door unit, outdoor unit and thermostat interact with one wire nut and only one wire be inserted under a screw. Failure another. In a traditional system, the thermostat sends to do so may result in intermittent operation. commands to the indoor and outdoor units via analog 24 VAC signals. It is a one-way communication path in that Typical 18 AWG thermostat wire may be used to wire the the indoor and outdoor units typically do not return informa- system components. However, communications reliability tion to the thermostat. may be improved by using a high quality, shielded, twisted On the other hand, the indoor unit, outdoor unit, and ther- pair cable for the data transmission lines. In either case, mostat comprising a ComfortNet system “communicate” 100 feet is the maximum length of wire between indoor unit digitally with one another. It is now a two-way communica- and outdoor unit, or between indoor unit and thermostat. tions path. The thermostat still sends commands to the F OUR-W IRE I NDOORAND O UTDOOR W IRING indoor and outdoor units. However, the thermostat may also request and receive information from both the indoor Typical wiring will consist of four wires between the indoor and outdoor units. This information may be displayed on unit and outdoor unit and between the indoor unit and ther- the ComfortNet thermostat. The indoor and outdoor units mostat. The required wires are: (a) data lines, 1 and 2; (b) also interact with one another. The outdoor unit may send thermostat “R” (24 VAC hot) and “C” (24 VAC common). commands to or request information from the indoor unit. This two-way digital communications between the thermo- stat and subsystems (indoor/outdoor unit) and between sub- systems is the key to unlocking the benefits and features of the ComfortNet system. 1CCTK0*** Thermostat Two-way digital communications is accomplished using 2 R only two wires. The thermostat and subsystem controls are power with 24 VAC. Thus, a maximum of 4 wires be- ComfortNet Compatible Furnace 12RC tween the equipment and thermostat is all that is required Integrated Control Module to operate the system. O PERATIONS W ITH CTK03AB AND CTK04 ComfortNet Compatible AC/HP 12RC Integrated Control Module 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 T WO-W IRE O UTDOOR, F OUR-W IRE I NDOOR W IRING humidity demand exists. Selecting “Off” means the Two wires only may be utilized between the indoor and out- humidification relay will not function. door units. For this wiring scheme, only the data lines, 1 2.If the CTK03AB and CTK04 are set up so the compres- and 2, are required between the indoor and outdoor units. A sor off delay is 0 min, it will display a cool / heat call 40VA, 208/230 VAC to 24VAC transformer must be installed immediately regardless of the delay built into the out- in the outdoor unit to provide 24VAC power to the outdoor door unit control board. This means the CTK03A* could unit’s electronic control. show COOL ON when the outdoor unit is still in a delay period. The recommendation is to set up the compres- sor 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. 51 ComfortNet™ System 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. 1C CTK0*** Thermostat 2R When using a CTK03A*or CTK04 thermostat, the included transformer must be used. ComfortNet Compatible W1W2Y1Y2 O 12RCG If your communicating thermostat kit does not include a Furnace Integrated transformer, an accessory kit is available separately by Control Module ordering part TFK01. Non-ComfortNet Compatible CY Single Stage AC S YSTEM W IRINGBETWEEN F URNACEAND N ON-C OMFORT N ET 1 CTK0*** C Thermostat 2R C OMPATIBLE S INGLE S TAGE A IR C ONDITIONER ComfortNet Compatible 12RC Furnace Integrated C OMFORT N ET S YSTEM A DVANCED F EATURES Control Module The ComfortNet system permits access to additional sys- ComfortNet Compatible tem information, advanced setup features, and advanced di- 40VA Transformer 12RC AC/HP Integrated agnostic/troubleshooting features. These advanced features Control Module are organized into a menu structure. 24 VAC 208/230 VAC S YSTEM W IRINGUSING T WO-W IRESBETWEEN F URNACEAND F OUR-W IRESBETWEEN F URNACEAND T HERMOSTAT C OMFORT N ET F URNACEWITH N ON-C OMFORT N ET A/C S INGLE S TAGE A IR C ONDITIONER Four wires are required between the furnace and thermo- stat. Two wires are required between the furnace control and single stage air conditioner. For this system configura- tion, the “Y1” terminal on the integrated furnace control be- comes an output rather than an input. 52 SYSTEM OPERATION ComfortNet™ System F URNACE A DVANCED F EATURES M ENUS CONFIGURATION Submenu ItemIndication (for Display Only; not User Modifiable) Number of Heat Stages (HT STG)Displays the number of furnace heating stages Input Rate (BTU/HR)Displays the furnace input rate in kBtu/hr Motor HP (1/2, ¾, or 1 MTR HP)Displays the furnace indoor blower motor horsepower DIAGNOSTICS Submenu ItemIndication/User Modifiable OptionsComments Fault 1 (FAULT #1)Most recent furnace faultFor display only Fault 2 (FAULT #2)Next most recent furnace faultFor display only Fault 3 (FAULT #3)Next most recent furnace faultFor display only Fault 4 (FAULT #4)Next most recent furnace faultFor display only Fault 5 (FAULT #5)Next most recent furnace faultFor display only Fault 6 (FAULT #6)Least recent furnace faultFor display only Selecting “YES” clears the Clear Fault History (CLEAR)NO or YES fault history NOTE: Consecutively repeated faults are shown a maximum of 3 times. IDENTIFICATION Submenu ItemIndication (for Display Only; not User Modifiable) Model Number (MOD NUM)Displays the furnace model number Serial Number (SER NUM)Displays the furnace serial number (Optional) Software (SOFTWARE)Displays the application software revision SET-UP Submenu ItemUser Modifiable OptionsComments Heat Airflow Trim (HT -10% to +10% in 2% increments, Trims the heating airflow by the selected TRM)default is 0%amount. Heat ON Delay (HT ON5, 10, 15, 20, 25, or 30 seconds, Selects the indoor blower heat ON delay default is 30 seconds Heat OFF Delay (HT OFF)30, 60, 90, 120, 150, or 180 Selects the indoor blower heat OFF delay seconds, default is 150 seconds Heat Airflow (HT ADJ)1, 2, 3, or 4Selects the nominal heating airflow (see Startup Procedure and Adjustment – Circulator Blower Speeds for additional information) STATUS Submenu ItemIndication (for Display Only; not User Modifiable) Mode (MODE)Displays the current furnace operating mode CFM (CFM)Displays the airflow for the current operating mode 53 SYSTEM OPERATION ComfortNet™ System NON-COMM (APPLIES ONLY TO A COMMUNICATING COMPATIBLE FURNACE MATCHED WITH A NON-COMMUNICATING COMPATIBLE SINGLE STAGE AIR CONDITIONER) Submenu ItemUser Modifiable OptionsComments Cool Airflow (CL CFM)18, 24, 30, 36, 42, 48, or 60, default Selects the airflow for the non-CT is 18compatible single stage AC unit Cool Airflow Trim (CL TRM)-10% to +10% in 2% increments, Selects the airflow trim amount for the non- default is 0%communicating compatible single stage AC unit Cool Airflow Profile (CL PRFL)A, B, C, or D, default is ASelects the airflow profile for the non- communicating compatible single stage AC unit Cool ON Delay (CL ON)5, 10, 20, or 30 seconds, default is Selects the indoor blower ON delay for the 5 secondsnon-communicating compatible single stage AC unit Cool OFF Delay (CL OFF)30, 60, 90, or 120 seconds, default Selects the indoor blower OFF delay for the is 30 secondsnon-communicating compatible single stage AC unit T HERMOSTAT M ENU bank of two dipswitches that provide termination functions for the communications transmission lines. Communica- If this furnace is installed with a ComfortNet compatible heat tions errors will result if these switches are not correctly pump, the system is recognized as a dual fuel system. The set. The table below indicates the switch position for the balance point temperature should be set via the thermostat bias and termination dipswitches along with the expected advanced menu. voltages. Note that the ON position is the correct position D IAGNOSTICS for all bias and termination dipswitches. The ComfortNet system is a fully communicating system, Accessing the furnace’s diagnostics menu provides ready and thus, constitutes a network. Occasionally the need to access to the last six faults detected by the furnace. Faults troubleshoot the network may arise. The integrated furnace are stored most recent to least recent. Any consecutively control has some on-board tools that may be used to trouble- repeated fault is stored a maximum of three times. Example: shoot the network. These tools are: red communications A clogged return air filter causes the furnace limit to trip LED, green receive (Rx) LED, and learn button. repeatedly. The control will only store this fault the first three consecutive times the fault occurs. Navigate to the diag- nostics menu as described above in Accessing and Navi- •Red communications LED – Indicates the status of gating the Advanced Features Menus. the network. The table below indicates the LED status and the corresponding potential problem. NOTE: It is highly recommended that the fault history be •Green receive LED – Indicates network traffic. The cleared when performing maintenance or servicing the table below indicates the LED status and the corre- furnace. sponding potential problem. N ETWORKTROUBLESHOOTING •Learn button – Used to reset the network. Depress Communications is achieved by taking the difference between the button for approximately 2 seconds to reset the two dc signals. The signals and transmission lines are re- network. ferred to as “data 1” and “data 2”. Each transmission line is biased to approximately 2.5Vdc. During data reception/trans- mission, the data lines vary between +5V and ground. (When data 1 is increasing towards +5V, data 2 is decreasing to- wards 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 ComfortNet™ System SYSTEM OPERATION S YSTEM T ROUBLESHOOTING 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. MFE!MFE!Joejdbujpo!Qpttjcmf!Dbvtft!Dpssfdujwf!Bdujpo)t*!Opuft!'!Dbvujpot! Tubuvt! Pgg! !Opsnbm!dpoejujpo!!Opof!!Opof!!Opof! 2!Gmbti! !Dpnnvojdbujpot!!Dpnnvojdbujpot!!Efqsftt!Mfbso!Cvuupo!!Efqsftt!podf! Gbjmvsf!Gbjmvsf!rvjdlmz!gps!b!qpxfs. !Wfsjgz!uibu!cvt!CJBT! vq!sftfu! boe!UFSN! Sfe! ejqtxjudift!bsf!jo!uif!!Efqsftt!boe!ipme! Dpnnvojdbujpot! PO!qptjujpo/!gps!3!tfdpoet!gps! MFE! bo!pvu.pg.cpy!sftfu! 3!Gmbtift! !Pvu.pg.cpy!sftfu!!Dpouspm!qpxfs!vq!!Opof!!Opof! !Mfbso!cvuupo! efqsfttfe! Pgg! !Op!qpxfs!!Op!qpxfs!up!gvsobdf!!Difdl!gvtft!boe!!Uvso!qpxfs!PGG! djsdvju!csfblfst<!qsjps!up!sfqbjs! !Dpnnvojdbujpot!!Pqfo!gvtf! sfqmbdf0sftfu! fssps! !Dpnnvojdbujpot!fssps! !Sfqmbdf!cmpxo!gvtf! !Difdl!gps!tipsut!jo! mpx!wpmubhf!xjsjoh!jo! gvsobdf0tztufn! !Sftfu!ofuxpsl!cz! efqsfttjoh!mfbso! cvuupo! !Difdl!ebub!20!ebub!3! wpmubhft! 2!Tufbez! !Op!ofuxpsl!gpvoe!!Csplfo0!ejtdpoofdufe!!Difdl!!Uvso!qpxfs!PGG! Gmbti! ebub!xjsf)t*!dpnnvojdbujpot!qsjps!up!sfqbjs! xjsjoh!)ebub!20!ebub!3! !Gvsobdf!jt!jotubmmfe!bt!!Wfsjgz!xjsft!bu! xjsft*! b!mfhbdz0!usbejujpobm!ufsnjobm!cmpdlt!bsf! tztufn!!Difdl!xjsf!tfdvsfmz!uxjtufe! dpoofdujpot!bu!uphfuifs!qsjps!up! Hsffo!Sfdfjwf! ufsnjobm!cmpdl!jotfsujoh!joup! MFE! ufsnjobm!cmpdl! !Wfsjgz!gvsobdf! jotubmmbujpo!uzqf!!Wfsjgz!ebub2!boe! )mfhbdz0!usbejujpobm!ps!ebub!wpmubhft!bt! dpnnvojdbujoh*!eftdsjcfe!bcpwf! !Difdl!ebub!20!ebub!3! wpmubhft! Sbqje! !Opsnbm!ofuxpsl!!Dpouspm!jt!ubmljoh!po!!Opof!!Opof! Gmbtijoh! usbggjd!ofuxpsl!bt!fyqfdufe! Po!Tpmje! !Ebub!20!Ebub!3!!Ebub!2!boe!ebub!3!!Difdl!!Uvso!qpxfs!PGG! njtt.xjsf!xjsft!sfwfstfe!bu!dpnnvojdbujpot!qsjps!up!sfqbjs! gvsobdf-!uifsnptubu-!xjsjoh!)ebub!20!ebub!3! !Wfsjgz!xjsft!bu! ps!DU!dpnqbujcmf!xjsft*! ufsnjobm!cmpdlt!bsf! pvuepps!BD0IQ! !Difdl!xjsf!tfdvsfmz!uxjtufe! !Tipsu!cfuxffo!ebub!2! dpoofdujpot!bu!uphfuifs!qsjps!up! boe!ebub!3!xjsft!ufsnjobm!cmpdl!jotfsujoh!joup! ufsnjobm!cmpdl! !Tipsu!cfuxffo!ebub!2!!Difdl!ebub!20!ebub!3! ps!ebub!3!xjsft!boe!S!wpmubhft!!Wfsjgz!ebub2!boe! )35WBD*!ps!D!)35WBD!ebub!wpmubhft!bt! dpnnpo*!eftdsjcfe!bcpwf! 55 SYSTEM OPERATION ComfortNet™ System TROUBLESHOOTING Wiring issues may be confirmed (or eliminated) by using the CTK0*** thermostat and sub base, a 4-position connec- E LECTROSTATIC D ISCHARGE (ESD) P RECAUTIONS tor (included with the kit), and a short section (~ 2ft) of ther- mostat wire. Connect the wire between the connector and NOTE: Discharge body’s static electricity before touching thermostat sub base. Connect the thermostat to the indoor unit. An electrostatic discharge can adversely affect electrical unit and apply power. If the thermostat identifies the indoor components. unit, then a wiring problem exists between the indoor unit Use the following precautions during furnace installation and and the permanent thermostat location. Repair or replace servicing to protect the integrated control module from dam- wiring. age. By putting the furnace, the control, and the person at the same electrostatic potential, these steps will help avoid exposing the integrated control module to electrostatic dis- Connect the thermostat to the outdoor unit. If the thermo- charge. This procedure is applicable to both installed and stat identifies the outdoor unit, then a wiring problem exists uninstalled (ungrounded) furnaces. between the indoor and outdoor units. Repair or replace 1.Disconnect all power to the furnace. Do not touch the wiring. integrated control module or any wire connected to NOTE: A 24VAC source will be needed to power the ther- the control prior to discharging your body’s electro- mostat and outdoor unit control. static charge to ground. D IAGNOSTIC C HART 2.Firmly touch a clean, unpainted, metal surface of the furnace away from the control. Any tools held in a WARNING person’s hand during grounding will be discharged. 3.Service integrated control module or connecting wiring HIGH VOLTAGE ! following the discharge process in step 2. Use cau- T OAVOIDPERSONALINJURYORDEATHDUETO tion not to recharge your body with static electricity; ELECTRICALSHOCK,DISCONNECTELECTRICALPOWER (i.e., do not move or shuffle your feet, do not touch un- PERFORMINGANYSERVICEORMAINTENANCE. BEFORE grounded objects, etc.). If you come in contact with an ungrounded object, repeat step 2 before touching Refer to the Troubleshooting Chart in the Appendix for as- control or wires. sistance in determining the source of unit operational prob- lems. The dual 7-segment LED display will display an error 4.Discharge your body to ground before removing a new code that may contain a letter and number. The error code control from its container. Follow steps 1 through 3 if may be used to assist in troubleshooting the unit. installing the control on a furnace. Return any old or new controls to their containers before touching any RESETTING FROM LOCKOUT ungrounded object. Furnace lockout results when a furnace is unable to achieve F OUR W IRE M OTOR T ROUBLESHOOTING ignition after three attempts during a single call for heat. It Any manual testing of the 4 wire seriallY communicating is characterized by a non-functioning furnace and a F!1 motor should only be done with the ULTRACHECK-EZ diag- code displayed on the dual 7-segment display. If the fur- nostic tool (part # UTT-01). All other methods may not be nace is in “lockout”, it will (or can be) reset in any of the reliable or cause damage to the 4 wire motor. See section following ways. S-16C for additional details. 1.Automatic reset. The integrated control module will automatically reset itself and attempt to resume normal C OMFORT N ET S YSTEM T ROUBLESHOOTING operations following a one hour lockout period. At system power-up, the CTK0*** thermostat will begin searching for any connected compatible equipment. The 2.Manual power interruption. Interrupt 115 volt power to thermostat will scroll "SEARCHING". The thermostat will the furnace. scroll<equipment> FOUND once it indentifies that piece 3.Manual thermostat cycle. Lower the thermostat so of equipment. In a typical installation, an indoor unit and that there is no longer a call for heat for 1 -20 seconds outdoor unit will be identified. then reset to previous setting. If the thermostat scrolls "SEARCHING" for several minutes,NOTE: If the condition which originally caused the lockout then it has failed to identify any connected equipment. Thestill exists, the control will return to lockout. Refer to the thermostat may identify one piece of equipment, but not theDiagnostic Chart for aid in determining the cause. other. Broken or improper wiring is the most likely cause for the thermostat to fail to identify any equipment. If an out- door unit is not identified, the thermostat will scroll "CHECK SYSTEM", indicating that no indoor unit was found. 56 SERVICING Some of the electronic boards being used today, with flame INCOMING POWER rectification, will not function properly and/or at all without METER READS METER READS 120 VOLTS 0 VOLTS polarization of incoming power. Some also require phasing between the primary and secondary sides of step-down transformers. VOLT / OHMVOLT / OHM METER METER GND GND THIS IS THE COMMON THIS IS L1 OR THE OR NEUTRAL LEG HOT POWER LEG These then should be wired to the furnace accordingly. CHECKING FOR PHASING - PRIMARY TO SECONDARY OF UNMARKED TRANSFORMERS* D N G C N METER READS METER READS 120 VOLTS 24 VOLTS R .L1 . . . . . VOLT / OHM VOLT / OHM METER METER LINE VOLTAGE VOLT / OHM TRANSFORMER METER (NEUTRAL) D N G C READS 96 VOLTS - IN PHASE R PRIMARY SECONDARY D N G LINE VOLTAGE C N L1 (HOT) L1 R VOLT / OHM METER VOLT / OHM METER READS 144 VOLTS - OUT OF PHASE If meter reads approximately 96 volts - the primary to secondary are in phase - if reads approximately 144 volts out of phase - reverse low voltage wires. D N G C NEUTRAL 120 V 24 V Some transformers will display phasing symbols as shown R L1 in the illustration to the left to assist in determining proper transformer phasing. PHASING SYMBOL 57 SERVICING 11 One CUBIC FEET GAS RATE -- CUBIC FEET PER HOUR Size of Test DialSize of Test Dial Seconds for Seconds for One One 1/41/21251/41/2125 RevolutionRevolution cu/ftcu/ftcu/ftcu/ftcu/ftcu/ftcu/ftcu/ftcu/ftcu/ft 9018036072018002550100200500 1036 821643276551636----97195486 1137 751503006001500234795189474 1238 691382775551385----92185462 1339 641292575141286224590180450 1440 601202404801200------176439 1541 561132254501125214386172429 1642 531062124241059------167419 1743 501002004001000--4182164409 1844 4795189379947204080160400 1945 4590180360900----78157391 2046 2147 4386171343857193876153383 4182164327818----75150375 2248 3978157313783------147367 2349 3775150300750183672144360 2450 3672144288720------141355 2551 2652 3469138277692----69138346 33671332656671734--136340 2753 3264129257643----67133333 2854 3162124248621------131327 2955 3060120240600163264129321 3056 3157 ----116232581------126316 2856113225563--3162124310 3258 ----109218545------122305 3359 2653106212529153060120300 3460 ----103206514 35 58 SERVICING Service ProblemNo HeatUnsatisfactory Heat POSSIBLE CAUSE Test Method DOTS IN ANALYSIS Remedy GUIDE INDICATE SYMPTOM Long Cycles Short Cycles Too Much Heat "POSSIBLE CAUSE" Not Enough Heat Burner Won't Ignite Soot and /or Fumes System Will Not Start Burner Ignites-Locks Out See Service Procedure Reference Burner Shuts Off prior to T'Stat being Satisfied Power FailureTest VoltageS-1 Blown FuseTest VoltageS-4 Loose ConnectionCheck WiringS-2 Shorted or Broken WiresCheck WiringS-3A No Low VoltageCheck TransformerS-4 Faulty ThermostatCheck ThermostatS-3A Faulty TransformerCheck TransformerS-4 Poor or High Resistance GroundMeasure Ground ResistanceS-17B Improper Heat Anticipator SettingAdjust Heat Anticipator SettingS-3B Improper Thermostat LocationRelocate ThermostatS-316 Faulty Limit or Roll Out SwitchTest ControlS-300 / S-302 Test Flame SensorS-314 Faulty Flame Sensor Faulty Ignition ControlTest ControlS-313 Gas Valve or Gas Supply Shut OffTurn Valves to On PositionS-317 Faulty Induced Draft BlowerTest Induced Draft MotorS-303 Faulty Blower Motor (ECM)Test Blower Motor (& ECM)S-16A,B,C Broken or Shorted Ignitor Test IgnitorS-308 Dirty Flame Sensor, Low UA Clean Flame SensorS-314 Stuck Gas ValveReplace Gas ValveS-304 Faulty Gas ValveReplace Gas ValveS-304 Open Auxiliary LimitReset ControlS-301 Improper Air Flow or DistributionCheck Duct StaticS-200 Cycling on LimitCheck Controls & Temperature RiseS-201 / S-300 Delayed IgnitionTest for Delayed IgnitionS-312 FlashbackTest for FlashbackS-309 / S-311 Orifice SizeCheck OrificesS-306 / S-311 Gas PressureCheck Gas PressureS-307 Cracked Heat ExchangerCheck Burner FlamesS-305 Replace with Proper Size FurnaceS-318 Furnace Undersized Furnace OversizedReplace with Proper Size FurnaceS-318 Faulty Pressure SwitchTest Pressure SwitchS-310 Blocked or Restricted FlueCheck Flue/Drawdown PressureS-310 Open Roll Out SwitchTest Flame Roll Out ControlS-302 Bouncing On Pressure SwitchTest Negative PressureS-310 59 SERVICING SERVICE NUMBERS S-1CHECKING VOLTAGE.......................61S-305CHECKING MAIN BURNERS.............69 S-306CHECKING ORIFICES.......................69 S-2CHECKING WIRING..........................61 S-307CHECKING GAS PRESSURE...........69 CHECKING THERMOSTAT, WIRING S-308CHECKING AND ANTICIPATOR............................61 HOT SURFACE IGNITOR..................71 S-3ATHERMOSTAT AND WIRING.............61 S-309CHECKING FOR FLASHBACK..........72 S-3BHEATING ANTICIPATOR....................61 S-310CHECKING PRESSURE CONTROL.72 S-200CHECKING DUCT STATIC................65 S-311HIGH ALTITUDE S-201CHECKING TEMPERATURE RISE...65 APPLICATION (USA)..........................72 S-300CHECKING PRIMARY S-312CHECKING FOR LIMIT CONTROL................................66 DELAYED IGNITION...........................73 S-301CHECKING AUXILIARY S-313CHECKING INTEGRATED LIMIT CONTROL................................67 IGNITION CONTROL BOARDS........73 S-302CHECKING FLAME ROLLOUT S-313AMEMORY CHIPS................................74 CONTROL.........................................67 S-314CHECKING FLAME SENSOR..........75 S-303INDUCED DRAFT BLOWER Motor...68 S-304CHECKING GAS VALVE (REDUNDANT)..................................68 60 SERVICING S-1 CHECKING VOLTAGECHECKING THERMOSTAT, WIRING AND ANTICIPATOR WARNING S-3A THERMOSTAT AND WIRING HIGHVOLTAGE D ISCONNECT ALL POWER BEFORE SERVICING OR WARNING CHANGING ANY ELECTRICAL WIRING. M ULTIPLE POWER SOURCES MAY BE PRESENT. F AILURE TO DO SO MAY CAUSE D ISCONNECT ALL POWER BEFORE SERVICING. PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. 1.Remove the blower compartment door to gain access to 1.Remove the burner door. the thermostat low voltage wires located at the furnace integrated control module terminals. 2.Remove cover from the Junction Box and gain access to incoming power lines. 2.Remove the thermostat low voltage wires at the furnace control panel terminal board. With Power ON: 3.Jumper terminals R to W (or W1 and W2 for two-stage models) on the integrated ignition control. WARNING With Power On (and Door Interlock Switch closed): L INE VOLTAGE NOW PRESENT WARNING 3.Using a voltmeter, measure the voltage across the hot and neutral connections. L INE VOLTAGE NOW PRESENT NOTE: To energize the furnace, the Door Interlock Switch must be engaged at this point. 4.Induced Draft Motor must run and pull in pressure switch. 4.No reading - indicates open wiring, open fuse, no power, 5.If the hot surface ignitor heats and at the end of the or faulty Door Interlock Switch from unit to fused dis- ignitor warm-up period the gas valve opens and the burn- connect service. Repair as needed. ers ignite, the trouble is in the thermostat or wiring. 5.With ample voltage at line voltage connectors, energize 6.With power off, check the continuity of the thermostat the furnace blower motor by jumpering terminals R to G and wiring. Repair or replace as necessary. on the integrated ignition control. If checking the furnace in the air conditioning mode, pro- 6.With the blower motor in operation, the voltage should ceed as follows. be 115 volts ± 10 percent. 7.With power off, Jumper terminals R to Y (or Y1 or Y2 for 7.If the reading falls below the minimum voltage, check two-stage models) to G. the line wire size. Long runs of undersized wire can cause 8.Turn on the power. low voltage. If wire size is adequate, notify the local power 9.If the furnace blower motor starts and the condensing company of the condition. unit runs, then the trouble is in the thermostat or wiring. 8.After completing check and/or repair, replace Junction Repair or replace as necessary. Box cover and reinstall the service panel doors. 10.After completing check and/or repair of wiring and check 9.Turn on electrical power and verify proper unit operation. and/or replacement of thermostat, reinstall blower com- S-2 CHECKING WIRING partment door. 11.Turn on electrical power and verify proper unit operation. WARNING S-3B HEATING ANTICIPATOR On older thermostats, the heating anticipator is a wire wound D ISCONNECT ALL POWER BEFORE SERVICING. adjustable heater which is energized during the "ON" cycle to help prevent overheating of the conditioned space. 1.Check wiring visually for signs of overheating, damaged insulation and loose connections. The anticipator is a part of the thermostat and if it should fail for any reason, the thermostat must be replaced. 2.Use an ohmmeter to check continuity of any suspected open wires. The heating anticipator setting for furnaces covered in this manual is 0.70 Amps. 3.If any wires must be replaced, replace with AWM, 105°C. 2/64 thick insulation of the same gauge or its equivalent. Modern thermostats do not have this type of heat anticipa- tor. Many have a selector switch to adjust the number of cycles per hour 61 SERVICING S-4CHECKING TRANSFORMER AND Control CIRCUITECM Control Connections A step-down transformer 120 volt primary to 24 volt second- ECM control connections are made through the integrated ary, 40 VA (Heating and Cooling Models) supplies ample ignition control. No other control connections are needed. capacity of power for either operation. 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 in- WARNING ductor is to reduce the line current by storing the electrical HIGHVOLTAGE energy in a magnetic field, such that the voltage AC wave- D ISCONNECT ALL POWER BEFORE SERVICING OR form leads the current AC waveform. In other words, the CHANGING ANY ELECTRICAL WIRING. M ULTIPLE POWER inductor reduces line current which extends the life of the SOURCES MAY BE PRESENT. F AILURE TO DO SO MAY CAUSE 3/4 and 1 horsepower motors. PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. 1.Remove blower compartment door to gain access to the thermostat low voltage wires located at the furnace inte- grated control module. 2.Remove the thermostat low voltage wires at the furnace integrated control module terminals. With Power On (and Door Interlock Switch closed): 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 deter- WARNING mine if the inductor is at fault, you can bypass by the induc- tor by disconnecting the black wire from the inductor and L INE VOLTAGE NOW PRESENT connecting it directly to the motor. If the motor operates then the inductor will need to be replaced. 3.Use a voltmeter, check voltage across terminals R and C. Must read 24 VAC. Checking ECM Motors 4.No voltage indicates faulty transformer, open fuse, bad wiring, bad splice, or open door interlock switch. ECMmotors connect directly to the AC Line Voltage. DO NOT insert contactors in series with the ECM Motor AC 5.Check transformer primary voltage at incoming line volt- Line. The control is powered continuously to insure reliable age connections, fuse, splices, and blower door inter- start-up. The connector plug is polarized, verify and reverify lock switch. correct connector orientation before applying power. DO NOT 6.If line voltage is available to the primary side of trans- force plug into motor and make sure power is off before in- former and not at secondary side, the transformer is serting power connector. DO NOT apply voltage to termi- inoperative. Replace. nals 1 or 2. 7.After completing check and/or replacement of trans- former and check and/or repair of control circuit, rein- stall blower compartment door. General Checks/Considerations 8.Turn on electrical power and verify proper unit operation. 1. Check power supply to the furnace. Ensure power sup- ply is within the range specified on rating plate. See sec- 4-Wire ECM Motors tion S-1. Description 2. Check motor power harness. Ensure wires are continu- ous and make good contact when seated in the connec- These models utilize an Nidec US motors, 4-wire variable tors. Repair or replace as needed. speed ECM blower motor. The ECM blower motor provides constant CFM. 3. Check motor control harness. Ensure wires are continu- ous and make good contact when seated in the connec- The motor is a serially communicating variable speed mo- tors. Repair or replace as needed. tor. Only four wires are required to control the motor: +Vdc, Common, Receive, and Transmit. 4. Check thermostat and thermostat wiring. Ensure ther- mostat is providing proper cooling/heating/continuous fan The +Vdc and Common wires provide power to the motor's demands. Repair or replace as needed. low voltage control circuits. Typical supply voltage is 9-15 volts DC. 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 interfer- Replace or repair as needed. ence between wheel and housing or wheel and motor. Repair or replace as needed. 7. Check housing for cracks and/or corrosion. Repair or Power Green Motor Indication(s) replace as needed. ButtonLEDAction Confirm 24VAC to 8. Check motor mounting bracket. Ensure mouting bracket TM UltraCheck-EZ tool. is tightly secured to the housing. Ensure bracket is not Not OFFOFF If 24VAC is confirmed, cracked or broken. Rotating diagnostic tool is inoperable. TM UltraCheck-EZ Diagnostic Tool Motor and control/end TM ONBlinkingRotatingbell are functioning The UltraCheck-EZ diaganostic tool is the preferred method properly. (part # UTT-01) to diagnose the ECM motor. Replace motor ONOFFRotating control/end bell. Not Check motor (see ONBlinking RotatingMotor Checks below). HIGH VOLTAGE! Replace motor Disconnect ALL power before servicing Not control/end bell; verify ONOFF or installing. Multiple power sources Rotatingmotor (see Motor may be present. Failure to do so may Checks below). cause property damage, personal injury or death. 9. Depress the orange power button to turn off motor. To use the diagnostic tool, perform the following steps: 10. Disconnect power. Disconnect diagnostic tool. 1. Disconnect power to the furnace. 11. Reconnect the 4-wire harness from control board to motor. 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. Electrical Checks - High Voltage Power Circuits 4. Connect one alligator clip from the diagnostic tool to a ground source. 5. Connect the other alligator clip to a 24VAC source. HIGH VOLTAGE! NOTE: The alligator clips are NOT polarized. Disconnect ALL power before servicing or installing. Multiple power sources TM diagnostic tool is equipped NOTE: The UltraCheck-EZ may be present. Failure to do so may with a nonreplaceable fuse. Connecting the tool to a source cause property damage, personal injury other than 24VAC could damage the tool and cause the or death. fuse to open. Doing so will render the diagnostic tool inop- erable. 1. Disconnect power to the furnace. 6. Turn on power to the furnace. 2. Disconnect the 5-circuit power connector to the ECM motor. WARNING 3. Turn on power to the furnace. Line Voltage now present. WARNING Line Voltage now present. 7. Depress the orange power button on the diagnostic tool to send a run signal to the motor. Allow up to 5 seconds for the motor to start.4. Measure voltage between pins 4 and 5 on the 5-circuit connector. Measured voltage should be the same as the NOTE:If the orange power button does not illuminate when supply voltage to the furnace. depressed, the tool either has an open fuse or is not prop- erly 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. 63 SERVICING Motor Control/End Bell Checks AC Line Hot Connection 5 AC Line Neutral Connection 4 HIGH VOLTAGE! Gnd 3 Disconnect ALL power before servicing 2 Lines 1 and 2 will be connected or installing. Multiple power sources for 120VAC Power Connector } may be present. Failure to do so may 1 applications only cause property damage, personal injury or death. POWER CONNECTOR (1/2 HP MOTORS) 1. Disconnect power to the furnace. "Motor Half“ (Viewed from Plug End) NOTE: Motor contains capacitors that can hold a charge for several minutes after disconnecting power. Wait 5 min- utes after removing power to allow capacitors to discharge. inductor AC Line Hot Connection 5 2. Disconnect the motor control harness and motor power harness. AC Line Neutral Connection 4 3. Remove the blower assembly from the furnace. Gnd 3 4. Remove the (3) screws securing the control/end bell to 2 Lines 1 and 2 will be connected the motor. Separate the control/end bell. Disconnect for 120VAC Power Connector } applications only 1 the 3-circuit harness from the control/end bell to remove the control/end bell from the motor. POWER CONNECTOR 5. Inspect the NTC thermistor inside the control/end bell (3/4 & 1 HP MOTORS) (see figure below). Replace control/end bell if thermistor "Motor Half“ is cracked or broken. (Viewed from Plug End) 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 fur- nace. See section S-1. 8. Disconnect power to the furnace. Reconnect the 5-cir- cuit power harness disconnected in step 2. Electrical Checks - Low Voltage Control Circuits 1. Turn on power to the furnace. WARNING 6. Inspect the large capacitors inside the control/end bell Line Voltage now present. (see figure below). Replace the control/end bell if any of the capacitors are bulging or swollen. 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 sec- tion S-313. 64 SERVICING Too great of an external static pressure will result in insuffi- cient air that can cause excessive temperature rise, result- ing 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 (in- clined manometer) to measure the static pressure of the return duct at the inlet of the furnace. (Negative Pres- sure) 2.Measure the static pressure of the supply duct. (Posi- 7. Locate the 3-circuit connector in the control/end bell. Usingtive Pressure) an ohmmeter, check the resistance between each termi- 3.Add the two (2) readings together for total external static nal in the connector. If the resistance is 100k or greater, pressure. the control/end bell is functioning properly. Replace the NOTE:Both readings may be taken simultaneously and control/end bell if the resistance is lower than 100k. read directly on the manometer if so desired. If an air condi- 8. Reassemble motor and control/end bell in reverse of dis- tioner coil or Electronic Air Cleaner is used in conjunction assembly. Replace blower assembly into the furnace. with the furnace, the readings must also include theses com- Motor Checksponents, 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, reg- HIGH VOLTAGE! isters, undersized and/or oversized poorly laid out duct work. 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 min- utes 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. Checking Static Pressure S-200 CHECKING DUCT STATIC S-201 CHECKING TEMPERATURE RISE The maximum and minimum allowable external static pres- The more air (CFM) being delivered through a given furnace, sures are found in the specification section. These tables the less the rise will be; so the less air (CFM) being deliv- also show the amount of air being delivered at a given static ered, the greater the rise. The temperature rise should be by a given motor speed or pulley adjustment. adjusted in accordance to a given furnace specifications and The furnace motor cannot deliver proper air quantities (CFM) its external static pressure. An incorrect temperature rise against statics other than those listed. 65 SERVICING PRIMARY LIMIT may result in condensing in or overheating of the heat ex- CONTROL changer. An airflow and temperature rise table is provided in the blower performance specification section. Determine and adjust temperature rise as follows: 1.Operate furnace with burners firing for approximately ten *** minutes. Check BTU input to furnace - do not exceed * 2 * input rating stamped on rating plate. Ensure all regis- ** ters 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. Primary Limit Control Location (90% Upflow Furnace Shown, Counterflow Similar) The following drawing illustrates the style of limit switches used on the 90% furnaces. SUPPLY ENCLOSED DISK AIR FRONT VIEWSIDE VIEW RETURN Primary Limit Control Style AIR (90% Furnaces) Temperature Rise Measurement WARNING 3.Subtract the return air temperature from the supply air HIGHVOLTAGE D ISCONNECT ALL POWER BEFORE SERVICING OR temperature to determine the air temperature rise. Al- CHANGING ANY ELECTRICAL WIRING. M ULTIPLE POWER low adequate time for thermometer readings to stabi- SOURCES MAY BE PRESENT. F AILURE TO DO SO MAY CAUSE lize. PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. 4.Adjust temperature rise by adjusting the circulator blower speed. Increase blower speed to reduce temperature 1.Remove burner compartment door to gain access to the rise. Decrease blower speed to increase temperature primary limit. rise. Refer to Circulator Blower Speed section in the 2.Remove low voltage wires at limit control terminals. Product Design section of this manual for speed chang- 3.With an ohmmeter, test between these two terminals ing details. Temperature rise is related to the BTUH out- as shown in the following drawing. The ohmmeter should put of the furnace and the amount of air (CFM) circu- read continuous unless heat exchanger temperature is lated over the heat exchanger. Measure motor current above limit control setting. If not as above, replace the draw to determine that the motor is not overloaded dur- control. ing 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. 66 SERVICING Manual or Automatic Reset Auxiliary Limits Located in Blower Side WARNING HIGHVOLTAGE VOLT / OHM D ISCONNECT ALL POWER BEFORE SERVICING OR METER M ULTIPLE POWER SOURCES MAY INSTALLING THIS UNIT. BE PRESENT. F AILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. 1.Remove the wires from the auxiliary limit control termi- nals. 2.Using an ohmmeter, test for continuity across the two terminals (only test when the auxiliary limit is at room COLOR IDENTIFYING temperature). TAB Testing Primary Limit Control (90% Furnaces) VOLT / OHM 4.After completing check and/or replacement of primary METER 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 RED RESET Charts in furnace Technical Manual for part number, tem- BUTTON perature setting and color(s) code. S-301CHECKING AUXILIARY LIMIT CONTROL The auxiliary limit control is designed to prevent furnace op- eration in case of main blower failure in horizontal or coun- COLOR IDENTIFYING terflow installations. It may also open if the power supply is TAB interrupted while the furnace is firing. Testing Auxiliary Limit Control The auxiliary limit control is suitable for both horizontal right and horizontal left installations. Regardless of airflow direc- tion, it does not need to be relocated. The (2) two auxiliary limits are located on the blower housing (one on each side), WARNING as shown in the following illustration. 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. AUXILIARY LIMIT CONTROL S-302CHECKING FLAME ROLLOUT CONTROL A temperature activated manual reset control is mounted to the manifold assembly on 90% furnaces, as shown in the BLOWER HOUSING following illustration. AUXILIARY LIMIT CONTROL Auxiliary Limit Control Location (Select 90% / 95% Furnaces) 67 SERVICING FLAME 1.Remove burner compartment door to gain access to the ROLLOUT induced draft blower motor. SWITCHES 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. 2 * ** 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 Flame Rollout Switch Location draft motor, reinstall burner compartment door. (90% Upflow Furnace Shown, Counterflow Similar) 7.Turn on electrical power and verify proper unit operation. The control is designed to open should a flame roll out oc- S-304CHECKING GAS VALVE (REDUNDANT) cur. An over firing condition or flame impingement on the A combination redundant operator type gas valve which pro- heat shield may also cause the control to open. If the rollout vides all manual and automatic control functions required for control opens, the air circulation blower will run continuously. gas fired heating equipment is used. The valve provides control of main burner gas flow, pressure WARNING regulation, and 100 percent safety shut-off. Two stage gas valves always require 24 volts between com- L INE VOLTAGE NOW PRESENT mon and low fire (main coil) to open. The furnace front cover pressure switch is wired in series with the low (main) sole- 1.Remove the burner compartment door to gain access to noid of the gas valve. In the event of a non-functioning gas the rollout switch(es) mounted to burner bracket. valve, always check the front cover pressure switch. Also 2.Reset the manual rollout switch. see section S-307 on Checking Gas Pressure and section 3.Remove wires from rollout switch. S-310 on Checking Pressure Switches. 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. Low (Main) Possible causes could be flame impingement, orifice plate Common out of position, burners with excessive cross-over slot di- High mension, over-firing, improper orifices, improper gas pres- sure, 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, rein- stall burner compartment door and verify proper unit op- eration. S-303 INDUCED DRAFT BLOWER MOTOR White-Rodgers 2-Stage Valve WARNING WARNING HIGHVOLTAGE DALL ISCONNECT POWER BEFORE SERVICING ISCONNECT ALL POWER BEFORE SERVICING OR D INSTALLING THIS UNIT. M ULTIPLE POWER SOURCES MAY BE PRESENT. F AILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. 68 SERVICING S-305 CHECKING MAIN BURNERS Orifices should be treated with care in order to prevent dam- age. They should be removed and installed with a box-end The main burners are used to provide complete combustion wrench in order to prevent distortion. In no instance should of various fuels in a limited space, and transfer this heat of an orifice be peened over and redrilled. This will change the the burning process to the heat exchanger. angle or deflection of the vacuum effect or entraining of pri- Proper ignition, combustion, and extinction are primarily due mary air, which will make it difficult to adjust the flame prop- to burner design, orifice sizing, gas pressure, primary and erly. This same problem can occur if an orifice spud of a secondary air, vent and proper seating of burners. different length is substituted. B URNERS Burners have been redesigned for 34.5" chassis furnaces. WARNING Overall length and width dimensions remain the same as 40" model burners. The burners used 34.5" models have DALLGEPS ISCONNECT AS AND LECTRICAL OWER UPPLY. burner head insert with larger diameter center hole and a larger number of surrounding holes. 1.Check orifice visually for distortion and/or burrs. 2.Check orifice size by the number stamped on the ori- fice. A GAS B STREAM The length of Dimension "A" determines the angle of Gas Stream "B". DENT OR BURR GAS B STREAM A dent or burr will cause a severe deflection of the gas stream. S-307 CHECKING GAS PRESSURE New 34.5 Burners Gas Supply Pressure Measurement WARNING CAUTION DALLGEPS ISCONNECT AS AND LECTRICAL OWER UPPLY. T O PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE In checking main burners, look for signs of rust, oversized INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES and undersized carry over ports restricted with foreign mate- OPERATING. rial, etc., burner cross-over slots should not be altered in size. Gas inlet and manifold pressures should be checked and S-306 CHECKING ORIFICES adjusted in accordance to the type of fuel being consumed. A/GMVC, A/GCVC model furnaces have factory installed The line pressure supplied to the gas valve must be within #45 natural gas orifices. the range specified below. The supply pressure can be mea- The only time resizing is required is when a reduction in sured at the gas valve inlet pressure tap or at a hose fitting firing rate is required for an increase in altitude or a funace is installed in the gas piping drip leg. The supply pressure being converted for use with L.P. gas. must be measured with the burners operating. To measure the gas supply pressure, use the following procedure. 69 SERVICING WARNING WARNING HIGHVOLTAGE D ISCONNECT ELECTRICAL POWER AND SHUT OFF GAS SUPPLY. D ISCONNECT ALL ELECTRICAL POWER AND SHUT OFF GAS SUPPLY BEFORE SERVICING OR INSTALLING THIS UNIT. 1.After turning off gas to furnace at the manual gas shutoff M ULTIPLE POWER SOURCES MAY BE PRESENT. F AILURE TO valve external to the furnace, remove burner compart- DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. ment door to gain access to the gas valve. 5.Disconnect manometer after turning off gas at manual 2.Connect a calibrated water manometer (or appropriate shutoff valve. Reinstall plug before turning on gas to fur- gas pressure gauge) at either the gas valve inlet pres- nace. sure tap or the gas piping drip leg as shown in the follow- ing figures. 6.Turn OFF any unnecessary gas appliances started in step 3. NOTE: At either location, a hose fitting must be installed prior to making the hose connection. 7.Turn on gas to furnace and check for leaks. If leaks are found, repair and then reinstall burner compartment door. NOTE: Use adapter kit #0151K00000S to measure gas pres- sure on White-Rodgers 36J54 gas valves. 8.Turn on electrical power and verify proper unit operation. WARNING GAS LINE GAS SHUTOFF VALVE HIGHVOLTAGE D ISCONNECT ALL ELECTRICAL POWER AND SHUT OFF GAS SUPPLY BEFORE SERVICING OR INSTALLING THIS UNIT. M ULTIPLE POWER SOURCES MAY BE PRESENT. F AILURE TO GAS LINE DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. TO FURNACE Gas Manifold Pressure Measurement and Adjust- OPEN TO ATMOSPHERE ment DRIP LEG CAP Natural Gas Adjustments WITH FITTING MANOMETER HOSE WARNING HIGHVOLTAGE MANOMETER DALL ISCONNECT ELECTRICAL POWER AND SHUT OFF GAS SUPPLY BEFORE SERVICING OR INSTALLING. Measuring Inlet Gas Pressure (Alternate Method) NOTE: Use apapter kit #0151K00000S to measure gas pres- sure on White-Rodgers 36J54 gas valves. 3.Turn ON the gas and electrical power supply and oper- Only small variations in gas pressure should be made by ate the furnace and all other gas consuming appliances adjusting the gas valve pressure regulator. The manifold pres- on the same gas supply line. sure must be measured with the burners operating. To mea- 4.Measure furnace gas supply pressure with burners fir- sure and adjust the manifold pressure, use the following pro- ing. Supply pressure must be within the range specified cedure. in the following table. 1.After turning off gas to furnace at the manual gas shutoff valve external to the furnace, remove burner compart- INLET GAS SUPPLY PRESSURE ment door to gain access to the gas valve. Natural GasMinimum: 4.5" w.c.Maximum: 10.0" w.c. 2.Connect a calibrated water manometer (or appropriate Propane GasMinimum: 11.0" w.c.Maximum: 13.0" w.c. gas pressure gauge) at the gas valve outlet pressure tap. Refer to Measuring Gas Pressure: Two-Stage Valves If supply pressure differs from above, make necessary ad- figure for two-stage gas valve outlet pressure tap con- justments to pressure regulator, gas piping size, etc., and/ nections. or consult with local gas utility. 70 SERVICING WARNING WARNING HIGHVOLTAGE L INE VOLTAGE NOW PRESENT DALL ISCONNECT ELECTRICAL POWER AND SHUT OFF GAS SUPPLY BEFORE SERVICING OR INSTALLING. 3.Turn ON the gas and electrical power supply and oper- ate the furnace. 4. White-Rodgers 36J54 Valves: Manifold Gas Pressure a.Back outlet pressure test screw (inlet/outlet pressure GasRateRangeNominal boss) out one turn (counterclockwise, not more than High Stage3.2 to 3.8" w.c.3.5" w.c. Natural Gas one turn). Low Stage1.6 to 2.2" w.c.1.9" w.c. b.Attach a hose and manometer to the outlet pressure outlet pressure boss. c.Turn ON the gas supply. WARNING d.Turn on power and close thermostat “R” and “W1” con- HIGHVOLTAGE tacts to provide a call for low stage heat. D ISCONNECT ALL ELECTRICAL POWER AND SHUT OFF GAS SUPPLY BEFORE SERVICING OR INSTALLING THIS UNIT. e.Measure the gas manifold pressure with burners fir- M ULTIPLE POWER SOURCES MAY BE PRESENT. F AILURE TO ing. Adjust manifold pressure using the Manifold Gas DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. 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 WARNING to decrease pressure. Replace regulator cover screw. HIGHVOLTAGE g.Close thermostat “R” and “W2” contacts to provide a DALL ISCONNECT ELECTRICAL POWER AND SHUT OFF GAS SUPPLY call for high stage heat. BEFORE SERVICING OR INSTALLING. 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. Manifold Gas Pressure i.Turn off all electrical power and gas supply to the sys- GasRateRangeNominal tem. High Stage9.7 to 10.3" w.c.10.0" w.c. Propane Gas Low Stage5.7 to 6.3" w.c.6.0" w.c. j.Remove the manometer hose from the hose barb fit- ting or outlet pressure boss. S-308CHECKING HOT SURFACE IGNITOR k.Turn outlet pressure test screw in to seal pressure port (clockwise, 7 in-lb minimum). 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 operat- ing temperature is approximately 2156°F - 2678°F. High Fire Regulator AdjustRegulator Vent WARNING D ISCONNECT ALL POWER BEFORE 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 igni- tor: 120 Volt Silicon Nitride : 120V Nitride Igniter should read Measuring Manifold Gas Pressure between 37 to 68 ohms. (36J54 Valve) 71 SERVICING 5.Reconnect ignitor. 3.Remove the pressure control hose from the control and interconnect with an inclined manometer as shown in the following figure. WARNING 4.With an ohm meter connected across the pressure switch terminals and with the inducer running, the switch L INE VOLTAGE NOW PRESENT should close and the ohm meter should show a com- plete circuit across the pressure switch. If the switch is 6.Place unit in heating cycle, measure current draw of not closed, compare the negative pressure to the clos- ignitor during preheat cycle. ing point specified for the particular switch. Either the The steady state current at 120V is 0.37 to 0.68 amps. switch is defective or the inducer/venting system is in- 7.After checking and/or replacing of hot surface ignitor, adequate. reinstall burner compartment door and verify proper unit operation. INDUCED DRAFT BLOWER S-309 CHECKING FOR FLASHBACK PRESSURE SWITCH Flashback will also cause burning in the burner venturi, but PRESSURE SWITCH is caused by the burning speed being greater than the gas- HOSE OPEN TO * ** air flow velocity coming from a burner port. ATMOSPHERE M1 P3 O F* F C2 ON * ** 1/4" TEE Flashback may occur at the moment of ignition, after a burner COIL COVER heats up or when the burner turns off. The latter is known as PRESSURE SWITCH extinction pop. INCLINED MANOMETER Since the end results of flashback and delayed ignition can INDUCED HOSE TO INDUCED be the same (burning in the burner venturi) a definite at- DRAFT DRAFT BLOWER TAP BLOWER tempt should be made to determine which has occurred. If flashback should occur, check for the following: Blower Pressure Switch 1.Improper gas pressure - adjust to proper pressure (See Negative Pressure Measurement S-307 CHECKING GAS PRESSURE).. (90% Upflow Furnace Shown, Counterflow Similar) 2.Check burner for proper alignment and/or replace burner. S-311 HIGH ALTITUDE APPLICATION (USA) 3.Improper orifice size - check orifice for obstruction. When furnaces are installed at high altitude, the appropriate S-310CHECKING PRESSURE CONTROL High Altitude Orifice or Pressure Switch Kit must be ap- The pressure control is a safety device to prevent the com- plied. This is required due to the natural reduction in the bustion cycle from occurring with inadequate venting caused density of both the gas fuel and combustion air as altitude by a restricted or blocked vent pipe. In addition to the high increases. The High Altitude Orifice Kit will provide the proper fire and low fire pressure switches, A/GMVC96 and A/GCVC design certified input rate within the specified altitude range. model furnaces have a "front cover pressure switch" wired High Altitude Orifice or Pressure Switch Kits are purchased in series with the gas valve. This pressure switch keeps according to the installation altitude and usage of either natu- the gas valve from opening in the event of condensate back- ral or propane gas. Refer to the Technical Manual or product ing up in the secondary heat exchanger. This could occur Specification Sheet for a tabular listing of appropriate alti- from improperly connected drains or a plugged drain tube. tude ranges and corresponding manufacturer's high altitude (Natural or Propane Gas) orifice or pressure switch kits. WARNING Donot derate the furnace by adjusting the manifold pres- sure to a lower pressure than specified on the furnace rating HIGHVOLTAGE plate. The combination of the lower air density and a lower ISCONNECT ALL POWER BEFORE SERVICING OR D manifold pressure will prohibit the burner orifice from draw- INSTALLING THIS UNIT. M ULTIPLE POWER SOURCES MAY BE PRESENT. F AILURE TO DO SO MAY CAUSE PROPERTY ing the proper amount of air into the burner. This may cause DAMAGE, PERSONAL INJURY OR DEATH. incomplete combustion, flashback, and possible yellow tip- ping. 1.Remove burner compartment door to gain access to pres- sure switch(es). 2.Remove wires from the pressure switch(es) electrical terminals. 72 SERVICING In some areas the gas supplier may artificially derate theThese tests must be completed within a given time frame gas in an effort to compensate for the effects of altitude. Ifdue to the operation of the ignition control. The trial for igni- the gas is artificially derated the appropriate orfice size musttion period is 4 seconds. 3 be determined based on the BTU/ftcontent of the derated The ignition control is capable of diagnosing many furnace gas and the altitude. Refer to the National Fuel Gas Code, failures to help in troubleshooting. The control utilizes a NFPA 54/ANSI Z223.1, and information provided by the gas dual, 7-segment LED display to indicate diagnostic codes. supplier to determine the proper orifice size. When the control is powered up normally the light will be on S-312 CHECKING FOR DELAYED IGNITION continuously. The display wil indicate "ON" when powered and in standby mode. This can be used to test for 120 volts Delayed ignition is a delay in lighting a combustible mixture and 24 volts to the control since both must be present for of gas and air which has accumulated in the combustion the light to be on. If this step fails, check for 120 volts to the chamber. control and check the transformer and its associated wiring. When the mixture does ignite, it may explode and/or rollout If this step is successful give the control a call for heat and causing burning in the burner venturi. wait five (5) seconds or until the furnace goes into lockout. If If delayed ignition should occur, the following should be the control detects a failure it will now be shown on the checked. Furnace design makes this extremely unlikely diagnostic indicator light/display. Refer to the Abnormal Op- unless safety controls have been by-passed or tampered erationsection in the Sequence of Operation section of this with. Never by-pass or alter furnace controls. manual for more detail on failure codes. 1.Improper gas pressure - adjust to proper pressure (See 1.Check for 120 volts from Line 1 (Hot) to Line 2 (Neutral) S-307 CHECKING GAS PRESSURE). at the ignition control. No voltage, check the door switch connections and wire harness for continuity. 2.Improper burner positioning - burners should be in locat- ing slots, level front to rear and left to right. 2.With the thermostat calling for heat, check for 24 volts from W1 to C terminal on the ignition control. No volt- 3.Carry over (lighter tube or cross lighter) obstructed - clean. age. Check transformer, room thermostat, and wiring. 4.Main burner orifice(s) deformed, or out of alignment to If you have 24 volts coming off the transformer but re- burner - replace. ceive approximately 13 volts on the terminal board be- S-313CHECKING INTEGRATED IGNITION tween (C) and (R), check for blown fuse. CONTROL BOARDS 3.Check for 120 volts to the induced draft blower (low-stage) NOTE:Failure to earth ground the furnace, reversing the by measuring voltage between Pin 3 and Pin 4 (on the 5- neutral and hot wire connection to the line (polarity), or a pin connector) located on circuit board. No voltage, check high resistance connection in the neutral line may cause for loose connection in the 5-pin connector or replace the control to lockout due to failure to sense flame. ignition control. Check for 120 volts to the induced draft blower (high- stage) by measuring voltage between Pin 2 and Pin 4 WARNING (on the 5-pin connector) located on circuit board. No volt- age, check for loose connection in the 5-pin connector, T O AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO THE UNIT D MUST BE PROPERLY POLARIZED AND GROUNDED. ISCONNECT POWER no call for high stage heat or replace ignition control. BEFORE PERFORMING SERVICE LISTED BELOW. The ground wire must run from the furnace all the way back to the electrical panel. Proper grounding can be confirmed by disconnecting the electrical power and measuring resis- tance 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 electro- mechanical device and is not field repairable. Complete unit must be replaced. WARNING L INE VOLTAGE NOW PRESENT 73 SERVICING 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 op- erational signals through the 4-pin wiring harness, connected between the motor and integrated control board.NOTE: For complete troubleshooting informa- tion 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 occur- rence 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 indi- vidual control board or motor is replaced. A memory chip is only required when all communicating components have been replaced with service parts contain- ing 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- ing component. In a fully communicating system, this would DE W2 12RCGW1Y1Y2O HUM include the communicating thermostat and communicating outdoor unit control board as the necessary data is stored in all communicating devices. GOODMAN PT# PCBKF104 4.If voltage is present in Steps 1 through 3 and the in- duced draft blower is operating, check for 120 volts to the ignitor during the preheat cycle. Measure voltage be- tween 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 sec- onds 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 furnace void of shared data will not function in a legacy or a. BEFORE replacing the ECM motor assembly or the a fully communicating installation. The furnace display would end bell, first check the motor with a Goodman #UTT- TM show “d0” indicating that there is no shared data in the fur- 01 UltraCheck-EZ diaganostic tool . If the motor nace control board. If it is ever necessary to use a memory runs with the diagnostic tool, the motor is good. To chip, the specific memory chip for your furnace number must check the end bell, see the previous variable speed be used. testing section of this manual before replacing the end bell. 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 3.Insert the memory card in the slot on the control board. WARNING HIGHVOLTAGE D ISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. M ULTIPLE POWER SOURCES MAY BE PRESENT. F AILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. 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 sen- sor 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 read- ing) is established, the hot surface ignitor will be de- energized. DE W2 12RCG W1 Y1Y2O HUM 6.The Integrated Ignition controls will have 1 to 4 micro- amps. If the micro-amp reading is less than the mini- Memory Card mum specified, check for high resistance wiring con- Connector nections, sensor to burner gap, dirty flame sensor, or Dual 7-Segment poor grounding. s LED’ 7.If absolutely no reading, check for continuity on all com- ponents and if good - replace ignition control module. 4.Power the system back up and allow a few minutes for NOTE:Contaminated fuel or combustion air can create a the network to establish communication between all nearly invisible coating on the flame sensor. This coating devices. works as an insulator causing a loss in the flame sense 5.Furnace control board will display "ON”. signal. If this situation occurs the flame sensor must be 6.Check operation. cleaned with steel wool. 7.Memory chip can be left on the control board (recom- mended) or removed once equipment is powered down again. S-314CHECKING FLAME SENSOR A flame sensing device is used in conjunction with the igni- tion 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 HIGHVOLTAGE ISCONNECT ALL POWER BEFORE SERVICING OR D INSTALLING THIS UNIT. M ULTIPLE POWER SOURCES MAY BE PRESENT. F AILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. CAUTION Maintenance Improper filter maintenance is the most common cause of I F YOU MUST HANDLE THE ITNITOR, HANDLE WITH CARE. T OUCHING inadequate heating or cooling performance. Filters should THE IGNITOR BODY WITH BARE FINGERS, ROUGH HANDLING, OR be cleaned (permanent) or replaced (disposable) every two VIBRATION COULD RESULT IN EARLY IGNITOR FAILURE. O NLY A months or as required. It is the owner's responsibility to keep QUALIFIED SERVICER SHOULD EVER HANDLE THE IGNITOR. air filters clean. When replacing a filter, it must be replaced ANNUAL INSPECTION with a filter of the same type and size. The furnace should be inspected by a qualified installer, or Filter Removal service agency at least once per year. This check should be Depending on the installation, differing filter arrangements performed at the beginning of the heating season. This will can be applied. Filters can be installed in the central return ensure that all furnace components are in proper working register, the bottom of the blower compartment (upflow only), order and that the heating system functions appropriately. a side panel external filter rack kit (upflow only), or the duct- Pay particular attention to the following items. Repair or work above a counterflow furnace. A media air filter or elec- service as necessary. tronic air cleaner can be used as an alternate filter. The filter •Flue pipe system. Check for blockage and/or leak- sizes given in the Product Design section of this manual or age. Check the outside termination and the connec- the product Specification Sheet must be followed to ensure tions at the furnace. proper unit performance. Refer to the following information •Combustion air intake pipe system (where applicable). for removal and installation of filters. Check for blockage and/or leakage. Check the out- FILTER REMOVAL PROCEDURE side termination and the connection at the furnace. •Heat exchanger. Check for corrosion and/or buildup Media Air Filter or Electronic Air Cleaner Removal within the heat exchanger passageways. Follow the manufacturer’s directions for service. •Burners. Check for proper ignition, burner flame, and Upright Counterflow Filter Removal flame sense. To remove filters from the ductwork above an upright coun- •Drainage system. Check for blockage and/or leakage. terflow installation: Check hose connections at and internal to furnace. 1.Turn off electrical power to furnace. •Wiring. Check electrical connections for tightness and/ 2.Remove access door in ductwork above furnace. or corrosion. Check wires for damage. 3.Remove filters. •Filters. 4.Remove blower compartment door. Vacuum compart- AIR FILTER ment. Replace blower compartment door. 5.Replace filters opposite of removal. WARNING 6.Replace access door in ductwork. N EVER OPERATE FURNACE WIHTOUT A FILTER INSTALLED AS DUST AND LINT WILL BUILD UP ON INTERNAL PARTS RESULTING IN LOSS OF Horizontal Unit Filter Removal EFFICIENCY, EQUIPMENT DAMAMGE, AND POSSIBLE FIRE. Filters in horizontal installations are located in the central return register. Filters must be used with this furnace. Filters do not ship with these furnaces but must be provided by the installer for INDUCED DRAFT AND CIRCULATION BLOWERS proper furnace operation. The bearings in the induced draft blower and circulator blower Remember that dirty filters are the most common cause of motors are permanently lubricated by the manufacturer. No inadequate heating or cooling performance. further lubrication is required. Check motor windings for ac- cumulation of dust which may cause overheating. Clean as necessary. 76 MAINTENANCE To conduct a heating performance test, the BTU input to the CONDENSATE DRAINAGE SYSTEM (QUALIFIED furnace must be calculated. SERVICER ONLY) The drain tubes, trap, and field supplied drain line must be After the heating cycle has been in operation for at least checked annually and cleaned as often as necessary to fifteen minutes and with all other gas appliances turned off, ensure proper condensate drainage. the gas meter should be clocked. FLAME SENSOR (QUALIFIED SERVICER ONLY) To find the BTU input, multiply the number of cubic feet of Under some conditions, the fuel or air supply can create agas consumed per hour by the heating value of the gas be- nearly invisible coating on the flame sensor. This coatinging used. (The calorific value of the gas being used is found acts as an insulator, causing a drop in the flame sensingby contacting your local utility.) signal. If this occurs, a qualified servicer must carefully clean EXAMPLE:It is found by the gas meter, that it takes forty the flame sensor with steel wool. After cleaning, the flame (40) seconds for the hand on the cubic foot dial to make one sensor output should be as listed on the specification sheet. complete revolution, with all appliances off, except the fur- nace. Take this information and locate it on the gas rate BURNERS chart. Observe the forty (40) seconds, locate and read across to the one (1) cubic foot dial column. There we find the num- ber 90, which shows that ninety (90) cubic feet of gas will be WARNING consumed in one (1) hour. HIGHVOLTAGE Let's assume the local gas utility has stated that the calo- E LECTRICAL COMPONENTS ARE CONTAINED IN BOTH rific value of the gas is 1,025 BTU per cubic foot. T COMPARTMENTS. O AVOID ELECTRICAL SHOCK, INJURY OR DEATH, DO NOT REMOVE ANY INTERNAL COMPARTMENT COVERS Multiplying the ninety (90) cubic feet by 1,025 BTU per cu- OR ATTEMPT ANY ADJUSTMENT. C ONTACT A QUALIFIED bic foot gives us an input of 92,250 BTUH. SERVICE AGENT AT ONCE IF AN ABNORMAL FLAME APPEARANCE SHOULD DEVELOP. Checking the BTU input on the rating plate of the furnace being tested. Periodically during the heating season make a visual check EXAMPLE: of the burner flames. Turn the furnace on at the thermostat. INPUT:92,000 BTU/HR Wait a few minutes since any dislodged dust will alter the OUTPUT CAP:84,000 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 CAUTION ports without curling downward, floating or lifting off the ports. A LWAYS CONNECT A MONOMETER TO THE OUTLET TAP AT THE GAS I VALVE BEFORE ADJUSTING THE PRESSURE REGULATOR. N NO CASE SHOULD THE FINAL MANIFOLD PRESSURE VARY MORE THAN PLUS OR MINUS .3 INCHES WATER COLUMN FROM 3.5 INCHES WATER COLUMN FOR NATURAL GAS OR 10 INCHES WATER COLUMN FOR PROPANE GAS. To adjust the pressure regulator on the gas valve, turn down Check the (clockwise) to increase pressure and input, and out (coun- Burner Flames for: terclockwise) to decrease pressure and input. 1. Stable, soft and blue. The dissipation of the heat transferred to the heat exchanger 2. Not curling, floating is now controlled by the amount of air circulated over its or lifting off. surface. The amount (CFM) of air circulated is governed by the exter- nal static pressure in inches of water column of duct work, cooling coil, registers, etc., applied externally to the unit Burner Flame versus the motor speed tap (direct drive) or pulley adjust- Proper equipment promotes faster, more efficient service and ments of the motor and blower (belt drive). accurate repairs resulting in fewer call backs. A properly operating unit must have the BTU per hour input HEATING PERFORMANCE TEST and CFM of air, within the limits shown to prevent short cy- cling of the equipment. As the external static pressure goes Before attempting to diagnose an operating fault, run a heat- up, the temperature rise will also increase. Consult the proper ing performance test and apply the results to the Service tables for temperature rise limitation. Problem Analysis Guide. 77 ACCESSORY WIRING DIAGRAMS HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. ALL FUEL SYSTEM CONTROL BOARD - AFE1860A 24VAC F1 3A P1-8+VDC POWER SUPPLY INPUT R +5VDC POWER P1-7 FURNACE DEMANDW1-FURN SUPPLY W1 W2-HP OUTPUT F P1-4+VDC BLOWER FAN DEMAND U OUTPUT G 24VAC P1-6C POWER SUPPLY INPUTG-STAT R (COMMON)C K1 N P1-5 SECOND STAGE FURNACE G-FURN DEMAND OUTPUT W2 A P1-2 COMPRESSOR OUTPUT C Y P1-3K2 E SECOND STAGE Y2-HP COMPRESSOR OUTPUT Y2 P1-1+VDC REVERSING VALVE OUTPUT O Y2-STAT 24VAC Y2-FURN P2-2K4 POWER SUPPLY OUT Y-STAT TO THERMOSTAT R Q1 Y-FURN T P2-1 CALL FOR REVERSING VALVE O H P2-7 CALL FORY-HP E COMPRESSOR Y P2-8K3 CALL FOR R EMERGENCY HEAT E M P2-5 CALL FOR Q2 +5VDC BLOWER FAN G O P2-9 CALL FOR S FURNACE HEAT W1 P2-3 POWER SUPPLY COMMONE/W1 T C OUT TO THERMOSTAT C A P2-4 CALL FOR 2ND STAGE 1.0K W2 FURNACE HEAT T P2-6 CALL FOR 2ND STAGE COMPRESSOR Y2 MICROPROCESSOR 24VAC O P3-9 POWER SUPPLY OUT TO HP CONTROL R 6.8K P3-8 HP CALL FOR FURNACE W2 (DURING DEFROST) H P3-7 REVERSING E Y VALVE OUTPUT O P3-2 COMPRESSOR A CONTACTOR OUTPUT Y 6.8K T P3-6 POWER SUPPLY COMMON C OUT TO HP CONTROL C P3-3 P OT-NO ODT (OUTDOOR P3-1 U THERMOSTAT) OT-NC M P3-4 P OT-C 2ND STAGE COMPRESSOR P3-5 DEMAND OUTPUT Y2 BREAK FOR ODT 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 VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. INTEGRATED IGNITION CONTROL DE W1W2 12RCGY1Y2O HUM WHITE BLACK GREEN 80 70 60 50 ON 40 30 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. 79