*MES80/*CES80 GAS FURNACE - CATEGORY 1 CATÉGORIE I These furnaces comply with requirements embodied in the American National Standard / National Standard of Canada ANSI Z21.47·CSA-2.3 Gas Fired Central Furnaces. Installer: Affix all manuals adjacent to the unit. ATTENTION INSTALLING PERSONNEL As a professional installer, you have an obligation to know the product better than the customer. This includes all safety precautions and related items.
TABLE OF CONTENTS Safety Considerations....................................................3 Fan Only Mode.................................................................18 Additional Safety Considerations...............................4 Start-Up Procedure And Adjustment........................19 Shipping Inspection..........................................................4 Furnace Operation.........................................................19 Electrostatic Discharge (Esd) Precautions..............
Safety Considerations WARNING Adhere to the following warnings and cautions when installing, adjusting, altering, servicing, or operating the furnace. To ensure proper installation and operation, thoroughly read this manual for specifics pertaining to the installation and application of this product. TO PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE, REFER TO THIS MANUAL .
RISQUE D'EMPOISONNEMENT AU MONOXYDE DE CARBONE Advertencia especial para la instalación de calentadores ó manejadoras de aire en áreas cerradas como estacionamientos ó cuartos de servicio. Las emisiones de monóxido de carbono pueden circular a través del aparato cuando se opera en cualquier modo. CO can cause serious illness including permanent brain damage or death.
Electrostatic Discharge (ESD) Precautions In such applications , the furnace must be installed with the following stipulations: • It must be installed per the installation instructions provided and per local and national codes. • It must be installed indoors in a building constructed on site. • It must be part of a ducted system and not used in a free air delivery application. • It must not be used as a “make-up” air unit. • All other warranty exclusions and restrictions apply.
WARNING WARNING TO PREVENT POSSIBLE EQUIPMENT DAMAGE , PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE OBSERVED WHEN INSTALLING THIS UNIT. TO PREVENT PROPERTY DAMAGE , PERSONAL INJURY OR DEATH DUE TO FIRE, DO NOT INSTALL THIS FURNACE IN A MOBILE HOME, TRAILER, OR RECREATIONAL VEHICLE. To ensure proper furnace operation, install, operate and Follow the instructions listed below when selecting a furnace maintain the furnace in accordance with these installation location.
For vertical (upflow or downflow) applications, the minimum cooling coil width shall not be less than furnace width minus 1”. Additionally, a coil installed above an upflow furnace or under a counterflow furnace may be the same width as the furnace or may be one size larger than the furnace. Example: a “C” width coil may be installed with a “B” width furnace. • • • • • • Vent Pipe Clearance to Combustibles6" using Single Wall Connector or 1" using B-1 vent.
Horizontal Installation Existing Furnace Removal NOTE: When an existing furnace is removed from a venting system serving other appliances, the venting system may be too large to properly vent the remaining attached appliances. WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death.
Thermostat Location AVERTISSEMENT In an area having good air circulation, locate the thermostat about five feet high on a vibration-free inside wall. Do not install the thermostat where it may be influenced by any of Si les יtapes dיcrites ci-dessous ne sont pas suivies pour chacun the following: • Drafts, or dead spots behind doors, in corners, or des appareils raccordיs au systטme de ventilation under cabinets.
Category I Venting (Vertical Venting) Upflow or Horizontal units are shipped with the induced draft blower discharging from the top of the furnace. (“Top” is as viewed for an upflow installation.) The induced draft blower WARNING can be rotated 90 degrees with the (0270F01119) chimney TO PREVENT POSSIBLE PERSONAL INJURY OR DEATH DUE TO transition bottom kit for Category I venting. For upflow modASPHYXIATION, THIS FURNACE MUST BE CATEGORY I VENTED.
14. Restore power to furnace. NOTE: In a horizontal installation the air conditioning coil must be adequately supported by proper brackets and supports. Inadequate coil support can result in furnace cabinet distortion and air leakage.
Junction Box Relocation WARNING WARNING HIGH VOLTAGE ! EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES AS A PRECAUTION WHEN REMOVING HOLE PLUGS. TO AVOID THE RISK OF INJURY, ELECTRICAL SHOCK OR DEATH, THE FURNACE MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH LOCAL CODES OR IN THEIR ABSENCE , WITH THE LATEST EDITION OF THE Line voltage connections can be made through either the right or left side panel. The furnace is shipped configured for a right side electrical connection.
To ensure proper unit grounding, the ground wire should run from the furnace ground screw located inside the furnace junction box all the way back to the electrical panel. NOTE: Do not use gas piping as an electrical ground. To confirm proper unit grounding, turn off the electrical power and perform the following check. 1. Measure resistance between the neutral (white) connection and one of the burners. 2. Resistance should measure 10 ohms or less.
Twinning Furnaces may be twinned without the use of a twinning kit. Furnaces must be the same model and equipped with PCBBF145 control boards. Follow the diagram provided in this manual. Connection of the “twin” terminals of each control together will allow simultaneous operation of two or more furnace indoor blowers to operate synchronously on a common duct system. Field installed low voltage thermostat wiring, 3/16” terminals are required to make this connection.
TWINNING CONNECTION DIAGRAM 595240 REV.
• • • • • • 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. Install a 1/8” NPT pipe plug fitting, accessible for test gage connection, immediately upstream of the gas supply connection to the furnace. Use two pipe wrenches when making connection to the gas valve to keep it from turning. The orientation of the gas valve on the manifold must be maintained as shipped from the factory.
Propane Gas Tanks and Piping A duct system must be installed in accordance with Standards of the National Board of Fire Underwriters for the Installation of Air Conditioning, Warm Air Heating and Ventilating Systems. Pamphlets No. 90A and 90B. WARNING IF THE GAS FURNACE IS INSTALLED IN A BASEMENT, AN EXCAVATED AREA OR CONFINED SPACE , IT IS STRONGLY RECOMMENDED TO A closed return duct system must be used, with the return duct connected to the furnace.
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 external filter rack kit (upflows), or the ductwork above a downflow furnace. As an alternative, a media air filter or electronic air cleaner can be used as the primary filter. • One of the most common causes of a problem in a forced air heating system is a blocked or dirty filter.
• Circulator blower is energized on T1 speed. Electronic White-Rodgers valves : Push the switch to the ON position. air cleaner terminals are energized. • Circulator blower runs, integrated control module 8. Replace the door on the front of the furnace. monitors safety circuits continuously. 9. Open the manual gas valve external to the furnace. • R and G thermostat contacts open, completing the call 10. Turn on the electrical power supply to the furnace. for fan. 11.
Gas Valve On/Off Selector Switch INLET GAS SUPPLY PRESSURE Inlet Pressure Tap Natural Gas Minimum: 4.5" w.c. Maximum: 10.0" w.c. Propane Gas Minimum: 11.0" w.c. Maximum: 13.0" w.c. Gas Line INLET OUTLET Pressure Regulator Adjustment (Under Cap Screw) Gas Shutoff Valve Outlet Pressure Tap Gas Line To Furnace White-Rodgers Model 36J22 1. Turn OFF gas to furnace at the manual gas shutoff valve external to the furnace. 2. Turn OFF all electrical power to the system. 3.
6. Turn ON power and close thermostat “R” and “W” contacts to provide a call for heat. 7. Using a leak detection solution or soap suds to check for leaks at outlet pressure tap. Bubbles forming indicate a leak. SHUT OFF GAS AND REPAIR ALL LEAKS IMMEDIATELY! 8. Measure the gas manifold pressure with burners firing. Adjust manifold pressure using the Manifold Gas Pressure table shown below. Manifold Gas Pressure Natural Gas 3.2" - 3.8" w.c. Propane Gas 9.7" - 10.3" w.c. 5.
Circulator Blower Speed Adjustment COOL MOTOR SPEED DIP SWITCH SETTING (S1-1, S1-2, S1-3) 1 2 3 1 2 3 OFF OFF OFF ON OFF OFF Position Motor Speed COOL WARNING TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, TURN OFF POWER TO THE FURNACE BEFORE CHANGING SPEED TAPS. Y Furnaces are equipped with a EEM circulator blower motor. This provides ease in adjusting blower speeds. Refer to the Blower Performance Data in the back of the manual for proper selection of heating and cooling speeds.
Excessive external static pressure will result in insufficient air that can cause excessive temperature rise. This can cause limit switch tripping and heat exchanger failure. To determine total external duct static pressure, proceed as follows; 1. With clean filters in the furnace, use a draft gauge (inclined manometer) to measure the static pressure of the return duct at the inlet of the furnace. (Negative Pressure) 2. Measure the static pressure of the supply duct. (Positive Pressure) 3.
59-5240 REV.
Primary Limit Fault Code Reset The primary limit control is located on the partition panel and monitors heat exchanger compartment temperatures. It is an automatic reset, temperature sensor. The limit guards against the overheating resulting from insufficient air passing over the heat exchanger. The last five fault codes can be erased from memory by depressing the fault recall switch for 5–10 seconds.
• • Wiring. Check that electrical connections are tight and free from corrosion. Filters. Flame Sensor (Qualified Servicer Only) Under some conditions, the fuel or air supply can create a nearly invisible coating on the flame sensor. This coating acts as an insulator causing a drop in the flame sense signal. If the flame sense signal drops too low the furnace will not sense flame and will lock out. The flame sensor should be carefully cleaned by a qualified servicer using steel wool.
Before Leaving an Installation • Cycle the furnace with the thermostat at least three times. Verify cooling and fan only operation. • Review the Owner’s Manual with the homeowner and discuss proper furnace operation and maintenance. • Leave literature packet near furnace. Repair and Replacement Parts • When ordering any of the listed functional parts, be sure to provide the furnace model, manufacturing, and serial numbers with the order.
Component ID 1 Tubular Heat Exchanger 2 Pressure Switch 3 Flue Pipe Connection 4 Induced Draft Blower (Chimney Transition Top Shipped Loose) 躀 5 Gas Line Entrance 6 Gas Valve 7 Rollout Limit 8 Junction Box 9 Wiring Harness Grommet 10 Gas Manifold 16 Gas Line Entrance (Alternate) 11 Inshot Burner 12 Transformer 15 Circulator Blower 14 Blower Door Interlock Switch 13 Integrated Control Module 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Tubular Heat Exchanger Pressure Switch Flue Pipe Connection Induced D
Troubleshooting Chart Symptoms of Abnormal Operation • Furnace fails to operate. Associated LED Code2 OFF PCBBF145 CONTROL BOARD Fault Description(s) Possible Causes Corrective Action • No 115 volt power • Manual disconnect to furnace, or no switch OFF, door power to furnace diagnostic LED provides no 24 volt power to switch open, or integrated control signal. integrated control 24 volt wires improperly module. connected or loose.
Troubleshooting Chart • Circulator blower runs continuously. No furnace operation. • Primary or auxiliary 4 limit circuit is open. • Integrated control module diagnostic LED is PCBBF145 CONTROL BOARD • Faulty primary or auxiliary limit switch. • Check primary/ auxiliary limit. • Insufficient conditioned Replace if necessary. 4 FLASHES air over the heat flashing FOUR (4) flashes. • Check filters and exchanger. Blocked ductwork for blockage.
Troubleshooting Chart Symptoms of Abnormal Operation Associated LED Code2 • Circulating blowers not PCBBF145 CONTROL BOARD Fault Description(s) •Twinning Fault Possible Causes Corrective Action • Furnace twin terminals • Install field wiring Cautions and Notes • Verify line voltage operating simultaneously. not connected together connecting twin supply is turned off No blower operation. by field wiring. terminals, check before proceeding continuity of wiring.
Blower Performance Data *CES80 Heating Airflow MODEL *CES 800403A* *CES 800603A* *CES 800804B* *CES 800805C* *CES 801005C* DIP SWITCHES S2-1 , S2-2 OFF OFF ON OFF* ON ON OFF ON** OFF OFF ON OFF* ON ON OFF ON OFF OFF ON OFF* ON ON OFF ON** OFF OFF ON OFF* ON ON OFF ON** OFF OFF ON OFF** ON ON OFF ON** CFM 668 785 862 1104 716 1054 960 1160 784 1295 1401 1596 1171 1175 1436 1782 803 1424 1626 1820 0.
Blower Performance Data *CES80 Cooling Airflow MODEL *CES 800403A* *CES 800603A* *CES 800804B* *CES 800805C* *CES 801005C* DIP SWITCHES S1-1 , S1-2 , S1-3 OFF OFF OFF OFF ON ON ON OFF ON ON ON ON ON OFF OFF ON ON OFF OFF ON OFF OFF OFF ON* OFF OFF OFF OFF ON ON ON OFF ON ON ON ON ON OFF OFF ON ON OFF OFF ON OFF OFF OFF ON* OFF OFF OFF OFF ON ON ON OFF ON ON ON ON ON OFF OFF ON ON OFF OFF ON OFF OFF OFF ON* OFF OFF OFF OFF ON ON ON OFF ON ON ON ON ON OFF OFF ON ON OFF OFF ON OFF OFF OFF ON* OFF OF
Blower Performance Data *MES80 Heating Airflow MODEL *MES 800403A* *MES 800603A* *MES 800603B* *MES 800604B* *MES 800803B* *MES 800804B* *MES 800804C* *MES 800805C* *MES 801005C* *MES 801205D* DIP SWITCHES S2-1 , S2-2 OFF OFF ON OFF* ON ON OFF ON** OFF OFF ON OFF* ON ON OFF ON** OFF OFF ON OFF* ON ON OFF ON** OFF OFF ON OFF* ON ON OFF ON** OFF OFF ON OFF* ON ON OFF ON OFF OFF ON OFF* ON ON OFF ON** OFF OFF ON OFF* ON ON OFF ON** OFF OFF ON OFF* ON ON** OFF ON** OFF OFF ON OFF* ON ON OFF
Blower Performance Data *MES80 Circulation Airflow MODEL *MES 800403A* *MES 800603A* *MES 800603B* *MES 800604B* *MES 800803B* *MES 800804B* *MES 800804C* *MES 800805C* *MES 801005C* *MES 801205D* DIP SWITCHES S2-3 , S2-4 OFF OFF ON OFF OFF ON ON ON OFF OFF ON OFF OFF ON ON ON OFF OFF ON OFF OFF ON ON ON OFF OFF ON OFF OFF ON ON ON OFF OFF ON OFF OFF ON ON ON OFF OFF ON OFF OFF ON ON ON OFF OFF ON OFF OFF ON ON ON OFF OFF ON OFF OFF ON ON ON OFF OFF ON OFF OFF ON ON ON OFF OFF ON OFF OF
Blower Performance Data *MES80 Cooling Airflow MODEL *MES 800403A* *MES 800603A* *MES 800603B* *MES 800604B* *MES 800803B* DIP SWITCHES S1-1 , S1-2 , S1-3 OFF OFF OFF OFF ON ON ON OFF ON ON ON ON ON OFF OFF ON ON OFF OFF ON OFF OFF OFF ON* OFF OFF OFF OFF ON ON ON OFF ON ON ON ON ON OFF OFF ON ON OFF OFF ON OFF OFF OFF ON* OFF OFF OFF OFF ON ON ON OFF ON ON ON ON ON OFF OFF ON ON OFF OFF ON OFF OFF OFF ON* OFF OFF OFF OFF ON ON ON OFF ON ON ON ON ON OFF OFF ON ON OFF OFF ON OFF OFF OFF ON* OFF OF
Blower Performance Data *MES80 MODEL *MES 800804B* *MES 800804C* *MES 800805C* *MES 801005C* *MES 801205D* DIP SWITCHES S1-1 , S1-2 , S1-3 OFF OFF OFF OFF ON ON ON OFF ON ON ON ON ON OFF OFF ON ON OFF OFF ON OFF OFF OFF ON* OFF OFF OFF OFF ON ON ON OFF ON ON ON ON ON OFF OFF ON ON OFF OFF ON OFF OFF OFF ON* OFF OFF OFF OFF ON ON ON OFF ON ON ON ON ON OFF OFF ON ON OFF OFF ON OFF OFF OFF ON* OFF OFF OFF OFF ON ON ON OFF ON ON ON ON ON OFF OFF ON ON OFF OFF ON OFF OFF OFF ON* OFF OFF OFF OFF ON ON
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. *MES80 / *CES80 Wiring Diagram Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.
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