INSTALLATION INSTRUCTIONS FOR *CVC96*BA & *MVC96*BA TWO-STAGE GAS FURNACE (Type FSP CATEGORY IV Direct or Non Direct Vent Air Furnace) (Type FSP CATÉGORIE IV Direct ou four á air soufflé non direct) 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. As a professional installer you have an obligation to know the product better than the customer.
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. FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in serious injury, death or property damage. Never test for gas leaks with an open flame.
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.
• 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 dealers for transportation damage. • • WARNING • SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, TURN OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE FURNACE BEFORE TURNING OFF THE ELECTRICAL SUPPLY. It must be part of a ducted system and not used in a free air delivery application.
• NOTE: The Commonwealth of Massachusetts requires that the following additional requirements must also be met: • Gas furnaces must be installed by a licensed plumber or gas fitter. • A T-handle gas cock must be used. • If the unit is to be installed in an attic, the passageway to and the service area around the unit must have flooring.
• • • • • • • • subbase instructions for installation details. Follow the instructions with the subbase for proper installation. Do not install the furnace directly on carpeting, tile, or other combustible material other than wood flooring.
5. Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum speed. Do not operate a summer exhaust fan. Clearance in accordance with local installation codes, the requirements of the gas supplier and the manufacturer’s installation instructions. Dégaugement conforme aux codes d’installation locaux, aux exigences du fournisseur de gaz et aux instructions d’installation du fabricant. 6.
other appliances. Refer to the latest edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1 or CAN/CSA B149.1-15 Installation Codes or applicable provisions of the local building codes for determining the combustion air requirements for the 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.
When installing a furnace horizontally, additional consideration must be given to the following: AVERTISSEMENT RISQUE D'INTOXICATION AU MONOXYDE DE CARBONE Si les étapes décrites ci-dessous ne sont pas suivies pour chacun des appareils raccordés au système de ventilation au moment de sa mise en marche, cela peut entraîner une intoxication au monoxyde de carbone ou la mort.
dard piping connections may also be used in these positions. Refer to Vent/Flue Pipe and Combustion Air Pipe for details concerning the conversion to the alternate vent/flue and combustion air connections. FREEZE PROTECTION Refer to Horizontal Applications and Conditions - Drain Trap and Lines. WARNING POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INSTALLED. THE APPROPRIATE KITS MUST BE APPLIED TO ENSURE SAFE AND PROPER FURNACE OPERATION.
ASTM D3138. Fittings must be DWV type fittings meeting ASTM D2661 and ASTM D3311 and, if used in Canada, must be CSA listed. Carefully follow the manufacturers’ instructions for cutting, cleaning, and solvent cementing PVC and/or ABS. Additionally, it is the responsibility of the installer to ensure that all piping and connections possess adequate structural integrity and support to prevent flue pipe separation, shifting, or sagging during furnace operation.
Vent Clearances Figure 7 Figure 5 NOTE: Refer to Location Requirements and Considerations for combustion air contaminant restrictions. The following bullets and diagram describe the restrictions concerning the appropriate location of vent/flue pipe and combustion air intake pipe (when applicable) terminations. Refer to Non-Direct Vent (Single Pipe) Piping and Direct Vent (Dual Pipe) Piping located in this section for specific details on termination construction.
Canada. If ABS is used as a combustion air pipe, it must be CSA certified. Always follow the manufacturer’s instructions in the use of primer and cement. Do not use primer and cement around potential sources of ignition. Do not use primer or cement beyond its expiration date. VENT-DRAIN The safe operation, as defined by ULC S636, of the vent system is based on following these installation instructions, the vent system manufacturer’s installation instructions, and proper use of primer and cement.
Insert flange. Cut 2 ½” long. Figure 11 RF000142 WARNING THE RUBBER ELBOW IS NOT DESIGNED TO SUPPORT A LOAD.
NON-DIRECT VENT (SINGLE PIPE) PIPING free-draining to proper condensate disposal location. A loop in the drain tube can serve as a trap. Non-direct vent installations require only a vent/flue pipe. The vent pipe can be run horizontally with an exit through the side of the building or run vertically with an exit through the roof of the building. The vent can also be run through an existing unused chimney; however, it must extend a minimum of 12 inches above the top of the chimney.
DOWN VENTING UPFLOW MODEL FURNACES ONLY Use alternate vent & combination air locations 6’ Max. Vent Pipe Floor Combustion Air Pipe Field Supplied Drain Tee on Vent Pipe t men e s a B 1/4” per foot min. slope to furnace ace wlsp a r C / Condensate trapped to prevent flue gas from escaping and routed to field supplied condensate disposal All piping and fittings must be joined per material manufacturers specifications to prevent separation and flue gas leaks.
5) Increased Clearance Configurations using (2) 45 deg. Long Sweep elbows should be considered equivalent to one 90 deg. elbow. 6” MAX 6) One 90° elbow should be secured to the combustion air intake connection. 4” MIN NOTE: For installations at or above 7,000 feet altitude, use 3” venting. VENT/FLUE PIPE TERMINATIONS 12" MIN. TO GRADE OR HIGHEST ANTICIPATED SNOW LEVEL Standard Horizontal Terminations (Dual Pipe) Figure 16 12" MIN.
The vent/flue and combustion air pipes may terminate vertically, as through a roof, or horizontally, as through an outside wall. VENT/FLUE TEE VENT/INTAKE TERMINATIONS FOR INSTALLATION OF MULTIPLE DIRECT VENT FURNACES If more than one direct vent furnace is to be installed vertically through a common roof top, maintain the same minimum clearances between the exhaust vent and air intake terminations of adjacent units as with the exhaust vent and air intake terminations of a single unit.
a. b. 2. 3. 4. 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: or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery backup is installed on the floor level where the gas equipment is to be installed.
installed at a height no higher than the bottom of the furnace collector box to prevent air conditioning condensate from backing up into the furnace if the common drain was blocked. CONDENSATE DRAIN LINES & DRAIN TRAP A condensing gas furnace achieves its high level of efficiency by extracting heat from the products of combustion to the point where condensation takes place.
2. Remove the two screws holding the drain trap to the blower deck. 3. Remove the trap and two hoses from the blower deck 4. Remove the two plugs from the right side of the cabinet and install them in the blower deck. 5. (Draining the Vent Elbow) Locate hose #2 (factory installed) and cut 1" away from the 45 degree bend, discard the 45 degree section. Insert hose #2 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. 6.
5. (Draining the Vent Elbow) Locate hose #6. Measuring from the non-grommet end; cut off and discard 1 ½” for a “D” width cabinet, 5” for a “C” width cabinet, 8 ½” for a “B” width cabinet. 6. Remove the rubber plug from vent – drain elbow side port. Place hose #6 on the vent – drain elbow side port and secure with a silver clamp . 7. Unused vent-drain elbow drip leg port must be sealed to prevent flue gases from escaping.
the cabinet. Draining from the right side requires re-location of the trap to outside the cabinet. DRAIN EXITING LEFT SIDE 1. Install a field supplied rubber coupling secured with a 1 1/4” clamp to enable removing the trap for future cleaning. Alternately, a PVC fitting may be glued on the trap outlet. 2. Install drain per local and National codes. DRAIN EXITING RIGHT SIDE Hose #7 Hose #8 Figure 30 1. Figure 29 2. 3. Remove the drain trap and factory installed drain tube assemblies.
Hose #4 15. Connect the hoses to the trap inlets and secure with silver clamps, drain trap outlet must point to the original bottom of the furnace. 16. Using the two sheet metal screws provided in the cabinet, secure the trap to the furnace. 17. Refer to Field Supplied Drain section for instructions on field supplied / installed drain on outlet of furnace trap.
to compensate for the natural reduction in the density of both the gas fuel and the combustion air at higher altitude. The gas valve has a manual ON/OFF control located on the valve itself. This control may be set only to the “ON” or “OFF” position. Refer to the lighting instructions label or Startup Procedure & Adjustment for use of this control during start up and shut down periods. For installations above 7000 feet, please refer to the furnace Specification Sheets for required kit(s).
• Use pipe joint compound on male threads ONLY. Always piping can be used outside the cabinet per local codes. 1/2” NPT pipe and fittings are required. For models with an “L” shaped manifold, a 4 1/2” long nipple is required. For models with a hook shaped manifold, a 2” long nipple is required. use pipe joint compound (pipe dope) that is APPROVED FOR ALL GASSES. DO NOT apply compound to the first two threads. • Use ground joint unions.
Alternate Union Location Grommet in Standard Gas Line Hole Isolate this unit from the gas supply piping system by closing its external manual gas shutoff valve before pressure testing supply piping system with test pressures equal to or less than 1/2 psig (3.48 kPA).
Complete information regarding tank sizing for vaporization, recommended regulator settings, and pipe sizing is available from most regulator manufacturers and propane gas suppliers. Too much external static pressure will result in insufficient air that can cause excessive temperature rise. This can cause limit switch tripping and heat exchanger failure. Since propane gas will quickly dissolve white lead and most standard commercial compounds, special pipe dope must be used.
NOTE: Airflow area will be reduced by approximately 18% if duct flanges are left in factory position. This could cause performance issues and noise issues. FILTERS - READ THIS SECTION BEFORE INSTALLING THE RETURN AIR DUCT CUT USING TIN SNIPS Digital Manometer SCRIBE LINES OUTLINING DUCT FLANGES Dual Flange Cut Outs Figure 38 Checking Static Pressure Figure 37 Filters must be used with this furnace. Discuss filter maintenance with the building owner.
Clean Comfort™ brand MERV 11 air cleaners have 5¼” media filters and are available in the following configurations. Consult your distributor for information on our complete line of IAQ Clean Comfort™ products.
plied with the furnace must be replaced, it must be replaced with wiring material having a temperature rating of at least 105° C. Any replacement wiring must be a copper conductor. 115 VOLT LINE CONNECTIONS Before proceeding with electrical connections, ensure that the supply voltage, frequency, and phase correspond to that specified on the unit rating plate. Power supply to the furnace must be NEC Class 1, and must comply with all applicable codes.
1. Remove the burner compartment door. 2. Remove and save the two screws securing the junction box to the side panel.Horizontal Installations 2. Remove and save the two screws securing the junction box to the side panel. 3. Relocate junction box and associated plugs and grommets to opposite side panel. Secure with screws removed in step 2.
single-stage 24VAC thermostat can be used. For proper operation the thermostat must be setup to control a singlestage AC outdoor unit and to control a single stage gas furnace. The control board does not accommodate an O wire thermostat input (reversing valve signal). If a heat pump is installed, the thermostat should be setup as stated above. Setting the thermostat for the heat pump control or multi stage control may result in incorrect performance.
QUICK START GUIIDE FOR NON-COMMUNICATING OUTDOOR UNITS INDOOR BOARD TERMINAL CONNECTIONS 1 EXTREMELY IMPORTANT: For two-stage gas heating, the system only needs a single W input. Internal algorithms will control staging of the gas furnace automatically based on the single W input. For non-communicating outdoor unit wiring see instructions below. 1) Use the wiring diagrams below to connect low voltage thermostat wires.
4) Go to the tonnage units menu () and select the tonnage value that corresponds to the desired airflow for the outdoor unit. See the following table. QUICK START GUIDE OUTDOOR UNIT) Airflow Tonnage Selection Airflow Tonnage Selection Airflow 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2 2.1 2.2 400 440 480 520 560 600 640 680 720 760 800 840 880 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3 3.1 3.2 3.3 3.4 3.5 920 960 1000 1040 1080 1120 1160 1200 1240 1280 1320 1360 1400 3.6 3.7 3.8 3.9 4 4.1 4.2 4.3 4.4 4.5 4.
Dehumidification NOTE: After scrolling to the desired option within a menu, that option may be flashing on the 7-segment displays. This indicates the option has not been officially selected. Pressing the Center button two times will select that option. The first press will stop the flashing. The second will make the selection official and return you to the main menu.
115 VOLT LINE CONNECTION OR ELECTRONIC AIR CLEANER RAMPING PROFILES The variable-speed circulator offers four different ramping profiles. These profiles may be used to enhance cooling performance and increaqse comfort level. Select ramping profiles on the user menu. WARNING TO AVOID PERSONAL INJURY OR DEATH, DUE TO ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING.
Canada, follow approved purging methods in CAN/CSA B149.115. Open to Atmosphere Check for leaks using an approved chloride-free soap and water solution, an electronic combustible gas detector, or other approved method. Verify that all required kits (propane gas, high altitude, etc.) have been appropriately installed. Manometer Hose Outlet Pressure Boss High Fire Regulator Adjust Regulator Vent FURNACE STARTUP 1. 2. 3. 4. Close the manual gas shutoff valve external to the furnace.
6. Turn OFF any unnecessary gas appliances stated in step three. GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT CAUTION TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE. ONLY MINOR ADJUSTMENTS SHOULD BE MADE BY ADJUSTING THE GAS VALVE PRESSURE REGULATOR. Only small variations in gas pressure should be made by adjusting the gas valve pressure regulator. The manifold pressure must be measured with the burners operating.
This tells us that at this rate, it would take 46 seconds to consume one cu. ft. of gas. 3600 / 46 = 78. This tells us that in one hour, the furnace would consume 78 cu. ft. of gas. The typical value range for 1 cu. ft. of natural gas is around 1000 BTU. Check with your gas utility, if possible. In this example, the furnace is consuming 78,000 BTUH. SUPPLY AIR NOTE: The final manifold pressure cannot vary by more than ± 0.3” w.c. for Natural and + 0.5” for LP from the specified setting.
• • Induced draft blower steps to low speed following prepurge. Low stage pressure switch contacts are closed. Igniter warm up begins upon Inducer draft blower step to low speed and presence of closed low stage pressure switch contacts. • Gas valve opens at end of igniter warm up period, delivering gas to burners and establishing flame. • Integrated control module monitors flame presence. Gas valve will remain open only if flame is detected.
FLAME SENSOR The flame sensor is a probe mounted to the burner/manifold assembly which uses the principle of flame rectification to determine the presence or absence of flame. Burner Flame Figure 65 TROUBLESHOOTING ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS NOTE: Discharge body’s static electricity before touching unit. An electrostatic discharge can adversely affect electrical components.
MENU OPTIONS LED Display Menu Description LED Display Enable or disable inverter boost operation. (compressor speed may increase when this feature is on) (inverter only) Boost mode will operate above this selected temperature. On = boost mode always on (default = 105°F) (inverter only) Cooling Airflow Profile setting (default = profile D shown as 4) Heat Pump compressor lockout temperature. Furnace will act as primary heat source below this temperature.
STATUS CODES LED Display Description of System Status Compressor Cooling, Low Stage (non-communicating units) Compressor Cooling, High Stage (non-communicating units) Compressor Heat, Low Stage (non-communicating units) Compressor Heat, High Stage (non-communicating units) Compressor Cooling, Single-Stage (single stage non-comm.
TROUBLESHOOTING CHART Symptom LED Status Corrective Actions Equipment lacks shared data Populate shared data set using memory card Normal operation None No 115 power to furnace or no 24 volt power to integrated control module Furnace fails to operate Integrated control module LED display provides no signal Fault Description None Blown fuse or tripped circuit breaker Integrated control module is nonfunctional Restore high voltage power to furnace and integrated control module.
TROUBLESHOOTING CHART Symptom LED Status Fault Description Corrective Actions Check filters for blockage, clean filters or remove obstruction Furnace operates at reduced performance or operates on low stage when high stage is expected Airflow is lower than demanded Check ductwork for blockage, remove obstruction and verify all registers are fully open Verify ductwork is appropriately sized for system, resize and/or replace ductwork if necessary Furnace fails to operate Grounding fault Ver
TROUBLESHOOTING CHART Symptom LED Status Fault Description Corrective Actions Flame sensed with no call for heat Induced draft blower and circulator blower runs continuously Correct short at flame sensor or in flame sensor wiring No furnace operation Short to ground in flame sense circuit Check for lingering or lazy flame Lingering burner flame Verify proper operation of gas valve Slow closing gas valve No furnace operation Normal furnace operation Open fuse Replace fuse Short in
TROUBLESHOOTING CHART Symptom LED Status Fault Description Corrective Actions Check filters and ductwork for blockage, clean filters or remove obstruction Furnace fails to operate Aux limit switch open (blower compartment) Check circulator blower speed and performance, correct speed or replace blower motor if necessary Tighten or correct wiring connection Furnace fails to operate Aux switch (condensate switch) open 48 Check evaporator drain pan, trap, piping
WIRING DIAGRAM 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.
Flue pipe system. Check for blockage and/or leakage. Check the outside termination and the connections at and internal to the furnace. • Wiring. Check electrical connections for tightness and/ or corrosion. Check wires for damage. DIAGNOSTIC CHART WARNING HIGH VOLTAGE ! TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER BEFORE PERFORMING ANY SERVICE OR MAINTENANCE.
CONDENSATE TRAP AND DRAIN SYSTEM (QUALIFIED SERVICER ONLY) Annually inspect the drain tubes, drain trap, and field-supplied drain line for proper condensate drainage. Check drain system for hose connection tightness, blockage, and leaks. Clean or repair as necessary. 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.
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