Installation Guide

ManualsBrandsGOODMAN ManualsForced Air Furnaces96% AFUE 120,000 BTU Multi Positional 2-Stage Variable Speed Natural Gas Furnace with 24.5 in. Cabinet

5151 San Felipe Suite 500

Houston, TX 77056

www.goodmanmfg.com • www.amana-hac.com

NSTALLATION

NSTRUCTIONS

FOR

*CVC96 & *MVC96

-S

TAGE

URNACE

IOG-2008

08/14

(Type FSP CATEGORY IV Direct

or Non Direct Vent Air Furnace)

These furnaces comply with requirements em-

bodied in the American National Standard / Na-

tional 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. This includes all safety

precautions and related items.

Prior to actual installation, thoroughly familiarize yourself

with this Instruction Manual. Pay special attention to all

safety warnings. Often during installation or repair it is

possible to place yourself in a position which is more

hazardous than when the unit is in operation.

Remember, it is your responsibility to install the product

safely and to know it well enough to be able to instruct a

customer in its safe use.

Safety is a matter of common sense...a matter of thinking

before acting. Most dealers have a list of specific good

safety practices...follow them.

The precautions listed in this Installation Manual are intended

as supplemental to existing practices. However, if there is

a direct conflict between existing practices and the content

of this manual, the precautions listed here take precedence.

RECOGNIZE THIS SYMBOL

AS A SAFETY PRECAUTION.

*NOTE: Please contact your distributor or our website for

the applicable Specification Sheet referred to in this manual.

TABLE OF CONTENTS

SAFETY CONSIDERATIONS.................................... 3

SHIPPING INSPECTION ......................................... 4

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ................. 4

TO THE INSTALLER ........................................... 4

PRODUCT DESCRIPTION ....................................... 4

FEATURES ................................................... 4

PRODUCT APPLICATION ....................................... 5

LOCATION REQUIREMENTS & CONSIDERATIONS ........... 6

CLEARANCES AND A CCESSIBILITY ................................ 7

EXISTING FURNACE REMOVAL .................................. 7

THERMOSTAT LOCATION ....................................... 8

COMBUSTION & VENTILATION AIR REQUIREMENTS ................ 8

INSTALLATION POSITIONS .................................... 8

HORIZONTAL APPLICATIONS & CONSIDERATIONS ......... 9

FURNACE SUSPENSION......................................... 9

FRONT COVER PRESSURE SWITCH TUBE LOCATION ............... 9

DRAIN TRAP AND LINES ....................................... 9

LEVELING ................................................... 9

ALTERNATE VENT/FLUE AND COMBUSTION AIR CONNECTIONS ..... 9

ALTERNATE ELECTRICAL AND GAS LINE CONNECTIONS ............10

DRAIN PAN .................................................10

FREEZE PROTECTION .........................................10

PROPANE GAS/HIGH ALTITUDE INSTALLATIONS ..........10

VENT/FLUE PIPE & COMBUSTION AIR PIPE ................10

DUAL CERTIFICATION: NON-DIRECT/DIRECT VENT ..............11

MATERIALS AND JOINING METHODS ............................11

PROPER VENT/FLUE AND COMBUSTION A IR PIPING PRACTICES ....11

TERMINATION LOCATIONS .....................................12

CANADIAN VENTING REQUIREMENTS ............................12

STANDARD FURNACE CONNECTIONS ............................12

NON-DIRECT VENT (SINGLE PIPE) PIPING .....................14

VENT/INTAKE TERMINATIONS FOR INSTALLATION

MULTIPLE DIRECT VENT FURNACES ....................17

CONCENTRIC VENT TERMINATION .............................. 17

SIDE WALL VENT KIT .......................................17

CONDENSATE DRAIN LINES & DRAIN TRAP ................17

GENERAL DRAIN INFORMATION ................................18

FIELD SUPPLIED DRAIN ......................................18

UPFLOW MODEL INSTALLED VERTICALLY .......................18

DRAIN EXITING RIGHT SIDE ...................................18

DRAIN EXITING LEFT SIDE ....................................18

UPFLOW MODEL INSTALLED HORIZONTALLY

WITH

RIGHT SIDE DOWN ...............................19

UPFLOW MODEL INSTALLED HORIZONTALLY WITH LEFT SIDE DOWN .19

COUNTERFLOW MODEL INSTALLED VERTICALLY..................20

DRAIN EXITING LEFT SIDE ....................................20

DRAIN EXITING RIGHT SIDE ...................................20

COUNTERFLOW MODEL INSTALLED HORIZONTALLY

WITH

RIGHT SIDE DOWN ...............................20

COUNTERFLOW MODEL INSTALLED HORIZONTALLY

WITH

LEFT SIDE DOWN ................................21

Summary of content (56 pages)

PAGE 1
INSTALLATION INSTRUCTIONS FOR *CVC96 & *MVC96 TWO-STAGE GAS FURNACE (Type FSP CATEGORY IV Direct or Non Direct Vent Air Furnace) 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. This includes all safety precautions and related items.
PAGE 2
ELECTRICAL CONNECTIONS ................................. 21 WIRING HARNESS ........................................... 21 115 VOLT LINE CONNECTIONS ............................... 21 JUNCTION BOX RELOCATION .................................. 22 24 VOLT THERMOSTAT WIRING ............................... 22 SINGLE-STAGE HEATING THERMOSTAT APPLICATION .............. 23 24 VOLT DEHUMIDISTAT WIRING .............................. 23 FOSSIL FUEL APPLICATIONS ...................................
PAGE 3
WARNING WARNING TO PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION , ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE, REFER TO THIS MANUAL . FOR ADDITIONAL ASSISTANCE OR INFORMATION , CONSULT A QUALIFIED INSTALLER , SERVICER AGENCY OR THE GAS SUPPLIER . GOODMAN WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES.
PAGE 4
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS DANGER NOTE: Discharge your body’s static electricity before touching unit. An electrostatic discharge can adversely affect electrical components. CARBON MONOXIDE POISONING HAZARD Special warning for installation of furnaces or air handling units in enclosed area such as garages, utility rooms or parking areas. Carbon monoxide producing devices (such as automobile, space heater, gas water heater, etc.
PAGE 5
enhanced setup features, and enhanced diagnostics. It also reduces the number of thermostat wires to a maximum of four. It may be also installed as part of a non-communicating system using a standard 24 VAC thermostat. • • This product may be installed with the ComfortNet thermostat and a non-ComfortNet compatible single stage air conditioning unit. However, this reduces the benefits of the ComfortNet system as the enhancements will only apply to the furnace.
PAGE 6
A copy of the CAN/CSA B149 Installation Codes can also be obtained from: CSA International 178 Rexdale Boulevard Etobicoke, Ontario, Canada M9W 1R3 • • LOCATION REQUIREMENTS & CONSIDERATIONS Follow the instructions listed below and the guidelines provided in the Combustion and Ventilation Air Requirements section when selecting a furnace location.
PAGE 7
• • • • • NOTES: • For servicing or cleaning, a 24” front clearance is required. • Unit connections (electrical, flue and drain) may necessitate greater clearances than the minimum clearances listed above. • In all cases, accessibility clearance must take precedence over clearances from the enclosure where accessibility clearances are greater. If the furnace is installed horizontally, ensure the access doors are not on the “up/top” or “down/bottom” side of the furnace.
PAGE 8
1. Seal any unused openings in the venting system. • • • • 2. Inspect the venting system for proper size and horizontal pitch, as required by the National Fuel Gas Code, ANSI Z223.1 or the Natural Gas and Propane Installation Code, CSA B149.1-05 and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition. Light fixtures or other appliances. Radiant heat from a fireplace.
PAGE 9
HORIZONTAL APPLICATIONS & CONSIDERATIONS DRAIN TRAP AND LINES When installing a furnace horizontally, additional consideration must be given to the following: In horizontal applications the condensate drain trap is secured to the furnace side panel, suspending it below the furnace. A minimum clearance of 5.5” below the furnace must be provided for the drain trap. Additionally, the appropriate downward piping slope must be maintained from the drain trap to the drain location.
PAGE 10
For installations above 7000 feet, please refer to the furnace Specification Sheets for required kit(s). M anifo ld P ressure Gas A ltitude Natural 0-7000 Figure 3B P ro pane 1 LP M -08* suppo rts Kit Orifice High Stage Lo w Stage P ressure Switch Change No ne # 45 3.5" w.c. 1.9" w.c. No ne 1.25mm 10.0" w.c. 6.0" w.c. No ne LP M -08* 1 bo th Ho neywell and White-Ro dgers 2-stage valves N O T E : In Canada, gas furnaces are o nly certified to 4500 feet.
PAGE 11
This furnace must not be connected to Type B, BW, or L vent or vent connector, and must not be vented into any portion of a factory built or masonry chimney except when used as a pathway for PVC as described later in this section. Never common vent this appliance with another appliance or use a vent which is used by a solid fuel appliance. Do not use commercially available “no hub connectors” other than those shipped with this product. CSA listed.
PAGE 12
• NO TRANSITION ON HORIZONTAL PLANE, THIS CREATES A WATER TRAP AND RESTRICTS FLUE GASES • • Figure 6 Piping must be adequately secured and supported to prohibit sagging, joint separation, and/or detachment from the furnace. Horizontal runs of vent/flue piping must be supported every three to five feet and must maintain a 1/4 inch per foot downward slope, back towards the furnace, to properly return condensate to the furnace’s drain system.
PAGE 13
VENT/FLUE PIPE ALTERNATE VENT/FLUE LOCATION The vent pipe outlet is sized to accept 2” pipe. Secure vent/ flue pipe directly into the furnace fitting with the appropriate glue. Alternately, a small section of 2" pipe may be glued in the furnace socket and a rubber coupling installed to allow removal for future service. Combustion Air and Vent piping should be routed in a manner to avoid contact with refrigerant lines, metering devices, condensate drain lines, etc.
PAGE 14
to prevent inadvertent blockage. The tee used in the vent/flue termination must be included when determining the number of elbows in the piping system. WARNING THE RUBBER ELBOW IS NOT DESIGNED TO SUPPORT A LOAD.
PAGE 15
DOWN VENTING UPFLOW MODEL FURNACES ONLY Figure 11 Use alternate vent & combination air locations Vent Pipe r Floo Combustion Air Pipe To Field Supplied Condensate Disposal ce lspa w a / Cr t men e s a B ot min. Slope 1/4” per fo Field Supplied Drain Tee on Vent Pipe Condensate trapped to previent flue gas from escaping All piping and fittings must be joined per material manufacturer’s specifications to prevent separation and flue gas leaks.
PAGE 16
VENT/FLUE 12" MIN. AND COMBUSTION AIR PIPE TERMINATIONS The vent/flue and combustion air pipes may terminate vertically, as through a roof, or horizontally, as through an outside wall. VENT/FLUE TEE (OPTIONAL) or 45° ELBOW TURNED DOWN or 90° ELBOW TURNED DOWN Vertical pipe terminations should be as shown in the following figure. Refer to Vent/Flue Pipe and Combustion Pipe - Termination Locations for details concerning location restrictions.
PAGE 17
CONCENTRIC VENT TERMINATION 90° ELBOWS Refer to the directions provided with the Concentric Vent Kit (DCVK) for installation specifications. SIDE WALL VENT KIT 3”-24” BETWEEN PIPES H orizontal Installation AIR INTAKE SCREEN (OPTIONAL) 12" MIN. ABOVE HIGHEST ANTICIPATED SNOW LEVEL Ve rtica l Installation Side Wall Vent Kit Figure 19 Combustion Air Intake may also be snorkeled to obtain 12” min ground clearance. This kit is to be used with 2” or 3” direct vent systems.
PAGE 18
UPFLOW MODEL INSTALLED VERTICALLY NOTE: In vertical installations, air conditioning coil condensate may drain into the furnace trap as long as there is a trap between the coil and the furnace trap and the drain pipe is not terminating below the water level of the furnace trap. The trap and factory installed hoses remain as shipped. The furnace drain may exit either the right or left side of the furnace cabinet. GENERAL DRAIN INFORMATION All furnace models come with a factory installed drain trap.
PAGE 19
4. Install smaller end of hose #3 on 45º elbow and secure with 1" clamp. 5. Refer to Field Supplied Drain section for instructions on field supplied / installed drain on outlet of furnace trap. UPFLOW MODEL INSTALLED HORIZONTALLY DOWN WITH UPFLOW MODEL INSTALLED HORIZONTALLY WITH LEFT SIDE DOWN Minimum 5 3/8" clearance is required for the drain trap beneath the furnace. RIGHT SIDE Minimum 5 3/8" clearance is required for the drain trap beneath the furnace.
PAGE 20
COUNTERFLOW MODEL INSTALLED VERTICALLY 3. (Draining the Vent Elbow) Insert the non-grommet end hose #10 into the cabinet back drain hole. Secure on vent – drain elbow barb fitting with a red clamp. 4. Insert 100º elbow into the cut end and secure with red clamp. 5. (Draining the Collector Box) Insert non-grommet end of hose #9 into the cabinet front drain hole and secure on collector box drain port with a silver clamp. 6. Mate the drain trap inlets to the hoses and secure with silver clamps. 7.
PAGE 21
COUNTERFLOW MODEL INSTALLED HORIZONTALLY SIDE DOWN WITH 17. Refer to Field Supplied Drain section for instructions on field supplied / installed drain on outlet of furnace trap. LEFT ELECTRICAL CONNECTIONS Minimum 5 3/8" clearance is required for the drain trap beneath the furnace. Hose #4 WARNING HIGH VOLTAGE ! TO AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO THE UNIT MUST BE POLARIZED AND GROUNDED .
PAGE 22
side (left side for counterflows) electrical connection with the junction box located inside the burner compartment. To make electrical connections through the opposite side of the furnace, the junction box must be relocated to the other side of the burner compartment prior to making electrical connections. To relocate the junction box, follow the steps shown below. use gas piping as an electrical ground. To confirm proper unit grounding, turn off the electrical power and perform the following check. 1.
PAGE 23
To use a single-stage thermostat, turn off power to the furnace, move the thermostat selection DIP switch to the OFF position. Set the desired transition time by setting the transition delay DIP switch to the desired ON/OFF position. Turn power back on. Refer to the following figure.
PAGE 24
FOSSIL FUEL APPLICATIONS 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 efficient means of heating (heat pump or gas furnace). A heat pump thermostat with three stages of heat is required to properly use a two-stage furnace in conjunction with a heat pump.
PAGE 25
HUM-IN HUM-OUT NEUTRAL 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 appliances operating. The minimum gas supply pressure must be maintained to prevent unreliable ignition. The maximum must not be exceeded to prevent unit overfiring. INLET GAS SUPPLY PRESSURE 24 VOLT COMMON Minimum: 4.5" w.c. Maximum: 10.0" w.c. Propane Gas Minimum: 11.0" w.c. Maximum: 13.0" w.
PAGE 26
• Use black iron or steel pipe and fittings for building piping. GAS VALVE Where possible, use new pipe that is properly chamfered, reamed, and free of burrs and chips. If old pipe is used, be sure it is clean and free of rust, scale, burrs, chips, and old pipe joint compound. This unit is equipped with a 24 volt gas valve controlled during furnace operation by the integrated control module. As shipped, the valve is configured for natural gas.
PAGE 27
Alternate Gas Line Location Manifold Burners Gas Valve Manual Shut Off Valve (upstream from ground joint pipe union) *Ground Joint Pipe Union *Ground Joint Pipe Union Alternate Union Location Grommet in Standard Gas Line Hole Manual Shut Off Valve (upstream from ground joint pipe union) Drip Leg Plug in Alternate Gas Line Hole Drip Leg Grommet in Standard Gas Line Hole Burners *NOTE: Union may be inside furnace cabinet where allowed by local codes.
PAGE 28
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. For satisfactory operation, propane gas pressure must be 10” WC at the furnace manifold with all gas appliances in operation. Maintaining proper gas pressure depends on three main factors: 1. Vaporization rate, depending on temperature of the liquid, and “wetted surface” area of the container or containers. 2. Proper pressure regulation.
PAGE 29
Pipe or Tu bin g Lengt h Feet 3/8" 1/2" 5/8" 3/4" 7 /8" 1/2" 3/4" 10 20 39 26 92 62 199 131 3 29 2 16 501 346 275 189 567 393 30 40 50 21 19 18 50 41 37 107 90 79 1 81 1 45 1 31 277 233 198 152 129 114 315 267 237 590 504 448 1,212 1,039 913 1,858 1,559 1,417 60 80 16 13 35 29 72 62 1 21 1 04 187 155 103 89 217 185 409 346 834 724 1,275 1,066 100 125 150 11 10 9 26 24 21 55 48 43 90 81 72 138 122 109 78 69 63 162 146 132 307 275 252 630 567 511 976 866 787 20
PAGE 30
BOTTOM RETURN AIR OPENING [UPFLOW MODELS] nace, but must be provided, sized and installed externally by the installer. Filters must comply with UL900 or CAN/ULCS111 standards. If the furnace is installed without filters, the warranty will be voided. The bottom return air opening on upflow models utilizes a “lance and cut” method to remove sheet metal from the duct opening in the base pan.
PAGE 31
6. Wait five minutes then smell for gas. Be sure check near the floor as some types of gas are heavier than air. 7. If you smell gas after five minutes, immediately follow the Safety Instructions on page 5 of this manual. If you do not smell gas after five minutes, move the furnace gas valve manual control to the ON position. 8. Replace the burner compartment door. 9. Open the manual gas shutoff valve external to the furnace. 10. Turn on the electrical power to the furnace. 11.
PAGE 32
leased within 5 seconds, the test mode will terminate and the system will return to normal operation. Otherwise, the test mode will continue uninterrupted. Regulator Vent High Fire Regulator Adjust 7. After completion of the 5-minute timer or test mode termination, whichever is earlier, the system will return to normal operation, either continuing an existing heat demand or going to the idle state.
PAGE 33
5. Turn ON the gas supply. 6. Turn on power and close thermostat “R” and “W1” contacts to provide a call for low stage heat. 7. Measure the gas manifold pressure with burners firing. Adjust manifold pressure using the Manifold Gas Pressure table shown below. 8. Remove regulator cover screw from the low (LO) outlet pressure regulator adjust tower and turn screw clockwise to increase pressure or counterclockwise to decrease pressure. Replace regulator cover screw. 9.
PAGE 34
3. If the 1/2 cu. ft. dial was used, multiply your number x 2. EXAMPLE: If it took 23 seconds to complete one revolution of the 1/2 ft. dial (23 x 2 = 46). SUPPLY AIR 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.
PAGE 35
The cooling system manufacturer’s instructions must be checked for required air flow. Any electronic air cleaners or other devices may require specific air flows, consult installation instructions of those devices for requirements. 3. Knowing the furnace model, locate the high stage cooling air flow charts in the Specification Sheet applicable to your model. Look up the cooling air flow determined in step 2 and find the required cooling speed and adjustment setting.
PAGE 36
• Profile D ramps up to 50% of the demand for 1/2 minute, then ramps to 85% of the full cooling demand airflow and operates there for approximately 7 1/2 minutes. The motor then steps up to the full demand airflow. Profile D has a 1/2 minute at 50% airflow OFF delay. OFF 7. Select the heating speed for your model from the heating speed chart in the Specification Sheet. The adjust setting (already established by the cooling speed selection) determines which set of speeds are available.
PAGE 37
COMFORTNET™ SYSTEM System OVERVIEW The ComfortNet system is a system that includes a ComfortNet compatible furnace and air conditioner or heat pump with a CTK0* thermostat. A valid ComfortNet system could also be a compatible furnace, CTK0* thermostat and non-compatible, single stage air conditioner. Any other system configurations are considered invalid ComfortNet systems and must be connected as a traditional (or non-communicating) system (see Electrical Connections for wiring connections).
PAGE 38
CTK0* WIRING COMFORTNET™ COMPATIBLE FURNACE WITH NON-COMFORTNET COMPATIBLE SINGLE-STAGE AIR CONDITIONER NOTE: A removable plug connector is provided with the control to make thermostat wire connections. This plug may be removed, wire connections made to the plug, and replaced. It is STRONGLY recommended that you do not connect multiple wires into a single terminal. Wire nuts are recommended to ensure one 18 AWG wire is used for each terminal. Failure to do so may result in intermittent operation.
PAGE 39
FURNACE ADVANCED FEATURES MENUS (accessed through the communicating thermostat) CONFIGURATION Submenu Item Number of Heat Stages (HT STG) Indication (for Display Only; not User Modifiable) Displays the number of furnace heating stages Input Rate (BTU/HR) Motor HP (1/2, ¾, or 1 MTR HP) Displays the furnace input rate in kBtu/hr Displays the furnace indoor blower motor horsepower DIAGNOSTICS Submenu Item Fault 1 (FAULT #1) Indication/User Modifiable Options Most recent furnace fault Comments For displa
PAGE 40
SET-UP Submenu Item Heat Airflow Trim (HT TRM) Heat ON Delay (HT ON User Modifiable Options -10% to +10% in 2% increments, default is 0% 5, 10, 15, 20, 25, or 30 seconds, default is 30 seconds Comments Trims the heating airflow by the selected amount.
PAGE 41
data 1 is increasing towards +5V, data 2 is decreasing towards ground and when data 1 is decreasing towards ground, data 2 is increasing towards +5V. Typically, the data 1 line is approximately 2.6Vdc and the data 2 transmission line is approximately 2.3Vdc. The voltage difference between data 1 and data 2 is typically 0.2 to 0.6 Vdc. THERMOSTAT MENU If this furnace is installed with a communicating compatible heat pump, the system is recognized as a dual fuel system.
PAGE 42
• SYSTEM TROUBLESHOOTING NOTE: Refer to the instructions accompanying the ComfortNet compatible outdoor AC/HP unit for troubleshooting information. Refer to the Troubleshooting Chart in the back of this manual for a listing of possible furnace error codes, possible causes and corrective actions. • NORMAL SEQUENCE OF OPERATION POWER UP • The normal power up sequence is as follows: • 115 VAC power applied to furnace. • Integrated control module performs internal checks.
PAGE 43
• • INTEGRATED CONTROL MODULE Electronic air cleaner terminal and circulator blower are de-energized. Furnace awaits next call from thermostat. The integrated control module is an electronic device which, if a potential safety concern is detected, will take the necessary precautions and provide diagnostic information through an LED. FAN ONLY MODE PRIMARY LIMIT The normal operational sequence in fan only mode is as follows: • R and G thermostat contacts close, initiating a call for fan.
PAGE 44
2. Firmly touch a clean, unpainted, metal surface of the furnace away from the control. Any tools held in a person’s hand during grounding will be discharged. 3. Service integrated control module or connecting wiring following the discharge process in step 2. Use caution not to recharge your body with static electricity; (i.e., do not move or shuffle your feet, do not touch ungrounded objects, etc.). If you come in contact with an ungrounded object, repeat step 2 before touching control or wires. 4.
PAGE 45
To remove filters from an external filter rack in an upright upflow installation, follow the directions provided with external filter rack kit. 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.
PAGE 46
DIP SWITCHES Switch Bank Purpose Heating Off Delay S1 Thermostat Setup Cooling Airflow S3 Trim Ramping Profile S4 Heating Airflow Dehum Trim S5 Continuous Fan Function 90 120 150 180 2 Stage Stat 2 Stage Stat 1 Stg Stat 5 min delay 1 Stg Stat auto delay A B C D Add 5% Minus 5% Add 10% Minus 10% A B C D A B C D Disabled Enabled Disabled Enabled 25% 50% 75% 100% 46 1 Off On Off On Off On Off On Off On Off On Dip Switch 2 3 Off Off On On On On Off Off Off Off On On Off On Off On Off Off On On Off On
PAGE 47
STATUS CODES INTERNAL CONTROL FAULT/NO POWER O n 0 NORMAL OPERATION LOCKOUT DUE TO EXCESSIVE RETRIES E 1 E 2 LOW STAGE PRESSURE SWITCH STUCK CLOSED AT START OF HEATING CYCLE E E E E OPEN HIGH LIMIT SWITCH 3 4 5 6 LOW STAGE PRESSURE SWITCH STUCK OPEN FLAME DETECTED WHEN NO FLAME SHOULD BE PRESENT OPEN FUSE LOW FLAME SIGNAL E 7 IGNITER FAULT OR IMPROPER GROUNDING E 8 HIGH STAGE PRESSURE SWITCH STUCK CLOSED AT START OF HEATING CYCLE E E E d d b b b b b HIGH STAGE PRESSURE SWITCH STUCK OPEN 9 A
PAGE 48
TROUBLESHOOTING CHART Symptoms of Abnormal Diagnostic/ Operation (Legacy & Status LED ComfortNet™ Thermostat) Codes Fault Description ComfortNet™ Thermostat Only Message Code INTERNAL FAULT EE Possible Causes Corrective Actions Notes & Cautions • Manual disconnect switch OFF, door switch open or 24 volt wire improperly connected or loose • Blown fuse or circuit breaker • Integrated control module has an internal fault • Assure 115 and 24 volt power to furnace and integrated control module.
PAGE 49
TROUBLESHOOTING CHART Symptoms of Abnormal Operation (Legacy & ComfortNet™ Thermostat) Diagnostic/ Status LED Codes Fault Description ComfortNet™ Thermostat Only Message Code Possible Causes Corrective Actions Notes & Cautions • Induced draft blower runs continuously with no further furnace operation. • Integrated control module LED display provides E2 error code. • ComfortNet™ thermostat “Call for Service” icon illuminated. • ComfortNet™ thermostat scrolls “Check Furnace” message.
PAGE 50
TROUBLESHOOTING CHART Symptoms of Abnormal Operation (Legacy & ComfortNet™ Thermostat) Diagnostic/ Status LED Codes Fault Description ComfortNet™ Thermostat Only Possible Causes Message Code IGNITER FAULT E7 • Improperly connected igniter. • Shorted igniter. • Poor unit ground. • Igniter relay fault on integrated control module. Corrective Actions • Check and correct wiring from integrated control module to igniter. • Replace shorted igniter. • Check and correct unit ground wiring.
PAGE 51
TROUBLESHOOTING CHART Symptoms of Abnormal Diagnostic/ Operation (Legacy Status LED Fault Description & ComfortNet™ Codes Thermostat) ComfortNet™ Thermostat Only Message Code Possible Causes Corrective Actions Notes & Cautions • Operation different than expected or no operation. • Integrated control module LED display provides d4 error code. • ComfortNet™ thermostat “Call for Service” icon illuminated. • ComfortNet™ thermostat scrolls “Check Furnace” message. d4 • Invalid memory card data.
PAGE 52
TROUBLESHOOTING CHART Symptoms of Abnormal Diagnostic/ Operation (Legacy Status LED Fault Description & ComfortNet™ Codes Thermostat) • Furnace fails to operate. • Integrated control module LED display provides b4 error code. • ComfortNet™ thermostat “Call for Service” icon illuminated. • ComfortNet™ thermostat scrolls “Check Furnace” message. b4 • Furnace fails to operate. • Integrated control module LED display provides b5 error code. • ComfortNet™ thermostat “Call for Service” icon illuminated.
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PAGE 54
WIRING DIAGRAM TO 115 VAC/ 1 Ø /60 HZ POWER SUPPLY WITH OVERCURRENT PROTECTION DEVICE GND HI 3 C 2 PM C NO NO FLAME SENSOR C GY FRONT COVER PRESSURE SWITCH AUTO RESET PRIMARY LIMIT CONTROL PU 1 9 WH/PU 6 3 HEAT OFF DLY T-STAT 24 VAC 115 VAC OR 5 2 GY GY FUSE FLAME SENSOR 115 VAC TO +VDC TH (4) 24 VAC AUTO RESET PRIMARY AUTO RESET AUXILIARY LIMIT LIMIT CONTROL CONTROLS HLO (10) Y1 PSO (7) W1 NO W2 Y2 TO MICRO HIGH FIRE PRESS.
PAGE 55
SPECIAL INSTRUCTIONS FOR PRODUCTS INSTALLED IN THE STATE OF MASSACHUSETTS VENT/FLUE TEE DISTANCE BETWEEN VENT AND GRADE COMBUSTION AIR INTAKE. DISTANCE BETWEEN COMBUSTION AIR INTAKE AND GRADE 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.
PAGE 56
NOTE: SPECIFICATIONS AND PERFORMANCE DATA LISTED HEREIN ARE SUBJECT TO CHANGE WITHOUT NOTICE. Quality Makes the Difference! “All of our systems are designed and manufactured with the same high quality standards regardless of size or efficiency. We have designed these units to significantly reduce the most frequent causes of product failure. They are simple to service and forgiving to operate. We use quality materials and components. Finally, every unit is run tested before it leaves the factory.