INSTALLATION INSTRUCTIONS FOR *MVC8 & *CVC8 GAS FURNACE (CATEGORY I ) Installer: Affix all manuals adjacent to the unit. These furnaces comply with requirements embodied in the American National Standard / National Standard of Canada ANSI Z21.47·CSA2.3 Gas Fired Central Furnaces. RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION. ATTENTION INSTALLING PERSONNEL As a professional installer, you have an obligation to know the product better than the customer.
Table of Contents SAFETY CONSIDERATIONS ........................................................................................................................................................... 4 ADDITIONAL SAFETY CONSIDERATIONS ................................................................................................................................... 5 SHIPPING INSPECTION ...............................................................................................................................
Table of Contents GAS SUPPLY PRESSURE MEASUREMENT .............................................................................................................................. 26 GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT .................................................................................................. 27 GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY) ........................................................................................................... 30 TEMPERATURE RISE .......
SAFETY CONSIDERATIONS 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 . Adhere to the following warnings and cautions when installing, adjusting, altering, servicing, or operating the furnace.
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.
may be also installed as part of a “legacy” system using a standard 24 VAC thermostat. ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS NOTE: Discharge body’s static electricity before touching unit. An electrostatic discharge can adversely affect electrical com- This product may also be installed with the ComfortNet thermostat and a non-ComfortNet compatible single stage air conponents. ditioning unit.
• • • • The furnace heat exchanger, components, duct system, air filters and evaporator coils are thoroughly cleaned following final construction clean up by a qualified person.
• • • • • • Ensure the temperature of the return air entering the furnace is between 55°F and 100°F when the furnace is heating. Provisions must be made for venting combustion products outdoors through a proper venting system. The length of flue pipe could be a limiting factor in locating the furnace. Ensure adequate combustion air is available for the furnace. Improper or insufficient combustion air can expose building occupants to gas combustion products that could include carbon monoxide.
• Return air ducts must be completely sealed to the furnace and terminate outside the enclosure surfaces. CLEARANCES AND ACCESSIBILITY Unobstructed front clearance of 24" for servicing is recommended. VE N T B1-V EN T SIN G LE 1" 6" SID ES FR O N T B AC K 1" 3" 0" TO P (P LEN U M ) 1" Top clearance for horizontal configuration - 1" INSTALLATION POSITIONS *MVC8 model furnaces may be installed vertically (upflow) or horizontally with left or right side down.
Corrections must be in accordance with the latest edition of Most homes will require outside air be supplied to the furnace the National Fuel Gas Code NFPA 54/ANSI Z223.1 and/or CAN/ area by means of ventilation grilles or ducts connecting directly to the outdoors or spaces open to the outdoors such as attics CSA B149 Installation Codes. or crawl spaces.
THIS PRODUCT IS NOT DESIGNED FOR COUNTERCLOCKWISE INDUCED DRAFT BLOWER ROTATION. Vent the furnace in accordance with the National Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition. EXTERIOR MASONRY CHIMNEYS (CATEGORY I FURNACES ONLY) Venting An exterior masonry chimney is defined as a “Masonry” chimTHIS FURNACE IS NOT DESIGN CERTIFIED TO BE HORI- ney exposed to the outdoors on one or more sides below the roof line.” The ability to use a clay lined masonry chimney ZONTALLY VENTED.
Wash Proper Chimney Termination? (Check 1) Roof Line Clay Tile Size: 8" x 8" x12" (Each x 24" Length) Attic Floor 1/2" to 1" Air Space Second Floor Chimney channel free of solid and liquid fuel appliances? (Check 2) Change venting arrangements (Fix 2) Crown in good condition (Check 3) Rebuild crown (Fix 3) and/or Reline (Fix 4) Cleanout free of debris? (Check 4) Reline (Fix 4) Liner in good condition? (Check 5) Reline (Fix 4) Dilution air available? (Check 6) Reline (Fix 4) Throat Damper Fi
If the chimney does not meet these termination requirements, Appliances which burn propane (sometimes referred to as LP but all other requirements in the checklist can be met, it may (liquefied petroleum)) gas are considered gas-fired appliances. be possible for a mason to extend the chimney. If this will not CHECK 3 - CHIMNEY CROWN CONDITION. be practical, see Fix 1. 10' or Less 2' Min. Damage from condensate usually shows up first in the crown.
Remember that all appliances must be vented inside the liner. CHECK 7 - COMPLETE THE INSTALLATION. Venting one appliance inside the liner and another appliance If Checks 1 through 6 have been satisfactory, and the liner is an outside the liner is not acceptable. acceptable size as determined by the tables in National Fuel Next, use a flashlight and small mirror to sight up the liner. B Gas Code NFPA 54/ANSI Z223.
FIX 3 - REBUILD THE CROWN • The previous liner was properly sized and installed, and suffered from condensation damage. It is required by your local building codes. If the chimney crown is damaged, a qualified mason must re• pair it in accordance with nationally recognized building codes or standards.
4. Attach the junction box to the left side of the furnace, using the screws removed in step 2. 5. Check the location of the wiring. Confirm that it will not be damaged by heat from the burners or by the rotation of the fan. Also confirm that wiring location will not interfere with filter removal or other maintenance. least 105° C. Any replacement wiring must be a copper conductor.
24 VOLT THERMOSTAT WIRING R IMPORTANT NOTE WIRE ROUTING MUST NOT INTERFERE WITH CIRCULATOR BLOWER OPERATION , FILTER REMOVAL OR ROUTINE MAINTENANCE . 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 .
To use a single-stage thermostat, turn off power to the furnace, FOSSIL FUEL APPLICATIONS move the thermostat selection DIP switch to the OFF position. Set the desired transition time by setting the transition delay This furnace can be used in conjunction with a heat pump in a DIP switch to the desired ON/OFF position. Turn power back fossil fuel application. A fossil fuel application refers to a combined gas furnace and heat pump installation which uses an on. Refer to the following figure.
HUM-IN HUM-OUT NEUTRAL 24 VOLT HUMIDIFIER A 24 volt humidifier can be powered by feeding one of the HUM terminals with a field installed wire from the R terminal or by connecting to the NO side of the low fire pressure switch. Accessories Wiring If it is necessary for the installer to supply additional line voltage wiring to the inside of the furnace, the wiring must conform to all local codes, and have a minimum temperature rating of 105°C.
NOTE: Do not remove the gas valve inlet plug before the gas If converting to LP gas, it is recommended that an LPLP0* kit line is installed. Replace if water or debris has been introduced. also be installed. The use of this kit will prevent the furnace from firing when the LP gas supply pressure is too low to support proper combustion. INLET GAS SUPPLY PRESSURE Natural Gas Minimum: 4.5" w.c. Maximum: 10.0" w.c. Propane Gas Minimum: 11.0" w.c. Maximum: 13.0" w.c.
• • • • 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. 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.
PROPANE GAS PIPING CHARTS PROPANE GAS TANKS AND PIPING 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. WARNING Pipe or Tubing Length, Feet 10 20 30 40 50 60 80 100 125 150 175 200 IF THE GAS FURNACE IS INSTALLED IN A BASEMENT , AN EXCAVATED AREA OR CONFINED SPACE , IT IS STRONGLY RECOMMENDED TO CONTACT A PROPANE SUPPLIER TO INSTALL A GAS DETECTING WARNING DEVICE IN CASE OF A GAS LEAK.
When the furnace is used in connection with a cooling unit, the furnace should be installed in parallel with or on the upstream side of the cooling unit to avoid condensation in the heating element. With a parallel flow arrangement, the dampers or other means used to control the flow of air must be adequate to prevent chilled air from entering the furnace and, if manually operated, must be equipped with means to prevent operation of either unit unless the damper is in the full heat or cool position.
HORIZONTAL INSTALLATIONS Filters must be installed in either the central return register or in the return air duct work. CIRCULATION AIR FILTERS One of the most common causes of a problem in a forced air heating system is a blocked or dirty filter. Circulating air filters must be inspected monthly for dirt accumulation and replaced if necessary. Failure to maintain clean filters can cause premature heat exchanger failure.
Air cleaner installation location Maximum Heating Airflow Filter (Media) Dimensions Part Number Air Cleaner Family Side or bottom return 1200 CFM 16 in X 20 in x 5¼" AM11-1620-5 Side or bottom return 1600 CFM 16 in X 25 in x 5¼" AM11-1625-5 Side or bottom return 1600 CFM 20 in X 20 in x 5¼" AM11-2020-5 Side or bottom return 2000 CFM 20 in X 25 in x 5¼" AM11-2025-5 Side return (for 2 separate returns) Side return (Right angle) 2 X 1600 CFM 2, 16 in X 25 in x 5¼" AM11-3225-5 AM11-3225
6. During test mode, if both push buttons are pressed for greater than 1 second, the display will blank to indicate push buttons are pressed. If both push buttons are released within 5 seconds, the test mode will terminate and the system will return to normal operation. Otherwise, the test mode will continue uninterrupted. 11. Adjust the thermostat to a setting above room temperature. 12. After the burners are lit, set the thermostat to desired temperature. FURNACE SHUTDOWN 1.
Regulator Vent Gas Valve On/Off Selector Switch High Fire Regulator Adjust Low Fire Regulator Adjust INLET GAS SUPPLY PRESSURE Natural Gas Minimum: 4.5" w.c. Maximum: 10.0" w.c. Propane Gas Minimum: 11.0" w.c. Maximum: 13.0" w.c. If supply pressure differs from table, make the necessary adjustments to pressure regulator, gas piping size, etc., and/or consult with local gas utility. 5. Turn OFF gas to furnace at the manual shutoff valve and disconnect manometer.
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.
AIR FLOW DATA TAP MODEL *CVC80603B*** *CVC80803B*** *CVC80805C*** *CVC81005C*** A B C D A B C D A B C D A B C D TAP Low High Low High Stage Stage Stage Stage Cool Cool Heat Heat 412 631 784 1107 570 839 851 1198 718 1050 922 1316 842 1239 981 1407 423 643 690 937 582 782 743 1045 690 982 807 1155 802 1200 870 1254 532 817 976 1401 732 1123 1048 1495 942 1445 1121 1579 1197 1861 1192 1684 556 848 1150 1591 838 1177 1188 1646 1031 1480 1211 1702 1299 1881 1284 1790 MODEL *MVC80603B*** *MVC80604B***
4. Adjust temperature rise by adjusting the circulator blower speed. Increase blower speed to reduce temperature rise. Decrease blower speed to increase temperature rise. Refer to Startup Procedure and Adjustment -Circulator Blower Speeds for speed changing details. GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY) The gas input rate to the furnace must never be greater than that specified on the unit rating plate. To measure natural gas input using the gas meter, use the following procedure. 1.
Switch Bank: S4 1. Determine the tonnage of the cooling system installed with the furnace. If the cooling capacity is in BTU/hr divide it by 12,000 to convert capacity to TONs. Example: Cooling Capacity of 30,000 BTU/hr. 30,000/12,000 = 2.5 Tons 2. Determine the proper air flow for the cooling system. Most cooling systems are designed to work with air flows between 350 and 450 CFM per ton. Most manufacturers recommend an air flow of about 400 CFM per ton. Example: 2.
NOTE: To enable adjustments and select -5, 5, -10 or 10% BLOWER HEAT OFF DELAY TIMINGS trim, you must set dip switch S5-2 to ON. If S5-2 is in the The integrated control module provides a selectable heat off OFF position, you will receive 0% trim. delay function. The heat off delay period may be set to 90, 120, • Profile D ramps up to 50% of the demand for 1/2 minute, 150, 180 seconds using the DIP switches or jumper provided then ramps to 85% of the full cooling demand airflow on the control module.
Two-way digital communications is accomplished using only two wires. The thermostat and subsystem controls are power with 24 VAC. Thus, a maximum of 4 wires between the equipment and thermostat is all that is required to operate the system. tively, of the furnaces’ maximum airflow capability. During continuous fan operation, the thermostat sends a fan request along with the continuous fan demand to the furnace. The furnace, in turn, sends the demand to the ECM motor.
NOTE: Use of a transformer is recommended if installing a dual COMFORTNET™ SYSTEM ADVANCED FEATURES fuel/fossil fuel system or anytime a CTK03/4 is used with a non-inverter split unit. Failure to use the transformer in the The ComfortNet system permits access to additional system outdoor unit could result in over loading of the furnace transformer. information, advanced setup features, and advanced diagnostic/troubleshooting features. These advanced features are orCTK0* ganized into a menu structure.
FURNACE ADVANCED FEATURES MENUS (ACCESSED THROUGH COMMUNICATING THERMOSTAT) DIAGNOSTICS Submenu Item Indication/User Modifiable Options Comments Fault 1 (FAULT #1) Most recent furnace fault For dis play only Fault 2 (FAULT #2) Next m ost recent furnace fault For dis play only Fault 3 (FAULT #3) Next m ost recent furnace fault For dis play only Fault 4 (FAULT #4) Next m ost recent furnace fault For dis play only Fault 5 (FAULT #5) Next m ost recent furnace fault For dis play only Fault 6 (
STATUS Mode (MODE) Subm e nu Ite m Indica tion (for Displa y Only; not Use r Modifia ble ) Displays the current furnace operating mode CFM (CFM) Displays the airflow for the current operating mode NON-COMM (APPLIES ONLY TO A COMMUNICATING COMPATIBLE FURNACE MATCHED WITH A NON-COMMUNICATING COMPATIBLE SINGLE STAGE AIR CONDITIONER) Submenu Item Cool Airflow (CL CFM) User Modifiable Options 18, 24, 30, 36, 42, 48, or 60, default is 18 Comments Selects the airflow for the noncommunicating compatible sing
LED Description Possible Cause Corrective Action Comments Off Normal condition None None None 1 Flash Communications Failure Communications Failure •Depress Learn Button •Verify that bus BIAS and TERM dipswitches are in the ON position.
• R and W1 (or R and W1/W2) thermostat contacts open, completing the call for heat. • Gas valve closes, extinguishing flame. • Induced draft blower is de-energized following a fifteen second post purge. Humidifier terminals are de-energized. FAN ONLY MODE The normal operational sequence in fan only mode is as follows: • R and G thermostat contacts close, initiating a call for fan. • Integrated control module performs safety circuit checks.
INTEGRATED CONTROL MODULE 1. Disconnect all power to the furnace. Do not touch the integrated control module or any wire connected to the control prior to discharging your body’s electrostatic charge to ground. 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. 2. Firmly touch a clean, unpainted, metal surface of the furnace away from the control.
RESETTING FROM LOCKOUT FILTERS Furnace lockout results when a furnace is unable to achieve CAUTION ignition after three attempts during a single call for heat. It is TO ENSURE PROPER UNIT PERFORMANCE, ADHERE TO THE FILTER SIZES characterized by a non-functioning furnace and a E 0 code GIVEN IN THE RECOMMENDED M INIMUM FILTER SIZE TABLE OR displayed on the dual 7-segment display. If the furnace is in SPECIFICATION SHEET APPLICABLE TO YOUR MODEL.
INDUCED DRAFT AND CIRCULATOR BLOWERS REPAIR AND REPLACEMENT PARTS The bearings in the induced draft blower and circulator blower motors are permanently lubricated by the manufacturer. No further lubrication is required. Check motor windings for accumulation of dust which may cause overheating. Clean as necessary. • When ordering any of the listed functional parts, be sure FLAME SENSOR (QUALIFIED SERVICER ONLY) to provide the furnace model, manufacturing, and serial numbers with the order.
TROUBLESHOOTING CHART Symptoms of Abnormal Diagnostic/ Operation (Legacy & Status LED ComfortNet™ Thermostat) Codes Fault Description • No 115 power to furnace or no 24 volt power to integrated control module • Blown fuse or circuit breaker • Integrated control module has an internal fault 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 • Blow
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.
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 • Furnace fails to operate. • Integrated control module LED display provides E7 error code.
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.
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.
STATUS CODES INTERNAL CONTROL FAULT/NO POWER O E E E n NORMAL OPERATION 0 1 2 LOCKOUT DUE TO EXCESSIVE RETRIES LOW STAGE PRESSURE SWITCH STUCK CLOSED AT START OF HEATING CYCLE LOW STAGE PRESSURE SWITCH STUCK OPEN E 3 E 4 OPEN HIGH LIMIT SWITCH E 5 E 6 OPEN FUSE E 7 E 8 IGNITER FAULT OR IMPROPER GROUNDING E 9 E A HIGH STAGE PRESSURE SWITCH STUCK OPEN E F d 0 d 4 AUXILIARY SWITCH OPEN b b b b 0 1 2 FLAME DETECTED WHEN NO FLAME SHOULD BE PRESENT LOW FLAME SIGNAL HIGH STAGE PRESSURE SWITCH S
AIR FLOW DATA TAP MODEL *CVC80603B*** *CVC80803B*** *CVC80805C*** *CVC81005C*** A B C D A B C D A B C D A B C D TAP Low High Low High Stage Stage Stage Stage Cool Cool Heat Heat 412 631 784 1107 570 839 851 1198 718 1050 922 1316 842 1239 981 1407 423 643 690 937 582 782 743 1045 690 982 807 1155 802 1200 870 1254 532 817 976 1401 732 1123 1048 1495 942 1445 1121 1579 1197 1861 1192 1684 556 848 1150 1591 838 1177 1188 1646 1031 1480 1211 1702 1299 1881 1284 1790 MODEL *MVC80603B*** *MVC80604B***
DIP SWITCHES S witc h B ank P urpos e Heating Off Delay S1 Therm os tat S etup Cooling A irflow S3 Trim Ram ping P rofile S4 Heating A irflow Dehum Trim S5 Continuous Fan Func tion 1 Dip S witc h 2 3 90 Off Off 120 On O ff 150 Off On 180 On On 4 2 S tage S tat On On 1 S tg S tat 5 m in delay O ff Off 1 S tg S tat auto delay O ff On A dd 5% Off O ff M inus 5% On Off A dd 10% O ff On M inus 10% On On A O ff Off B On O ff C O ff On D On On A Off Off B
*MVC8, *CVC8 HONEYWELL GAS VALVE WIRING DIAGRAM TO 115 VAC/ 1 Ø /60 HZ POWER SUPPLY WITH OVERCURRENT PROTECTION DEVICE GND WH 2 WH DISCONNECT FLAME SENSOR YL WH BR PU 1 GND BURNER COMPARTMENT DOOR SWITCH JUNCTION BOX INDUCTOR COIL (ON SOME MODELS) INDOOR AIR CIRCULATOR BLWR GN INDUCED DRAFT BLOWER WH RD BK 3 2 OR RD PU CONTROL ROL (TWO O ON ON SOME MODELS) MODELS S) FS OR BK EAC LINE TRIM % YL HEAT AF YL RD 15 10 11 12 7 8 9 4 5 6 DEHUM ENABLE TRIM ENABLE CONT FAN HEAT
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