Escolar Documentos
Profissional Documentos
Cultura Documentos
(CATEGORY I )
NOTE: Please contact your distributor or our website for the applicable Specification Sheet
referred to in this manual.
WARNING
GOODMAN WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY
DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES.
IF YOU INSTALL OR PERFORM SERVICE ON THIS UNIT, YOU ASSUME
RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROPERTY DAMAGE
WHICH MAY RESULT. MANY JURISDICTIONS REQUIRE A LICENSE TO
INSTALL OR SERVICE HEATING AND AIR CONDITIONING EQUIPMENT.
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. CARBON MONOXIDE POISONING HAZARD
Special Warning for Installation of Furnace or Air Handling Units in
Enclosed Areas such as Garages, Utility Rooms or Parking Areas
WARNING
IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED Carbon monoxide producing devices (such as an automobile, space
EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY heater, gas water heater, etc.) should not be operated in enclosed areas
DAMAGE , PERSONAL INJURY OR LOSS OF LIFE. such as unventilated garages, utility rooms or parking areas because of
the danger of carbon monoxide (CO) poisoning resulting from the exhaust
DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND emissions. If a furnace or air handler is installed in an enclosed area such
LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE. as a garage, utility room or parking area and a carbon monoxide producing
device is operated therein, there must be adequate, direct outside
WHAT TO DO IF YOU SMELL GAS: ventilation.
DO NOT TRY TO LIGHT ANY APPLIANCE.
DO NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY PHONE
This ventilation is necessary to avoid the danger of CO poisoning which
IN YOUR BUILDING. can occur if a carbon monoxide producing device continues to operate in
IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR’S the enclosed area. Carbon monoxide emissions can be (re)circulated
throughout the structure if the furnace or air handler is operating in any
PHONE. FOLLOW THE GAS SUPPLIER’S INSTRUCTIONS. mode.
IF YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE
CO can cause serious illness including permanent brain damage or death.
DEPARTMENT.
-
INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED B10259-216
INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.
WARNING
WARNING
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF,
THIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS TURN OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE
WHICH MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE FURNACE BEFORE TURNING OFF THE ELECTRICAL SUPPLY.
KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH
DEFECTS OR OTHER REPRODUCTIVE HARM.
WARNING
WARNING POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO
FIRE, EXPLOSION, SMOKE, SOOT, CONDENSATION, ELECTRICAL SHOCK
HEATING UNIT SHOULD NOT BE UTILIZED WITHOUT REASONABLE, OR CARBON MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION,
ROUTINE, INSPECTION , MAINTENANCE AND SUPERVISION. IF THE
REPAIR OPERATION, OR MAINTENANCE OF THIS PRODUCT.
BUILDING IN WHICH ANY SUCH DEVICE IS LOCATED WILL BE VACANT,
CARE SHOULD BE TAKEN THAT SUCH DEVICE IS ROUTINELY INSPECTED,
WARNING
MAINTAINED AND MONITORED. IN THE EVENT THAT THE BUILDING
MAYBE EXPOSED TO FREEZING TEMPERATURES AND WILL BE VACANT, TO PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER
ALL WATER‐BEARING PIPES SHOULD BE DRAINED, THE BUILDING SHOULD INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE,
BE PROPERLY WINTERIZED, AND THE WATER SOURCE CLOSED . IN THE REFER TO THIS MANUAL . FOR ADDITIONAL ASSISTANCE OR
EVENT THAT THE BUILDING MAY BE EXPOSED TO FREEZING INFORMATION, CONSULT A QUALIFIED INSTALLER, SERVICER AGENCY OR
TEMPERATURES AND WILL BE VACANT, ANY HYDRONIC COIL UNITS THE GAS SUPPLIER.
SHOULD BE DRAINED AS WELL AND, IN SUCH CASE , ALTERNATIVE HEAT
SOURCES SHOULD BE UTILIZED. WARNING
THIS UNIT MUST NOT BE USED AS A “CONSTRUCTION HEATER” DURING
WARNING THE FINISHING PHASES OF CONSTRUCTION ON A NEW STRUCTURE. THIS
TO PREVENT POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR TYPE OF USE MAY RESULT IN PREMATURE FAILURE OF THE UNIT DUE TO
DEATH DUE TO ELECTRICAL SHOCK , THE FURNACE MUST BE LOCATED TO EXTREMELY LOW RETURN AIR TEMPERATURES AND EXPOSURE TO
PROTECT THE ELECTRICAL COMPONENTS FROM WATER. CORROSIVE OR VERY DIRTY ATMOSPHERES.
4
PRODUCT APPLICATION
WARNING This procedure is applicable to both installed and non-installed
(ungrounded) furnaces.
TO PREVENT PERSONAL INJURY OR DEATH DUE TO ASPHYXIATION, THIS 1. Disconnect all power to the furnace. Do not touch the
FURNACE MUST BE CATEGORY I VENTED. DO NOT VENT USING
integrated control module or any wire connected to the
CATEGORY III VENTING. control prior to discharging your body’s electrostatic
PROVISIONS MUST BE MADE FOR VENTING COMBUSTION PRODUCTS charge to ground.
OUTDOORS THROUGH A PROPER VENTING SYSTEM. THE LENGTH OF
2. Firmly touch a clean, unpainted, metal surface of the
FLUE PIPE COULD BE A LIMITING FACTOR IN LOCATING THE FURNACE.
furnaces near the control. Any tools held in a person’s
ADDITIONAL SAFETY CONSIDERATIONS hand during grounding will be discharged.
• This furnace is approved for Category I Venting only. 3. Service integrated control module or connecting wiring
• Provisions must be made for venting combustion following the discharge process in step 2. Use caution
products outdoors through a proper venting system. not to recharge your body with static electricity; (i.e., do
The length of flue pipe could be a limiting factor in not move or shuffle your feet, do not touch ungrounded
locating the furnace. objects, etc.). If you come in contact with an ungrounded
object, repeat step 2 before touching control or wires.
SHIPPING INSPECTION 4. Discharge your body to ground before removing a new
control from its container. Follow steps 1 through 3 if
All units are securely packed in shipping containers tested installing the control on a furnace. Return any old or
according to International Safe Transit Association specifica- new controls to their containers before touching any
tions. The carton must be checked upon arrival for external ungrounded object.
damage. If damage is found, a request for inspection by carrier’s
agent must be made in writing immediately. TO THE INSTALLER
The furnace must be carefully inspected on arrival for damage Before installing this unit, please read this manual thoroughly
and bolts or screws which may have come loose in transit. In to familiarize yourself with specific items which must be ad-
the event of damage the consignee should: hered to, including but not limited to: unit maximum external
1. Make a notation on delivery receipt of any visible damage static pressure, gas pressures, BTU input rating, proper elec-
to shipment or container. trical connections, circulating air temperature rise, minimum or
2. Notify carrier promptly and request an inspection. maximum CFM, and motor speed connections, and venting.
3. With concealed damage, carrier must be notified as soon These furnaces are designed for Category I venting only.
as possible - preferably within five days.
IMPORTANT NOTE TO THE OWNER REGARDING PRODUCT
4. File the claim with the following support documents within
a nine month statute of limitations. WARRANTY
• Original or certified copy of the Bill of Lading, or Complete warranty details and instructions are available from
indemnity bond. your local dealer or at www.goodmanmfg.com and www.amana-
• Original paid freight bill or indemnity in lieu thereof. hac.com. Your warranty certificate is supplied as a separate
• Original or certified copy of the invoice, showing trade document with the unit installed by your contractor. Read the
and other discounts or reductions. limited warranty certificate carefully to determine what is and is
• Copy of the inspection report issued by carrier’s not covered and keep the warranty certificate in a safe place. If
representative at the time damage is reported to carrier. you are unable to locate the warranty certificate please contact
your installing contractor or contact customer service (877-254-
The carrier is responsible for making prompt inspection of dam- 4729) to obtain a copy.
age and for a thorough investigation of each claim. The distribu-
tor or manufacturer will not accept claims from dealers for trans- To receive the Lifetime Heat Exchanger Limited Warranty, good
portation damage. for as long as you own your home, and the 10-year Parts Lim-
ited Warranty, online registration must be completed within 60
Keep this literature in a safe place for future reference. days of installation. Online registration is not required in Cali-
fornia or Quebec.
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
IMPORTANT: To register your Goodman brand unit, go to
NOTE: Discharge body’s static electricity before touching unit.
www.goodmanmfg.com. Click on the word “Warranty” located
An electrostatic discharge can adversely affect electrical com-
on the left side of the home page. Next, click on the word
ponents.
“Product Registration” located on the left side of the Warranty
Use the following precautions during furnace installation and page and complete the forms in the manner indicated on the
servicing to protect the integrated control module from dam- Product Registration page.
age. By putting the furnace, the control, and the person at the
To register your Amana brand unit, go to www.amana-hac.com.
same electrostatic potential, these steps will help avoid expos-
Click on the word “Warranty” located on the top right of the
ing the integrated control module to electrostatic discharge.
5
LOCATION REQUIREMENTS AND CONSIDERATIONS
home page. Next, click on the word “Product Registration”
• It must be installed per the installation instructions
located on the left side of the Warranty page and complete the
provided and per local and national codes.
forms in the manner indicated on the Product Registration page.
• It must be installed indoors in a building constructed
Product limited warranty certificates for models currently in pro- on site.
duction can be viewed at www.goodmanmfg.com or www.amana- • It must be part of a ducted system and not used in a
hac.com. If your model is not currently in production or does free air delivery application.
not appear on the website, please contact your installing con- • It must not be used as a “make-up” air unit.
tractor or contact customer service at (877-254-4729) to obtain
• All other warranty exclusions and restrictions apply.
a copy of your warranty certificate.
This furnace may be used as a construction site heater ONLY
Each product overview page contains a Product Warranty link;
if the following conditions are met:
by clicking on it you will be able to view the limited warranty
• The vent system is permanently installed per these
coverage for that specific product. To view warranty registration
installation instructions.
information, click on the Product Warranty text on the left navi-
gation panel on the home page of each website. The Online • A room thermostat is used to control the furnace. Fixed
Product Registration pages are located in this same section. jumpers that provide continuous heating CANNOT be
used.
• Return air ducts are provided and sealed to the furnace.
WARNING • A return air temperature range between 60ºF (16ºC)
TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO and 80ºF (27ºC) is maintained.
FIRE, DO NOT INSTALL THIS FURNACE IN A MOBILE HOME, TRAILER, OR • Air filters are installed in the system and maintained
RECREATIONAL VEHICLE. during construction, replaced as appropriate during
construction, and upon completion of construction are
replaced.
PRODUCT DESCRIPTION • The input rate and temperature rise are set per the
furnace rating plate.
FEATURES
• 100% outside air is provided for combustion air
This furnace is a part of the ComfortNet™ family of products. requirements during construction. Temporary ducting
The CTK01 ComfortNet thermostat kit allows this furnace to be can be used.
installed as part of a digitally communicating system. The NOTE: Do not connect the temporary duct directly to
ComfortNet system provides automatic airflow configuration, the furnace. The duct must be sized for adequate
enhanced setup features, and enhanced diagnostics. It also combustion and ventilation in accordance with the
reduces the number of thermostat wires to a maximum of four. latest edition of the National Fuel Gas Code NFPA 54/
It may be also installed as part of a “legacy” system using a ANSI Z223.1 orCAN/CSA B149.1 Installation Codes.
standard 24 VAC thermostat. • The furnace heat exchanger, components, duct
system, air filters and evaporator coils are thoroughly
This product may also be installed with the ComfortNet ther-
cleaned following final construction clean up.
mostat and a non-ComfortNet compatible single stage air con-
ditioning unit. However, this reduces the benefits of the • All furnace operating conditions (including ignition, input
ComfortNet system as the enhancements will only apply to the rate, temperature rise and venting) are verified
furnace. according to these installation instructions.
6
LOCATION REQUIREMENTS AND CONSIDERATIONS
To ensure proper furnace operation, install, operate and LOCATION REQUIREMENTS AND CONSIDERATIONS
maintain the furnace in accordance with these installa-
tion and operation instructions, all local building codes Your unit model type determines which installation procedures
must be used. For *MVC8 models, you must follow instruc-
and ordinances. In their absence, follow the latest edition of
the National Fuel Gas Code (NFPA 54/ANSI Z223.1), and/or tions for Horizontal Left, Horizontal Right or Upflow installa-
CAN/CSA B149 Installation Codes, local plumbing or waste tions only. These furnaces are not approved for Downflow in-
water codes, and other applicable codes. stallations.
Downflow models *DVC8 ARE NOT APPROVED FOR HORI-
A copy of the National Fuel Gas Code (NFPA 54/ANSI Z223.1) ZONTAL OR UPFLOW INSTALLATIONS. For these models,
can be obtained from any of the following: use only the instructions for downflow installation only.
American National Standards Institute
1430 Broadway
New York, NY 10018 WARNING
TO PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE,
National Fire Protection Association
PERSONAL INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE
1 Batterymarch Park
OBSERVED WHEN INSTALLING THIS UNIT.
Quincy, MA 02269
CSA International Follow the instructions listed below when selecting a furnace
8501 East Pleasant Valley location. Refer also to the guidelines provided in Section V,
Cleveland, OH 44131 Combustion and Ventilation Air Requirements.
• Centrally locate the furnace with respect to the
A copy of the CAN/CSA B149 Installation Codes can also be
proposed or existing air distribution system.
obtained from:
CSA International • Ensure the temperature of the return air entering the
furnace is between 55°F and 100°F when the furnace
178 Rexdale Boulevard
is heating.
Etobicoke, Ontario, Canada M9W 1R3
• Provisions must be made for venting combustion
The rated heating capacity of the furnace should be greater products outdoors through a proper venting system.
than or equal to the total heat loss of the area to be heated. The length of flue pipe could be a limiting factor in
The total heat loss should be calculated by an approved method locating the furnace.
or in accordance with “ASHRAE Guide” or “Manual J-Load Cal- • Ensure adequate combustion air is available for the
culations” published by the Air Conditioning Contractors of furnace. Improper or insufficient combustion air can
America. expose building occupants to gas combustion products
that could include carbon monoxide. Refer to
In the USA, this furnace MUST be installed in accordance with Combustion and Ventilation Air Requirements section.
the latest edition of the ANSI Z223.1 booklet entitled “National
• The furnace must be level. If the furnace is to be set
Fuel Gas Code” (NFPA 54), and the requirements or codes of
on a floor that may become wet or damp at times, the
the local utility or other authority having jurisdiction. In Canada,
furnace should be supported above the floor on a
this furnace must be installed in accordance with the current
concrete base sized approximately 1-1/2" larger than
CAN/CGA-B149.1 & 2 Gas Installation Codes, local plumbing
the base of the furnace.
or waste water codes and other applicable codes. Additional
• Ensure upflow or horizontal furnaces are not installed
helpful publications available from the NFPA are, NFPA 90A -
directly on carpeting, or any other combustible
Installation of Air Conditioning and Ventilating System and NFPA
material. The only combustible material allowed is
90B - Warm Air Heating and Air Conditioning System.
wood.
All venting shall be in accordance with PART 7, Venting of Equip- • Exposure to contaminated combustion air will result
ment, of the National Fuel Gas Code, ANSI Z223.1, or appli- in safety and performance-related problems. Do not
cable local building and/or air conditioning codes. These pub- install the furnace where the combustion air is exposed
lications are available from: to the following substances:
National Fire Protection Association, Inc. chlorinated waxes or cleaners
Batterymarch Park, Quincy, MA 02269 chlorine-based swimming pool chemicals
water softening chemicals
NOTE: Furnaces with NOx screens meet the California NOx
deicing salts or chemicals
emission standards and California seasonal efficiency stan- carbon tetrachloride
dards. ANNUAL inspections of the furnace and its vent system halogen type refrigerants
is strongly recommended. cleaning solutions (such as perchloroethylene)
printing inks
paint removers
varnishes
7
LOCATION REQUIREMENTS AND CONSIDERATIONS
hydrochloric acid Vent Pipe Clearance to Combustibles-
cements and glues 6" using Single Wall Connector or 1"
using B-1 vent.
antistatic fabric softeners for clothes dryers
and masonry acid washing materials
Top - 1"
• If the furnace is used in connection with a cooling unit,
Back - 0"
install the furnace upstream or in parallel with the
cooling unit coil. Premature heat exchanger failure
will result if the cooling unit coil is placed ahead of the
Side
furnace. Clearance - 1"
• If the furnace is installed in a residential garage,
position the furnace so that the burners and ignition
source are located not less than 18 inches (457 mm)
above the floor. Protect the furnace from physical
damage by vehicles.
• If the furnace is installed horizontally, the furnace
access doors must be vertical so that the burners fire
horizontally into the heat exchanger. Do not install Front Clearance - 3"
the unit with the access doors on the “up/top” or “down/
bottom” side of the furnace. • Adequate combustion/ventilation air must be supplied
• Do not connect this furnace to a chimney flue that to the closet.
serves a separate appliance designed to burn solid • Furnace must be completely sealed to floor or base.
fuel. Combustion/ ventilation air supply pipes must
• For counterflow installations, the air conditioning coil terminate 12" from top of closet and 12" from floor of
must be downstream from the heat exchanger of the closet. DO NOT remove solid base plate for side
furnace. return.
• Counterflow installation over a noncombustible floor. • Return air ducts must be completely sealed to the
Before setting the furnace over the plenum opening, furnace and terminate outside the enclosure surfaces.
ensure the surface around the opening is smooth and
CLEARANCES AND ACCESSIBILITY
level. A tight seal should be made between the furnace
base and floor by using a silicon rubber caulking Unobstructed front clearance of 24" for servicing is recom-
compound or cement grout. mended.
• Counterflow installation over a combustible floor. If VEN T TO P
SID ES FR O N T B AC K
installation over a combustible floor becomes B1-V EN T S IN G LE (P LE N U M )
necessary, use an accessory subbase (see 1" 6" 1" 3" 0" 1"
Specification Sheet applicable to your model for details). Top clearance for horizontal configuration - 1"
A special accessory subbase must be used for upright
counterflow unit installations over any combustible HORIZONTAL INSTALLATION (*MVC8 MODELS ONLY)
material including wood. Follow the instructions with Line contact to framing is permitted when installed in the hori-
the subbase for proper installations. Do not install the zontal configuration. Line contact is defined as the portion of
furnace directly on carpeting, tile, or other combustible the cabinet that is formed by the intersection of the top and
material other than wood flooring. (NOTE: The subbase side. ACCESSIBILITY CLEARANCE, WHERE GREATER,
will not be required if an air conditioning coil is installed SHOULD TAKE PRECEDENCE OVER MINIMUM FIRE PRO-
between the supply air opening on the furnace and the TECTION CLEARANCE. A gas-fired furnace for installation in
floor. a residential garage must be installed so that the ignition source
and burners are located not less than eighteen inches (18")
above the floor and is protected or located to prevent physical
damage by vehicles. A gas furnace must not be installed di-
rectly on carpeting, tile, or other combustible materials other
than wood flooring.
FURNACE SUSPENSION
If suspending the furnace from rafters or joist, use 3/8" threaded
rod and 2”x2”x3/8” angle iron as shown below. The length of
rod will depend on the application and the clearances neces-
sary.
8
COMBUSTION & VENTILATION CATEGORY I VENTING AIR REQUIREMENTS
g. If improper venting is observed during any of the above
tests, the common venting system must be corrected.
10
EXTERIOR MASONRY CHIMNEYS - CATEGORY I FURNACES ONLY
11. Reconnect the induced draft blower power leads. NOTE: Wash
If the wires are not long enough, pull extra wire from the Roof Line
wire bundle in the blower compartment.
12. Reconnect the flue pipe, and the pressure switch tubing. Clay Tile Size: 8" x 8" x12"
(Each x 24" Length)
Ensure that all wires and the pressure switch tubing is
Attic Floor
at least one inch from the flue pipe, or any other hot
surface. 1/2" to 1" Air Space
Vent the furnace in accordance with the National Fuel Gas Damper
First Floor
Code NFPA54/ANSI Z223.1-latest edition. In Canada, vent the Water Heater
furnace in accordance with the national standard of Canada, Breech F.A.F. Vent
Connector
Vent Connector
CAN/CSA B149.1 and CAN/CSA B149.2- latest editions and Fan Assisted
Forced Air
Natural Draft
Water Heater
Clean Out
amendments. Furnace
Basement Floor
11
EXTERIOR MASONRY CHIMNEYS - CATEGORY I FURNACES ONLY
If the chimney does not meet these termination requirements,
Proper Chimney but all other requirements in the checklist can be met, it may
Termination?
(Check 1) be possible for a mason to extend the chimney. If this will not
be practical, see Fix 1.
10' or Less
Chimney
Cleanout free of
debris? Reline
(Fix 4) Chimney
(Check 4)
NOTE: No Height
above parapet
required when distance Chimney
Dilution air Wall or from walls or parapet is
available? Reline Parapet more than 10 feet.
(Check 6) (Fix 4)
12
EXTERIOR MASONRY CHIMNEYS - CATEGORY I FURNACES ONLY
Liquid fuel appliances include oil furnaces, oil-fired boilers and Next, use a flashlight and small mirror to sight up the liner. B
oil-fired water heaters. vent must be supported so as to not come into direct contact
with the chimney walls or tile liner. If it is not, it can probably be
Appliances which burn propane (sometimes referred to as LP rehung so as to be acceptable. A thimble or fire stop may be
(liquefied petroleum)) gas are considered gas-fired appliances. helpful here.
CHECK 3 - CHIMNEY CROWN CONDITION. Flexible liners should be hung straight or nearly straight. If it is
Damage from condensate usually shows up first in the crown. spiraled in the chimney and in good condition, it should be
If any of the following trouble signs are present, the condition of rehung. To do this, break the top seal; pull up and cut off the
the crown is not satisfactory: excess liner length, and refit the top seal. Use caution when
a) Crown leaning doing this, as the cut edges of flexible liners may be sharp.
b) Bricks missing The surfaces of the liner must be physically sound. If gaps or
c) Mortar missing holes are present, the metal liner must be removed and re-
d) Tile liner cracked placed (Fix 4). Finally, confirm that the metal liner is the cor-
e) No tile liner rect size for the appliances to be installed. Use the GAMA
f) Salt staining at mortar joints. (White stains, and mortar tables and rules.
becomes sandy and/or erodes.) If a metal liner is not present, a clay tile liner must be present,
For problems a, b, or c, see Fix 3. If problems d, e, or f are or the chimney must be lined (Fix 4).
present, see Fix 4. IMPORTANT: It may be necessary to follow Use a flashlight and small mirror at the cleanout or vent con-
both Fix 3 and Fix 4. nector to inspect the clay tile liner. If any of the following prob-
lems are present:
CHECK 4 - DEBRIS IN CLEANOUT.
• Tile sections misaligned
A cleanout (dropleg) must be present such that the upper edge • Tile sections missing
of the cleanout cover is at least 12 inches below the lower edge
• Gaps between tile sections
of the lowest chimney inlet opening.
• Signs of condensate drainage at the cleanout or vent
A chimney without a cleanout could become partially blocked connectors
by debris. If no cleanout is present, the chimney must be re-
• Mortar protruding from between tile sections
lined (Fix 4). Remove the cleanout cover, and examine the
cleanout for debris. If significant amounts of any of the following • Use of sewer pipe or drainage pipe rather than an
are found: approved fire clay tile reline the chimney (Fix 4).
• Fuel oil residue
Next, measure the size of the liner. It may be possible to do
• Bricks this from the cleanout. The liner must be at least as large as
• Mortar or sand the minimum size established by the tables in National Fuel
• Pieces of the tile liner Gas Code NFPA 54/ANSI Z223.1 - latest edition and in the
• Rusted pieces of the metallic liner - reline the chimney National Standard of Canada, CAN/CSA B149.1 and CAN/CSA
(Fix 4). B149.2 - latest editions and amendments. If the liner is too
small or too large, then the chimney must be relined (Fix 4).
CHECK 5 - LINER CONDITION.
If a metal liner is present, it must be checked. It cannot be CHECK 6 - DILUTION AIR.
assumed that all existing metal liners are correctly installed
If gas-fired appliances are to be vented into a clay tile liner, a
and in good condition.
source of dilution air is required.
Remove the lowest existing vent connector, and examine the
Dilution air cannot be obtained through:
inside of the elbow or tee at the base of the liner. A small amount
of soot may be considered acceptable, provided the installer • Induced draft appliances
vacuums it away. If rusted pieces of the liner have collected • Natural draft appliances with vent dampers
here, the metal liner must be removed and replaced (Fix 4).
Sufficient dilution air can ordinarily be obtained through the draft
Next, gently tap the inside of the liner with a Phillips screw- hood of a natural draft appliance only if the appliance’s vent
driver. If the screwdriver perforates the liner, or if the tapping connector does not include a vent damper. If dilution air will not
does not sound like metal hitting metal, the liner must be re- be available, the chimney must be relined (Fix 4).
moved and replaced (Fix 4).
CHECK 7 - COMPLETE THE INSTALLATION.
Remember that all appliances must be vented inside the liner.
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
13
ELECTRICAL CONNECTIONS
Gas Code NFPA 54/ANSI Z223.1 - latest edition and in the FIX 3 - REBUILD THE CROWN
National Standard of Canada, CAN/CSA B149.1 and CAN/CSA
B149.2 - latest editions and amendments, then the clay tile If the chimney crown is damaged, a qualified mason must re-
liner can probably be used as a vent for the gas appliances. pair it in accordance with nationally recognized building codes
However, the installer must keep in mind the following factors or standards. One such standard which may be referenced is
which may render the tile liner unsuitable for use as a vent: the Standard for Chimneys, Fireplaces, Vents, and Solid Fuel
• Extremely cold weather Burning Appliances, ANSI/NFPA 211.
For sizing of flexible liners, see Note 22 and the tables in the
National Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition
14
ELECTRICAL CONNECTIONS
and in the National Standard of Canada, CAN/CSA B149.1 and
CAN/CSA B149.2 - latest editions and amendments. WARNING
To install the liner, read and follow the liner manufacturer’s in-
HIGH VOLTAGE !
structions and your local codes. Excess liner length should be TO AVOID THE RISK OF INJURY, ELECTRICAL SHOCK OR
DEATH, THE FURNACE MUST BE ELECTRICALLY
pulled out of the chimney and cut off. Use caution when doing
GROUNDED IN ACCORDANCE WITH LOCAL CODES OR IN
this, as the cut edges of flexible liners may be sharp. Do not
spiral excess liner inside of the chimney. Support the liner as THEIR ABSENCE, WITH THE LATEST EDITION OF THE
recommended by the liner manufacturer. NATIONAL ELECTRIC CODE.
15
ELECTRICAL CONNECTIONS
JUNCTION BOX RELOCATION To ensure proper unit grounding, the ground wire should run
from the furnace ground screw located inside the furnace junc-
WARNING tion box all the way back to the electrical panel. NOTE: Do
not use gas piping as an electrical ground. To confirm proper
EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES AS A unit grounding, turn off the electrical power and perform the
PRECAUTION WHEN REMOVING HOLE PLUGS.
following check.
1. Measure resistance between the neutral (white)
Line voltage connections can be made through either the right connection and one of the burners.
or left side panel. The furnace is shipped configured for a right 2. Resistance should measure 10 ohms or less.
side electrical connection. To make electrical connections
through the opposite side of the furnace, the junction box must This furnace is equipped with a blower door interlock switch
be relocated to the left side prior to making electrical connec- which interrupts unit voltage when the blower door is opened for
tions. To relocate the junction box, perform the following steps. servicing. Do not defeat this switch.
16
ELECTRICAL CONNECTIONS
DIP switch to the desired ON/OFF position. Turn power back
Thermostat
R Single Stage Heating with on. Refer to the following figure.
Single Stage Cooling
OFF ON
Heat OFF Delay Move to the ON position
DIP Switches to select two-stage
R
Furnace Integrated thermostat or OFF to
Control Module select single stage
thermostat
NEU 3 Thermostat
Y C
Dehumidistat 4 Stage Delay
Remote [Optional] Move to the ON position
Condensing Unit S1 to select Auto transition
(Single-Stage Cooling) delay or OFF for 5 minute
transition delay
Single Stage Heating with Single Stage Cooling
24 VOLT DEHUMIDISTAT WIRING
NOTE: To apply a single-stage Heating Thermostat,
the thermostat selector switch on the The optional usage of a dehumidistat allows the furnace’s
Integrated Control Module must be set on
single-stage. circulator blower to operate at a slightly lower speed (85%
of desired speed) during a combined thermostat call for cool-
Thermostat
Two-Stage Heating ing and dehumidistat call for dehumidification. This can be
with
R Single-Stage Cooling done through an independent dehumidistat or through a
thermostat’s DEHUM terminal (if available). This lower blower
speed enhances dehumidification of the conditioned air as
Furnace Integrated
R Control Module it passes through the AC coil. For proper function, a dehu-
midistat applied to this furnace must operate on 24 VAC
Y C NEU
Dehumidistat and utilize a switch which opens on humidity rise. Refer to
[Optional]
Remote the “Thermostat Wiring Diagrams” figure for additional wir-
Condensing Unit
(Single-Stage Cooling) ing details.
( )
Thermostat 2. Secure the dehumidistat neutral wire (typically the
Two-Stage Heating
Y2 W1 W2 with white lead) to the terminal marked “DEHUM” on the
Two-Stage Cooling
furnace integrated control module.
3. Secure the dehumidistat hot wire (typically the black
Furnace Integrated
Y2 W1 W2 Control Module lead) to the terminal marked “R” on the furnace
integrated control module.
Y2 NEU 4. Secure the dehumidistat ground wire (typically the
Dehumidistat
[Optional] green lead) to the ground screw on the furnace junction
Remote
Condensing Unit box. NOTE: Ground wire may not be present on all
(Two-Stage Cooling)
dehumidistats.
Two-Stage Heating with Two-Stage Cooling 5. Turn ON power to furnace.
Thermostat Wiring Diagrams To enable the dehumidify function on the integrated control
module, set the dehumidification ENABLE dipswitch from
SINGLE-STAGE HEATING THERMOSTAT APPLICATION OFF to ON.
A single-stage thermostat with only one heating stage may be Once the switch is set, the dehumidify function is enabled
used to control this furnace. The application of a single-stage during a combination call for cooling (T-Stat) and dehumidi-
thermostat offers a timed transition from low to high fire. The fication (DEHUM-Stat).
furnace will run on low stage for a fixed period of time before OFF ON
stepping up to high stage to satisfy the thermostat’s call for 9 DEHUM Move to the ON position
heat. The delay period prior to stepping up can be set at either to enable dehumidification
10 Unused
a fixed 5 minute time delay or a load based variable time be-
S5
tween 1 and 12 minutes (AUTO mode). If the AUTO mode is
selected, the control averages the cycle times of the previous
FOSSIL FUEL APPLICATIONS
three cycles and uses the average to determine the time to
transition from low stage to high stage. This furnace can be used in conjunction with a heat pump in
a fossil fuel application. A fossil fuel application refers to a
To use a single-stage thermostat, turn off power to the furnace,
combined gas furnace and heat pump installation which uses
move the thermostat selection DIP switch to the OFF position.
an outdoor temperature sensor to determine the most cost
Set the desired transition time by setting the transition delay
efficient means of heating (heat pump or gas furnace).
17
GAS SUPPLY AND PIPING
A heat pump thermostat with three stages of heat is required to to all local codes, and have a minimum temperature rating of
properly use a two-stage furnace in conjunction with a heat 105°C. All line voltage wire splices must be made inside the
pump. Refer to the fossil fuel kit installation instructions for furnace junction box.
additional thermostat requirements.
The integrated control module humidifier terminals (HUM) are
Strictly follow the wiring guidelines in the fossil fuel kit installa- energized with 115 volts whenever the induced draft blower is
tion instructions. All furnace connections must be made to the energized. The integrated control module electronic air cleaner
furnace two-stage integrated control module and the “FUR- terminals (EAC) are energized with 115 volts whenever the cir-
NACE” terminal strip on the fossil fuel control board. culator blower is energized.
115 VOLT LINE CONNECTION OF ACCESSORIES (HUMIDIFIER 24 VOLT HUMIDIFIER
AND ELECTRONIC AIR CLEANER)
A 5" long brown wire in the wire harness at the low fire pressure
switch provides 24 VAC humidifier control. This wire is pow-
WARNING
ered any time the pressure switch is closed. To connect 24
HIGH VOLTAGE ! VAC HUM, connect the 24 VAC line of the humidifier to the 5”
TO AVOID PERSONAL INJURY OR DEATH DUE TO brown wire. The connection can be made by either stripping
ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER the wire and using a wire nut or by using a field supplied quick
BEFORE SERVICING OR CHANGING ANY ELECTRICAL connect terminal. The wiring must conform to all local and
WIRING. 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 furnace integrated control module is equipped with line the 24 VAC transformer). Do not connect 115V humidifier to
voltage accessory terminals for controlling power to an optional these terminals.
field-supplied humidifier and/or electronic air cleaner.
GAS SUPPLY AND PIPING
The accessory load specifications are as follows:
Humidifier 1.0 Amp maximum at 120 VAC The furnace rating plate includes the approved furnace gas in-
Electronic Air Cleaner 1.0 Amp maximum at 120 VAC
put rating and gas types. The furnace must be equipped to
operate on the type of gas applied. This includes any conver-
Turn OFF power to the furnace before installing any accesso- sion kits required for alternate fuels and/or high altitude.
ries. Follow the humidifier or air cleaner manufacturers’ in-
CAUTION
structions for locating, mounting, grounding, and controlling
these accessories. Accessory wiring connections are to be TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE
made through the 1/4" quick connect terminals provided on the INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT
furnace integrated control module. The humidifier and elec- RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES
tronic air cleaner hot terminals are identified as HUM and EAC. OPERATING.
The humidifier and electronic air cleaner neutral terminals are
identified as NEUTRAL. All field wiring must conform to appli- Inlet gas supply pressures must be maintained within the ranges
cable codes. Connections should be made as shown. 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.
Inlet Gas Supply Pressure
Natural Gas Minimum: 5.0" w.c. Maximum:10.0" w.c.
Propane Gas Minimum: 11.0" w.c. Maximum:13.0" w.c.
If it is necessary for the installer to supply additional line volt- At all altitudes, the manifold pressure must be within 0.3 inches
age wiring to the inside of the furnace, the wiring must conform w.c. of that listed in the Specification Sheet applicable to your
model for the fuel used. At all altitudes and with either fuel, the
18
CIRCULATING AIR AND FILTERS
air temperature rise must be within the range listed on the fur- GAS PIPING CONNECTIONS
nace nameplate. Should this appliance be converted to LP,
refer to the instructions included in the factory authorized LP WARNING
conversion kit.
TO AVOID POSSIBLE UNSATISFACTORY OPERATION OF EQUIPMENT
HIGH ALTITUDE DERATE DAMAGE DUE TO UNDERFIRING OR EQUIPMENT, USE THE PROPER SIZE
OF NATURAL /PROPANE GAS PIPING NEEDED WHEN RUNNING PIPE FROM
IMPORTANT NOTE: The furnace will naturally derate itself with
THE METER/TANK TO THE FURNACE.
altitude. Do not attempt to increase the firing rate by changing
orifices or increasing the manifold pressure. This can cause
poor combustion and equipment failure. When sizing a trunk line, be sure to include all appliances
which will operate simultaneously.
High altitude installations may require both a pressure switch
and an orifice change. These changes are necessary to com- The gas piping supplying the furnace must be properly sized
pensate for the natural reduction in the density of both the gas based on the gas flow required, specific gravity of the gas, and
fuel and the combustion air at higher altitude. length of the run. The gas line installation must comply with
local codes, or in their absence, with the latest edition of the
For installations above 7000 feet, please refer to your distribu- National Fuel Gas Code, NFPA 54/ANSI Z223.1.
tor for required kit(s). Natural Gas Capacity of Pipe
Manifold Pressure Pressure In Cubic Feet of Gas Per Hour (CFH)
Gas Altitude Kit Orifice Length of Nominal Black Pipe Size
High Stage Low Stage Switch Change
Pipe in Feet 1/2" 3/4" 1" 1 1/4" 1 1/2"
Natural None #43 3.5" w.c. 1.9" w.c. None 10 132 278 520 1050 1600
0-7000 LPM-05*1 20 92 190 350 730 1100
Propane #55 10.0" w.c. 6.0" w.c. None
LPM-06*2 30 73 152 285 590 980
40 63 130 245 500 760
1
LPM-05* supports White-Rodgers 2-stage valve only 50 56 115 215 440 670
2 60 50 105 195 400 610
LPM-06* supports Honeywell and White-Rodgers 2-stage valves
NOTE: In Canada, gas furnaces are only certified to 4500 feet. 70 46 96 180 370 560
80 43 90 170 350 530
90 40 84 160 320 490
Contact the distributor for a tabular listing of appropriate
100 38 79 150 305 460
manufacturer’s kits for propane gas and/or high altitude instal- (Pressure 0.5 psig or less and pressure drop of 0.3" W.C.; Based on
lations. The indicated kits must be used to insure safe and 0.60 Specific Gravity Gas)
proper furnace operation. All conversions must be performed
by a qualified installer, or service agency. CFH = BTUH Furnace Input
Heating Value of Gas (BTU/Cubic Foot)
19
GAS SUPPLY AND PIPING
• Install a manual shutoff valve between the gas meter When the gas piping enters through the left side of the furnace,
and unit within six feet of the unit. If a union is installed, the installer must supply the following fittings (starting from the
the union must be downstream of the manual shutoff gas valve):
valve, between the shutoff valve and the furnace. • 90 degree elbow.
• Tighten all joints securely. • Straight pipe to reach the exterior of the furnace.
• Connect the furnace to the building piping by one of • A ground joint union, drip leg, and manual shutoff valve
the following methods: must also be supplied by the installer. In some cases,
– Rigid metallic pipe and fittings. the installer may also need to supply a transition piece
from 1/2 inch to another pipe size.
– Semi-rigid metallic tubing and metallic fittings.
Aluminum alloy tubing must not be used in exterior COUNTERFLOW INSTALLATIONS
locations. When the gas piping enters through the left side of the furnace,
– Use listed gas appliance connectors in accordance the installer must supply a straight pipe and a 90 degree elbow
with their instructions. Connectors must be fully in to reach the exterior of the furnace.
the same room as the furnace.
A ground joint union, drip leg and manual shutoff valve must
– Protect connectors and semi-rigid tubing against also be supplied by the installer. In most cases, the installer
physical and thermal damage when installed. may also need to supply a transition piece from ½” to another
Ensure aluminum-alloy tubing and connectors are pipe size. When the gas piping enters through the right side of
coated to protect against external corrosion when the furnace, the installer must supply the following fittings (start-
in contact with masonry, plaster, or insulation, or ing at the gas valve):
subjected to repeated wetting by liquids such as • Close Nipple
water (except rain water), detergents, or sewage. • 90 Degree Elbow
Location of Manual Valve • Straight Pipe to Reach Exterior of Furnace.
(Installed Ahead of
Ground Joint Pipe Union) GAS PIPING CHECKS
Height Required
By Local Code Before placing unit in operation, leak test the unit and gas con-
nections.
Ground Joint Pipe Union
To Be Installed Ahead of
Gas Valve WARNING
`` TO AVOID THE POSSIBILITY OF EXPLOSION OR FIRE, NEVER USE A MATCH
Drip Leg OR OPEN FLAME TO TEST FOR LEAKS.
Reducing Coupling
1/2” x 1/8” with 1/8” Check for leaks using an approved chloride-free soap and wa-
Pipe Plug to Measure ter solution, an electronic combustible gas detector, or other
Line Gas Pressure
approved testing methods.
UPFLOW INSTALLATIONS
When the gas piping enters through the right side of the fur-
nace, the installer must supply the following fittings (starting
NOTE: Never exceed specified pressures for testing. Higher
from the gas valve):
pressure may damage the gas valve and cause subsequent
• Close nipple.
overfiring, resulting in heat exchanger failure.
• 90 degree elbows.
• Straight pipe to reach the exterior of the furnace . Disconnect this unit and shutoff valve from the gas supply pip-
ing system before pressure testing the supply piping system
A ground joint union, drip leg, and manual shutoff valve must with pressures in excess of 1/2 psig (3.48 kPa).
also be supplied by the installer. In some cases, the installer
may also need to supply a transition piece from 1/2" to another This unit must be isolated from the gas supply system by clos-
pipe size. ing its manual shutoff valve before pressure testing of gas sup-
ply piping system with test pressures equal to or less than 1/2
psig (3.48 kPa).
20
CIRCULATING AIR AND FILTERS
PROPANE GAS TANKS AND PIPING
5 to 15 PSIG
First Stage (20 PSIG Max.)
Regulator Continuous
WARNING 11" W.C.
IF THE GAS FURNACE IS INSTALLED IN A BASEMENT, AN EXCAVATED
AREA OR CONFINED SPACE , IT IS STRONGLY RECOMMENDED TO 200 PSIG Second Stage
Maximum Regulator
CONTACT A PROPANE SUPPLIER TO INSTALL A GAS DETECTING WARNING
DEVICE IN CASE OF A GAS LEAK.
• SINCE PROPANE GAS IS HEAVIER THAN AIR, ANY LEAKING GAS CAN
SETTLE IN ANY LOW AREAS OR CONFINED SPACES.
• PROPANE GAS ODORANT MAY FADE, MAKING THE GAS UNDETECTABLE
EXCEPT WITH A WARNING DEVICE. Propane Gas Installation (Typ.)
A gas detecting warning system is the only reliable way to PROPANE GAS PIPING CHARTS
detect a propane gas leak. Rust can reduce the level of odorant Sizing Between First and Second Stage Regulator*
in propane gas. Do not rely on your sense of smell. Contact a Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting.
Capacities in 1,000 BTU/hour.
local propane gas supplier about installing a gas detecting Pipe or
Tubing Size, O.D. Type L Nominal Pipe Size
warning system. If the presence of gas is suspected, follow Tubing
Schedule 40
Length,
the instructions on Page 3 of this manual. Feet 3/8" 1/2" 5/8" 3/4" 7/8" 1/2" 3/4"
10 730 1,700 3,200 5,300 8,300 3,200 7,500
All propane gas equipment must conform to the safety stan- 20 500 1,100 2,200 3,700 5,800 2,200 4,200
30 400 920 2,000 2,900 4,700 1,800 4,000
dards of the National Board of Fire Underwriters, NBFU Manual 40 370 850 1,700 2,700 4,100 1,600 3,700
58. 50 330 770 1,500 2,400 3,700 1,500 3,400
60 300 700 1,300 2,200 3,300 1,300 310
80 260 610 1,200 1,900 2,900 1,200 2,600
For satisfactory operation, propane gas pressure must be 10 100 220 540 1,000 1,700 2,600 1,000 2,300
inch WC at the furnace manifold with all gas appliances in 125 200 490 900 1,400 2,300 900 2,100
150 190 430 830 1,300 2,100 830 1,900
operation. Maintaining proper gas pressure depends on three 175 170 400 780 1,200 1,900 770 1,700
main factors: 200 160 380 730 1,100 1,800 720 1,500
1. Vaporization rate, depending on temperature of the liquid, Sizing Between Second Stage and Appliance Regulator*
Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting.
and “wetted surface” area of the container or containers. Capacities in 1,000 BTU/hour.
Pipe or Nominal Pipe Size
Tubing Size, O.D. Type L
2. Proper pressure regulation. (Two-stage regulation is Tubing Schedule 40
Length,
recommended for both cost and efficiency). Feet 3/8" 1/2" 5/8" 3/4" 7/8" 1-1/8" 1/2" 3/4" 1" 1-1/4" 1-1/2"
10 39 92 199 329 501 935 275 567 1,071 2,205 3,307
3. Pressure drop in lines between regulators, and between 20 26 62 131 216 346 630 189 393 732 1,496 2,299
second stage regulator and the appliance. Pipe size will 30
40
21
19
50
41
107
90
181
145
277
233
500
427
152
129
315
267
590
504
1,212
1,039
1,858
1,559
depend on length of pipe run and total load of all 50 18 37 79 131 198 376 114 237 448 91 1,417
60 16 35 72 121 187 340 103 217 409 834 1,275
appliances. 80 13 29 62 104 155 289 89 185 346 724 1,066
100 11 26 55 90 138 255 78 162 307 630 976
125 10 24 48 81 122 224 69 146 275 567 866
Complete information regarding tank sizing for vaporization, rec- 150 9 21 43 72 109 202 63 132 252 511 787
ommended regulator settings, and pipe sizing is available from 200 8 19 39 66 100 187 54 112 209 439 665
250 8 17 36 60 93 172 48 100 185 390 590
most regulator manufacturers and propane gas suppliers.
Since propane gas will quickly dissolve white lead and most CIRCULATING AIR AND FILTERS
standard commercial compounds, special pipe dope must be
used. Shellac-based compounds resistant to the actions of WARNING
liquefied petroleum gases such as Gasolac®, Stalactic®,
Clyde’s® or John Crane® are satisfactory. NEVER ALLOW THE PRODUCTS OF COMBUSTION, INCLUDING CARBON
MONOXIDE, TO ENTER THE RETURN DUCT WORK OR CIRCULATION AIR
Refer to the following illustration for typical propane gas instal- SUPPLY.
lations and piping.
Duct systems and register sizes must be properly designed for
the CFM and external static pressure rating of the furnace.
Ductwork should be designed in accordance with the recom-
mended methods of “Air Conditioning Contractors of America”
Manual D.
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.
21
START-UP PROCEDURE AND ADJUSTMENT
A closed return duct system must be used, with the return duct To determine total external duct static pressure, proceed as
connected to the furnace. NOTE: Ductwork must never be follows;
attached to the back of the furnace. For installations requiring
more than 1800 CFM, use a bottom return or two sided return. 1. With clean filters in the furnace, use a draft gauge (inclined
Supply and return connections to the furnace may be made manometer) to measure the static pressure of the return
with flexible joints to reduce noise transmission. To prevent the duct at the inlet of the furnace. (Negative Pressure)
blower from interfering with combustion air or draft when a cen- 2. Measure the static pressure of the supply duct. (Positive
tral return is used, a connecting duct must be installed be- Pressure)
tween the unit and the utility room wall. A room, closet, or
alcove must not be used as a return air chamber. 3. The difference between the two numbers is .4” w.c.
When the furnace is used in connection with a cooling unit, the Example:
furnace should be installed in parallel with or on the upstream static reading from return duct = -.1" w.c.
side of the cooling unit to avoid condensation in the heating
element. With a parallel flow arrangement, the dampers or other static reading from supply duct = .3" w.c.
means used to control the flow of air must be adequate to
prevent chilled air from entering the furnace and, if manually total external static pressure on this system = .4" w.c.
operated, must be equipped with means to prevent operation of NOTE: Both readings may be taken simultaneously and read
either unit unless the damper is in the full heat or cool position.
directly on the manometer if so desired. If an air conditioner
When the furnace is installed without a cooling coil, it is rec- coil or Electronic Air Cleaner is used in conjunction with the
ommended that a removable access panel be provided in the furnace, the readings must also include theses components,
outlet air duct. This opening shall be accessible when the fur- as shown in the following drawing.
nace is installed and shall be of such a size that the heat 4. Consult proper tables for the quantity of air.
exchanger can be viewed for visual light inspection or such that
a sampling probe can be inserted into the airstream. The ac- If the total external static pressure exceeds the maximum listed
cess panel must be made to prevent air leaks when the furnace on the furnace rating plate, check for closed dampers, regis-
is in operation. ters, undersized and/or oversized poorly laid out duct work.
NOTE: An undersized opening will cause reduced airflow. The FURNACE STARTUP
bottom return is set up as a knock out. 1. Close the manual gas shutoff valve external to the furnace.
2. Turn off the electrical power to the furnace.
UPRIGHT INSTALLATIONS 3. Set the room thermostat to the lowest possible setting.
4. Remove the burner compartment door.
Depending on the installation and/or customer preference, dif-
fering filter arrangements can be applied. Filters can be in- NOTE: This furnace is equipped with an ignition device which
stalled in the central return register or a side panel external automatically lights the burner. Do not try to light the burner by
filter rack kit (upflows), or the ductwork above a downflow fur- hand.
nace. As an alternative, a media air filter or electronic air cleaner 5. Move the furnace gas valve manual control to the OFF
can be used as the primary filter. position.
6. Wait five minutes then smell for gas. Be sure check
CIRCULATION AIR FILTERS
near the floor as some types of gas are heavier than air.
One of the most common causes of a problem in a forced air 7. If you smell gas after five minutes, immediately follow
heating system is a blocked or dirty filter. Circulating air filters the Safety Instructions on page 2 of this manual. If you
must be inspected monthly for dirt accumulation and replaced do not smell gas after five minutes, move the furnace
if necessary. Failure to maintain clean filters can cause prema- gas valve manual control to the ON position.
ture heat exchanger failure. 8. Replace the burner compartment door.
A new home may require more frequent replacement until all 9. Open the manual gas shutoff valve external to the furnace.
construction dust and dirt is removed. Circulating air filters are 10. Turn on the electrical power to the furnace.
to be installed in the return air duct external to the furnace 11. Adjust the thermostat to a setting above room
cabinet. temperature.
M INIM UM FILTER SIZES for DISPOSABLE FILTERS 12. After the burners are lit, set the thermostat to desired
FURNACE INPUT FILTER SIZE temperature.
70M 768 in 2
90M 960 in 2 FURNACE SHUTDOWN
115M 1022 in 2
D ISP OSA B LE N OM IN A L 300 F .M . F A C E VELOC IT Y 1. Set the thermostat to the lowest setting.
The integrated control will close the gas valve and
extinguish flame. Following a 15 second delay, the
induced draft blower will be de-energized. After a 120,
HORIZONTAL INSTALLATIONS 150, 180 or 210-second delay period (field selectable
Filters must be installed in either the central return register or delay OFF [90, 120, 150, 180] plus 30-second ramp
in the return air duct work. down), the circulator blower de-energizes.
2. Remove the burner compartment door and move the
START-UP PROCEDURE AND ADJUSTMENT furnace gas valve manual control to the OFF position.
3. Close the manual gas shutoff valve external to the furnace.
Furnace must have a 115 VAC power supply properly connected 4. Replace the burner compartment door.
and grounded. Proper polarity must be maintained for correct
operation. In addition to the following start-up and adjustment GAS SUPPLY PRESSURE MEASUREMENT
items, refer to further information in Operational Checks sec-
tion. CAUTION
HEAT ANTICIPATOR SETTING TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE
INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT
The heat anticipator in the room thermostat must be correctly
adjusted to obtain the proper number of cycles per hour and to RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES
prevent “overshooting” of the setting. Set the heat anticipator OPERATING.
setting to 0.7 amps. Follow the thermostat manufacturer’s
instructions on how to adjust the heat anticipator setting. The line pressure supplied to the gas valve must be within the
FURNACE OPERATION range specified below. The supply pressure can be measured
at the gas valve inlet pressure boss or at a hose fitting installed
Purge gas lines of air prior to startup. Be sure not purge lines in the gas piping drip leg. The supply pressure must be mea-
into an enclosed burner compartment. sured with the burners operating. To measure the gas supply
Check for leaks using an approved chloride-free soap and wa- pressure, use the following procedure.
ter solution, an electronic combustible gas detector, or other
23
START-UP PROCEDURE AND ADJUSTMENT
Common
Terminal(C)
Open to Manometer
Atmosphere Hose High Fire Coil
Terminal (HI)
INLET OUTLET
Low Fire Coil
Terminal (LO)
Open to Manometer
Hose Manometer
Atmosphere
Low Fire 1. Turn OFF gas to furnace at the manual gas shutoff valve
Regulator external to the furnace.
Adjust
Inlet 2. Connect a calibrated water manometer (or appropriate
Pressure gas pressure gauge) at either the gas valve inlet pressure
Boss
Manometer
High Fire Coil Coaxial Coil boss or the gas piping drip leg. See Honeywell VR9205
Terminal (HI) Terminal (M) gas valve figure or White-Rodgers 36G54 gas valve figure
On/Off Switch Common
Terminal(C) for location of inlet pressure boss.
24
START-UP PROCEDURE AND ADJUSTMENT
9. Close thermostat “R” and “W2” contacts to provide a
Gas Line
call for high stage heat.
Gas
Shutoff
10. Remove regulator cover screw from the high (HI) outlet
Valve pressure regulator adjust tower and turn screw clockwise
to increase pressure or counterclockwise to decrease
pressure. Replace regulator cover screw.
Gas Line
To Furnace
11. Turn off all electrical power and gas supply to the system.
12. Remove the manometer hose from the hose barb fitting
or outlet pressure boss.
Open To
Atmosphere 13. Replace outlet pressure tap:
Drip Leg Cap a. Honeywell VR9205 valve: Remove the 1/8" NPT hose
With Fitting
barb fitting from the outlet pressure tap. Replace the
outlet pressure boss plug and seal with a high quality
Manometer Hose thread sealer.
b. White-Rodgers 36G54 valve: Turn outlet pressure test
screw in to seal pressure port (clockwise, 7 in-lb
minimum).
Manometer 14. Turn on electrical power and gas supply to the system.
Measuring Inlet Gas Pressure (Alt. Method) 15. Close thermostat contacts “R” and “W1/W2” to energize
GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT the valve.
25
START-UP PROCEDURE AND ADJUSTMENT
4. Calculate the furnace input in BTUs per hour (BTU/hr). HEAT EXCHANGER
RADIATION "LINE OF SIGHT"
Input equals the sum of the installation’s gas heating
value and a conversion factor (hours to seconds) divided
by the number of seconds per cubic foot. The measured SUPPLY
AIR
input must not be greater than the input indicated on the
unit rating plate. TSUPPLY
EXAMPLE:
Installation’s gas heating (HTG) value: 1,000 BTU/ft3
(Obtained from gas supplier) RISE = TSUPPLY - TRETURN
26
START-UP PROCEDURE AND ADJUSTMENT
The cooling system manufacturer’s instructions must be
checked for required air flow. Any electronic air cleaners or 100% CFM 100% CFM
other devices may require specific air flows, consult installa- OFF OFF
tion instructions of those devices for requirements.
1 min
3. Knowing the furnace model, locate the high stage cooling
air flow charts in the Specification Sheet applicable to • Profile B ramps up to full cooling demand airflow by
your model. Look up the cooling air flow determined in first stepping up to 50% of the full demand for 30 seconds.
step 2 and find the required cooling speed and adjustment The motor then ramps to 100% of the required airflow. A
setting. one (1) minute OFF delay at 100% of the cooling airflow
Example: A *MVC80704BX furnace installed with a 2.5 is provided.
ton air conditioning system. The air flow
needed is 1000 CFM. Looking at the cooling 100% CFM 100% CFM
speed chart for *MVC80704BX, find the air 50% CFM OFF
OFF
flow closest to 1000 CFM. A cooling airflow 1/2 min 1 min
of 990 CFM can be attained by setting the
cooling speed to “C” and the adjustment to
“-” (minus).
• Profile C ramps up to 85% of the full cooling demand
4. Continuous fan speed is 30% of the furnace’s maximum airflow and operates there for approximately 7 1/2
airflow capability. minutes. The motor then steps up to the full demand
Example: If the furnace’s maximum airflow capability airflow. Profile C also has a one (1) minute 100% OFF
is 2000 CFM, the continuous fan speed will delay.
be 0.30 x 2000 CFM = 600 CFM.
5. Locate the blower speed selection DIP switches on the OFF
100% CFM
OFF
integrated control module. Select the desired “cooling”
speed tap by positioning switches 1 and 2 appropriately.
Select the desired “adjust” tap by positioning switches
3 and 4 appropriately. Refer to the following figure for
Switch Bank: S3
switch positions and their corresponding taps. Verify
Cooling DIP Switch No.
CFM by noting the number displayed on the dual 7-
segment LED display. Airflow 1 2
6. The multi-speed circulator blower also offers several A OFF OFF
custom ON/OFF ramping profiles. These profiles may B ON OFF
be used to enhance cooling performance and increase C OFF ON
comfort level. The ramping profiles are selected using D* ON ON
DIP switches 5 and 6. Refer to the following figure for (*Indicates factory setting)
switch positions and their corresponding taps. Refer to
Switch Bank: S3
the bullet points below for a description of each ramping
DIP Switch No.
profile. Verify CFM by noting the number displayed on Adjust Taps
3 4
the dual 7-segment LED display.
Normal* OFF OFF
Switch Bank: S4 10% ON OFF
Ramping DIP Switch No. -10% OFF ON
Profiles 5 6 Normal ON ON
27
START-UP PROCEDURE AND ADJUSTMENT
In general lower heating speeds will: reduce electrical consump-
7. Select the heating speed for your model from the heating tion, lower operating sound levels of the blower, and increase
speed chart in the Specification Sheet. The adjust setting the outlet air temperature delivered to the home. The speeds
(already established by the cooling speed selection) available allow the blower performance to be optimized for the
determines which set of speeds are available. The particular homeowner’s needs.
selected speed must provide a temperature rise within
the rise range listed with the particular model. BLOWER HEAT OFF DELAY TIMINGS
Example: The *MVC80704BX is set for 990 CFM on The integrated control module provides a selectable heat off
cooling, the “ADJUST” is set to “+” (plus). delay function. The heat off delay period may be set to 90, 120,
The four heating speeds available are “A 150, 180 seconds using the DIP switches or jumper provided
Plus”, “B Plus”, “C Plus”, and “D Plus”. “A on the control module. The delay is factory shipped at 150
Plus” has a rise of 38°F for both stages seconds but may be changed to suit the installation require-
which is within the 20-50°F rise range for ments and/or homeowner preference. Refer to the following fig-
the *MVC80704BX . This setting will keep ures for switch positions and corresponding delay times.
electrical consumption to a minimum. Set
Switch Bank: S1
the “Heat” speed DIP switches to “A”.
DIP Switch No.
Heat OF F Delay
Switch Bank: S4 1 2
Heating DIP Switch No. 90 seconds OFF OFF
Airflow 7 8 120 seconds ON OFF
A OFF OFF 150 seconds * OFF ON
B* ON OFF 180 seconds ON ON
C OFF ON (*Indic ates factory setting)
D ON ON Heat Off Delay Dipswitches
(*Indicates factory setting)
8. Select the desired “heating” speed tap by positioning
switches 7 and 8 appropriately. Refer to figure above.
Verify CFM by noting the number displayed on the dual
7-segment LED display.
Speed Selection Dip Switches Model Tap Low Stage High Stage Low Stage High Stage
Cool Cool Heat Heat
Cool Adjust Profile Heat
Selection Selection Selection Selection A 390 600 735 1050
Switches Switches Switches Switches B 520 800 805 1150
TAP 1 2 3 4 5 6 7 8 *DVC80703BX* C 650 1000 875 1250
D 780 1200 935 1350
A OFF OFF OFF OFF OFF OFF OFF OFF
A 520 800 945 1350
B ON OFF ON OFF ON OFF ON OFF B 715 1100 1015 1450
C OFF ON OFF ON OFF ON OFF ON *DVC80905CX* C 910 1400 1085 1550
D 1170 1800 1155 1650
D ON ON ON ON ON ON ON ON
A 553 850 1085 1550
Profiles Pre-Run Short-Run OFF Delay B 748 1150 1155 1650
A ------- -------- 60 sec/100%
*DVC81155CX* C 943 1450 1225 1750
D 1203 1850 1260 1800
B ------- 30 sec/50% 60 sec/100%
A 390 600 875 1250
C ------- 7.5 min/82% 60 sec/100%
*MVC80704BX* B 520 800 945 1350
D 30 sec/50% 7.5 min/82% 30 sec/50% C 715 1100 1015 1450
To set airflow: (1) Select model and desired
D 910 1400 1085 1550
high stage cooling airflow. Determine the corresponding tap A 520 800 1050 1500
( A, B, C, or D ). Set dip switches 1 and 2 to the appropriate
ON / OFF positions. (2) Select model and desired high stage *MVC80905CX* B 715 1100 1120 1600
heating airflow. Determine the corresponding tap ( A, B, C, or C 910 1400 1190 1700
D ). Set dip switches 7 and 8 to the appropriate ON / OFF D 1170 1800 1260 1800
positions. (3) Select the airflow adjustment factor taps A and
D are 1; Tap B is +10%; Tap C -10%. Set dip switches 3 and 4 A 520 800 1210 1725
to the appropriate ON / OFF positions.
To set Comfort Mode: Select desired Comfort Mode profile
*MVC81155CX* B 715 1100 1225 1750
(see profiles above). Set switches 5 and 6 to the appropriate
C 910 1400 1245 1775
ON / OFF positions. D 1175 1800 1260 1800
NOTE: Airflow data shown applies to legacy mode operation only. For a fully communicating
system, please see the outdoor unit’s installation instructions for cooling and pump heating
airflow data. See ComfortNet™ System - Airflow Consideration section for details.
28
COMFORTNET™ SYSTEM
CT Compatible AC/HP
1 2 R C
Integrated Control Module C Y Non-CT Compatible
Single Stage AC
System Wiring using Four-Wires
System Wiring between Furnace and Non-CT Compatible
TWO-WIRE OUTDOOR, FOUR-WIRE INDOOR WIRING Single Stage Air Conditioner
Two wires can be utilized between the indoor and outdoor units. COMFORTNET SYSTEM ADVANCED FEATURES
For this wiring scheme, only the data lines, 1 and 2, are needed
The ComfortNet system permits access to additional system
required between the indoor and outdoor units. A 40VA, 208/
information, advanced setup features, and advanced diagnos-
230 VAC to 24VAC transformer must be installed in the out-
tic/troubleshooting features. These advanced features are or-
door unit to provide 24VAC power to the outdoor unit’s elec-
ganized into a menu structure. The menus are accessed and
tronic control. The transformer is included with the CTK01AA
navigated as described in the following section.
kit. See kit instructions for mounting and wiring instructions.
30
COMFORTNET™ SYSTEM
ACCESSING AND NAVIGATING THE ADVANCED FEATURES MENUS the change is not accepted, the display will show “FAIL” then
revert to the Fault Screen.
The advanced system features are accessed using the
ComfortNet thermostat. These advanced features are accessed Some parameters being displayed switch between the item
as follows: name and the item value. Touch the Hold key to momentarily
• On the CT thermostat Home Screen Display, touch stop the display from switching.
the Menu key to display additional key choices. To exit an equipment submenu and revert back to the equip-
• Touch and hold the Installer Config key for ment menus, touch the Menu key. Touch Menu again to revert
approximately 3 seconds to enter the Thermostat back to the Thermostat Options Menu. Touch the Run Sched-
Options Configuration menu. ule key to step out of all menus and back to the CT thermostat
• Touch and hold the Installer Config key again for Home Screen Display.
approximately 3 seconds to enter the Advanced
THERMOSTAT MENU
Installer Configuration menu.
If this furnace is installed with a CT compatible heat pump, the
system is recognized as a dual fuel system. The balance
point temperature should be set via the thermostat advanced
menu. Navigate to the THERMOSTAT menu. Press the IN-
STALLER CONFIG key. Navigate to the SETUP menu and
press the INSTALLER CONFIG button. Navigate to dF BAL
PNT. Adjust the dual fuel system balance point using the back/
forward arrows.
Set Time
DIAGNOSTICS
Installer Set R un
Clean Display Sch ed u le
Config Schedule
Advanced Advanced
Menu Menu
Run Run
Schedule Schedule
_
view settings. If a setting can be adjusted, and + keys will
_
appear. Use the or + keys to adjust the setting to the
desired value. Touch the or to step to the next item.
_
+
31
COMFORTNET™ SYSTEM
FURNACE ADVANCED FEATURES MENUS
CONFIGURATION
Submenu Item Indication (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 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 (FAULT #6) Least recent furnace fault For dis play only
Selecting “YES” c lears the fault
Clear Fault History (CLEAR) NO or YES
history
NOTE: Consecutively repeated faults are shown a maximum of 3 times
IDENTIFICATION
Submenu Item Indication (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 Item User Modifiable Options Comments
Heat Airflow Trim (HT TRM) -10% to +10% in 2% increments, Trims the heating airflow by the selected
default is 0% amount.
Heat ON Delay (HT ON 5, 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 seconds, Selects the indoor blower heat OFF delay
default is 150 seconds
Heat Airflow (HT ADJ) 1, 2, 3, or 4 Selects the nominal heating airflow (see
Startup Procedure and Adjustment –
Circulator Blower Speeds for addition
information)
STATUS
Submenu Item Indication (for Display Only; not User Modifiable)
Mode (MODE) Displays the current furnace operating mode
CFM (CFM) Displays the airflow for the current operating mode
32
COMFORTNET™ SYSTEM
NON-COMM (APPLIES ONLY TO A CT COMPATIBLE FURNACE MATCHED
WITH A NON-CT COMPATIBLE SINGLE STAGE AIR CONDITIONER)
Submenu Item User Modifiable Options Comments
Cool Airflow (CL CFM) 18, 24, 30, 36, 42, 48, or 60, default Selects the airflow for the non-CT
is 18 compatible 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% CT compatible single stage AC unit
Cool Airflow Profile (CL PRFL) A, B, C, or D, default is A Selects the airflow profile for the non-CT
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 seconds non-CT 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 seconds non-CT compatible single stage AC unit
NETWORK TROUBLESHOOTING shoot the network may arise. The integrated furnace control
Communications is achieved by taking the difference has some on-board tools that may be used to troubleshoot the
between two dc signals. The signals and transmission lines network. These tools are: red communications LED, green
are referred to as “data 1” and “data 2”. Each transmission receive (Rx) LED, and learn button.
line is biased to approximately 2.5Vdc. During data recep- • Red communications LED – Indicates the status of
tion/transmission, the data lines vary between +5V and the network. The table below indicates the LED status
ground. (When data 1 is increasing towards +5V, data 2 is and the corresponding potential problem.
decreasing towards ground and when data 1 is decreasing • Green receive LED – Indicates network traffic. The
towards ground, data 2 is increasing towards +5V. Typically, table below indicates the LED status and the
the data 1 line is approximately 2.6Vdc and the data 2 corresponding potential problem.
transmission line is approximately 2.3Vdc. The voltage • Learn button – Used to reset the network. Depress
difference between data 1 and data 2 is typically 0.2 to 0.6 the button for approximately 2 seconds to reset the
Vdc. network.
2 BIAS
3 TERM
33
OPERATIONAL CHECKS & SAFETY CIRCUIT DESCRIPTION
LED LED Indication Possible Causes Corrective Action(s) Notes & Cautions
Status
Off x Normal condition x None x None x None
1 Flash x Communications x Communications x Depress Learn Button x Depress once
Failure Failure x Verify that bus BIAS quickly for a power-
and TERM up reset
Red
dipswitches are in the x Depress and hold
Communications
ON position. for 2 seconds for
LED
an out-of-box reset
2 Flashes x Out-of-box reset x Control power up x None x None
x Learn button
depressed
Off x No power x No power to furnace x Check fuses and x Turn power OFF
x Communications x Open fuse circuit breakers; prior to repair
error x Communications error replace/reset
x Replace blown fuse
x Check for shorts in
low voltage wiring in
furnace/system
x Reset network by
depressing learn
button
x Check data 1/ data 2
voltages
1 Steady x No network found x Broken/ disconnected x Check x Turn power OFF
Flash data wire(s) communications prior to repair
x Furnace is installed as wiring (data 1/ data 2 x Verify wires at
a legacy/ traditional wires) terminal blocks are
system x Check wire securely twisted
connections at together prior to
Green Receive terminal block inserting into
LED x Verify furnace terminal block
installation type x Verify data1 and
(legacy/ traditional or data voltages as
communicating) described above
x Check data 1/ data 2
voltages
Rapid x Normal network x Control is “talking” on x None x None
Flashing traffic network as expected
On Solid x Data 1/ Data 2 x Data 1 and data 2 x Check x Turn power OFF
miss-wire wires reversed at communications prior to repair
furnace, thermostat, wiring (data 1/ data 2 x Verify wires at
or CT™ compatible wires) terminal blocks are
outdoor AC/HP x Check wire securely twisted
x Short between data 1 connections at together prior to
and data 2 wires terminal block inserting into
x Short between data 1 x Check data 1/ data 2 terminal block
or data 2 wires and R voltages x Verify data1 and
(24VAC) or C (24VAC data voltages as
common) described above
TROUBLESHOOTING
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
Burner Flame
NOTE: Discharge body’s static electricity before touching unit.
An electrostatic discharge can adversely affect electrical
components.
SAFETY CIRCUIT DESCRIPTION
Use the following precautions during furnace installation and
servicing to protect the integrated control module from dam-
A number of safety circuits are employed to ensure safe and
age. By putting the furnace, the control, and the person at the
proper furnace operation. These circuits serve to control any
same electrostatic potential, these steps will help avoid expos-
potential safety hazards and serve as inputs in the monitoring
ing the integrated control module to electrostatic discharge.
and diagnosis of abnormal function. These circuits are con-
This procedure is applicable to both installed and uninstalled
tinuously monitored during furnace operation by the integrated
(ungrounded) furnaces.
control module.
1. Disconnect all power to the furnace. Do not touch the
INTEGRATED CONTROL MODULE integrated control module or any wire connected to the
control prior to discharging your body’s electrostatic
The integrated control module is an electronic device which, if
charge to ground.
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. Any tools held in a
PRIMARY LIMIT person’s hand during grounding will be discharged.
The primary limit control is located on the partition panel and 3. Service integrated control module or connecting wiring
monitors heat exchanger compartment temperatures. It is a following the discharge process in step 2. Use caution
normally-closed (electrically), automatic reset, temperature-ac- not to recharge your body with static electricity; (i.e., do
tivated sensor. The limit guards against overheating as a result not move or shuffle your feet, do not touch ungrounded
of insufficient conditioned air passing over the heat exchanger. objects, etc.). If you come in contact with an ungrounded
AUXILIARY LIMIT object, repeat step 2 before touching control or wires.
4. Discharge your body to ground before removing a new
The auxiliary limit controls are located on or near the circulator control from its container. Follow steps 1 through 3 if
blower and monitors blower compartment temperatures. They installing the control on a furnace. Return any old or
are a normally-closed (electrically), auto-reset sensors. These new controls to their containers before touching any
limits guard against overheating as a result of insufficient con- ungrounded object.
ditioned air passing over the heat exchanger.
DIAGNOSTIC CHART
ROLLOUT LIMIT
The rollout limit controls are mounted on the burner/manifold WARNING
assembly and monitor the burner flame. They are normally- HIGH VOLTAGE !
closed (electrically), manual-reset sensors. These limits guard TO AVOID PERSONAL INJURY OR DEATH DUE TO
against burner flames not being properly drawn into the heat ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER
exchanger. BEFORE PERFORMING ANY SERVICE OR MAINTENANCE.
PRESSURE SWITCHES
Refer to the Troubleshooting Chart at the end of this manual for
The pressure switches are normally-open (closed during op- assistance in determining the source of unit operational prob-
eration) negative air pressure-activated switches. They moni- lems. The dual 7-segment LED display will display an error
tor the airflow (combustion air and flue products) through the code that may contain a letter and number. The error code may
heat exchanger via pressure taps located on the induced draft be used to assist in troubleshooting the unit.
blower and the coil front cover. These switches guard against
insufficient airflow (combustion air and flue products) through
the heat exchanger and/or blocked condensate drain condi-
tions.
36
MISCELLANEOUS
FAULT RECALL • Flue pipe system. Check for blockage and/or leakage.
Check the outside termination and the connections at
The ignition control is equipped with a momentary push-button and internal to the furnace.
switch that can be used to display the last six faults on the • Heat exchanger. Check for corrosion and/or buildup
dual 7-segment LED’s. The control must be in Standby Mode within the heat exchanger passageways.
(no thermostat inputs) to use the feature. Depress the switch
• Burners. Check for proper ignition, burner flame, and
for approximately 2 seconds. Release the switch when the
flame sense.
LED’s are turned off. The last six faults will be displayed most
• Drainage system. Check for blockage and/or leakage.
recent to least recent on the dual 7-segment LED’s.
Check hose connections at and internal to furnace.
NOTE: Consecutively repeated faults are stored a maximum of • Wiring. Check electrical connections for tightness and/
three times. Example: A clogged return air filter causes the or corrosion. Check wires for damage.
furnace limit to trip repeatedly. The control will only store this • Filters.
fault the first three consecutive times the fault occurs.
FILTERS
RESETTING FROM LOCKOUT
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 dis- GIVEN IN THE RECOMMENDED MINIMUM FILTER SIZE TABLE OR
played on the dual 7-segment display. If the furnace is in “lock- SPECIFICATION SHEET APPLICABLE TO YOUR MODEL.
out”, it will (or can be) reset in any of the following ways.
1. Automatic reset. The integrated control module will FILTER MAINTENANCE
automatically reset itself and attempt to resume normal
operations following a one hour lockout period. Improper filter maintenance is the most common cause of in-
2. Manual power interruption. Interrupt 115 volt power to adequate heating or cooling performance. Filters should be
the furnace. cleaned (permanent) or replaced (disposable) every two months
3. Manual thermostat cycle. Lower the thermostat so that or as required. When replacing a filter, it must be replaced with
there is no longer a call for heat for 1 -20 seconds then a filter of the same type and size.
reset to previous setting.
FILTER REMOVAL
NOTE: If the condition which originally caused the lockout still
Depending on the installation, differing filter arrangements can
exists, the control will return to lockout. Refer to the Diagnostic
be applied. Filters can be installed in either the central return
Chart for aid in determining the cause.
register or a side panel external filter rack (upflow only). A
MAINTENANCE media air filter or electronic air cleaner can be used as an alter-
nate filter. Follow the filter sizes given in the Recommended
Minimum Filter size table to ensure proper unit performance.
WARNING
To remove filters from an external filter rack in an upright upflow
TO AVOID ELECTRICAL SHOCK, INJURY OR DEATH,
installation, follow the directions provided with external filter
DISCONNECT ELECTRICAL POWER BEFORE PERFORMING ANY
rack kit.
MAINTENANCE. IF YOU MUST HANDLE THE IGNITER,
HANDLE WITH CARE. TOUCHING THE IGNITER ELEMENT HORIZONTAL UNIT FILTER REMOVAL
WITH BARE FINGERS, ROUGH HANDLING OR VIBRATION
COULD DAMAGE THE IGNITER RESULTING IN PREMATURE Filters in horizontal installations are located in the central re-
FAILURE. ONLY A QUALIFIED SERVICER SHOULD EVER
turn register or the ductwork near the furnace.
HANDLE THE IGNITER. To remove:
1. Turn OFF electrical power to furnace.
ANNUAL INSPECTION 2. Remove filter(s) from the central return register or
The furnace should be inspected by a qualified installer, or ser- ductwork.
vice agency at least once per year. This check should be per- 3. Replace filter(s) by reversing the procedure for removal.
formed at the beginning of the heating season. This will ensure 4. Turn ON electrical power to furnace.
that all furnace components are in proper working order and MEDIA AIR FILTER OR ELECTRONIC AIR CLEANER REMOVAL
that the heating system functions appropriately. Pay particular
attention to the following items. Repair or service as neces- Follow the manufacturer’s directions for service.
sary.
37
MISCELLANEOUS
BURNERS 9. Severe heat exchanger fouling is an indication of an
operational problem. Perform the checks listed in
Visually inspect the burner flames periodically during the heat- Startup Procedure and Adjustments to reduce the
ing season. Turn on the furnace at the thermostat and allow chances of repeated fouling.
several minutes for flames to stabilize, since any dislodged
dust will alter the flames normal appearance. Flames should BEFORE LEAVING AN INSTALLATION
be stable, quiet, soft, and blue (dust may cause orange tips
but they must not be yellow). They should extend directly • Cycle the furnace with the thermostat at least three
outward from the burners without curling, floating, or lifting off. times. Verify cooling and fan only operation.
Flames must not impinge on the sides of the heat exchanger • Review the Owner’s Manual with the homeowner and
firing tubes. discuss proper furnace operation and maintenance.
INDUCED DRAFT AND CIRCULATOR BLOWERS • Leave literature packet near furnace.
The bearings in the induced draft blower and circulator blower REPAIR AND REPLACEMENT PARTS
motors are permanently lubricated by the manufacturer. No fur-
ther lubrication is required. Check motor windings for accumu- • When ordering any of the listed functional parts, be sure
lation of dust which may cause overheating. Clean as neces- to provide the furnace model, manufacturing, and serial
sary. numbers with the order.
FLAME SENSOR (QUALIFIED SERVICER ONLY) • Although only functional parts are shown in the parts
list, all sheet metal parts, doors, etc. may be ordered by
Under some conditions, the fuel or air supply can create a
description.
nearly invisible coating on the flame sensor. This coating acts
as an insulator causing a drop in the flame sense signal. If the • Parts are available from your distributor.
flame sense signal drops too low the furnace will not sense Functional Parts List-
flame and will lock out. The flame sensor should be carefully Gas Valve Blower Motor
cleaned by a qualified servicer using emery cloth or steel wool. Gas Manifold Blower Wheel
Following cleaning, the flame sense signal should be as indi- Natural Gas Orifice Blower Mounting Bracket
cated in the Specifications Sheet. Propane Gas Orifice Blower Cutoff
Igniter Blower Housing
FLUE PASSAGES (QUALIFIED SERVICER ONLY) Flame Sensor Inductor
The heat exchanger flue passageways should be inspected at Rollout Limit Switch Heat Exchanger
the beginning of each heating season. If necessary, clean the Primary Limit Switch Auxiliary Limit Switch
passageways as outlined below. Pressure Switch Integrated Control Module
1. Turn OFF the electrical power and gas supply to the Induced Draft Blower Transformer
furnace. Door Switch
2. Disconnect the gas line and remove the burner/ manifold
assembly by removing the screws securing the assembly
to the partition panel.
3. Disconnect the flue pipe system from the induced draft
blower.
4. Remove the induced draft blower and collector box cover.
5. Clean the primary heat exchanger tubes using a wire
brush attached to a length of high grade stainless steel
cable, such as drain cleanout cable. Attach a variable
speed reversible drill to the other end of the cable. Slowly
rotate the cable with the drill and insert it into one of the
heat exchanger tubes. While reversing the drill, work
the cable in and out several times to obtain sufficient
cleaning. Repeat for each tube.
6. Clean residue from furnace using a vacuum cleaner.
7. Replace the parts removed in the previous steps in
reverse order.
8. Turn on electrical power and gas to furnace. Check for
leaks and proper unit operation.
38
ComfortNet™
Symptoms of Abnormal Operation (Legacy Diagnostic/Status
Fault Description Thermostat Only Possible Causes Corrective Actions Notes & Cautions
& ComfortNet™ Thermostat) LED Codes
Message Code
x Furnace fails to operate None x No 115 power to furnace INTERNAL EE x Manual disconnect switch OFF, x Assure 115 and 24 volt power to x Turn power OFF prior to
x Integrated control module LED display or no 24 volt power to FAULT door switch open or 24 volt wire furnace and integrated control repair.
provides no signal. integrated control improperly connected or loose module. x Replace integrated control
x ComfortNet™ thermostat “Call for module x Blown fuse or circuit breaker x Check integrated control module module fuse with 3A
Service” icon illuminated x Blown fuse or circuit x Integrated control module has an fuse (3A). Replace if necessary. automotive fuse.
x ComfortNet™ thermostat scrolls “Check breaker internal fault x Check for possible shorts in 115 x Read precautions in
Furnace” message x Integrated control and 24 volt circuits. Repair as “Electrostatic Discharge”
module has an internal necessary. section of manual.
fault x Replace bad integrated control x Replace integrated control
module. module with current
replacement parts.
x LED display indicates OP x Normal operation None None x Normal operation x None x Normal operation
OP
x Furnace fails to operate x Furnace lockout due to LOCKOUT E0 x Failure to establish flame. Cause x Locate and correct gas x Turn power OFF prior to
x Integrated control module LED display
E0 an excessive number of may be no gas to burners, front interruption. repair.
provides E0 error code. ignition “retries” (3 total) cover pressure switch stuck open, x Check front cover pressure x Igniter is fragile, handle
x ComfortNet™ thermostat “Call for bad igniter or igniter alignment, switch operation (hose, wiring, with care.
Service” icon illuminated. improper orifices, or contact operation). Correct if x Sand flame sensor with
x ComfortNet™ thermostat scrolls “Check coated/oxidized or improperly necessary. emery cloth.
Furnace” message. connected flame sensor. x Replace or realign igniter. x See “Vent/Flue Pipe”
x Loss of flame after establishment. x Check flame sense signal. Sand section for piping details.
Cause may be interrupted gas sensor if coated and/or oxidized.
supply, lazy burner flames x Check flue piping for blockage,
(improper gas pressure or proper length, elbows, and
restriction in flue and/or termination.
combustion air piping), front x Verify proper induced draft
cover pressure switch opening, or blower performance.
improper induced draft blower
performance.
x Furnace fails to operate. x Low stage pressure PS1 E1 x Low stage pressure switch x Replace low stage pressure x Turn power OFF prior to
E1
39
x Integrated control module LED display switch circuit is closed at CLOSED contacts sticking. switch. repair.
provides E1 error code. start of heating cycle. x Shorts in pressure switch circuit x Repair short in wiring. x Replace pressure switch
x ComfortNet™ thermostat “Call for wiring. with correct replacement
Service” icon illuminated. part.
x ComfortNet™ thermostat scrolls “Check
Furnace” message.
x Induced draft blower runs continuously x Low stage pressure PS1 OPEN E2 x Pressure switch hose blocked x Inspect pressure switch hose. x Turn power OFF prior to
with no further furnace operation.
E2 switch circuit is not pinched, or connected improperly. Repair/replace if necessary. repair.
x Integrated control module LED display closed. x Blocked flue and/or inlet air pipe, x Inspect flue and/or inlet air x Replace pressure switch
provides E2 error code. blocked drain system or weak piping for blockage, proper with correct replacement
x ComfortNet™ thermostat “Call for induced draft blower. length, elbows, and termination. part.
Service” icon illuminated. x Incorrect pressure switch set point x Check drain system. Correct as x Replace induced draft
x ComfortNet™ thermostat scrolls “Check or malfunctioning switch necessary. blower with correct
Furnace” message. contacts. x Check induced draft blower replacement part.
x Loose or improperly connected performance. Correct as
wiring. necessary.
x Correct pressure switch set point
or contact motion.
x Tighten or correct wiring
connection.
TROUBLESHOOTING CHART
ComfortNet™
Symptoms of Abnormal Operation Diagnostic/Status
Fault Description Thermostat Only Possible Causes Corrective Actions Notes & Cautions
(Legacy & ComfortNet™ Thermostat) LED Codes
Message Code
x Circulator blower runs continuously. No x Primary limit or HIGH E3 x Insufficient conditioned air over x Check filters and ductwork for x Turn power OFF prior to
furnace operation.
E3 auxiliary limit circuit is LIMIT the heat exchanger. Blocked blockage. Clean filters or repair.
x Integrated control module LED display open. OPEN filters, restrictive ductwork, remove obstruction. x See Specification Sheet
provides E3 error code. x Rollout limit circuit is improper circulator blower speed, x Check circulator blower speed applicable to your model
x ComfortNet™ thermostat “Call for open. or failed circulator blower motor. and performance. Correct speed for allowable rise range
Service” icon illuminated. x Flame rollout. or replace blower motor if and proper circulator
x ComfortNet™ thermostat scrolls “Check x Misaligned burners, blocked flue necessary. speed.
Furnace” message. and/or air inlet pipe, or failed x Check burners for proper x See "Vent/Flue Pipe"
induced draft blower. alignment. section for piping details.
x Loose or improperly connected x Check flue and air inlet piping
wiring. for blockage, proper length,
elbows, and termination. Correct
as necessary.
x Check induced draft blower for
proper performance. Replace if
necessary.
x Tighten or correct wiring
connection.
x Induced draft blower and circulator blower x Flame sensed with no IMPROPER E4 x Short to ground in flame sense x Correct short at flame sensor or x Turn power OFF prior to
TROUBLESHOOTING CHART
40
x ComfortNet™ thermostat displays
“Battery Power”.
x Normal furnace operation. x Flame sense micro amp WEAK E6 x Flame sensor is coated/oxidized. x Sand flame sensor if x Turn power OFF prior to
x Integrated control module LED display
E6 signal is low FLAME x Flame sensor incorrectly coated/oxidized. repair.
provides E6 error code. positioned in burner flame. x Inspect for proper sensor x Sand flame sensor with
x Lazy burner flame due to alignment. emery cloth.
improper gas pressure or x Check inlet air piping for x See "Vent/Flue Pipe"
combustion air. blockage, proper length, elbows, section for piping details.
and termination. x See rating plate for proper
x Compare current gas pressure to gas pressure.
rating plate. Adjust as needed.
x Furnace fails to operate. x Problem with igniter IGNITER E7 x Improperly connected igniter. x Check and correct wiring from x Turn power OFF prior to
x Integrated control module LED display
E7 circuit. FAULT x Shorted igniter. integrated control module to repair.
provides E7 error code. x Poor unit ground. igniter. x Replace igniter with
x ComfortNet™ thermostat “Call for x Igniter relay fault on integrated x Replace shorted igniter. correct replacement part.
Service” icon illuminated. control module. x Check and correct unit ground x Replace control with
x ComfortNet™ thermostat scrolls “Check wiring. correct replacement part.
Furnace” message. x Check igniter output from
control. Replace if necessary.
ComfortNet™
Symptoms of Abnormal Operation Diagnostic/Status
Fault Description Thermostat Only Possible Causes Corrective Actions Notes & Cautions
(Legacy & ComfortNet™ Thermostat) LED Codes
Message Code
x Furnace fails to operate on high stage; x High stage pressure PS2 E8 x High stage pressure switch x Replace high stage pressure x Turn power OFF prior to
furnace operates normally on low stage.
E8 switch circuit is closed at CLOSED contacts sticking. switch. repair.
x Integrated control module LED display start of heating cycle. x Shorts in pressure switch circuit x Repair short in wiring x Replace pressure switch
provides E8 error code. x Induced draft blower is wiring. with correct replacement
operating. part.
x Furnace is operating on
low stage only
x Furnace fails to operate on high stage; x High stage pressure PS2 OPEN E9 x Pressure switch hose blocked x Inspect pressure switch hose. x Turn power OFF prior to
furnace operates normally on low stage.
E9 switch circuit is not pinched, or connected Repair/replace if necessary. repair.
x Integrated control module LED display closed. improperly. x Inspect flue and/or inlet air x Replace pressure switch
provides E9 error code. x Induced draft blower is x Blocked flue and/or inlet air pipe, piping for blockage, proper with correct replacement
operating. blocked drain system or weak length, elbows, and termination. part.
x Furnace is operating on induced draft blower. Check drain system. Correct as x Replace induced draft
low stage only x Incorrect pressure switch set necessary. blower with correct
point or malfunctioning switch x Check induced draft blower replacement part.
contacts. performance. Correct as
x Loose or improperly connected necessary.
wiring. x Correct pressure switch set point
or contact motion.
x Tighten or correct wiring
connection.
x Furnace fails to operate. x Polarity of 115 volt AC REVERSED EA x Polarity of 115 volt AC power to x Review wiring diagram to x Turn power OFF prior to
x Integrated control module LED display
EA is reversed PLTY furnace or integrated module is correct polarity. repair.
provides EA error code. revered. x Verify proper ground. Correct if
x ComfortNet™ thermostat “Call for x Poor unit ground necessary.
Service” icon illuminated. x Check and correct wiring.
x ComfortNet™ thermostat scrolls “Check
Furnace” message.
x Furnace fails to operate. x Data not yet on network. NO NET d0 x Furnace does not contain any x Populate shared data set using x Turn power OFF prior to
d0
41
x Integrated control module LED display DATA shared data. memory card. repair
provides d0 error code. x Use memory card for the
x ComfortNet™ thermostat “Call for specific model.
Service” icon illuminated. x Insert memory card
x ComfortNet™ thermostat scrolls “Check BEFORE turning power
Furnace” message. ON. Memory card may be
removed after data is
loaded.
x Turn power OFF before
removing memory card.
x Error code will be cleared
once data is loaded.
TROUBLESHOOTING CHART
ComfortNet™
Symptoms of Abnormal Operation Diagnostic/Status
Fault Description Thermostat Only Possible Causes Corrective Actions Notes & Cautions
(Legacy & ComfortNet™ Thermostat) LED Codes
Message Code
x Operation different than expected or no x Invalid memory card INVALID d4 x Shared data set on memory card x Verify shared data set is correct x Turn power OFF prior to
operation.
d4 data. MC DATA has been rejected by integrated for the specific model. Re- repair
x Integrated control module LED display control module populate data using correct x Use memory card for the
provides d4 error code. memory card if required. specific model.
x ComfortNet™ thermostat “Call for x Insert memory card
Service” icon illuminated. BEFORE turning power
x ComfortNet™ thermostat scrolls “Check ON. Memory card may be
Furnace” message. removed after data is
loaded.
x Turn power OFF before
removing memory card.
x Error code will be cleared
once data is loaded.
x Furnace fails to operate. x Circulator blower motor MOTOR b0 x Loose wiring connection at x Tighten or correct wiring x Turn power OFF prior to
x Integrated control module LED display
b0 is not running when it NOT RUN circulator motor power leads or connection. repair
provides b0 error code. should be running. circulator motor power leads x Verify continuous circuit x Replace inductor with
x ComfortNet™ thermostat “Call for disconnected. through inductor. Replace if correct replacement part.
Service” icon illuminated. x Open circuit in inductor or loose open or short circuit. x Replace circulator motor
wiring connection at inductor (3/4
TROUBLESHOOTING CHART
x ComfortNet™ thermostat scrolls “Check x Check circulator blower motor. with correct replacement
Furnace” message. Hp and 1 Hp models only). Replace if necessary. part.
x Failed circulator blower motor.
x Furnace fails to operate. x Integrated control MOTOR b1 x Loose wiring connection at x Tighten or correct wiring x Turn power OFF prior to
x Integrated control module LED display
b1 module has lost COMM circulator motor control leads. connection. repair
provides b1 error code. communications with x Failed circulator blower motor. x Check circulator blower motor. x Replace circulator motor
x ComfortNet™ thermostat “Call for circulator blower motor. x Failed integrated control module. Replace if necessary. with correct replacement
Service” icon illuminated. x Check integrated control module. part.
x ComfortNet™ thermostat scrolls “Check Replace if necessary. x Replace integrated control
Furnace” message. module with correct
replacement part.
42
x Furnace fails to operate. x Circulator blower motor MOTOR b2 x Incorrect circulator blower motor x Verify circulator blower motor x Turn power OFF prior to
x Integrated control module LED display
b2 horse power in shared MISMATCH in furnace. horse power is the same repair
provides b2 error code. data set does not match x Incorrect shared data set in specified for the specific furnace x Replace motor with correct
x ComfortNet™ thermostat “Call for circulator blower motor integrated control module. model. Replace if necessary. replacement part.
Service” icon illuminated. horse power. x Verify shared data set is correct x Use memory card for the
x ComfortNet™ thermostat scrolls “Check for the specific model. Re- specific model
Furnace” message. populate data using correct x Insert memory card
memory card if required. BEFORE turning power
ON. Memory card may be
removed after data is
loaded.
x Turn power OFF before
removing memory card.
x Error code will be cleared
once shared data and
motor horse power match.
x Furnace operates at reduced performance. x Circulator blower motor MOTOR b3 x Blocked filters. x Check filters for blockage. x Turn power OFF prior to
x Airflow delivered is less than expected.
b3 is operating in a power, LIMITS x Restrictive ductwork. Clean filters or remove repair.
x Integrated control module LED display temperature, or speed x Undersized ductwork. obstruction.
provides b3 error code. limiting condition. x High ambient temperatures. x Check ductwork for blockage.
Remove obstruction. Verify all
registers are fully open.
x Verify ductwork is appropriately
sized for system. Resize/replace
ductwork if necessary.
x See "Product Description" and
"Location Requirements &
Considerations" for furnace
installation requirements.
ComfortNet™
Symptoms of Abnormal Operation Diagnostic/Status
Fault Description Thermostat Only Possible Causes Corrective Actions Notes & Cautions
(Legacy & ComfortNet™ Thermostat) LED Codes
Message Code
x Furnace fails to operate. x Circulator blower motor MOTOR b4 x Abnormal motor loading, sudden x Check filters, filter x Turn power OFF prior to
x Integrated control module LED display
b4 senses a loss of rotor TRIPS change in speed or torque, sudden grills/registers, duct system, and repair.
provides b4 error code. control. blockage of furnace air inlet or furnace air inlet/outlet for
x ComfortNet™ thermostat “Call for x Circulator blower motor outlet. blockages.
Service” icon illuminated. senses high current. x High loading conditions, blocked
x ComfortNet™ thermostat scrolls “Check filters, very restrictive ductwork,
Furnace” message. blockage of furnace air inlet or
outlet.
x Furnace fails to operate. x Circulator blower motor MTR LCKD b5 x Obstruction in circulator blower x Check circulator blower for x Turn power OFF prior to
x Integrated control module LED display
b5 fails to start 10 ROTOR housing. obstructions. Remove and repair
provides b5 error code. consecutive times. x Seized circulator blower motor repair/replace wheel/motor if x Replace motor with correct
x ComfortNet™ thermostat “Call for bearings. necessary. replacement part.
Service” icon illuminated. x Failed circulator blower motor. x Check circulator blower motor x Replace wheel with correct
x ComfortNet™ thermostat scrolls “Check shaft rotation and motor. replacement part.
Furnace” message. Replace motor if necessary.
x Furnace fails to operate. x Circulator blower motor MOTOR b6 x High AC line voltage to furnace. x Check power to furnace. Verify x Turn power OFF prior to
x Integrated control module LED display
b6 shuts down for over or VOLTS x Low AC line voltage to furnace. line voltage to furnace is within repair.
provides b6 error code. under voltage condition. x High ambient temperatures. the range specified on the
x ComfortNet™ thermostat “Call for x Circulator blower motor furnace rating plate.
Service” icon illuminated. shuts down due to over x See "Product Description" and
x ComfortNet™ thermostat scrolls “Check temperature condition on "Location Requirements &
Furnace” message. power module. Considerations" for furnace
installation requirements.
x Furnace fails to operate. x Circulator blower motor MOTOR b7 x Error with integrated control x Check integrated control module. x Turn power OFF prior to
x Integrated control module LED display
b7 does not have enough PARAMS module. Verify control is populated with repair.
provides b7 error code. information to operate x Motor has a locked rotor correct shared data set. See data x Replace with correct
x ComfortNet™ thermostat “Call for properly. condition. errors above for details. replacement part(s).
Service” icon illuminated. x Motor fails to start 40 x Check for locked rotor condition x Use memory card for the
consecutive times. (see error code above for
43
x ComfortNet™ thermostat scrolls “Check specific model.
Furnace” message. details).
x Furnace operates at reduced performance x Airflow is lower than LOW ID b9 x Blocked filters. x Check filters for blockage. x Turn power OFF prior to
or operates on low stage when high stage is
b9 demanded. AIRFLOW x Restrictive ductwork. Clean filters or remove repair.
expected. x Undersized ductwork. obstruction.
x Integrated control module LED display x Check ductwork for blockage.
provides b9 error code. Remove obstruction. Verify all
registers are fully open.
x Verify ductwork is appropriately
sized for system. Resize/replace
ductwork if necessary.
TROUBLESHOOTING CHART
STATUS CODES
O P NORMAL OPERATION
E 5 OPEN FUSE
b 2 BLOWER HP MIS-MATCH
F CONTINUOUS FAN
44
AIR FLOW DATA
Speed Selection Dip Switches Model Tap Low Stage High Stage Low Stage High Stage
Cool Cool Heat Heat
Cool Adjust Profile Heat
Selection Selection Selection Selection A 390 600 735 1050
Switches Switches Switches Switches B 520 800 805 1150
TAP 1 2 3 4 5 6 7 8 *DVC80703BX* C 650 1000 875 1250
D 780 1200 935 1350
A OFF OFF OFF OFF OFF OFF OFF OFF
A 520 800 945 1350
B ON OFF ON OFF ON OFF ON OFF B 715 1100 1015 1450
C OFF ON OFF ON OFF ON OFF ON *DVC80905CX* C 910 1400 1085 1550
D 1170 1800 1155 1650
D ON ON ON ON ON ON ON ON
A 553 850 1085 1550
Profiles Pre-Run Short-Run OFF Delay B 748 1150 1155 1650
A ------- -------- 60 sec/100%
*DVC81155CX* C 943 1450 1225 1750
D 1203 1850 1260 1800
B ------- 30 sec/50% 60 sec/100%
A 390 600 875 1250
C ------- 7.5 min/82% 60 sec/100%
*MVC80704BX* B 520 800 945 1350
D 30 sec/50% 7.5 min/82% 30 sec/50% C 715 1100 1015 1450
To set airflow: (1) Select model and desired
D 910 1400 1085 1550
high stage cooling airflow. Determine the corresponding tap A 520 800 1050 1500
( A, B, C, or D ). Set dip switches 1 and 2 to the appropriate
ON / OFF positions. (2) Select model and desired high stage *MVC80905CX* B 715 1100 1120 1600
heating airflow. Determine the corresponding tap ( A, B, C, or C 910 1400 1190 1700
D ). Set dip switches 7 and 8 to the appropriate ON / OFF D 1170 1800 1260 1800
positions. (3) Select the airflow adjustment factor taps A and
D are 1; Tap B is +10%; Tap C -10%. Set dip switches 3 and 4 A 520 800 1210 1725
to the appropriate ON / OFF positions.
To set Comfort Mode: Select desired Comfort Mode profile
B 715 1100*MVC81155CX*
1225 1750
(see profiles above). Set switches 5 and 6 to the appropriate
C 910 1400 1245 1775
ON / OFF positions. D 1175 1800 1260 1800
NOTE: Airflow data shown applies to legacy mode operation only. For a fully communicating system,
please see the outdoor unit’s installation instructions for cooling and pump heating airflow data. See
ComfortNet™ System - Airflow Consideration section for details.
DIP SWITCHES
Sw it ch DIP Sw itc h No.
Pu r p o s e Fu n ctio n
Ban k 1 2 3 4 5 6 7 8 9 10
90 s ec onds OFF OFF --- -- - --- --- -- - --- --- -- -
Heat OFF 120 s ec onds ON OFF --- -- - --- --- -- - --- --- -- -
Delay 150 s ec onds * OFF ON --- -- - --- --- -- - --- --- -- -
180 s ec onds ON ON --- -- - --- --- -- - --- --- -- -
S1
1-Stage T-s tat -- - --- OFF -- - --- --- -- - --- --- -- -
Thermos tat 2- Stage T-Stat -- - --- ON -- - --- --- -- - --- --- -- -
Setup 5- Min Delay -- - --- --- OFF --- --- -- - --- --- -- -
A uto Delay -- - --- --- ON --- --- -- - --- --- -- -
Bus BIA S BIA S ON* ON* --- -- - --- --- -- - --- --- -- -
S2
TERM Bus Termination -- - --- ON* -- - --- --- -- - --- --- -- -
A OFF OFF --- -- - --- --- -- - --- --- -- -
Cooling B ON OFF --- -- - --- --- -- - --- --- -- -
Speed Tap C OFF ON --- -- - --- --- -- - --- --- -- -
D* ON ON --- -- - --- --- -- - --- --- -- -
S3
Normal* -- - --- OFF OFF --- --- -- - --- --- -- -
A djus t 10% -- - --- ON OFF --- --- -- - --- --- -- -
Taps -10% -- - --- OFF ON --- --- -- - --- --- -- -
Normal -- - --- ON ON --- --- -- - --- --- -- -
A* -- - --- --- -- - OFF OFF -- - --- --- -- -
Ramping B -- - --- --- -- - ON OFF -- - --- --- -- -
Prof iles C -- - --- --- -- - OFF ON -- - --- --- -- -
D -- - --- --- -- - ON ON -- - --- --- -- -
S4
A -- - --- --- -- - --- --- OFF OFF --- -- -
Heating B* -- - --- --- -- - --- --- ON OFF --- -- -
Speed Tap C -- - --- --- -- - --- --- OFF ON --- -- -
D -- - --- --- -- - --- --- ON ON --- -- -
Dis abled* -- - --- --- -- - --- --- -- - --- OFF Unus ed
S5 DEHUM
Enabled -- - --- --- -- - --- --- -- - --- ON Unus ed
(*Indic ates f ac tory s etting)
--- Not applic able
45
*MVC8_AA WIRING DIAGRAM
TO
115 VAC/ 1
POWER SUPPLY W ITH
JUNCTION BOX
PROTECTION DEVICE
24V HUM. BK
YL
C C WH
NO NO
YL
2 1
TO 115VAC/ 1 Ø /60 HZ POWER SUPPLY WITH
YL OVERCURRENT PROTE CTION DEVICE
HI 3 WH
BK
GND
C 2
WH
PM 1
DISCONNECT
CHASSIS GROUND
PU PU RD DOOR
OR
SWITCH
YL
JUNCTION BOX
DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT.
MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY
INDUCTOR COIL
PU 70kBTU,90kBTU,
YL
115kBTU MODELS
ONLY
INDOOR
3 AIR
2 RD CIRCULATOR
GN
BLWR
1
WH
GND
CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
EAC
BLWR
BR
NEUTRAL
24 V HUMIDIFIER
WH
1
W2
W1
G
C
R
3A
DEHUM
Y2
Y1
IGN NEUTRAL
RD
HOT SURFACE
DIAGNOSTIC SEE YL IGNITER
BK
LED'S
NOTE 5 FS
3 2 1 RD
FLAME SENSOR
RD
WH
HEAT OFF
DELAY
12 11 10 RD 40 VA
FUSE 3 A
DIP SWITCHES
1
YL
24V THERMOSTAT CONNECTIONS
HLO (10)
DELAY Y1
2
BL
3 PSO (7)
ADJUST
4 LOW FIRE PRESS.
COOL 24V HUM. SWITCH
W1 PS1 (2) C
NO
OR W2
LINE PS2 (12) NO
1 TO
BK Y2 MICRO
C
HIGH FIRE
2
FS PRESS. SWTICH
3
G
EAC
WH 4 O HLI (1)
NEUTRAL
WH
HUM
5
DEHUM
MVL (13)
PM
24V HUM.
MVH (14)
RD HI
C MVC (8)
ECM M TR BL
WH C
H A RNE S S WH GAS
GY
GND (5)
BK VALVE
BK TR (11) GND
4
BK BK
3
5 BK
2
TO GND (4)
1
4 WH R
3 GR + VDC (1)
2 GND
1 PK BLOWER INDOOR
RX (2)
COMPARTMENT AIR
TO CIRCULATOR
DOOR SWITCH TX (3)
MICRO BLWR
(OPEN WHEN
DOOR OPEN)
CIRCULATOR INDUCTOR COIL
BLOW ER 70kBTU,90kBTU, INTEGRATED CONTROL MODULE
115kBTU MODELS
ONLY HUMIDIFIER
NOTES:
COLOR CODES: LOW VOLTAGE (24 V) EQUIPMENT GND
1. SET HEAT ANTICIPATOR ON RO OM THERMOSTAT AT 0.7 AMPS. PK PINK
LOW VOLTAGE FIE LD FIELD GND
2. MANUFACTURER'S SPECIFIED REPLACEMENT PARTS MUST BE BR BRO W N
USED WHEN SERVICING.
WH WHITE HI VOLTAGE (115 V) FIELD SPLICE
3. IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE
FURNACE MUST BE REPLACED, IT MUST BE REPLACED WITH
BL BLUE
GY GRAY H I VOLTAGE FI E LD
WIRING MATERIAL HAVING A TEMPERATURE RATING OF AT SWITCH (TEMP.)
LEAST 105°C. USE COPPER CONDUCTORS ONLY. RD RED JUNCTION
4. UNIT MUST BE PERMANENTLY GROUNDED AND CONFORM TO YL YELLOW IGNITER
N.E.C. AND LOCAL CODES. O R OR ANGE TE R MINAL
5. TO RECALL THE LAST 6 FAULTS, MOST RECENT TO LEAST PU PURPLE INTERNAL TO SWITC H (PRESS.)
RECENT, DEPRESS SWITCH FOR MORE THAN 2 SECONDS WHILE
GN GREEN INTEGRATED CONTROL OVERC U R R ENT
IN STANDBY (NO THERMOSTAT INPUTS)
BK BLACK PLUG CONNECTION PROT. D EVICE
0140F00606 REV. A
Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.
46
*MVC8_AB, *DVC8_AA WIRING DIAGRAM
TO
GND 115 VAC/ 1 Ø /60 HZ
POWER SUPPLY WITH
JUNCTION BOX
ID BLOWER TWO-STAGE PRESSURE OVERCURRENT
SWITCH ASSEMBLY PROTECTION DEVICE
L
BK WARNING:DISCONNECT
24V HUM. HIGH FIRE POWER BEFORE
HOT YL PRESSURE SERVICING. WIRING
LOW FIRE N
SURFACE PRESSURE C C SWITCH WH TO UNIT MUST BE
IGNITER SWITCH NO NO DISCONNECT PROPERLY POLARIZED
2 CIRCUIT
AND GROUNDED.
YL
2 1 CONNECTOR
TO 115VAC/ 1 Ø /60 HZ POWER SUPPLY WITH
YL
HI 2 WH OVERCURRENT PROTECTION DEVICE
BK
L GND N
TWO STAGE C 3 BL FLAME WARNING:
WH
CHASSIS GROUND
CONTROLS
PU PU RD DOOR
OR
SWITCH
YL
JUNCTION BOX
AUTO RESET PRIMARY
LIMIT CONTROL INDUCTOR COIL
DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT.
PU
MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY
70kBTU,90kBTU,
YL
115kBTU MODELS
INDUCED ONLY
INDOOR
3 WH DRAFT AIR
2 RD CIRCULATOR
BLOWER
GN
BLWR
1 BK
GND
WH
BURNER COMPARTMENT GND
LINE NEUTRAL
CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
EAC NEUTRAL
BLWR
BR
24 V HUMIDIFIER
WH
DEHUM
Y2
W2
W1
3A
Y1
R
2
C
O
IGN NEUTRAL
RD
HOT SURFACE
DIAGNOSTIC SEE YL IGNITER
BK
LED'S
NOTE 5 FS
3 2 1 RD
FLAME SENSOR
WH
HEAT OFF
DELAY
12 11 10 RD 40 VA
FUSE 3 A TRANSFORMER
DIP SWITCHES
UNUSED TH (4)
DEHUM 15 14 13 BR R
24 VAC AUTO RESET PRIMARY
BL AUTO RESET AUXILIARY LIMIT LIMIT CONTROL
HEAT
WH TO +VDC CONTROLS
4 CIRCUIT MOTOR
1
HIGH VOLTAGE!
YL HLO (10)
CONNECTOR
DELAY Y1
2 RD
BL
PSO (7)
24V THERMOSTAT CONNECTIONS
3
ADJUST 24
LOW FIRE PRESS.
4 VAC SWITCH
COOL 24V HUM.
W1 PS1 (2) C
115
VAC NO
OR W2
LINE
40 VA PS2 (12) NO
5 CIRCUIT CONNECTOR
1 TO
BK TRANSFORMER Y2 MICRO
C
HIGH FIRE
2
FS PRESS. SWTICH MANUAL RESET ROLLOUT
3 G LIMIT CONTROLS
EAC
WH 4
NEUTRAL O HLI (1)
HUM
WH 5
DEHUM
MVL (13)
PM
24V HUM.
MVH (14)
RD HI
C MVC (8)
ECM MTR BL
WH C
HARNESS WH GAS
GY
GND (5)
VALVE
BK BK GND
BK TR (11)
4
BK
3
5 BK
2
TO GND (4)
1
4 WH R
3 GR + VDC (1)
2 GND
1 PK BLOWER INDOOR
RX (2)
COMPARTMENT AIR
TO CIRCULATOR
DOOR SWITCH TX (3)
MICRO BLWR
(OPEN WHEN
DOOR OPEN)
CIRCULATOR INDUCTOR COIL
BLOWER 70kBTU,90kBTU, INTEGRATED CONTROL MODULE
115kBTU MODELS
ONLY HUMIDIFIER
NOTES:
COLOR CODES: LOW VOLTAGE (24V) EQUIPMENT GND
1. SET HEAT ANTICIPATOR ON ROOM THERMOSTAT AT 0.7 AMPS. PK PINK
LOW VOLTAGE FIELD FIELD GND
2. MANUFACTURER'S SPECIFIED REPLACEMENT PARTS MUST BE BR BROWN
USED WHEN SERVICING.
WH WHITE HI VOLTAGE (115V) FIELD SPLICE
3. IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE
FURNACE MUST BE REPLACED, IT MUST BE REPLACED WITH
BL BLUE
HI VOLTAGE FIELD
WIRING MATERIAL HAVING A TEMPERATURE RATING OF AT GY GRAY SWITCH (TEMP.)
LEAST 105 C. USE COPPER CONDUCTORS ONLY. RD RED JUNCTION
4. UNIT MUST BE PERMANENTLY GROUNDED AND CONFORM TO YL YELLOW IGNITER
N.E.C. AND LOCAL CODES. OR ORANGE TERMINAL
5. TO RECALL THE LAST 6 FAULTS, MOST RECENT TO LEAST PU PURPLE INTERNAL TO SWITCH (PRESS.)
RECENT, DEPRESS SWITCH FOR MORE THAN 2 SECONDS WHILE
GN GREEN INTEGRATED CONTROL OVERCURRENT
IN STANDBY (NO THERMOSTAT INPUTS)
BK BLACK PLUG CONNECTION PROT. DEVICE
0140F00660 REV. A
Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.
47
Goodman Manufacturing Company, L.P.
5151 San Felipe, Suite 500, Houston, TX 77056
www.goodmanmfg.com
© 2009-2010 Goodman Manufacturing Company, L.P.
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