- Computers & electronics
- Computer components
- System components
- Processors
- Allied Air
- A97USMV
- Installation Guide
advertisement
INSTALLATION INSTRUCTIONS
A97USMV
Warm Air Gas Furnace
Upflow/Horizontal Left and Right Air Discharge
This manual must be left with the homeowner for future reference.
This is a safety alert symbol and should never be ignored. When you see this symbol on labels or in manuals, be alert to the potential for personal injury or death.
CAUTION
As with any mechanical equipment, personal injury can result from contact with sharp sheet metal edges. Be careful when you handle this equipment.
WARNING
Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Installation and service must be performed by a licensed professional installer (or equivalent), service agency or the gas supplier.
NOTICE
A thermostat is not included and must be ordered separately.
• A Comfort Sync™ thermostat must be used in communicating applications.
• In non-communicating applications, a traditional non-communication thermostat may be used.
In all cases, setup is critical to ensure proper system operation.
Field wiring for both communicating and noncommunicating applications is illustrated in these instructions.
Unit Dimensions ...................................................................................... 2
Parts Arrangement................................................................................... 3
Gas Furnace ............................................................................................ 4
Shipping and Packing List ....................................................................... 4
Safety Information ................................................................................ 4
Use of Furnace as a Construction Heater ............................................... 5
General .................................................................................................... 6
Setting Equipment ................................................................................... 6
Filters ......................................................................................................11
Duct System ...........................................................................................11
Pipe and Fittings Specifications ............................................................. 12
Joint Cementing Procedure ................................................................... 13
Venting Practices ................................................................................... 14
Vent Piping Guidelines .......................................................................... 14
Gas Piping ............................................................................................ 28
TABLE OF CONTENTS
Electrical .............................................................................................31
Integrated Control .................................................................................. 40
Blower Motor Performance .................................................................... 48
Unit Start Up .......................................................................................... 54
Gas Pressure Measurement.................................................................. 55
High Altitude Information ....................................................................... 56
Proper Combustion................................................................................ 56
Other Unit Adjustments.......................................................................... 59
Heating Sequence of Operation ............................................................ 60
Service .............................................................................................62
Planned Service .................................................................................... 64
Integrated Control Diagnostic Codes ..................................................... 65
Configuring Unit Size Codes ................................................................. 66
Troubleshooting ..................................................................................... 67
Repair Parts List .................................................................... 73
*P507028-03*
(P) 507028-03
Manufactured By
Allied Air Enterprises LLC
A Lennox International, Inc. Company
215 Metropolitan Drive
West Columbia, SC 29170
507028-03 Issue 1622 Page 1 of 74
Unit Dimensions - inches (mm)
* NOTE - C/D20 size units that require second stage air volumes over 1800 cfm (850 L/S) must have one of the following:
1. Single side return air with transition, to accommodate
20 x 25 x 1 in. (508 x 635 x 25 mm) air filter.
2. Single side return air with optional RAB Return Air Base
3. Bottom return air.
4. Return air from both sides.
5. Bottom and one side return air.
See Blower Performance Tables for additional information.
* Optional External Side Return Air Filter Kit is not for use with the optional RAB Return Air Base.
Page 2 of 74 Issue 1622 507028-03
A97USMV Exploded View
507028-03
Figure 1
Issue 1622 Page 3 of 74
A97USMV Gas Furnace
The A97USMV Category IV gas furnace is equipped with a variable capacity, varable speed integrated control. Each
A97USMV is shipped ready for installation in the upflow, horizontal left air discharge or horizontal right air discharge position.
The furnace is equipped for installation in natural gas applications only. A change over kit must be ordered for
LP/propane applications.
The A97USMV must be installed only as a Direct Vent gas central furnace
NOTE: In Direct Vent installations, combustion air is taken from outdoors and flue gases are discharged outdoors. See
Figure 2 for applications including roof termination.
Safety Information
DANGER
DANGER OF EXPLOSION!
There are circumstances in which odorant used with
LP/Propane gas can lose its scent. In case of a leak,
LP/Propane gas will settle close to the floor and may be difficult to smell. An LP/Propane leak detector should be installed in all LP applications.
WARNING
Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Installation and service must be performed by a licensed professional installer (or equivalent), service agency or the gas supplier.
Figure 2
Shipping and Packing List
1 - Assembled A97USMV unit.
1 - Bag assembly containing the following:
1 - Snap bushing
1 - Snap Plug
1 - Wire tie
1 - Condensate trap
1 - Condensate trap cap
1 - Condensate trap cap clamp
1 - 3/4” Threaded PVC street elbow
Check equipment for shipping damage. If you find any damage, immediately contact the last carrier.
Please refer to specification sheets for available accessories.
CAUTION
As with any mechanical equipment, personal injury can result from contact with sharp sheet metal edges. Be careful when you handle this equipment.
Use only the type of gas approved for use with this furnace.
Refer to unit nameplate.
Building Codes
In the USA, installation of gas furnaces must conform with local building codes. In the absence of local codes, units must be installed according to the current National Fuel
Gas Code (ANSI Z223.1/NFPA 54). The National Fuel Gas
Code is available from the American National Standards
Institute, Inc., 11 West 42nd Street, New York, NY 10036 .
Installed Locations
In Canada, installation must conform with current National
Standard of Canada CSA-B149 Natural Gas and Propane
Installation Codes, local plumbing or waste water codes and other applicable local codes.
The furnace is designed for installation clearances to combustible material as listed on the unit nameplate and in the tables in Figures 10 and 11. Accessibility and service clearances must take precedence over fire protection clearances.
NOTE: For installation on combustible floors, the furnace shall not be installed directly on carpeting, tile, or other combustible material other than wood flooring.
Page 4 of 74 Issue 1622 507028-03
For installation in a residential garage, the furnace must be installed so that the burner(s) and the ignition source are located no less than 18 inches (457 mm) above the floor.
The furnace must be located or protected to avoid physical damage by vehicles. When a furnace is installed in a public garage, hangar, or other building that has a hazardous atmosphere, the furnace must be installed according to recommended good practice requirements and current
National Fuel Gas Code or CSA B149 standards.
Note: Furnace must be adjusted to obtain a temperature rise (100% percent capacity) within the range(s) specified on the unit nameplate. Failure to do so may cause erratic limit operation and may also result in premature heat exchanger failure.
This furnace must be installed so that its electrical components are protected from water.
Installed in Combination with a Cooling Coil
When this furnace is used with cooling units, it shall be installed in parallel with, or on the upstream side of, cooling units to avoid condensation in the heating compartment.
With a parallel flow arrangement, a damper (or other means to control the flow of air) must adequately prevent chilled air from entering the furnace. If the damper is manually operated, it must be equipped to prevent operation of either the heating or the cooling unit, unless it is in the full HEAT or COOL setting. See Figure 3.
Heating Unit Installed Parallel to Air Handler Unit
Heating Unit Installed Upstream of Cooling Unit
Figure 3
When installed, this furnace must be electrically grounded according to local codes. In addition, in the United States, installation must conform with the current National Electric
Code, ANSI/NFPA No. 70. The National Electric Code
(ANSI/NFPA No. 70) is available from the following address:
National Fire Protection Association
1 Battery March Park
Quincy, MA 02269
NOTE: This furnace is designed for a minimum continuous return air temperature of 60°F (16°C) or an intermitent operation down to 55°F (13°C) dry blub for cases where a night setback thermostat is used. Return air temperature must not exceed 85°F (29°C)dry bulb.
In Canada, all electrical wiring and grounding for the unit must be installed according to the current regulations of the Canadian Electrical Code Part I (CSA Standard C22.1) and/or local codes.
CAUTION
Do Not set thermostat below 60° F (16° C) in heating mode. Setting thermostat below 60° F (16° C) reduces the number of heating cycles. Damage to the unit may occur that is not covered by the warranty.
The A97USMV furnace may be installed in alcoves, closets, attics, basements, garages, crawl spaces and utility rooms.
This furnace design has not been CSA Certified for installation in mobile homes, recreational vehicles, or outdoors.
Use of Furnace as Construction Heater
These units are not recommended for use as a construction heater during any phase of construction. Very low return air temperature, harmful vapors and operation of the unit with clogged or misplaced filters will damage the unit.
These units may be used for heating of buildings or structures under construction, if the following conditions are met:
• The vent system must be permanently installed per these installation instructions.
• A room thermostat must control the furnace. The use of fixed jumpers that will provide continuous heating is not allowed.
• The return air duct must be provided and sealed to the furnace.
• Return air temperature range between 60°F (16°C) and
80°F (27°C) must be maintained.
• Air filters must be installed in the system and must be maintained during construction.
507028-03 Issue 1622 Page 5 of 74
• Air filters must be replaced upon construction completion.
• The input rate and temperature rise must be set per the furnace rating plate.
• One hundred percent (100%) outdoor air must be provided for combustion air requirements during construction.
• The furnace heat exchanger, components, duct system, air filters and evaporator coils must be thoroughly cleaned following final construction cleanup.
• All furnace operating conditions (including ignition, input rate, temperature rise and venting) must be verified according to these installation instructions.
• When the furnace is installed in an attic or other insulated space, keep insulation away from the furnace.
• When the furnace is installed in an unconditioned space, consider provisions required to prevent freezing of condensate drain system.
Installation – Setting Equipment
WARNING
Do not install the furnace on its front or its back. See
Figure 4.
General
WARNING
The State of California has determined that this product may contain or produce a chemical or chemicals, in very low doses, which may cause serious illness or death. It may also cause cancer, birth defects or other reproductive harm.
WARNING
Do not connect the return air ducts to the back of the furnace. Doing so will adversely affect the operation of the safety control devices, which could result in personal injury or death.
CAUTION
These units should not be installed in areas normally subject to freezing temperatures.
These instructions are intended as a general guide and do not supersede local codes in any way. Consult authorities having jurisdiction before installation.
In addition to the requirements outlined previously, the following general recommendations should be considered when installing one of these furnaces:
• Place the furnace as close to the center of the air distribution system as possible. The furnace should also be located close to the vent termination point.
Upflow Applications
This gas furnace can be installed as shipped in the upflow position. Refer to Figure 10 for clearances.
Select a location that allows for the required clearances that are listed on the unit nameplate. Also consider gas supply connections, electrical supply, vent connection, condensate trap and drain connections, and installation and service clearances (24 inches [610 mm] at unit front). The unit must be level from side to side, for proper operation. It is recommended to tilt the unit slightly toward the drain to insure proper drainage. See Figure 5.
Figure 4
Page 6 of 74 Issue 1622 507028-03
SETTING EQUIPMENT
UNIT MUST BE LEVEL SIDE TO SIDE IN ALL APPLICATIONS FOR PROPER OPERATION.
A SLIGHT TILT TOWARD THE DRAIN IS RECOMMENDED FOR PROPER DRAINAGE.
TILT THE UNIT SLIGHTLY (MAX. 1/2”) FROM BACK TO FRONT TO AID IN THE DRAINING OF THE HEAT EXCHANGER.
Figure 5
507028-03 Issue 1622 Page 7 of 74
Side Return Air
(with transition and filter)
Removing the Bottom Panel
Remove the two screws that secure the bottom cap to the furnace. Pivot the bottom cap down to release the bottom panel. Once the bottom panel has been removed, reinstall the bottom cap. See Figure 7.
Removing the Bottom Panel
Figure 6
A97USMV applications which include side return air and a condensate trap installed on the same side of the cabinet
(trap can be installed remotely within 5 feet) require either a return air base or field fabricated transition to accommodate an optional IAQ accessory taller than 14.5”. See Figure 6.
Optional Return Air Base
(Upflow Applications Only)
Figure 7
FRONT VIEW SIDE VIEW
1
NOTE: Optional side return air filter kits are not for use with return air base.
Both the unit return air opening and the base return air opening must be covered by a single plenum or IAQ cabinet.
Minimum unit side return air opening dimensions for units requiring 1800 cfm or more of air (W x H): 23 x 11 in. (584 x 279 mm).
The opening can be cut as needed to accommodate plenum or IAQ cabinet while maintaining dimensions shown.
Side return air openings must be cut in the field. There are cutting guides stenciled on the cabinet for the side return air opening.
The size of the opening must not extend beyond the markings on the furnace cabinet.
² To minimize pressure drop, the largest opening height possible (up to 14 inches) is preferred.
Figure 8
Page 8 of 74 Issue 1622 507028-03
NOTE: Units with 1/2 hp blower motor are equipped with three flexible legs and one rigid leg. The rigid leg is equipped with a shipping bolt and a flat white plastic washer (rather than the rubber mounting grommet used with a flexible mounting leg).
See Figure 9. The bolt and washer must be removed before the furnace is placed into operation.
After the bolt and washer have been removed, the rigid leg will not touch the blower housing.
Units with 1/2 HP
Blower Motor
Installation Clearances
Figure 9
Allow for clearances to combustible materials as indicated on the unit nameplate. Minimum clearances for closet or alcove installations are shown in Figure 10.
WARNING
Blower access panel must be securely in place when blower and burners are operating. Gas fumes, which could contain carbon monoxide, can be drawn into living space resulting in personal injury or death.
WARNING
Improper installation of the furnace can result in personal injury or death. Combustion and flue products must never be allowed to enter the return air system or air in the living space. Use sheet metal screws and joint tape to seal return air system to furnace.
In platform installations with furnace return, the furnace should be sealed airtight to the return air plenum. A door must never be used as a portion of the return air duct system. The base must provide a stable support and an airtight seal to the furnace. Allow absolutely no sagging, cracks, gaps, etc.
For no reason should return and supply air duct systems ever be connected to or from other heating devices such as a fireplace or stove, etc. Fire, explosion, carbon monoxide poisoning, personal injury and/or property damage could result.
* Front clearance in alcove installation must be 24 in. (610 mm).
Maintain a minimum of 24 in. (610 mm) for front service access.
† Allow proper clearances to accommodate condensate trap installation.
‡ For installations on a combustible floor, do not install the furnace directly on carpeting, tile or other combustible materials other than wood flooring.
Figure 10
Return Air – Upflow Units
Return air can be brought in through the bottom or either side of the furnace installed in an upflow application. If the furnace is installed on a platform with bottom return, make an airtight seal between the bottom of the furnace and the platform to ensure that the furnace operates properly and safely. The furnace is equipped with a removable bottom panel to facilitate installation.
Markings are provided on both sides of the furnace cabinet for installations that require side return air. Cut the furnace cabinet at the maximum dimensions shown on page 2.
507028-03 Issue 1622 Page 9 of 74
Setting and Upflow Unit
When the side return air inlets are used in an upflow application, it may be necessary to install shims on the bottom of the furnace.
Horizontal Applications
The A97USMV furnace can be installed in horizontal applications with either right or left hand air discharge.
Refer to Figure 11 for clearances in horizontal applications.
Horizontal Application
Installation Clearances
Right-Hand Discharge
NOTE: Heavy gauge sheet metal straps may be used to suspend the unit from roof rafters or ceiling joists. When straps are used to suspend the unit in this way, support must be provided for both the ends. The straps must not interfere with the plenum or exhaust piping installation.
Cooling coils and supply and return air plenums must be supported separately.
NOTE: When the furnace is installed on a platform in a crawlspace, it must be elevated enough to avoid water damage and to allow the evaporator coil to drain.
Typical Horizontal Application
Figure 12
* Front clearance in alcove installation must be 24 in. (610 mm).
Maintain a minimum of 24 in. (610 mm) for front service access.
** An 8” service clearance must be maintained below the unit to provide for servicing of the condensate trap. Unless the trap is mounted remotely.
‡ For installations on a combustible floor, do not install the furnace directly on carpeting, tile or other combustible materials other than wood flooring.
Figure 11
Suspended Installation of Horizontal Unit
This furnace may be installed in either an attic or a crawlspace. Either suspend the furnace from roof rafters or floor joists, as shown in Figure 12 or install the furnace on a platform, as shown in Figure 13. A horizontal suspension kit (51W10) may be ordered or use equivalent.
Platform Installation of Horizontal Unit
1. Select location for unit keeping in mind service and other necessary clearances. See Figure 11.
2. Construct a raised wooden frame and cover frame with a plywood sheet. If unit is installed above finished space, fabricate an auxiliary drain pan to be installed under unit.
Set unit in drain pan as shown in Figure 13. Leave 8 inches for service clearance below unit for condensate trap, unless trap is installed remotely.
3. Provide a service platform in front of unit. When installing the unit in a crawl space, a proper support platform may be created using cement blocks.
4. Route auxiliary drain line so that water draining from this outlet will be easily noticed by the homeowner.
5. If necessary, run the condensate line into a condensate pump to meet drain line slope requirements. The pump must be rated for use with condensing furnaces. Protect the condensate discharge line from the pump to the outside to avoid freezing.
6. Continue with exhaust, condensate and intake piping installation according to instructions.
Page 10 of 74 Issue 1622 507028-03
* Gas Connector may be used for Canadian installation if acceptable by local authority having jurisdiction.
Figure 13
Return Air - Horizontal Applications
Return air must be brought in through the end of a furnace installed in the horizontal position. The furnace is equipped with a removable bottom panel to facilitate installation. See
Figure 7.
Filters
This unit is not equipped with a filter or rack. A field provided filter is required for the unit to operate properly. Table 1 lists recommended filter sizes.
A filter must be in place when the unit is operating!
NOTE: In upflow applications where side return air filter is installed on same side as the condensate trap, make sure that clearance is maintained to ensure future access to the filter access panel.
Duct System
Use industry approved standards to size and install the supply and return air duct system. This will result in a quiet and low static system that has uniform air distribution.
NOTE: Operation of this furnace in heating mode (indoor blower operating at selected heating speed) with an external static pressure which exceeds 0.8 inches w.c. may result in erratic limit operation.
Supply Air Plenum
If the furnace is installed without a cooling coil, a removable access panel should be installed in the supply air duct. The access panel should be large enough to permit inspection
(by reflected light) of the heat exchanger for leaks after the furnace is installed. If present, this access panel must always be in place when the furnace is operating and it must not allow leaks into or from the supply air duct system.
Return Air Plenum
Return air must not be drawn from a room where this furnace, or any other gas fueled appliance (i.e., water heater), or carbon monoxide producing device (i.e., wood fireplace) is installed. When return air is drawn from a room, a negative pressure is created in the room. If a gas appliance is operating in a room with negative pressure, the flue products can be pulled back down the vent pipe and into the room. This reverse flow of the flue gas may result in incomplete combustion and the formation of carbon monoxide gas. This toxic gas might then be distributed throughout the house by the furnace duct system.
Return air can be brought in through the bottom or either side of the furnace. If a furnace with bottom return air is installed on a platform, make an airtight seal between the bottom of the furnace and the platform to ensure that the unit operates properly and safely. Use fiberglass sealing strips, caulking, or equivalent sealing method between the plenum and the furnace cabinet to ensure a tight seal. If a filter is installed, size the return air duct to fit the filter frame.
Table 1
507028-03 Issue 1622 Page 11 of 74
Pipe and Fittings Specifications
All pipe, fittings, primer and solvent cement must conform with American National Standard Institute and the American
Society for Testing and Materials (ANSI/ASTM) standards.
The solvent shall be free flowing and contain no lumps, undissolved particles or any foreign matter that adversely affects the joint strength or chemical resistance of the cement. The cement shall show no gelation, stratification, or separation that cannot be removed by stirring. Refer to
Table 2 for approved piping and fitting materials.
PIPING AND FITTINGS SPECIFICATIONS
Schedule 40 PVC (Pipe)
Schedule 40 PVC (Cellular Core Pipe)
Schedule 40 PVC (Fittings)
Schedule 40 CPVC (Pipe)
Schedule 40 CPVC (Fittings)
SDR-21 PVC or SDR-26 PVC (Pipe)
SDR-21 CPVC or SDR-26 CPVC (Pipe)
Schedule 40 ABS Cellular Core DWV
(Pipe)
Schedule 40 ABS (Pipe)
Schedule 40 ABS (Fittings)
ABS-DWV (Drain Waste & Vent)
(Pipe & Fittings)
PVC-DWV (Drain Waste & Vent)
Pipe & Fittings)
D1785
F891
D2466
F441
F438
D2241
F442
F628
D1527
D2468
D2661
D2665
PRIMER & SOLVENT CEMENT
PVC & CPVC Primer
PVC Solvent Cement
CPVC Solvent Cement
ABS Solvent Cement
PVC/CPVC/ABS All Purpose Cement For
Fittings & Pipe of the same material
ABS to PVC or CPVC Transition Solvent
Cement
CANADA PIPE & FITTING & SOLVENT
CEMENT
PVC & CPVC Pipe and Fittings
PVC & CPVC Solvent Cement
ABS to PVC or CPVC Transition Cement
POLYPROPYLENE VENTING SYSTEM
PolyPro® by Duravent
InnoFlue® by Centrotherm
ASTM
SPECIFICATION
F656
D2564
F493
D2235
D2564, D2235,
F493
D3138
MARKING
ULCS636
ULC-S636
ULC-S636
Table 2
CAUTION
Solvent cements for plastic pipe are flammable liquids and should be kept away from all sources of ignition.
Do not use excessive amounts of solvent cement when making joints. Good ventilation should be maintained to reduce fire hazard and to minimize breathing of solvent vapors. Avoid contact of cement with skin and eyes.
IMPORTANT
The exhaust and intake connections are made of PVC.
Use PVC primer and solvent cement when using PVC vent pipe. When using ABS vent pipe, use transitional solvent cement to make connections to the PVC fittings in the unit.
Use PVC primer and solvent cement or ABS solvent cement meeting ASTM specifications, refer to Table 2. As an alternate, use all purpose cement, to bond ABS, PVC, or
CPVC pipe when using fittings and pipe made of the same materials. Use transition solvent cement when bonding ABS to either PVC or CPVC.
Low temperature solvent cement is recommended. Metal or plastic strapping may be used for vent pipe hangers.
Uniformly apply a liberal coat of PVC primer for PVC.
Canadian Applications Only – Pipe, fittings, primer and solvent cement used to vent (exhaust) this applicance must be certified to ULCS636 and supplied by a single manufacturer as part of an approved vent (exhaust) system.
In addition, the first three feet of vent pipe from the furnace flue collar must be accessible for inspection.
Table 3 lists the available exhaust termination kits, as well as vent pipe equivalencies which must be used when sizing vent pipe.
Page 12 of 74 Issue 1622 507028-03
A97USMV
070
090
110
135
2
2-1/2
3
2
2-1/2
3
2
2-1/2
3
3
VENT PIPE
DIA.
(in.)
OUTDOOR TERMINATION KITS USAGE
STANDARD
Outdoor Exhaust Accelerator
(Dia. X
Length)
Outdoor
Exhaust
Accelerator
(Dia. X
Length)
Flush
Mount
Kit
1-1/2”
Concentric
Kit
1-1/2” X 12”
YES
YES
YES
2” X 12” 51W11 *
71M80 or
+44W92++
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
CONCENTRIC
2”
Concentric
Kit
69M29 or
+44W92++
YES
YES
YES
YES
YES
YES
3”
Concentric
Kit
60L46 or 44W93+
YES
YES
YES
YES
YES
YES
YES
* Kit 51W11 is provided with a 1-1/2” accelerator which must be for all 2 and 2-1/2” PVC installations.
+ Termination kits 44W92 and 44W93 are approved for use in Canadian installations to meet CSAB149.
++ The 44W92 Concentric kit is provided with a 1-1/2” accelerator Which must be installed on the exhaust outlet
when this kit is used with this furnace.
Table 3
Joint Cementing Procedure
All cementing of joints should be done according to the specifications outlined in ASTM D2855.
DANGER
6. Promptly apply solvent cement to end of pipe and inside socket surface of fitting. Cement should be applied lightly but uniformly to inside of socket. Take care to keep excess cement out of socket. Apply second coat to end of pipe.
507028-03
DANGER OF EXPLOSION!
Fumes from PVC glue may ignite during system check.
Allow fumes to dissipate for at least 5 minutes before placing unit into operation.
1. Measure and cut vent pipe to desired length.
2. Debur and chamfer end of pipe, removing any ridges or rough edges. If end is not chamfered, edge of pipe may remove cement from fitting socket and result in a leaking joint.
3. Clean and dry surfaces to be joined.
4. Test fit joint and mark depth of fitting on outside of pipe.
5. Uniformly apply a liberal coat of PVC primer for PVC or use a clean dry cloth for ABS to clean inside socket surface of fitting and male end of pipe to depth of fitting socket.
NOTE: Time is critical at this stage. Do not allow primer to dry before applying cement.
7. Immediately after applying last coat of cement to pipe, and while both inside socket surface and end of pipe are wet with cement, forcefully insert end of pipe into socket until it bottoms out. Turn PVC pipe 1/4 turn during assembly (but not after pipe is fully inserted) to distribute cement evenly. core pipe.
NOTE:
DO NOT turn ABS or cellular
Assembly should be completed within 20 seconds after last application of cement. Hammer blows should not be used when inserting pipe.
Issue 1622
8. After assembly, wipe excess cement from pipe at end of fitting socket. A properly made joint will show a bead around its entire preimeter. Any gaps may indicate a defective asembly due to insufficient solvent.
9. Handle joints carefully until completely set.
Page 13 of 74
Venting Practices
Piping Suspension Guidelines
NOTE: Isolate piping at the point where it exits the outside wall or roof in order to prevent transmission of vibration to the structure.
Wall Thickness Guidelines
1. In areas where piping penetrates joist or interior walls, hole must be large enough to allow clearance on all sides of pipe through center of hole using a hanger.
2. When furnace is installed in a residence where unit is shut down for an extended period of time, such as a vacation home, make provisions for draining condensate collection from trap and lines.
Exhaust Piping (Figures 18 and 19)
3. Route piping to outside of structure. Continue with installation following instructions given in piping termination section.
CAUTION
Do not discharge exhaust into an existing stack or stack that also serves another gas appliance. If vertical discharge through an existing unused stack is required, insert PVC pipe inside the stack until the end is even with the top or outlet end of the metal stack.
Figure 14
CAUTION
The exhaust vent pipe operates under positive pressure and must be completely sealed to prevent leakage of combustion products into the living space.
If this gas furnace replaces a furnace which was commonly vented with another gas appliance, the size of the existing vent pipe for that gas appliance must be checked. Without the heat of the original furnace flue products, the existing vent pipe is probably oversized for the single water heater or other appliance. The vent should be checked for proper draw with the remaining appliance.
Figure 15
Page 14 of 74
Vent Piping Guidelines
This unit is installed only as a Direct Vent gas central furnace.
NOTE: In Direct Vent installations, combustion air is taken from outdoors and flue gases are discharged outdoors.
Intake and exhaust pipe sizing – Size pipe according to
Tables 4 and 5. Table 4 lists the minimum vent pipe lengths permitted. Table 5 lists the maximum pipe lengths permitted.
Regardless of the diameter of pipe used, the standard roof and wall terminations described in section Exhaust Piping
Terminations should be used. Exhaust vent termination pipe is sized to optimize the velocity of the exhaust gas as it exits the termination. Refer to Table 6.
In some applications which permit the use of several different sizes of vent pipe, a combination vent pipe may be used.
Contact Allied Air Technical Service for more information concerning sizing of vent systems which include multiple pipe sizes.
Use the steps in Figure 17 to correctly size vent pipe diameter.
Issue 1622 507028-03
EXHAUST PIPE
Horizontal Application
NOTE: All horizontal runs of exhaust pipe must slope back toward unit.
A minimum of 1/4” (6 mm) drop for each 12” (305 mm) of horizontal run is mandatory for drainage.
NOTE: Exhaust pipe MUST be glued to furnace exhaust fittings.
NOTE : Exhaust piping should be checked carefully to make sure there are no sags or low spots.
Figure 16
NOTE: T he exhaust collar on all models is sized to accommodate 2” Schedule 40 vent pipe. In horizontal applications, transition to exhaust pipe larger than 2” must be made in vertical runs of the pipe. A 2” elbow must be added before the pipe is transitioned to any size larger than
2”. This elbow must be added to the elbow count used to determine acceptable vent lengths. Contact Allied Air
Technical Service for more information concerning sizing of vent systems which include multiple pipe sizes.
IMPORTANT
Do not use screens or perforated metal in exhaust or intake terminations. Doing so will cause freeze-ups and may block the terminations.
MINIMUM VENT PIPE LENGTHS
* Any approved termination may be added to the minimum equivalent length listed.
Table 4
507028-03 Issue 1622
Figure 17
Page 15 of 74
Maximum Allowable Intake or Exhaust Vent Length (feet)
Page 16 of 74
Table 5
Issue 1622 507028-03
Maximum Allowable Intake or Exhaust Vent Length (feet)
*Size intake and exhaust pipe length separately. Values in table are for intake or exhaust not combined total. Both intake and exhaust must be same pipe size.
507028-03
Table 5
Issue 1622 Page 17 of 74
TYPICAL EXHAUST PIPE CONNECTIONS AND CONDENSATE TRAP INSTALLATION
IN UPFLOW APPLICATIONS
Figure 18
TYPICAL EXHAUST PIPE CONNECTIONS AND CONDENSATE TRAP INSTALLATION
IN HORIZONTAL AIR APPLICATIONS
(RIGHT HAND DISCHARGE SHOWN)
Page 18 of 74
Figure 19
Issue 1622 507028-03
VENT TERMINATION CLEARANCES
FOR DIRECT VENT INSTALLATiONS IN THE USA AND CANADA
507028-03
Figure 20
Issue 1622 Page 19 of 74
General Guidelines for Vent Terminations
In Direct Vent applications, combustion air is taken from outdoors and the flue gases are discharged to the outdoors.
This gas furnace is classified as a direct vent, Category IV gas furnace.
In Direct Vent applications, the vent termination is limited by local building codes. In the absence of local codes, refer to the current National Fuel Gas Code ANSI Z223-1/NFPA 54 in U.S.A., and current CSA-B149 Natural Gas and Propane
Installation Codes in Canada for details.
Position termination according to location given in Figure
20. In addition, position termination so it is free from any obstructions and 12” above the average snow accumulation.
At vent termination, care must be taken to maintain protective coatings over building materials (prolonged exposure to exhaust condensate can destroy protective coatings). It is recommended that the exhaust outlet not be located within 6 feet (1.8m) of a condensing unit because the condensate can damage the painted coating.
NOTE: See Table 6 for maximum allowed exhaust pipe length without insulation in unconditioned space during winter design temperatures below 32 ° F (O ° C) . If equired exhaust pipe should be insulated with 1 / 2 ” (13mm)
Armaflex or equivalent . In extreme cold climate areas ,
3 / 4 ” (19mm) Armaflex or equivalent may be necessary .
Insulation on outside runs of exhaust pipe must be painted or wrapped to protect insulation from deterioration . Exhaust pipe insulation may not be necessary in some specific applications .
IMPORTANT
Do not use screens or perforated metal in exhaust terminations. Doing so will cause freeze-ups and may block the terminations.
IMPORTANT
FOR CANADIAN INSTALLATIONS ONLY:
In accorddance to CSA International B149 installation codes, the minimum allowed distance between the combustion air intake inlet and the exhaust outlet of other appliances shall not be less than 12 inches (305 mm).
Maximum Allowable Vent pipe Length without Insulation in Unconditioned Space for Winter Design
Temperatures Modulating High Efficiency Furnace
Winter Design Temperatures 1
ºF (ºC)
Vent Pipe
Diameter
32 to 21
(0 to -6)
20 to 1
(-7 to -17)
0 to -20
(-18 to -29)
2 in.
2-1/2 in.
3 in.
2 in.
2-1/2 in.
3 in.
2 in.
2-1/2 in.
3 in.
PVC
070
11
2 PP PVC
9 14
090
2 PP PVC
12 18
110
2 PP PVC
15
135
2 PP
N/A N/A
7 N/A
N/A N/A
10
6
N/A
6
12
8
N/A
8
N/A
13
N/A
13
N/A N/A 6 4 8 6 N/A N/A
N/A N/A N/A N/A N/A N/A N/A N/A
N/A N/A N/A N/A N/A N/A N/A N/A
N/A N/A N/A N/A N/A N/A N/A N/A
N/A N/A N/A N/A N/A N/A N/A N/A
N/A N/A N/A N/A N/A N/A N/A N/A
1
2
Refer to 99% Minimum Design Temperature table provided in the current edition of the ASHRAE Fundamentals Handbook.
Poly-Propylene vent pipe (PP) by Duravent and Centrotherm
NOTE - Concentric terminations are the equivalent of 5’ and should be considered when measuring pipe length.
NOTE- Maximum uninsulated vent lengths listed may include the termination (vent pipe exterior to the structure ) and cannot exceed 5 linear feet or the maximum allowable intake or exhaust vent length listed in table 5 or 6.
NOTE - If insulation is required an unconditioned space, it must be located on the pipe closed to the furnace.
Table 6
Page 20 of 74 Issue 1622 507028-03
Field Supplied Wall Terminator or
(15F74) Wall Ring Termination Kit
See venting Table 5 for maximum venting lengths with this arrangement.
* Use wall support every 24” (610 mm). Use two wall supports if extension is greater than 24” (610 mm) but less than 48” (1219 mm).
NOTE: One wall support must be 6” (152 mm) from top of each pipe
(intake and exhaust).
507028-03
Figure 24
Issue 1622 Page 21 of 74
FIELD SUPPLIED WALL TERMINATION with INTAKE ELBOW
EXHAUST PIPE TERMINATION SIZE REDUCTION
See venting Table 5 for maximum venting lengths with this arrangement.
* Use wall support every 24” (610 mm). Use two wall supports if extension is greater than 24” (610 mm) but less than 48” (1219 mm).
NOTE: One wall support must be 6” (152 mm) from top of each pipe
(intake and exhaust).
* 070 and 090 units installed with flush mount termination must use the 1-1/2” accelerator supplied with the kit.
Table 7
5. On field supplied terminations for sidewall exit, exhaust piping may extend a maximum of 12 inches (305 mm) for 2” PVC and 20 inches (508 mm) for 3” (76 mm) PVC beyond the outside wall. Intake piping should be as short as possible. See Figures 22 and 23.
6. On field supplied terminations, a minimum distance between the end of the exhaust pipe and the end of the intake pipe without a termination elbow is 8” and a minimum distance of 6” with a termination elbow. See
Figures 22 and 23.
7. If intake and exhaust piping must be run up a side wall to position above snow accumulation or other obstructions, piping must be supported every 24” (610 mm) as shown in Figures 22 and 23. In addition, close coupled wall termination must be extended for use in this application. See Figures 22 and 23. When exhaust and intake piping must be run up an with pipe sized per
Table 7. The intake piping may be equipped with a 90° elbow turndown. Using turndown will add 5 feet (1.5 m) to the equivalent length of the pipe.
DIRECT VENT CONCENTRIC ROOFTOP TERMINATION
71M80, 69M29 or 60L46 (US)
44W92 or 44W93 (Canada)
Page 22 of 74
Figure 25
Issue 1622
Figure 26
507028-03
DIRECT VENT CONCENTRIC WAL TERMINATION
71M80, 69M29 OR 60L46 (US)
44W92 or 44W93 (Canada)
FLUSH-MOUNT SIDE WALL TERMINATION
51W11
Figure 25
Figure 26
507028-03
Figure 27
Issue 1622 Page 23 of 74
DIRECT VENT APPLICATION
USING EXISTING CHIMNEY
NOTE: Do not discharge exhaust gases directly into any chimney or vent stack. If vertical discharge through an existing unused chimney or stack is required, insert piping inside chimney until the pipe open end is above top of chimney and terminates as illustrated. In any exterior portion of chimney, the exhaust vent must be insulated.
Figure 30
Condensate Piping
This unit is designed for either right or left side exit of condensate piping in upflow applications. In horizontal applications, the condensate trap must extend below the unit. An 8” service clearance is required for the condensate trap. Refer to Figure 34 for condensate trap locations.
NOTE: If necessary the condensate trap may be installed up to 5 ft. away using PVC pipe from the furnace. Piping from furnace must slope down a minimum of 1/4” per ft. toward trap.
CONDENSATE TRAP AND PLUG LOCATIONS
(Unit shown in upflow position)
1. Determine which side condensate piping will exit the unit, location of trap, field-provided fittings and length of PVC pipe required to reach available drain.
2. Use a 1/2” rachet drive or flat blade screw driver and remove plug (Figure 31) from the cold end header box at the appropriate location on the side of the unit. Install field-provided 3/4 NPT male fitting into cold end header box. Use Teflon tape or appropriate pipe dope.
3. Install the cap over the clean out opening at the base of the trap. Secure with clamp. See Figure 38.
4. Install drain trap using appropriate PVC fittings, glue all joints. Glue the provided drain trap as shown in
Figure 38. Route the condensate line to an open drain.
Condensate line must maintain a 1/4” downward slope from the furnace to the drain .
5. Figures 33 and 34 show the furnace and evaporator coil using a separate drain. If necessary the condensate line from the furnace and evaporator coil can drain together.
See Figures 35, 36 and 37.
Upflow furnace (Figure 32) - In upflow furnace applications the field provided vent must be minimum
1” to a maximum 2” length above the condensate drain outlet connection. Any length above 2” may result in a flooded heat exchanger if the combined primary drain line were to become restricted.
Horizontal furnace (Figure 33 or 37) In horizontal furnace applications the field provided vent must be a minimum
4” to a maximum 5” length above the condensate drain outlet connection. Any length above 5” may result in a flooded heat exchanger if the combined primary drain line were to become restricted.
NOTE: In horizontal applications it is recommended to install a secondary drain pan underneath the unit and trap assembly.
6. If unit will be started immediately upon completion of installation, prime trap per procedure outlined in Unit
Start-Up section.
NOTE: In upflow applications where side return air filter is installed on same side as the condensate trap, filter rack MUST be installed beyond condensate trap or trap must be relocated to avoid interference.
Figure 31
Page 24 of 74 Issue 1622
Condensate line must slope downward away from the trap to drain. If drain level is above condensate trap, condensate pump must be used. Condensate drain line should be routed within the conditioned space to avoid freezing of condensate and blockage of drain line. If this is not possible, a heat cable kit may be used on the condensate trap and line.
Heating cable kit is available in various lengths; 6 ft. (1.8 m) - kit no. 26K68; 24 ft. (7.3 m) - kit no. 26K69; and 50 ft.
(15.2 m) - kit no. 26K70.
CAUTION
Do not use copper tubing or existing copper condensate lines for drain line.
507028-03
CONDENSATE TRAP LOCATIONS
(Unit shown in upflow position with remote trap)
Figure 32
A97USMV With Evaporator Coil Using a Separate Drain
(Unit shown in horizontal Left hand discharge position )
507028-03
Evaporator Coil Using A Separate Drain
Figure 33
CAUTION
A separate drain line must be run to the drain from the condensate trap. DO NOT connect the condensate trap drain into the drain line from the evaporator coil.
Figure 34
Issue 1622 Page 25 of 74
IMPORTANT
When combining the furnace and evaporator coil drains together, the A/C condensate drain outlet must be vented to relieve pressure in order for the furnace pressure switch to operate properly.
Condensate Trap with Optional Overflow Switch
Evaporator Coil using a Common Drain
Figure 36
Figure 35
Evaporator Coil using a Common Drain
(Unit shown in Horizontal Left-Hand Discharge Position)
Page 26 of 74
Figure 37
Issue 1622 507028-03
TRAP / DRAIN ASSEMBLY USING 1/2” PVC OR 3/4” PVC
°
°
°
°
°
°
507028-03 Issue 1622 Page 27 of 74
Gas Piping
CAUTION
If a flexible gas connector is required or allowed by the authority that has jurisdiction, black iron pipe shall be installed at the gas valve and extend outside the furnace cabinet. The flexible connector can then be added between the black iron pipe and the gas supply line.
IMPORTANT
Compounds used on threaded joints of gas piping must be resistant to the actions of liquified petroleum gases.
WARNING
Do not exceed 600 in.-lbs. (50 ft.-lbs.) torque when attaching the gas piping to the gas valve.
1. Gas piping may be routed into the unit through either the left or right hand side in upflow applications, and either the top or bottom in horizontal applications. Supply piping enters into the gas valve from the side of the valve as shown in Figures 36 and 37.
2. When connecting gas supply, factors such as length of run, number of fittings and furnace rating must be considered to avoid excessive pressure drop. Table 7 list recommended pipe sizes for typical applications.
NOTE: Use two wrenches when connecting gas piping to avoid transferring torque to the manifold.
3. Gas piping must not run in or through air ducts, clothes chutes, chimneys or gas vents, dumb waiters or elevator shafts. Center gas line through piping hole. Gas line should not touch side of unit. See Figures 36 and 37.
4. Piping should be sloped 1/4 “ per 15 feet (6 mm per 5.6 m) upward toward the gas meter from the furnace. The piping must be supported at proper intervals, every 8 to 10 feet (2.44 to 3.05 m), using suitable hangers or straps. Install a drip leg in vertical pipe runs to serve as a trap for sediment or condensate.
5. A 1/8” N.P.T. plugged tap or pressure post is located on the gas valve to facilitate test gauge connection. See
Figure 42.
6. In some localities, codes may require installation of a manual main shut off valve and union (furnished by installer) external to the unit. Union must be of the ground joint type.
Figure 35
Leak Check
After gas piping is completed, carefully check all piping connections (factory and field installed) for gas leaks. Use a leak detecting solution or other preferred means. Do not test with open flame
The furnace must be isolated from the gas supply system by closing its individual manual shut-off valve during any pressure testing of the gas supply system at pressures more than or equal to 1/2 psig (3.48 kPa, 14 inches w.c.).
IMPORTANT
When testing gas lines using pressures in excess of
1/2 psig (3.48kPa), gas valve must be disconnected and isolated. See Figure 35. Gas valves can be damaged if subjected to pressures greater than 1/2 psig (3.48 kPa).
WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warnings exactly could result in serious injury, death, or property damage.
Never use an open flame to test for gas leaks. Check all connections using a commercially available soap solution made specifically for leak detection. Some soaps used for leak detection are corrosive to certain metals. Carefully rinse piping thoroughly after leak test has been completed.
Page 28 of 74 Issue 1622 507028-03
NOTE: BLACK IRON PIPE ONLY TO BE ROUTED INSIDE OF CABINET
Figure 36
Horizontal Applications
Possible Gas Piping Configurations
507028-03
NOTE: BLACK IRON PIPE ONLY TO BE ROUTED INSIDE OF CABINET
Figure 37
Issue 1622 Page 29 of 74
Removal of the Furnace from Common Vent
In the event that an existing furnace is removed from a venting system commonly run with separate gas appliances, the venting system is likely to be too large to properly vent the remaining attached appliances.
Conduct the following test while each appliance is operating and the other appliances (which are not operating) remain connected to the common venting system. If the venting system has been installed improperly, you must correct the system as indicated in the general venting requirements section.
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death.
The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances connected to the venting system are not in operation:
1. Seal any unused openings in the common venting system.
2. Inspect the venting system for proper size and horizontal pitch. Determine that there is no blockage, restriction, leakage, corrosion, or other deficiencies which could cause an unsafe condition.
3. Close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn ON clothes dryers and any appliances not connected to the common venting system. Turn ON any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.
4. Follow the lighting instructions. Turn ON the appliance that is being inspected. Adjust the thermostat so that the appliance operates continuously.
5. After the main burner has operated for 5 minutes, test for leaks of flue gases at the draft hood relief opening.
Use the flame of a match or candle.
6. After determining that each appliance connected to the common venting system is venting properly, (step
3) return all doors, windows, exhaust fans, fireplace dampers, and any other gas burning appliances to their previous mode of operation.
7. If a venting problem is found during any of the preceding tests, the common venting system must be modified to correct the problems.
Resize the common venting system to the minimum vent pipe size determined by using the appropriate tables in the current standards of the National Fuel Gas Code
ANSI Z223.1.
GAS PIPE CAPACITY - FT³/HR (kL/HR)
NOTE: Capacity given in cubic feet of gas per hour (kilo liters of gas per hour) and based on 0.60 specific gravity gas.
Table 7
Page 30 of 74 Issue 1622 507028-03
Electrical
ELECTROSTATIC DISCHARGE (ESD)
Precautions and Procedures
CAUTION
Electrostatic discharge can affect electronic components.
Take precautions during furnace installation and service to protect the furnace’s electronic controls. Precautions will help to avoid control exposure to electrostatic discharge by putting the furnace, the control and the technician at the same electrostatic potential. Neutralize electrostatic charge by touching hand and all tools on an unpainted unit surface, such as the gas valve or blower deck, before performing any service procedure.
The unit is equipped with a field makeup box. The makeup box may be moved to the right side of the furnace to facilitate installation. If the makeup box is moved to the right side, clip the wire ties that bundle the wires together. The excess wire must be pulled into the blower compartment. Secure the excess wire to the existing harness to protect it from damage. Seal unused openings on left side with plugs removed from right side.
1. The power supply wiring must meet Class I restrictions.
Protected by either a fuse or circuit breaker, select circuit protection and wire size according to unit nameplate.
NOTE: Unit nameplate states maximum current draw. See table for maximum over-current protection.
INTERIOR MAKE-UP BOX INSTALLATION
Figure 38
INTERIOR MAKE-UP BOX INSTALLATION
Table 8
2. Holes are on both sides of the furnace cabinet to facilitate wiring.
3. Install a separate (properly sized) disconnect switch near the furnace so that power can be turned off for servicing.
4. Before connecting the thermostat check to make sure the wires will be long enough for servicing at a later date.
Make sure that the thermostat wire is long enough to facilitate future removal of blower for service.
5. Complete the wiring connections to the equipment. Use the provided unit wiring diagram and the field wiring diagram shown in Figure 40 and Table 11. Use 18 gauge wire or larger that is suitable for Class II rating for thermostat connections.
6. Electrically ground the unit according to local codes or, in the absence of local codes, according to the current
National Electric Code (ANSI/HFPA No. 70) for the
USA and current Canadian Electric Code Part 1 (CSA standard C22.1) for Canada. A green ground wire is provided in the field makeup box.
7. One line voltage “EAC” 1/4” spade terminal is provided on the furnace integrated control. Any electronic air cleaner or other 120V accessory rated up to one amp can be connected to this terminal with the neutral leg of the circuit being connected to one of the provided neutral terminals. See Figure 45 for location of terminal.
This terminal is energized when the indoor blower is operating.
Figure 39
507028-03 Issue 1622 Page 31 of 74
8. One line voltage “HUM” 1/4” spade terminal is provided on the furnace integrated control. Any humidifier or other 120V accessory rated up to one amp can be connected to this terminal with the neutral leg of the circuit being connected to one of the provided neutral terminals. See Figure 41 for location of terminal. This terminal is energized in the heating mode when the indoor blower is operating.
9. One 24V “H” terminal is provided on the furnace integrated control terminal block. Any humidifier rated up to 0.5 amp can be connected to this terminal with the ground leg of the circuit being connected to either ground or the “C” terminal. See Figure 41 for location of terminal.
10. Install the room thermostat according to the instructions provided with the thermostat. See Table 11 for thermostat connections. If the furnace is being matched with a heat pump, refer to the instruction packaged with the dual fuel thermostat.
Run Length – Non Communicating
Table 9
Thermostat Selection
A Comfort Sync™ thermostat must be used in comunicating applications. Refer to the instructions provided with the thermostat for installation, set-up and operation.
This unit is designed to operate in a variable rate capacity mode using a two-stage thermostat. This unit will automatically adjust firing rate based upon thermostat cycle times.
For optimal performance use a high quality electronic digital thermostat or any other with adjustable settings for 1st stage
/ 2nd stage on / off differentials and adjustable stage timers.
The following is a two-stage thermostat setup for optimal variable rate capacity mode:
First heat stage differential set to 1/2 to 1° F; second heat stage differential set to 1/2 or 1° F; second heat stage upstage timer disabled, or set to maximum (1 hr. minimum).
Indoor Blower Speeds
1. When the thermostat is set to “FAN ON”, the indoor blower will run continuously at a percentage of the second stage cooling speed when there is no cooling or heating demand.
2. When the unit is running in the heating mode, the integrated control will automatically adjust the blower speed to match the furnace firing rate. This speed can be adjusted up or down by 7.5% or 15% using DIP switches 14 through 16 for the low heat speed and 17 through 19 for the high heat speed.
3. When there is a cooling demand, the indoor blower will run on the cooling speed designated by the positions of
DIP switches 8 through 11.
Generator Use - Voltage Requirements
The following requirements must be kept in mind when specifying a generator for use with this equipment:
• The furnace requires 120 volts ± 10% (Range: 108 volts to 132 volts).
• The furnace operates at 60 Hz ± 5% (Range: 57 Hz to
63 Hz).
• The furnace integrated control requires both polarity and proper ground. Both polarity and proper grounding should be checked before attempting to operate the furnace on either permanent or temporary power.
• Generator should have a wave form distortion of less than 5% THD (Total Harmonic Distortion).
Page 32 of 74 Issue 1622 507028-03
Typical A97USMV Field Wiring Diagram for Standard Non-Communicating Thermostat
Figure 44
507028-03 Issue 1622 Page 33 of 74
Page 34 of 74
Figure 45
Issue 1622 507028-03
507028-03
Figure 46
Issue 1622 Page 35 of 74
Field Wiring Connections for Non-Communicating Thermostat Applications
*”R” required on some units.
Page 36 of 74
Table 12A
Issue 1622 507028-03
Field Wiring for Non-Communicating Applications (continued)
* “R” required on some units.
507028-03
Table 12B
Issue 1622 Page 37 of 74
Field Wiring for Non-Communicating Applications (continued)
* Connect W1 to W1 ONLY if using defrost tempering kit 67M41.
NOTE: Do NOT make a wire connection between the room thermolstat L terminal and the L terminal of the A97USMV integrated control.
Table 12C
Page 38 of 74 Issue 1622 507028-03
Typical A97USMV Wiring Diagram
507028-03
Figure 47
Issue 1622 Page 39 of 74
Integrated Control
COMBUSTION
AIR INDUCER
CONNECTOR
FLAME
SENSE
DIAGNOSTIC
PUSH BUTTON
DIP SWITCHES
NEUTRAL
TERMINALS
IGNITOR
CONNECTOR
LINE VOLTAGE
TERMINALS
HUM
EAC
OUTDOOR AIR
SENSOR
TERMINALS
FACTORY TEST
HEADER PINS.
DISCHARGE AIR
SENSOR
TERMINALS
FACTORY USE ONLY.
TB83 OUTDOOR
TB84 INDOOR
RS-BUS LINK (TB82, future use)
I+ = DATA HIGH CONNECTION
I - = DATA LOW CONNECTION
RS-BUS OUTDOOR (TB83)
R = 24VAC
I + = DATA HIGH CONNECTION
I - = DATA LOW CONNECTION
C = 24VAXC COMMON
RS-BUS INDOOR (TB84)
R = 24VAC
I + = DATA HIGH CONNECTION
I - = DATA LOW CONNECTION
C = 24VAXC COMMON
1/4” QUICK CONNECT TERMINALS
HUM = 120 VAC OUTPUT TO HUMIDIFIER
XMFR = 120 VAC OUTPUT TO TRANSFORMER
LI = 120 VAC INPUT TO CONTROL
CIRC = 120 VAC OUTPUT TO CIRCULATING BLOWER
EAC = 120 VAC OUTPUT TO ELECTRICAL AIR CLEANER
NEUTRALS = 120 VAC NEUTRAL
7-SEGMENT
DIAGNOSTIC LED
W915
W951
W914
INDOOR
BLOWER
CONNECTOR
W915 Y1 TO Y2
W951 R TO O
W914 R TO DS
L - use only with communicating T'stat and non-communicating outdoor unit.
THERMOSTAT CONNECTIONS (TB1)
DS = DEHUMIDIFICATION SIGNAL
W2 = HEAT DEMAND FROM 2ND STAGE T/STAT
W1 = HEAT DEMAND FROM 1ST STAGE T/STAT
R = CLASS 2 VOLTAGE TO THERMOSTAT
G = MANUAL FAN FROM T'STAT
C = THERMOSTAT SIGNAL GROUND CONNECTED TO
TRANSFORMER GRD (TR) & CHASIS GROUND (GRD)
Y1 = THERMOSTAT 1ST STAGE COOL SIGNAL
Y2 = THERMOSTAT 2ND STAGE COOL SIGNAL
O = THERMOSTAT SIGNAL TO HEAT PUMP
REVERSING VALVE
H = 24V HUMIDIFIER OUTPUT. DO NOT CONNECT
TO COMFORTSENSE ® THERMOSTAT
L = USE ONLY WITH A COMMUNICATING
THERMOSTAT AND A NON-COMMUNICATING
OUTDOOR UNIT
DH = DEHUMIDIFICATION OUTPUT
COMMUNICATING THERMOSTAT ONLY
Figure 48
Page 40 of 74 Issue 1622 507028-03
8. One line voltage “HUM” 1/4” spade terminal is provided on the furnace integrated control. Any humidifier or other 120V accessory rated up to one amp can be connected to this terminal with the neutral leg of the circuit being connected to one of the provided neutral terminals. See Figure 41 for location of terminal. This terminal is energized in the heating mode when the indoor blower is operating.
9. One 24V “H” terminal is provided on the furnace integrated control terminal block. Any humidifier rated up to 0.5 amp can be connected to this terminal with the ground leg of the circuit being connected to either ground or the “C” terminal. See Figure 41 for location of terminal.
10. Install the room thermostat according to the instructions provided with the thermostat. See Table 11 for thermostat connections. If the furnace is being matched with a heat pump, refer to the instruction packaged with the dual fuel thermostat.
Run Length – Non Communicating
Table 13
Thermostat Selection
This unit is designed to operate in a variable rate capacity mode using a two-stage thermostat. This unit will automatically adjust firing rate based upon thermostat cycle times.
For optimal performance use a high quality electronic digital thermostat or any other with adjustable settings for 1st stage
/ 2nd stage on / off differentials and adjustable stage timers.
The following is a two-stage thermostat setup for optimal variable rate capacity mode:
First heat stage differential set to 1/2 to 1° F; second heat stage differential set to 1/2 or 1° F; second heat stage upstage timer disabled, or set to maximum (1 hr. minimum).
Indoor Blower Speeds
1. When the thermostat is set to “FAN ON”, the indoor blower will run continuously at a percentage of the second stage cooling speed when there is no cooling or heating demand.
2. When the unit is running in the heating mode, the integrated control will automatically adjust the blower speed to match the furnace firing rate. This speed can be adjusted up or down by 7.5% or 15% using DIP switches 14 through 16 for the low heat speed and 17 through 19 for the high heat speed.
3. When there is a cooling demand, the indoor blower will run on the cooling speed designated by the positions of
DIP switches 8 through 11.
Generator Use - Voltage Requirements
The following requirements must be kept in mind when specifying a generator for use with this equipment:
• The furnace requires 120 volts ± 10% (Range: 108 volts to 132 volts).
• The furnace operates at 60 Hz ± 5% (Range: 57 Hz to
63 Hz).
• The furnace integrated control requires both polarity and proper ground. Both polarity and proper grounding should be checked before attempting to operate the furnace on either permanent or temporary power.
• Generator should have a wave form distortion of less than 5% RHD.
507028-03 Issue 1622 Page 41 of 74
Thermostat Selection Switch Settings
Table 15
These units are equipped with an integrated control. This control manages ignition timing, combustion air inducer speed, heating mode fan OFF delays and indoor blower speeds based on selections made using the control DIP switches and onboard links. The control includes an internal feature which automatically resets the ignition control when it has been locked out.
NOTE: All DIP switches are factory shipped in the “OFF” position.
Heating Operation DIP Switch Settings - Figure 41
Switch 1 - Thermostat Selection - This unit may be used with either a single stage or two stage thermostat. The thermostat selection is made using a DIP switch which must be properly positioned for the particular application. The
DIP switch is factory positioned for use with a two stage thermostat. If a single stage thermostat is to be used, the
DIP switch must be repositioned. See Table 12.
Switch 2 - Operating Mode with Two Stage Thermostat
If a two stage thermostat is used, the furnace can operate in either variable capacity or conventional two stage mode.
When variable capacity mode is selected, the firing rate of the unit is varied to maximize comfort. Conventional two stage mode is the factory default setting. See Table 12.
Switch 3 - Second Stage Heat On Delay - If a single stage thermostat is used, the integrated control can be used to energize second stage heat after either 7 minutes or 12 minutes of first stage heat operation. See Table 12.
Switches 4 and 5 - Blower Off Delay The blower On delay of 30 seconds is not adjustable. The blower Off delay (time that the blower operates after the heating demand has been satisfied) can be adjusted by moving switches 4 and 5 on the integrated control. The unit is shipped from the factory with a blower Off delay of 90 seconds. The blower Off delay affects comfort and is adjustable to satisfy individual applications. Adjust the blower Off delay to achieve a supply air temperature between 90° and 110° F at the exact moment that the blower is de-energized. Longer Off delay settings provide lower supply air temperatures; shorter settings provide higher supply air temperatures. Table 13 provides the blower Off timings that will result from different switch settings.
Blower Off Delay Switch Settings
Table 16
Indoor Blower Operation DIP Switch Settings
Switches 6 and 7 - Continuous Indoor Fan Operation -
Blower Speed - The unit is shipped from the factory with the DIP switches positioned for medium low (38%) speed during continuous indoor blower operation. Continuous fan setting is 38% of cool setting and is not adjustable.
Page 42 of 74 Issue 1622 507028-03
T h e rm o s ta t
1 H e a t / 1 C o o l
N O T E - U s e D IP s w itc h 3 to s e t s e c o n d -s ta g e h e a t O N d e la y .
O F F -7 m in u te s .
O N -1 2 m in u te s .
D IP S w itc h S e ttin g s a n d O n -B o a rd L in k s (fig u re N O T A G )
D IP S w itc h 1 W 9 1 5
(Y 1 to Y 2 )
T w o -S ta g e
C o o lin g
W 9 1 4
(D S to R )
D e h u m id ific a tio n o r
H a rm o n y III
£
W 9 5 1
(O to R )
H e a t P u m p s
O N In ta c t In ta c t In ta c t
S1
T’STAT
W irin g C o n n e c tio n s
CONTROL
TERM. STRIP
OUTDOOR
UNIT
*
1 H e a t / 2 C o o l
N O T E - U s e D IP s w itc h 3 to s e t s e c o n d -s ta g e h e a t O N d e la y .
O F F -7 m in u te s .
O N -1 2 m in u te s .
S1
T’STAT
CONTROL
TERM. STRIP
OUTDOOR
UNIT
*
1 H e a t / 2 C o o l w ith t’s ta t w ith d e h u m id ific a tio n m o d e
N O T E - U s e D IP s w itc h 3 to s e t s e c o n d -s ta g e h e a t O N d e la y .
O F F -7 m in u te s .
O N -1 2 m in u te s .
O N C u t C u t In ta c t
S1
T’STAT
CONTROL
TERM. STRIP
OUTDOOR
UNIT
*
50 702 8-01
507028-03
Issue 123 5
Issue 1622
Page 37 of 78
Page 43 of 74
Low Voltage Field Wiring
Field Wiring for Non-Communicating Applications (continued)
T h e rm o s ta t
D IP S w itc h S e ttin g s a n d O n -B o a rd L in k s (fig u re N O T AG )
D IP S w itc h 1 W 9 1 5
(Y 1 to Y 2 )
T w o -S ta g e
C o o lin g
W 9 1 4
(D S to R )
D e h u m id ific a tio n o r
H a rm o n y
III
£
W 9 5 1
(O to R )
H e a t P u m p s
2 H e a t / 2 C o o l O F F C u t In ta c t In ta c t
S1
T’STAT
W irin g C o n n e c tio n s
CONTROL
TERM. STRIP
OUTDOOR
UNIT
*
2 H e a t / 2 C o o l w ith t’s ta t w ith d e h u m id ific a tio n m o d e
O F F C u t C u t In ta c t
S1
T’STAT
CONTROL
TERM. STRIP
OUTDOOR
UNIT
*
2 H e a t / 1 C o o l O F F In ta c t In ta c t In ta c t
S1
T’STAT
CONTROL
TERM. STRIP
OUTDOOR
UNIT
*
Page 38 of 78
Page 44 of 74
Issue 123 5
Issue 1622
50 702 8-01
507028-03
Thermostat
Dual Fuel
Single Stage
Heat Pump thermostat w/dual fuel capabilities
Capable of
2 stage gas heat control
DIP Switch 1
OFF
Low Voltage Field Wiring
Single Stage
DIP Switch Settings & On Board Links (Figure 41)
DIP Switch W915
(Y1 to Y2)
Two Stage
Cooling
W914
(DS to R)
Dehumidification
W951
(O to R)
Heat Pumps
Intact Intact Cut
Thermostat
Dual Fuel
Two Stage
Heat Pump thermostat w/dual fuel capabilities
Capable of
2 stage gas heat control
2 Stage
DIP Switch Settings & On Board Links (Figure 41)
DIP Switch W915
(Y1 to Y2)
Two Stage
Cooling
W914
(DS to R)
Dehumidification
W951
(O to R)
Heat Pumps
DIP Switch 1
OFF
Cut Intact Cut
507028-03
Table 14
Issue 1622 Page 45 of 74
Switches 8 and 9 - Cooling Mode Blower Speed-
The unit is shipped from the factory with the DIP switches positioned for high speed (4) indoor blower motor operation during the cooling mode. The table below provides the cooling mode blower speeds that will result from different switch settings.
Cooling Mode Blower Speeds
Cooling Mode Blower Speed Ramping
Table 19
Ramping Option “A” (Factory Selection)
• Motor runs at 50% for 30 seconds.
• Motor then runs at 82% for approximately 7-1/2 min utes.
• If demand has not been satisfied after 7-1/2 minutes, motor runs at 100% until demand is satisfied.
• Once demand is met, motor runs at 50% for 30 seconds then ramps down to stop.
Table 17
Switches 10 and 11 - Cooling Mode Blower Speed
Adjustment - The unit is shipped from the factory with the DIP switches positioned for NORMAL (no) adjustment.
The DIP switches may be positioned to adjust the blower speed by +10% or -10% to better suit the application. Table
18 provides blower speed adjustments that will result from different switch settings. Refer to air flow tables for values.
With switches 10 an 11 set to ON, motor will bypass ramping profiles and all delays and will immediately run at selected
COOLING speed upon a call for cool. LED will continue to operate as normal. This mode is used to check motor operation.
Cooling Mode Blower Speed Adjustment
Ramping Option “B”
•
•
Motor runs at 82% for approximately 7-1/2 minutes.
If demand has not been satisfied after 7-1/2 minutes, motor runs at 100% until demand is satisfied.
Once demand is met, motor ramps down to stop.
Table 18
Switches 12 and 13 - Cooling Mode Blower Speed
Ramping Blower speed ramping may be used to enhance dehumidification performance. The switches are factory set at option A which has the greatest effect on blower motor performance. Table 19 provides the cooling mode blower speed ramping options that will result from different switch settings. The cooling mode blower speed ramping options are detailed below.
NOTE: The OFF portion of the selected ramp profile only applies during heat pump operation in dual fuel applications.
Ramping Option “C”
• Motor runs at 100% until demand is satisfied.
• Once demand is met, motor runs at 100% for 45 seconds then ramps down to stop.
Ramping Option “D”
• Motor runs at 100% until demand is satisfied.
• Once demand is met, motor ramps down to stop.
Page 46 of 74 Issue 1622 507028-03
Switches 14 through 19 - Heating Mode Blower Speed
These switches are factory set at the OFF position which provides 100% of normal speed during HIGH HEAT demand,
70% of normal speed during MIDRANGE HEAT demand and
40% of normal speed during LOW HEAT demand. Switches
14, 15 and 16 are used to adjust the LOW HEAT blower motor speed. Switches 17, 18 and 19 are used to adjust the HIGH HEAT blower motor speed. Table 18 provides the heating mode blower speeds that will result from different switch settings.
Low Heat Blower Speeds
Table 20
High Heat Blower Speeds
Table 21
On Board Links
On Board links must be clipped (when applicable) before unit is placed into operation with a non-communicating thermostat.
On Board Link W914 DS to R (Figure??)
On Board link W914, is a clippable connection between terminals DS and R on the integrated control. W914 must be cut when installed with a thermostat which features humidity control. Refer to Table ?? for operation sequence in applications for this unit, a thermostat which features humidity control and a single speed outdoor unit. Table
?? gives the operation sequence in applications with a two speed outdoor unit.
On Board Link W951 R to O (Figure ??)
On Board link W951 is a clippable connection between terminals R and O on the integrated control. W951 must be cut when the furnace is installed in applications which include a heat pump unit and thermostat which features dual fuel use. If the link is left intact, terminal “O” will remain energized eliminating the HEAT MODE in the heat pump.
On Board Link W915 Y1 to Y2 (Figure ??)
On Board linkW915 si a clippable connection between terminals Y1 and Y2 on the integrated control. W915 must be cut if two stage cooling will be used. If the link is not cut the outdoor unit will operate in second stage cooling only.
Diagnostic LED (Figure ??)
The seven segment diagnostic LED displays operating status, target airflow, error codes and other information.
The table on page 58 lists diagnostic LED codes.
Diagnostic Push Button (Figure ??)
The diagnostic push button is located adjacent to the seven segment diagnostic LED. This button is used to enable the
Error Code Recall mode and the Field Test mode. Press the button and hold it to cycle through a menu of options. Every five seconds a new menu item will be displayed. When the button is released, the displayed item will be selected.
Once all items in the menu have been displayed, the menu resumes from the beginning until the button is released.
Error Code Recall Mode
Select “E: from the menu to access the most recent 10 error codes. Select “c” from the Error Code Recall menu to clear all error codes. Button must be pressed a second time while
“c” is flashing to confirm command to delete codes. Press the button until a solid “-” is displayed to exit the Error Code
Recall mode.
Field Test Mode
Use the diagnostic push button to scroll through the menu as described above. Release the button when the LED flashes “-” to select the Field Test mode.
While in the Field Test mode the technician can:
• Initiate furnace ignition and move to and hold low-fire rate by applying a R to W1 jumper.
• Initiate furnace ignition sequence and move to an hold high-fire rate by applying a jumper from R to W1 and
W2.
• Initiate furnace ignition sequence and move to and hold mid-fire rate by applying a jumper to R and W2.
• Apply then remove the jumper from R to W1 and W2 to change the firing rate from low fire to mid fire and high fire.
• A vent calibration sequence can be initiated even if a thermostat signal is not present. Press and hold the push button until a solid “C” is displayed. Release the button and calibration will begin. The furnace will perform the high-fire and low-fire pressure switch calibrations and display “CAL”. After calibration , the
LED will return to the flashing “-” display.
During Field Test mode operation, all safety switches are still in the circuit (they are not by-passed) and indoor blower performance and timings will match DIP switch selections.
Current furnace firing rate, indoor blower CFM and flame signal will be displayed. To exit the Field Test mode, press and hold the button. The menu will resume from the beginning. Also, cycle the main power to exit the Field Test mode. The integrated control will automatically exit the Field
Test mode after 45 minutes of operation
507028-03 Issue 1622 Page 47 of 74
A96UHMV070B12S BLOWER PERFORMANCE (less filter)
HEATING BLOWER PERFORMANCE
BOTTOM RETURN AIR
BLOWER DATA
Heating Adjust CFM Selections
Increase (+15%) Heat CFM
Increase (+7.5%) Heat CFM
Default Heat CFM
Decrease (-7.5% ) Heat CFM
Decrease (-15% ) Heat CFM
COOLING BLOWER PERFORMANCE
40%
538
496
453
419
385
Heating Input Range and Blower Volume - CFM
50%
636
60%
735
70%
833
80%
931
588
539
498
458
680
624
578
531
772
710
657
604
864
796
736
676
90%
1030
956
881
815
749
100%.
1128
1048
967
895
822
Cooling Adjust CFM
Selections
First Stage Cool Speed- cfm
Low
Medium
Low
740 Increase (+10%) Cool CFM
Default Cool CFM
Decrease(-10%) Cool CFM
600
555
500
A96UHMV070B12S BLOWER PERFORMANCE (less filter)
RIGHT SIDE RETURN AIR
HEATING BLOWER PERFORMANCE
665
600
Medium
High
840
770
680
Blower Speed Selections
High
(Default)
970
855
790
Low
860
810
705
Second Stage Cool Speed-cfm
Medium
Low
1060
960
840
Medium
High
1215
1130
1005
High
(Default)
1365
1265
1140
Heating Adjust CFM Selections
Increase (15%) Heat CFM
Increase (+7.5%) Heat CFM
Default Heat CFM
Decrease (-7.5%) Heat CFM
Decrease(-15%) Heat CFM
COOLING BLOWER PERFORMANCE
40%
531
490
449
413
378
Heating Input Range and Blower Volume - CFM
50% 60% 70% 80% 90%
625
579
718
667
812
756
906
845
999
933
533
487
442
616
561
506
700
635
571
784
709
635
867
783
699
100%
1093
1022
951
857
763
Cooling Adjust CFM
Selections
Increase (+10%) Cool CFM
Default Cool CFM
Decrease (-10%) Cool CFM
Low
590
540
500
Blower Speed Selections
First Stage Cool Speed- cfm
Medium Medium High
Low
Low
705
High
805
(Default)
955 840
Second Stage Cool Speed-cfm
Medium Medium
Low
1050
High
1205
High
(Default)
1355
640
580
725
665
820
720
750
685
945
805
1130
990
1230
1110
The effect of static pressure is included in air volumes shown.
The following control configurations are available. See Installation Instructions for details and DIP switch settings.
Heat Modes Available (Heating Blower Performance Table):
Single stage thermostat:
- 40%, 70%. 100% input (three-stage) with time delays in-between
Two-stage thermostat:
- Variable Rate Capacity Mode - furnace automatically adjusts firing rate based on first- and second-stage cycle times
- W1 demand at 70% input, W2 demand at 100% input. No delay between stages
Cool Mode Available (Cooling Blower Performance table):
First stage COOL (two-stage air conditioning units only) is approximately 70% of the same second stage COOL speed position,
Continuous Fan speeds are approximately 38% of the same second-stage COOL speed position minimum 300 cfm.
Page 48 of 74 Issue 1622 507028-03
BLOWER DATA
A96UHMV070B12S BLOWER PERFORMANCE (less filter)
RIGHT SIDE RETURN AIR WITH OPTIONAL RETURN AIR BASE
HEATING BLOWER PERFORMANCE
Heating Adjust CFM Selections
Increase (+15%) Heat CMS
Increase (-7.5%) Heat CFM
Default Heat CFM
Decrease (-7.5% ) Heat CFM
Decrease (-15% ) Heat CFM
COOLING BLOWER PERFORMANCE
Cooling Adjust CFM
Selections
40%
519
480
441
408
375
Heating Input Range and Blower Volume - CFM
50% 60% 70% 80% 90%
614
570
526
486
446
709
660
611
564
517
805
751
696
643
589
900
841
781
721
660
996
931
866
799
732
1
1091
1021
951
877
803
Low
Blower Speed Selections
First Stage Cool Speed- cfm Second Stage Cool Speed-cfm
Medium
Low
Medium
High
High
(Default)
Low Medium
Low
Medium
High
High
(Default)
Increase (+10%) Cool CFM
Default Cool CFM
Decrease (-10%) Cool CFM
585
520
490
715
655
595
815
755
670
950
840
745
855
790
720
1045
945
845
1205
1090
985
1350
1255
1130
A96UHMV090C12S BLOWER PERFORMANCE (less filter) BOT -
TOM RETURN AIR HEATING
BLOWER PERPORMANCE
Heating Adjust CFM Selections
40%
Heating Input Range and Blower Volume - CFM
50% 60% 70% 80% 90% 100%
Increase (15%) Heat CFM
Increase (+7.5%) Heat CFM
Default Heat CFM
Decrease(-7.5% ) Heat CFM
734
697
660
616
572
827
792
737
687
637
821
867
814
757
701
1014
953
891
828
788
1108
1038
968
899
830
1201
1123
1045
970
895
1295
1209
1122
1041
959 Decrease (-15% ) Heat CFM
COOLING BLOWER PERFORMANCE
Cooling Adjust CFM
Selections
Increase (+10%) Cool CFM
Default Cool CFM
Decrease (-10%) Cool CFM
Low
625
565
520
Medium
Low
710
670
610
Medium
High
830
760
685
Blower Speed Selections
First Stage Cool Speed- cfm
High
(Default)
950
860
785
Low
875
800
720
Second Stage Cool Speed-cfm
Medium
Low
1040
945
840
Medium
High
1210
1100
970
The effect of static pressure is included in air volumes shown.
The following control configurations are available. See Installation Instructions for details and DIP switch settings.
Heat Modes Available (Heating Blower Performance Table):
Single stage thermostat:
- 40%, 70%. 100% input (three-stage) with time delays in-between
Two-stage thermostat:
- Variable Rate Capacity Mode - furnace automatically adjusts firing rate based on first- and second-stage cycle times
- W1 demand at 70% input, W2 demand at 100% input. No delay between stages
Cool Mode Available (Cooling Blower Performance table):
First stage COOL (two-stage air conditioning units only) is approximately 70% of the same second stage COOL speed position,
Continuous Fan speeds are approximately 38% of the same second-stage COOL speed position minimum 300 cfm.
High
(Default)
1380
1240
1115
507028-03 Issue 1622 Page 49 of 74
BLOWER DATA
A96UHMV090C12S BLOWER PERFORMANCE (less filter)
RIGHT SIDE RETURN AIR
HEATING BLOWER PERFORMANCE
Heating Adjust CFM Selections
Increase (+15%) Heat CFM
40%
702
50%
792
Heating Input Range and Blower Volume- CFM
60%
881
70%
971
80%
1061
90%
1150
100%
1240
Increase (+7.5%) Heat CFM
Default Heat CFM
Decrease (-7.5% ) Heat CFM
Decrease (-15% ) Heat CFM
COOLING BLOWER PERFORMANCE
Cooling Adjust CFM
Selections
673
644
608
571
757
723
676
630
841
802
745
689
926
880
814
747
1010
959
882
806
1094
1037
951
864
1178
1116
1020
923
Low
First Stage Cool Speed-cfm
Medium Medium
Low High
Blower Speed Selections
High
(Default)
Low
Second Stage Cool Speed-cfm
Medium Medium
Low High
High
(Default)
Increase (+10%) Cool CFM
Default Cool CFM
610
560
705
640
795
715
920
810
840
770
1015
910
1165
1050
1300
1190
Decrease (-10%) Cool CFM
Heating Adjust CFM Selections
525 605
A96UHMV090C123 BLOWER PERFORMANCE (less filter) RIGHT
SIDE RETURN AIR WITH OPTIONAL RETURN AIR BASE HEAT -
ING BLOWER PERFORMANCE
40%
665
50%
725
60%
695
70%
795
Heating Input Range and Blower Volume - CFM
80%
945
90%
1110
100%
Increase (15%) Heat CFM
Increase (+7.5%) Heat CFM
Default Heat CFM
Decrease(-7.5% ) Heat CFM
Decrease (-15% ) Heat CFM
COOLING BLOWER PERFORMANCE
Cooling Adjust CFM
Selections
721
678
637
606
576
810
760
711
673
635
899
842
784
740
695
988
923
858
806
754
1076
1004
932
873
814
1165
1085
1005
939
873
1254
1167
1079
1006
933
Increase (+10%) Cool CFM
Default Cool CFM
Low
605
570
First Stage Cool Speed- cfm
Blower Speed Selections
Second Stage Cool Speed-cfm
Medium Medium High Low Medium Medium
Low
715
660
High
810
735
(Default)
930
820
850
775
Low
995
905
High
1165
1050
Decrease (-10%) Cool CFM 530 600 670 725 710 800 945
The effect of static pressure is included in air volumes shown.
The following control configurations are available. See Installation Instructions for details and DIP switch settings.
Heat Modes Available (Heating Blower Performance Table):
Single stage thermostat:
- 40%, 70%. 100% input (three-stage) with time delays in-between
Two-stage thermostat:
- Variable Rate Capacity Mode - furnace automatically adjusts firing rate based on first- and second-stage cycle times
- W1 demand at 70% input, W2 demand at 100% input. No delay between stages
Cool Mode Available (Cooling Blower Performance table):
First stage COOL (two-stage air conditioning units only) is approximately 70% of the same second stage COOL speed position,
Continuous Fan speeds are approximately 38% of the same second-stage COOL speed position minimum 300 cfm.
High
(Default)
1305
1205
1070
Page 50 of 74 Issue 1622 507028-03
BLOWER DATA
A96UHMV090C16S BLOWER PERFORMANCE (less filter)
BOTTOM RETURN AIR
HEATING BLOWER PERFORMANCE
Heating Adjust CFM Selections
Increase (+15%) Heat CFM
40%
835
Heating Input Range and Blower Volume- CFM
50%
968
60%
1101
70%
1234
80%
1367
90%
1500
1
1633
Increase (+7.5%) Heat CFM
Default Heat CFM
Decrease (-7.5% ) Heat CFM
Decrease (-15% ) Heat CFM
COOLING BLOWER PERFORMANCE
Cooling Adjust CFM
Selections
Low
776
716
652
589
902
836
767
699
First Stage Cool Speed-cfm
Medium
Low
Medium
High
1028
955
882
809
1155
1075
997
919
Blower Speed Selections
High
(Default)
Low
1281
1195
1112
1029
1407
1314
1227
1139
Second Stage Cool Speed-cfm
Medium
Low
Medium
High
1534
1434
1342
1249
High
(Default)
Increase (+10%) Cool CFM
Default Cool CFM
840
780
Low
1005
915
1155
1045
1315
1190
1165
1075
1375
1265
1580
1440
1770
1645
Decrease (-10%) Cool CFM 1320
A96UHMV090C16S BLOWER PERFORMANCE (less filter)
RIGHT SIDE RETURN AIR
HEATING BLOWER PERFORMANCE
Heating Adjust CFM Selections
Increase (15%) Heat CFM
Increase (+7.5%) Heat CFM
Default Heat CFM
Decrease(-7.5% ) Heat CFM
Decrease (-15% ) Heat CFM
690 835
40%
812
759
706
644
582
955
Heating Input Range and Blower Volume - CFM
50%
943
882
821
755
690
1070
60%
1073
1005
936
867
797
935
70%
1204
1127
1051
978
905
1145
80%
1334
1250
1165
1089
1013
90%
1465
1372
1280
1200
1120
1465
100%
1595
1495
1395
1312
1228
COOLING BLOWER PERFORMANCE
Cooling Adjust CFM
Selections First Stage Cool Speed- cfm
Medium
Low
Medium
High
Blower Speed Selections
High
(Default)
Low
Second Stage Cool Speed-cfm
Medium
Low
Medium
High
High
(Default)
Increase (+10%) Cool CFM
Default Cool CFM
820
755
1005
880
1135
1025
1290
1150
1140
1040
1340
1235
1525
1395
Decrease (-10%) Cool CFM 680 815 925 1065 910 1120 1275
The effect of static pressure is included in air volumes shown.
The following control configurations are available. See Installation Instructions for details and DIP switch settings.
Heat Modes Available (Heating Blower Performance Table):
Single stage thermostat:
- 40%, 70%. 100% input (three-stage) with time delays in-between
Two-stage thermostat:
- Variable Rate Capacity Mode - furnace automatically adjusts firing rate based on first- and second-stage cycle times
- W1 demand at 70% input, W2 demand at 100% input. No delay between stages
Cool Mode Available (Cooling Blower Performance table):
First stage COOL (two-stage air conditioning units only) is approximately 70% of the same second stage COOL speed position,
Continuous Fan speeds are approximately 38% of the same second-stage COOL speed position minimum 300 cfm.
1725
1565
1400
507028-03 Issue 1622 Page 51 of 74
BLOWER DATA
A96UHMV090C16S BLOWER PERFORMANCE (less filter)
RIGHT SIDE RETURN AIR WITH OPTIONAL RETURN AIR BASE
HEATING BLOWER PERFORMANCE
Heating Adjust CFM Selections Heating input Range and Blower Volume - CFM
Increase (+15%) Heat CFM
Increase (+7.5%) Heat CFM
Default Heat CFM
Decrease (-7.5%)’Heat CFM
Decrease (-15%) Heat CFM
COOLING BLOWER PERFORMANCE
40%
828
766
703
650
596
50%
956
888
819
762
704
60%
1084
1010
936
874
812
70%
1213
1132
1052
986
921
80%
1341
1255
1168
1099
1029
90%
1469
1377
1285
1211
1137
100%
1597
1499
1401
1323
1245
Cooling Adjust CFM
Selections
Low
Blower Speed Selections
First Stage Cool Speed- cfm Second Stage Cool Speed-cfm
Medium Medium High Low Medium Medium High increase (+10%) Cool CFM
Default Cool CFM
Decrease (-10%) Cool CFM
840
775
695
Low
955
910
815
High
1120
1010
930
(Default)
1280
1170
1045
1160
1060
925
Low
1360
1240
1130
High
1530
1400
1295
(Default)
1740
1590
1440
A96UHMV090C20S BLOWER PERFORMANCE (less filter)
BOTTOM RETURN AIR
HEATING BLOWER PERFORMANCE
Heating Adjust CFM Selections
Increase (+15%) Heat CFM
40%
665
Heating input Range and Blower Volume - CFM
50%
830
60%
995
70%
1159
80%
1324
90%
1488
100%
1653
Increase (+7,5%) Heat CFM
Default Heat CFM
Decrease (-7.5%) Heat CFM
Decrease (-15% ) Heat CFM
COOLING BLOWER PERFORMANCE
Cooling Adjust CFM
Selections
618
571
507
443
774
718
644
570
930
865
781
697
1085
1012
917
823
1241
1159
1054
950
1397
1306
1191
1076
1553
1453
1328
1203 increase (+10%) Cool CFM
Default Cool CFM
Low
933
836
First Stage Cool Speed- cfm
Medium Medium
Low High
High
(Default)
1054 1274 1466
978 1121
Blower Speed Selections
1336
Low
1385
1226
Second Stage Cool Speed-cfm
Medium Medium High
Low
1593
1463
High
1818
1647
(Default)
2019
1884
Decrease (-10%) Cool CFM 740 868 1010 1152 1063 1320 1504
The effect of static pressure is included in air volumes shown.
The following control configurations are available. See Installation Instructions for details and DIP switch settings.
Heat Modes Available (Heating Blower Performance Table):
Single stage thermostat:
- 40%, 70%. 100% input (three-stage) with time delays in-between
Two-stage thermostat:
- Variable Rate Capacity Mode - furnace automatically adjusts firing rate based on first- and second-stage cycle times
- W1 demand at 70% input, W2 demand at 100% input. No delay between stages
Cool Mode Available (Cooling Blower Performance table):
First stage COOL (two-stage air conditioning units only) is approximately 70% of the same second stage COOL speed position,
Continuous Fan speeds are approximately 38% of the same second-stage COOL speed position minimum 300 cfm.
1675
Page 52 of 74 Issue 1622 507028-03
BLOWER DATA
A96UHMV090C20S BLOWER PERFORMANCE (less filter)
RIGHT SIDE RETURN AIR
HEATING BLOWER PERFORMANCE
Heating Adjust CFM Selections
Increase (+15%) Heat CFM
Increase (+7.5%) Heat CFM
Default Heat CFM
Decrease (-7.5%)’Heat CFM
Decrease (-15%) Heat CFM
COOLING BLOWER PERFORMANCE
40%
684
623
562
502
441
Heating input Range and Blower Volume - CFM
50%
835
769
702
633
564
60%
986
914
842
765
687
70%
1136
1059
953
896
810
80%
1287
1205
1123
1028
932
90%
1437
1350
1263
1159
1055
100%
1588
1496
1403
1291
1178
Cooling Adjust CFM
Selections
Low
First Stage Cool Speed- cfm
Medium
Low
Medium
High
Blower Speed Selections
High
(Default)
Low
Second Stage Cool Speed-cfm
Medium
Low
Medium
High
High
(Default) increase (+10%) Cool CFM
Default Cool CFM
911
805
Low
1043
960
1227
1087
1434
1296
1335
1173
1559
1433
1719
1568
1986
1811
Decrease (-10%) Cool CFM
Decrease (-15% ) Heat CFM
COOLING BLOWER PERFORMANCE
1451
A96UHMV090C20S BLOWER PERFORMANCE (less fil ter) RIGHT SIDE RETURN AIR WITH OPTIONAL RETURN
AIR BASE HEATING BLOWER PERFORMANCE
Heating Adjust CFM Selections
Increase (+15%) Heat CFM
Increase (+7,5%) Heat CFM
Default Heat CFM
Decrease (-7.5%) Heat CFM
700 840
40%
686
626
566
502
437
991
Heating input Range and Blower Volume - CFM
50%
837
771
705
633
560
1115
60%
987
916
844
764
683
1049
70%
1138
1060
983
895
806
1283
80%
1288
1205
1121
1026
930
90%
1439
1349
1260
1157
1053
1603
100%
1589
1494
1399
1288
1176
Cooling Adjust CFM
Selections
First Stage Cool Speed- cfm
Medium
Low
Medium
High
Blower Speed Selections
High
(Default)
Low
Second Stage Cool Speed-cfm
Medium
Low
Medium
High
High
(Default)
1982
1807
1619 increase (+10%) Cool CFM
Default Cool CFM
913
827
1037
953
1230
1088
1415
1278
1329
1177
1560
1414
1740
1586
Decrease (-10%) Cool CFM 741 855 995 1117 1044 1261 1432
The effect of static pressure is included in air volumes shown.
The following control configurations are available. See Installation Instructions for details and DIP switch settings.
Heat Modes Available (Heating Blower Performance Table):
Single stage thermostat:
- 40%, 70%. 100% input (three-stage) with time delays in-between
Two-stage thermostat:
- Variable Rate Capacity Mode - furnace automatically adjusts firing rate based on first- and second-stage cycle times
- W1 demand at 70% input, W2 demand at 100% input. No delay between stages
Cool Mode Available (Cooling Blower Performance table):
First stage COOL (two-stage air conditioning units only) is approximately 70% of the same second stage COOL speed position,
Continuous Fan speeds are approximately 38% of the same second-stage COOL speed position minimum 300 cfm.
507028-03 Issue 1622 Page 53 of 74
Unit Start Up
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING
Do not use this furnace if any part has been underwater.
A flood damaged furnace is extremely dangerous.
Attempts to use the furnace can result in fire or explosion.
Immediately call a qualified service technician to inspect the furnace and to replace all gas controls, control system parts, and electrical parts that have been wet or to replace the furnace, if deemed necessary.
WARNING
Danger of explosion. Can cause injury or product or property damage. Should the gas supply fail to shut off or if overheating occurs, shut off the gas valve to the furnace before shutting off the electrical supply.
BEFORE PLACING THE UNIT INTO OPERATION
Smell all around the furnace area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.
The gas valve on these units are equipped with a gas control switch. Use only your hand to move the control switch.
Never use tools. If the switch will not move by hand, do not try to repair it. Force or attempted repair may result in a fire or explosion.
Placing the Furnace into Operation:
These units are equipped with an automatic ignition system.
Do not attempt to manually light burners on this furnace.
Each time the thermostat calls for heat, the burners will automatically light. The ignitor does not get hot when there is no call for heat on units with this ignition system.
WARNING
If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or death.
CAUTION
Before attempting to perform any service or maintenance, turn the electrical power to unit OFF at disconnect switch.
WARNING
During blower operation, the ECM motor emits energy that may interfere with pacemaker operation.
Interference is reduced by both the sheet metal cabinet and distance.
Priming Condensate Trap
The condensate trap should be primed with water prior to startup to ensure proper condensate drainage. Either pour
10 fl. oz. (300 ml) of water into the trap, or follow these steps to prime the trap:
1. Follow the lighting instructions to place the unit into operation.
2. Set the thermostat to initiate a heating demand.
3. Allow the burners to fire for approximately 3 minutes.
4. Adjust the thermostate to deactivate the heating demand.
5. Wait for the combustion air inducer to stop. Set the thermostat to initiate a heating demand and again allow the burners to fire for approximately 3 minutes.
6. Ajust the thermostat to deactivate the heating demand and again wait for the combustion air inducer to stop.
At this point, the trap should be primed with sufficient water to ensure proper condensate drain operation.
Page 54 of 74 Issue 1622
Gas Valve Operation (Figure 49)
1. STOP!
Read the safety information at the beginning of this sectioin.
2. Set the thermostat to the lowest setting.
3. Turn all electrical power to the unit.
4. This furnace is equipped with an ignition device which automatically lights the burners. DO NOT try to light the burners by hand.
5. Remove the access panel.
6. Move the gas valve switch to the OFF position. See
Figure 42.
7. Wait five minutes to clear out any gas. If you then smell gas, STOP!
Immediately call the gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions. If you do not smell gas go to the next step.
8. Move gas valve switch to the ON position. See Figure
42. DO Not force.
Figure 49
507028-03
9. Replace the access panel.
10. Turn on all electrical power to the unit.
11. Set the thermostat to desired setting.
NOTE: When unit is initially started, steps 1 through 11 may need to be repeated to purge air from gas line.
12. If the Appliance will not operate, follow the instructions
“Turning Off Gas to Unit” and call the gas supplier.
Turning Off Gas to Unit
1. Set the thermostat to the lowest settling.
2. Turn all electrical power to the unit if service is to be performed.
3. Remove the access panel.
4. Move the gas valve switch to the OFF position.
5. Replace the access panel.
Failure To Operate
If the unit fails to operate, check the following:
1. Is the thermostat calling for heat?
2. Are access panels securely in place?
3. Is the main disconnect switch closed?
4. Is there a blown fuse?
5. Is the filter dirty or plugged? Dirty or plugged filters will cause the limit conrol to shut the unit off.
6. Is gas turned on at the meter?
7. Is the manual main shut Off valve open?
8. Is the gas valve turned on?
9. Is the unit ignition system in lock out: If the unit locks out again, inspect the unit for blockages.
10. Is blower harness connected to ignition control?
Furnace will not operate unless harness is connected.
Gas Pressure Measurement
Gas Flow (Approximate)
NOTE: To obtain accurate reading, shut off all other gas appliances connected to meter.
Supply Pressure Measurement
A threaded plug on the inlet side of the gas valve provides access to the supply pressure tap. Remove the threaded plug, install a field provided barbed fitting and connect a manometer to measure supply pressure. Replace the threaded plug after measurements have been taken.
Manifold Pressure Measurement
To correctly measure manifold pressure, the differential pressure between the positive gas manifold and the negative burner box must be considered. Use pressure test adapter kit (available as part 10L3) to assist in measurement.
1. Remove the threaded plug from the outlet side of the gas valve and install a field provided barbed fitting.
Connect test gauge “+” connection to barbed fitting to measure manifold pressure.
2. Tee into the gas valve regulator vent hose and connect test gauge “-” connection.
3. Start unit on low heat (40% rate) and allow 5 minutes for unit to reach steady state.
4. While waiting for the unit to stabilize, notice the flame.
Flame should be stable and should not lift from burner.
Natural gas should burn blue.
5. After allowing unit to stabilize for 5 minutes, record manifold pressure and compare to value given in Table
25.
6. Repeat steps 3, 4 and 5 on HIGH HEAT.
NOTE: Shut unit off and remove manometer as soon as an accurate reading has been obtained. Take care to remove barbed fitting and replace threaded plug.
CAUTION
DO NOT attempt to make adjustments to the gas valve.
Table 24
Furnace should operate at least 5 minutes before checking gas flow. Determine time in seconds for two revolutions of gas through the meter. (Two revolutions assures a more accurate time.) Divide by two and compare to time in
Table 21. If manifold pressure matches Table 24 and rate is incorrect, check gas orifices for proper size and restriction.
Remove temporary gas meter if installed.
NOTE: A natural to LP/propane gas changeover kit is necessary to convert this unit. Refer to the changeover kit installation instruction for the conversion procedure.
507028-03 Issue 1622
Operating Pressure Signal
Operating pressure signal can be taken while the manifold pressure check is taken (using two measuring devices). Or, taken after the manifold pressure measurement is complete.
1. Tee into the negative line between the gas valve and pressure switch and connect to measuring device negative “-”.
2. Tee into the positive line between the gas valve and pressure switch and connect to measuring device positive “+”.
3. Start unit on low heat (40% rate) and allow 5 minutes for unit to reach steady state.
4. After allowing unit to stabilize for 5 minutes, record operating pressure signal and compare to value given in Table 25.
5. Repeat steps 3 - 4 on high heat.
Page 55 of 74
Table 25
Manifold and Operating Signal Pressures in inches 0-7500 ft (0-2286 m)
NOTE: A natural to LP/propane gas changeover kit (Table 26) is necessary to convert this unit. Refer to the changeover kit installation instructions for the conversion procedure.
High Altitude Information
NOTE: In Canada, certification for installation at elevations over 4500 feet (1372 m) is the jurisidiction of local authorities.
These units require no manifold pressure adjustments for operation at altitudes up to 7,500 feet (2286 m) above sea level. Table 26 lists conversion kit requirements, pressure switch requirements and manifold pressures at all altitudes.
The combustion air pressure switch is factory set and requires no adjustment.
Model
Input
Size
Conversion Kit Requirements
LP/Propane
Kit
0 - 10,000
(0-3048 m)
High Altitude Pressure Switch Kit
0 - 7,500
(0 - 2286 m)
7,501 - 10,000
(2287 - 3048m)
70
90
110
135
68W77 Not required 14T65
Table 26
Proper Combustion
Furnace should operate a minimum of 15 minutes with correct manifold pressure and gas flow rate before checking combustion. Take combustion sample beyond the flue outlet and compare to the tables below. The maximum carbon monoxide reading should not exceed 100 ppm.
High Fire
Table 27
Low Fire
Table 28
Page 56 of 74 Issue 1622 507028-03
BLOWER DATA
A96UHMV110C20S BLOWER PERFORMANCE (less filter)
BOTTOM RETURN AIR
HEATING BLOWER PERFORMANCE
Heating Adjust CFM Selections
Increase (+15%) Heat CFM
Increase (+7.5%) Heat CFM
Default Heat CFM
Decrease (-7.5%)’Heat CFM
Decrease (-15%) Heat CFM
COOLING BLOWER PERFORMANCE
Cooling Adjust CFM
Selections
40%
861
825
789
731
673
Heating input Range and Blower Volume - CFM
50%
1049
1000
951
883
816
60%
1237
1174
1112
1035
958
70%
1424
1349
1274
1187
1101
80%
1612
1524
1436
1339
1243
90%
1800
1699
1597
1491
1386
100%
1988
1874
1759
1644
1528
Low
Blower Speed Selections
First Stage Cool Speed- cfm Second Stage Cool Speed-cfm
Medium
Low
Medium
High
High
(Default)
Low Medium
Low
Medium
High
High
(Default) increase (+10%) Cool CFM
Default Cool CFM
937
864
Low
1064
972
1247
1146
1407
1282
1312
1219
1560
1405
1744
1569
1955
1796
Decrease (-10%) Cool CFM
Decrease (-15% ) Heat CFM
COOLING BLOWER PERFORMANCE
1428
A96UHMV110C20S BLOWER PERFORMANCE (less filter)
RIGHT SIDE RETURN AIR
HEATING BLOWER PERFORMANCE
Heating Adjust CFM
Selections
Increase (+15%) Heat CFM
Increase (+7,5%) Heat CFM
Default Heat CFM
Decrease (-7.5%) Heat CFM
790 888
40%
733
708
683
632
580
1025
Heating input Range and Blower Volume - CFM
50%
825
794
763
707
650
1167
60%
1009
967
924
857
790
1075
70%
1194
1139
1085
1007
929
1272
80%
1378
1312
1245
1157
1069
90%
1562
1484
1406
1307
1209
1634
100%
1747
1657
1566
1457
1348
Cooling Adjust CFM
Selections
First Stage Cool Speed- cfm
Medium
Low
Medium
High
Blower Speed Selections
High
(Default)
Low
Second Stage Cool Speed-cfm
Medium
Low
Medium
High
High
(Default) increase (+10%) Cool CFM
Default Cool CFM
Decrease (-10%) Cool CFM
918
820
722
1053
964
852
1198
1095
987
1366
1231
1116
1270
1170
1059
1519
1363
1218
1712
1555
1401
The effect of static pressure is included in air volumes shown.
The following control configurations are available. See Installation Instructions for details and DIP switch settings.
Heat Modes Available (Heating Blower Performance Table):
Single stage thermostat:
- 40%, 70%. 100% input (three-stage) with time delays in-between
Two-stage thermostat:
- Variable Rate Capacity Mode - furnace automatically adjusts firing rate based on first- and second-stage cycle times
- W1 demand at 70% input, W2 demand at 100% input. No delay between stages
Cool Mode Available (Cooling Blower Performance table):
First stage COOL (two-stage air conditioning units only) is approximately 70% of the same second stage COOL speed position,
Continuous Fan speeds are approximately 38% of the same second-stage COOL speed position minimum 300 cfm.
1899
1774
1581
507028-03 Issue 1622 Page 57 of 74
BLOWER DATA
A96UHMV110C20S BLOWER PERFORMANCE (less filter)
RIGHT SIDE RETURN AIR WITH OPTIONAL RETURN AIR BASE
HEATING BLOWER PERFORMANCE
Heating Adjust CFM Selections Heating input Range and Blower Volume - CFM
Increase (+15%) Heat CFM
Increase (+7.5%) Heat CFM
Default Heat CFM
Decrease (-7.5%)’Heat CFM
Decrease (-15%) Heat CFM
COOLING BLOWER PERFORMANCE
Cooling Adjust CFM
Selections
Low
40%
893
814
736
680
623
Blower Speed Selections
Medium
Low
50%
1068
986
903
833
762
First Stage Cool Speed- cfm
Medium
High
60%
1243
1157
1071
986
901
High
(Default)
70%
1419
1329
1238
1139
1040
80%
1594
1500
1406
1293
1179
90%
1770
1672
1573
1446
1318
Second Stage Cool Speed-cfm
Low Medium
Low
Medium
High
100%
1945
1843
1741
1599
1457
High
(Default) increase (+10%) Cool CFM
Default Cool CFM
918
839
1022
955
1205
1084
1371
1235
1268
1158
1487
1369
1726
1568
1913
1764
Decrease (-10%) Cool CFM
A96UHMV135D20S BLOWER PERFORMANCE (less filter)
BOTTOM RETURN AIR
HEATING BLOWER PERFORMANCE
Heating Adjust CFM
Selections
760 865
Heating input Range and Blower Volume - CFM
40%
984
50%
1109
60%
1030
70%
1224
80%
1393
90%
1575
100%
Increase (+15%) Heat CFM
Increase (+7,5%) Heat CFM
Default Heat CFM
Decrease (-7.5%) Heat CFM
Decrease (-15% ) Heat CFM
COOLING BLOWER PERFORMANCE
Cooling Adjust CFM
Selections
1033
957
881
817
753
1200
1113
1026
956
886
1367
1269
1172
1095
1019
1534
1426
1317
1235
1152
1701
1582
1463
1374
1284
1868
1738
1608
1513
1417
2035
1895
1754
1652
1550 increase (+10%) Cool CFM
Default Cool CFM
Blower Speed Selections
First Stage Cool Speed- cfm
Low
935
834
Medium
Low
1074
983
Medium
High
1260
1116
High
(Default)
1450
1306
Second Stage Cool Speed-cfm
Low Medium
Low
Medium
High
High
(Default)
1353
1202
1567
1448
1751
1616
Decrease (-10%) Cool CFM 732 867 1023 1145 1080 1290 1472
The effect of static pressure is included in air volumes shown.
The following control configurations are available. See Installation Instructions for details and DIP switch settings.
Heat Modes Available (Heating Blower Performance Table):
Single stage thermostat:
- 40%, 70%. 100% input (three-stage) with time delays in-between
Two-stage thermostat:
- Variable Rate Capacity Mode - furnace automatically adjusts firing rate based on first- and second-stage cycle times
- W1 demand at 70% input, W2 demand at 100% input. No delay between stages
Cool Mode Available (Cooling Blower Performance table):
First stage COOL (two-stage air conditioning units only) is approximately 70% of the same second stage COOL speed position,
Continuous Fan speeds are approximately 38% of the same second-stage COOL speed position minimum 300 cfm.
1994
1828
1668
Page 58 of 74 Issue 1622 507028-03
Model
Input
Size
LP/Propane
Kit
0 - 10,000
(0 - 3048 m)
Conversion Kit Requirements and Manifold Test Pressures
High Altitude Pressure
Switch Kit
0 - 7,500
(0 - 2286 m)
7,501 - 10,000
(2287 - 3048 m)
Manifold Pressure at All Altitudes (In. w.g.)
High Fire
(100% rate)
Gas Orifice
Low Fire
(35% rate)
Natural Gas LP/Propane Natural Gas LP/Propane Nat
Size
LP
-070
-090
-110
-135
68W77 Not required 72W89 0.40 - 0.60
1.2 - 1.8
3.2 - 3.8
NOTE: The values given in table 23 are measurements only. The gas valve should not be adjusted.
9.5 - 10.5
.0625
.034
Table 24
Manifold Pressure Measurement
To correctly measure manifold pressure, the differential pressure between the positive gas manifold and the negative burner box must be considered. Use pressure test adapter kit (available as part 10L34) to assist in measurement.
Pressure Switches (Two)
The pressure switches are located on the cold end header box. These switches check for proper combustion air inducer operation before allowing ignition trial. The switches are factory set and require no adjustment.
1. Remove the threaded plug from the outlet side of the gas valve and install a field provided barbed fitting.
Connect test gauge “+” connection to barbed fitting to measure manifold pressure.
2. Tee into the gas valve regulator vent hose and connect test gauge “-” connection.
3. Start unit on low heat (35% rate) and allow 5 minutes for unit to reach steady state.
4. While waiting for the unit to stabilize, notice the flame.
Flame should be stable and should not lift from burner.
Natural gas should burn blue.
5. After allowing unit to stabilize for 5 minutes, record manifold pressure and compare to value given in Table
24.
6. Repeat steps 3, 4 and 5 on HIGH HEAT.
Temperature Rise
After the furnace has been started and supply and return air temperatures have been allowed to stabilize, check the temperature rise with the unit operating at 100 percent firing rate. If necessary, adjust the blower speed to maintain the temperture rise within the range shown on the unit nameplate. Increase the blower speed to decrease the temperature. Decrease the blower speed to increase the temperature. Decrease the blower speed to increase the temperature rise. Failure to adjust the temperature rise may cause erratic limit operation.
Thermostat Heat Anticipation
Set the heat anticipator setting (if adjustable) according to the amp draw listed on the wiring diagram that is attached to the unit.
NOTE: Shut unit off and remove manometer as soon as an accurate reading has been obtained. Take care to remove barbed fitting and replace threaded plug.
DO NOT
CAUTION
attempt to make adjustments to the gas valve.
Electronic Ignition
The integrated control has a feature that serves as an automatic reset device for ignition control lockout caused by ignition failure. This type of lockout is usually due to low gas line pressure. After one hour of continuous thermostat demand for heat, the control will break and remake thermostat demand to the furnace and automatically reset the control to begin the ignition sequence.
Other Unit Adjustments
Primary Limit
The primary limit is located on the heating compartment vestibule panel. This limit is factory set and requires no adjustment.
Flame Rollout Switches (Two)
These manually reset switches are located on the inside of the burner box. If tripped, check for adequate combustion air before resetting.
Exhaust and Air Intake Pipe
1. Check exhaust and air intake connections for tightness and to make sure there is not blockage.
2. Are pressure switches closed? Obstructed exhaust pipe will cause unit to shut off at pressure switches. Check termination for blockages.
3. Reset manual flame rollout switches on burner box cover.
507028-03 Issue 1622 Page 59 of 74
Heating Sequence of Operation
The integrated control initiates a pressure switch calibration at the initial unit start-up on a call for heat. The ignition control will also initiate a calibration any time main power is turned off and back on and a heating demand is present.
Additional calibrations may be initiated by the service technician during field test sequence. The following heating sequence of operation assumes completion of a successful calibration.
NOTE: The thermostat selection DIP switch on the integrated control is factory set in the “TWO STAGE” position.
Applications Using a Two Stage Thermostat
A-Heating Sequence - Control Thermostat Selection
DIP switch in “Two Stage” Position (Factory Settling)
1. On a call for heat, thermostat first stage contacts close sending a signal to the integrated control. The integrated control runs a self diagnostic program and checks high temperature limit switches for normally closed contacts and pressure switches for normally open contacts. The combustion air inducer is energized at ignition speed, Which is approximately the same as the inducer speed at 70 percent firing rate.
2. Once the control receives a signal that the low fire pressure switch has closed, the combustion air inducer begins a 15 second prepurge in the ignition speed.
3. After the prepurge is complete, a 20 second initial ignitor warm up period begins. The combustion air inducer continues to operate at the ignition speed.
4. After the 20 second warm up period has ended, the gas valve is energized and ignition occurs. At the same time, the control module sends a signal to begin an indoor blower 30 second ON delay. When the delay ends, the indoor blower motor is energized at a speed that matches the firing rate. After the 10 second ignition stabilization delay expires, the inducer speed is adjusted to the appropriate target rate. The inducer will remain at the 70 percent speed as long as the thermostat has a first stage heating demand.
5. If second stage heat is required, the thermostat second stage heat contacts close and send a signal to the integrated control. The integrated control initiates a 30 second secon stage recognition delay.
6. At the end of the recognition delay and on all subsequent calls for heat in the same heating cycle, the intergrated control energizes the combustion air inducer at high speed. The control also checks the high fire pressure switch to make sure it is closed. As the inducer speed is increased to high, the indoor blower motor is adjusted to a speed which is appropriate for the target rate.
7. When the demand for high fire (second stage) heat is satisfied, the gas valve is de-energized and the field selected indoor blower off delay begins. The combustion air inducer begins a 20 second post purge period.
8. When the combustion air post purge period is complete, the inducer is de-energized. The indoor blower is deenergized at the end of the off delay.
Application Using a Two Stage Thermostat
B - Heating Sequence - Control Thermostat Selection
DIP switch in “Variable Capacity” Position
1. On a call for heat, thermostat first stage contacts close sending a signal to the integrated control. The integrated control runs a self diagnostic program and checks high temperature limit switches for normally closed contacts and pressure switches for normally open contacts. The combustion air inducer is energized at ignition speed, which is approximately the same as the inducer speed at 70 percent firing rate.
2. Once the control receives a signal that the low fire pressure switch has closed, the combustion air inducer begins a 15 second prepurge in low speed.
3. After the prepurge is complete, a 20 second initial ignitor warm-up period begins. The combustion air inducer continues to opeate at the ignition speed.
4. After the 20 second warm up period has ended, the gas valve is energized and ignition occurs. At the same time, the control module begins an indoor blower 30 second ON delay. When the delay ends, the indoor blower motor is energized at a speed that matches the firing rate. After the 10 second ignition stabilization delay expires, the inducer speed is adjusted to the appropriate target rate. If the furnace is operating in the initial heating cycle after power up, the initial firing rate will be approximately 35 percent. The firing rate on subsequent cycles will be automatically adjusted by the integrated control based on thermostat cycles. The firing rate will vary and will range from 35 percent to 90 percent. The furnace will continue this operation as long as the thermostat has a first stage heating demand.
Page 60 of 74 Issue 1622 507028-03
5. If second-stage heat is required, the thermostat second stage heat contacts close and send a signal to the integrated control. The integrated control either increases the firing rate to 70 percent (if the current rate is at or below 60 percent) or increases the firing rate by
10 percent (if the current rate is above 60 percent). If the call for heat continues 5 minutes beyond this initial upstage, the rate will be increased by 10 percent every
5 minutes until the call for heat is satisfied or the furnace reaches 100 percent rate. As the firing rate increases, the indoor blower motor is adjusted to a speed which is appropriate for the target rate.
6. If second-stage heat demand is satisfied, but first stage is still present, the furnace will continue to operate at the present firing rate until the heat cycle ends.
7. When the demand for first and second stage heat is satisfied, the gas valve is de-energized and the fieldselected indoor blower off delay begins. The combustion air inducer begins a 20 second post-purge period.
8. When the combustion air post purge period is complete, the inducer is de-energized. The indoor blower is deenergized at the end of the off delay.
Applications Using A Single-Stage Thermostat
C - Heating Sequence -- Control Thermostat Selection
DIP switch in “Single Stage” Position
1. On a call for heat, thermostat first stage contacts close sending a signal to the integrated control. The integrated control runs a self-diagnostic program and checks high temperature limit switches for normally closed contacts and pressure switches for normally open contacts. The combustion air inducer is energized at the ignition speed, which is approximately the same as the inducer speed at 70 percent firing rate.
2. Once the control receives a signal that the low fire pressure switch has closed, the combustion air inducer begins a 15 second prepurge at the ignition speed.
3. After the prepurge is complete, a 20 second initial ignitor warm up period begins. The combustion air inducer continues to operate at the ignition speed.
4. After the 20 second warm up period has ended, the gas valve is energized and ignition occurs, which initiates a
10 second ignition stabilization delay. At the same time, the control module sends a signal to begin an indoor blower 30 second ON delay. When the delay ends, the indoor blower motor is energized at a speed which is appropriate for the firing rate. After the 10 second ignition stabilization delay expires, the inducer speed is adjusted to 35 percent speed. The integrated control also initiates a second-stage on delay (factory set at 7 minutes; adjustable to 12 minutes).
5. If the heating demand continues beyond the secondstage on delay, the integrated control energizes the combustion air inducer at 70 percent speed. The indoor blower motor is adjusted to a speed which matches the target rate. A fixed, 1O minute third stage on delay is initiated.
6. If the heating demand continues beyond the thirdstage on delay, the integrated control energizes the inducer at high speed. The indoor blower motor is adjusted to a speed which is appropriate for the target rate.
7. When the thermostat heating demand is satisfied, the gas valve is de-energized and the combustion air inducer begins a 20 second post purge. The field selected indoor blower off delay begins.
8. When the combustion air post purge period is complete, the inducer is de-energized. The indoor blower is deenergized at the end of the off delay.
507028-03 Issue 1622 Page 61 of 74
Service
WARNING
ELECTRICAL SHOCK, FIRE,
OR EXPLOSION HAZARD.
Failure to follow safety warnings exactly could result in dangerous operation, serious injury, death or property damage.
Improper servicing could result in dangerous operation, serious injury, death, or property damage.
Before servicing, disconnect all electrical power to furnace.
When servicing controls, label all wires prior to disconnecting. Take care to reconnect wires correctly.
Verify proper operation after servicing.
At the beginning of each heating season, system should be checked as follows by a qualified service technician:
Blower
Check the blower wheel for debris and clean if necessary.
The blower motors are prelubricated for extended bearing life. No further lubrication is needed.
WARNING
The blower access panel must be securely in place when the blower and burners are operating. Gas fumes, which could contain carbon monoxide, can be drawn into living space resulting in personal injury or death.
Filters
All filters are installed external to the unit. Filters should be inspected monthly. Clean or replace the filters when necessary to ensure proper furnace operation. Table 1 lists recommended filter sizes.
Exhaust and air intake pipes
Check the exhaust and air intake pipes and all connections for tightness and to make sure there is no blockage.
NOTE: After any heavy snow, ice or frozen fog event the furnace vent pipes may become restricted. Always check the vent system and remove any snow or ice that may be obstructing the plastic intake or exhaust pipes.
Electrical
1. Check all wiring for loose connections.
2. Check for the correct voltage at the furnace (furnace operating).
Page 62 of 74
3. Check amp-draw on the blower motor.
Motor Nameplate_____________ Actual___________
Winterizing and Condensate Trap Care
1. Turn off power to the unit.
2. Have a shallow pan ready to empty condensate water.
3. Remove the drain cap from the condensate trap and empty water. Inspect the trap then reinstall the drain cap.
Cleaning Heat Exchanger
If cleaning the heat exchanger becomes necessary, follow the below procedures and refer to Figure 1 when disassembling unit. Use papers or protective covering in front of furnace while removing heat exchanger assembly.
1. Turn off electrical and gas supplies to the furnace.
2. Remove the furnace access panels.
3. Disconnect the 2 pin plug from the gas valve.
4. Remove gas supply line connected to gas valve.
Remove the burner box cover and remove gas valve manifold assembly.
5. Remove sensor wire from sensor. Disconnect 2 pin plug from the ignitor.
6. Disconnect wires from flame rollout switches.
7. Remove four burner box screws at the vestibule panel and remove burner box. Set burner box assembly aside.
NOTE: If necessary, clean burners at this time. Follow procedures outlined in Burner Cleaning section.
8. Loosen the clamps to the flexible exhaust coupling.
9. Disconnect condensate drain line from the cold end header box.
10. Disconnect condensate drain tubing from flue collar.
Remove screws that secures the flue collar into place.
Remove flue collar. It may be necessary to cut the exiting exhaust pipe for removal of the fitting.
11. Mark and disconnect all combustion air pressure tubing from cold end header collector box.
12. Mark and remove wires from pressure switches.
Remove pressure switches. Keep tubing attached to pressure switches.
13. Disconnect the 4 pin plug from the combustion air inducer. Remove two screws which secure combustion air inducer to collector box. Remove combustion air inducer assembly. Remove ground wire from vest panel.
14. Remove electrical junction box from the side of the furnace.
15. Mark and disconnect any remaining wiring to heating compartment components. Disengage strain relief bushing and pull wiring and bushing through the hole in the blower deck.
16. Remove the primary limit from the vestibule panel.
17. Remove two screws from the front cabinet flange at the blower deck. Spread cabinet sides slightly to allow clearance for removal of heat exchanger.
Issue 1622 507028-03
18. Remove screws along vestibule sides and bottom which secure vestibule panel and heat exchanger assembly to cabinet. Remove two screws from blower rail which secure bottom heat exchanger flange. Remove heat exchanger from furnace cabinet.
19. Back wash heat exchanger with soapy water solution or steam. If steam is used it must be below 275°F (135°C).
20. Thoroughly rinse and drain the heat exchanger. Soap solutions can be corrosive. Take care to rinse entire assembly.
21. Reinstall heat exchanger into cabinet making sure that the clamshells of the heat exchanger assembly are resting on the support located at the rear of the cabinet.
Remove the indoor blower to view this area through the blower opening.
22. Re-secure the supporting screws along the vestibule sides and bottom to the cabinet.
23. Reinstall cabinet screws on front flange at blower deck.
24. Reinstall the primary limit on the vestibule panel.
25. Route heating component wiring through hole in blower deck and reinsert strain relief bushing.
26. Reinstall electrical junction box.
27. Reinstall the combustion air inducer. Reconnect the 4 pin plug to the wire harness.
28. Reinstall pressure switches and reconnect pressure switch wiring.
29. Carefully connect combustion air pressure switch hosing from pressure switches to proper stubs on cold end header collector box.
30. Reconnect condensate drain line to the cold end header box.
31. Use securing screws to reinstall flue collar to the top cap on the furnace. Reconnect exhaust piping and exhaust drain tubing.
32. Replace flexible exhaust adapter on combustion air inducer and flue collar. Secure using two existing hose clamps.
33. Reinstall burner box assembly in vestibule area.
34. Reconnect flame roll-out switch wires.
35. Reconnect sensor wire and reconnect 2 pin plug from ignitor.
36. Secure burner box assembly to vestibule panel using four existing screws. Make sure burners line up in center of burner ports.
37. Reinstall gas valve manifold assembly. Reconnect gas supply line to gas valve.
38. Reinstall burner box cover.
39. Reconnect 2 pin plug to gas valve.
40. Replace the blower compartment access panel.
41. Refer to instruction on verifying gas and electrical connections when re-establishing supplies.
42. Follow lighting instructions to light and operate furnace for 5 minutes to ensure that heat exchanger is clean and dry and that furnace is operating properly.
43. Replace heating compartment access panel.
Cleaning the Burner Assembly
1. Turn off electrical and gas power supplies to furnace.
Remove upper and lower furnace access panels.
2. Disconnect the 2 pin plug from the gas valve.
3. Remove the burner box cover.
4. Disconnect the gas supply line from the gas valve.
Remove gas valve/manifold assembly.
5. Mark and disconnect sensor wire from the sensor.
Disconnect wires from flame rollout switches.
6. Remove four screws which secure burner box assembly to vest panel. Remove burner box from the unit.
7. Use the soft brush attachment on a vacuum cleaner to gently clean the face of the burners. Visually inspect the inside of the burners and crossovers for any blockage caused by foreign matter. Remove any blockage.
8. Reinstall the burner box assembly using the existing four screws. Make sure that the burners line up in the center of the burner ports.
9. Reconnect the sensor wire and reconnect the 2 pin plug to the ignitor wiring harness. Reconnect wires to flame rollout switches.
10. Reinstall the gas valve manifold assembly. Reconnect the gas supply line to the gas valve. Reinstall the burner box cover.
11. Reconnect 2 pin plug to gas valve.
12. Replace the blower compartment access panel.
13. Refer to instruction on verifying gas and electrical connections when re-establishing supplies.
14. Follow lighting instructions to light and operate furnace for 5 minutes to ensure that heat exchanger is clean and dry and that furnace is operating properly.
15. Replace heating compartment access panel.
507028-03 Issue 1622 Page 63 of 74
Planned Service
A service technician should check the following items during an annual inspection. Power to the unit must be shut off for the service technician’s safety.
Burners - Must be inspected for rust, dirt, or signs of water.
Vent pipe - Must be inspected for signs of water, cracked, damaged or sagging pipe, or disconnected joints.
Unit appearance - Must be inspected for rust, dirt, signs of water, burnt or damaged wires, or components.
Blower access door - Must be properly in place and provide a seal between the return air and the room where the furnace is installed.
Return air duct - Must be properly attached and provide an air seal to the unit.
Operating performance - Unit must be observed during operation to monitor proper performance of the unit and the vent system.
Combustion gases - Flue products must be analyzed and compared to the unit specifications.
Problems detected during the inspection may make it necessary to temporarily shut down the furnace until the items can be repaired or replaced.
Instruct the homeowners to pay attention to their furnace . Situations can arise between annual furnace inspections that may result in unsafe operation.
Page 64 of 74 Issue 1622 507028-03
Integrated Control Diagnostic Codes
Press the diagnostic push button and hold it to cycle through a menu of options. Every five seconds a new menu item will be displayed.
Release the button when the desired mode is displayed.
When a solid “P” is displayed, the furnace capacity/ size is programmed.
When the solid “E” is displayed, the control enters the Error Code Recall mode. Error Code Recall mode menu options: No change (displaying error history) remains in Error Code Recall mode; solid “b” exits Error Code Recall mode; and solid “c” clears the error history. Must press button while flashing “c” is displayed to clear error codes.
When the solid “-” is displayed, the control enters the Field Test mode. Field Test mode menu options: Solid “C” starts pressure switch calibration; blinking “-” exits Field Test mode.
507028-03 Issue 1622 Page 65 of 74
Configuring Unit Size Codes
Power-Up - Number displayed represents by integrated control unit size code (furnace model and capacity). If three horizontal bars are displayed followed by continuous E203, furnace control does not recognize unit size code. Configure per the following:
To enter Field Test
Mode: push and hold button next to
7-segment LED display until solid dash symbol appears. Release button.
Yes
B
Furnace control in IDLE mode
No heating, cooling or indoor fan operation)
No
Turn room thermostat to OFF
CODE
1
2
FURNACE
If alarm is present, furnace control will display error code. If alarm is not present solid dash starts blinking on
7-segment LED display.
B
Push and hold button until the solid P symbol is displayed on the 7-segment
LED. Release button. This mode allows the user to select a unit size code number that matches the furnace model size and capacity.
IMPORTANT: Field replacement controls may need to be manually configured to validate furnace unit size code.
3
Solid P starts blinking on
7-Segment LED
3
Push and hold button. Integrated control will display unit size code number for each furnace model for five seconds.
When the correct unit size code is displayed, release button. Selected code will flash for
10-second period. During that period, hold push button until code stops blinking (disappear for 2 seconds). Integrated control will store code in memory and will automatically exit Field Test Mode and reset. (If second period expires or push button is held less than five seconds, control will automatically exit Field Test Mode and go into
IDLE mode without storing unit size code. If this happens, programming function must be repeated).
Verify that the selected unit size code is correct and stored in non-volatile memory by cycling the 24 volt power to the furnace control. (At 24 volt power-up of the furnace control, the
7-segment LED will display a unit size code. If three horizontal bars display, board does not recognize unit size code. Programming function must be repeated)
FINISHED
Page 66 of 74 Issue 1622 507028-03
Troubleshooting: Heating Sequence of Operation
Ignition and Call for Low Fire With Two Stage
Thermostat
507028-03 Issue 1622 Page 67 of 74
Troubleshooting : Heating Sequence of Operation (continued)
Call for High Fire With Two Stage Thermostat
2
1
2 Stage
Thermostat
1st Call for High
Fire?
YES
2nd Stage
Recognition Delay
(30 Seconds)
NO
Combustion Air Inducer ON
(100% Rate Speed)
High
Pressure Switch
Closes Within
10 Seconds?
NO
Increase Combustion
Air Inducer Speed
if Not at 100%
Rate Speed
Error Code
Flashes
YES
Adjust Indoor
Blower to
Appropiate speed
3A Wait for Call for Heat Satisfied
Wait 5
Minutes
Page 68 of 74
1
2
System will always light at 70% even if 2nd stage call for heat is in place
If the high pressure switch does not close within 5 attempts, the system will operate at low fire for the remainder of the call for heat at request
Issue 1622 507028-03
Troubleshooting : Heating Sequence of Operation (continued)
Call for Heat Satisfied
RUN MODE (TWO-STAGE THERMOSTAT)
FIRST OR SECOND-STAGE CALL FOR HEAT
ALL INPUTS MONITORED (LIMIT, PRESSURE,
CALL FOR HEAT/COOL, FLAME LEVEL).
3A 3B
RUN MODE (SINGLE-STAGE THERMOSTAT)
ALL INPUTS MONITORED (LIMIT, PRESSURE,
CALL FOR HEAT/COOL, FLAME LEVEL).
2nd Stage Heat
2nd Stage
Call for Heat satisfied?
YES
NO
Combustion Air Inducer switched to 70% rate speed
Adjust Indoor Blower to appropiate speed
1st Stage Heat
1st Stage
Call for Heat satisfied?
YES
Gas valve
De-Energized
NO
Combustion Air Inducer OFF after 20-Second Post Purge
Indoor Blower OFF after OFF Delay
1
Wait for Call
Two-Stage
Thermostat
OR 4
Wait for Call
Single-Stage
Thermostat
507028-03 Issue 1622 Page 69 of 74
Troubleshooting: Heating Sequence of Operation
S
T
A
G
E
1
S
T
H
E
A
T
C
A
L
L
F
O
R
1
IGNITION AND CALL FOR LOW FIRE WITH TWO-STAGE
THERMOSTAT
I
L
G
H
T
O
F
F
Safety
Check
Verify There
Is No Main Burner
Flame
Limit
Switch
Closed?
YES
Rollout
Circuit
Closed?
YES
Low
Pressure
Switch
Open?
NO
NO
NO
De-Energize
Gas Valve
De-Energize
Gas Valve
Error Code Flashes
After 5 Seconds
Indoor blower OFF
Heat OFF Delay
After
(Low Heat Speed)
Combustion Air
Inducer On
(100% rate speed)
Error Code
Flashes
Indoor Blower
ON (100%)
YES
Limit
Closes Within 3
Minutes?
NO
Indoor Blower OFF
After Heat OFF Delay
(High Heat Speed)
Combustion
Air Inducer
On (100% rate speed)
Indoor Blower
ON (70%)
Error Code
Flashes
Rollout
Circuit
Closes?
YES
Soft Lockout:
Error Code
Flashes
NO Combustion Air
Inducer OFF
After Post-Purge
1
High
Pressure
Switch
Open?
NO
Error Code Flashes
After 5 Seconds
Indoor Blower OFF After
Heat OFF Delay
Low Pressure
Switch Opens
YES
High Pressure
Switch Opens
Hard Lockout:
Error Code
YES
Combustion Air
Inducer ON at 70%
Rate Speed
YES
Call
For
Heat?
YES
NO
NO
Low
Pressure Switch
Closed Within 150
Seconds?
NO
Pressure Switch
Calibration
YES
Pre-Purge
15 Seconds
Calibration
Successful?
NO
Wait
5 minutes
4
Calibrations
Attempted?
YES
Soft Lockout:
Error Code
Flashes
NO
Call For
Heat
Ends?
YES
Ignitor ON
20 Seconds
Gas Valve
Energized
Interpurge
(15 Seconds)
NO
Indoor
Blower
ON?
YES
Indoor blower OFF
After Heat OFF Delay
NO
Ignition Trial Begins
(Ignitor ON)
Indoor Blower Delay
Timer Started
1
Flame
Sensed Within
4 seconds?
NO
Gas Valve
De-energized
Ignitor OFF
5th
Unsuccessful
Trial?
YES
Post-Purge
(20Seconds)
Combustion
Air Inducer
OFF
Soft Lockout:
Error Code
Flashes 1
YES
Ignitor OFF
Wait For Ignition
Stabilization Delay
Set Target Firing Rate
Based on Thermostat
Signals Present
1 SOFT LOCKOU T IS RESE T AUTOMATICALLY AFTER ONE HOUR WITH A CALL FOR HE AT ACTIVE,
OR BY CYCLING THE CAL L FOR HE AT, OR B Y CYCLING POWER TO THE CONTROL.
2 HARD LOCKOU T IS RESE T BY CYCLING POWER TO THE CONTROL.
2
Call For 2nd Stage Heat
OR
3A
Call For Heat Satisfied
Page 61
Page 70 of 74 Issue 1622 507028-03
Troubleshooting : Cooling Sequence of Operation
CALL FOR COOLING
5
1st Stage Cooling
Request Received
Energize 1st Stage
Cooling Contactor
(Compressor & Fan)
Indoor Blower On
After 2-second delay
1
Energize Indoor Blower
(Per Ramping Profile)
2
1
2nd Stage
Cooling
Request?
YES
Energize 2nd Stage
Cooling Contactor
(Compressor & Fan)
NO
YES
Energize Indoor Blower
(High Cooling mode)
2
2nd Stage
Cooling Request
Still Active?
YES
NO
De-Energize 2nd
Stage Cooling
Contactor
(Compressor & Fan)
Maintain Indoor Blower
(High Cooling mode)
1st Stage
Cooling Request
Still Active?
YES
NO
Energize and
Maintain Indoor Blower at
Low Cooling mode
De-Energize 1st
Stage Cooling
Contactor
(Compressor & Fan)
De-Energize Indoor Blower
Per Ramping Profile
2
YES
1st Stage
Cooling Request
Still Active?
NO
507028-03 Issue 1622 Page 71 of 74
Troubleshooting : Continuous Fan Sequence of Operation
Continuous Low Speed Indoor Blower Sequence of Operation
6
Call for
Continuous Blower
Indoor Blower On
(Speed Determined by
Dip Switch settings)
Request for Cooling
Received?
YES
Maintain Indoor
Blower at set speed
NO
Request for Heat
Received?
YES
NO
Maintain Indoor
Blower at set speed
5
1
OR
4
Go to Call for Cooling
Go to Call for Heat -- Two-Stage Thermostat
Go to Call for Heat -- Single-Stage Thermostat
Call for Fan
Removed?
NO
Maintain Indoor
Blower at set speed
1
YES
De-Energize
Indoor Blower Per
Ramping Profile
1
Indoor blower low cooling mode and high cooling mode, have specific ON - OFF and speed ramping profiles. The specific profile is selected using the dip switches on the control.
Page 72 of 74 Issue 1622 507028-03
REPAIR PARTS LIST
The following repair parts are available through Allied Air distributors. When ordering parts, include the complete furnace model number listed on the nameplate. All service must be performed by a licensed professional installer (or equivalent), service agency, or gas supplier.
Cabinet Parts
Outer Access Panel
Blower Access Panel
Top Cap
Control Panel Parts
Transformer
Integrated Control Board
Door Interlock Switch
Circuit Breaker
Heating Parts
Flame Sensor
Heat Exchanger Assembly
Gas Manifold
Combustion Air Inducer
Gas Valve
Main Burner Cluster
Main Burner Orifices
Pressure Switch
Ignitor
Primary Limit Control
Flame Rollout Switches
Blower Parts
Blower Wheel
Motor
Motor Mounting Frame
Blower Housing Cut Off Plate
Power Choke (1 HP only)
507028-03 Issue 1622 Page 73 of 74
REQUIREMENTS for COMMONWEALTH of MASSACHUSETTS
Modifications to NFPA-54, Chapter 10
Revise NFPA-54 section 10.8.3 to add the following requirements:
For all side wall, horizontally vented, gas-fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned
4. INSPECTION. The state or local gas inspector of the side wall, horizontally vented, gas-fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1 through 4.
or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above the finished grade in the area of the venting, including but
EXEMPTIONS: The following equipment is exempt from
24 CMR 5.08(2)(a) 1 through 4: not limited to decks and porches, the following requirements shall be satisfied:
1. INSTALLATION OF CARBON MONOXIDE
DETECTORS.
At the time of installation of the side wall, horizontally vented, gas-fueled equipment, the installing plumber or gas fitter shall observe that a hard-wired carbon monoxide detector with an alarm and battery backup is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gas fitter shall observe that a batteryoperated or hard-wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall, horizontally vented, gas-fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard-wired carbon monoxide detectors.
a. In the event that the side wall, horizontally equipment is installed in a crawl space or an attic, the hard-wired carbon monoxide
detector with alarm and battery backup may be
installed on the next adjacent floor level.
1. The equipment listed in Chapter 10 entitled “Equipment
Not Required to Be Vented” in the most current edition of NFPA 54 as adopted by the Board; and
2. Product Approved side wall, horizontally vented, gas-fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.
MANUFACTURER REQUIREMENTS -
GAS EQUIPMENT VENTING SYSTEM PROVIDED.
When the manufacturer of Product Approved side wall, horizontally vented, gas-fueled equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:
1. Detailed instructions for the installation of the venting system design or the venting system components: and
2. A complete parts list for the venting system design or venting system.
MANUFACTURER REQUIREMENTS -
GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED.
When the manufacturer of Product Approved sidewall, b. In the event that the requirements of this subdivision at the time of completion of cannot be met
installation, the owner shall have a period of thirty
(30) days to comply with the above requirements;
provided, however, that during said thirty (30) day
period, a battery-operated carbon monoxide
detector with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS.
Each carbon monoxide detector as required in accordance with the above provisions shall comply with
NFPA 720 and be ANSI/UL 2034 listed and IAS certified.
3. SIGNAGE . A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented, gas-fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP
CLEAR OF ALL OBSTRUCTIONS.” horizontally vented, gas-fueled equipment does not provide the parts for venting the flue gases, but identifies “special venting systems,” the following requirements shall be satisfied by the manufacturer:
1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation instructions; and
2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.
A copy of all installation instructions for all Product
Approved side wall, horizontally vented, gas-fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.
Page 74 of 74 Issue 1622 507028-03
advertisement
Related manuals
advertisement
Table of contents
- 3 Parts Arrangement
- 4 Gas Furnace
- 4 Shipping and Packing List
- 4 Safety Information
- 6 General
- 6 Setting Equipment
- 11 Filters
- 13 Joint Cementing Procedure
- 14 Venting Practices
- 14 Vent Piping Guidelines
- 28 Gas Piping
- 31 Electrical
- 40 Integrated Control
- 48 Blower Motor Performance
- 54 Unit Start Up
- 55 Gas Pressure Measurement
- 56 Proper Combustion
- 59 Other Unit Adjustments
- 62 Service
- 64 Planned Service
- 67 Troubleshooting