ComfortNET AMVC8 Operating instructions

Service Instructions
TM
Goodman®
& Amana® Brand
80% Communicating Gas Furnaces
GMVC8, AMVC8, ADVC8
& Accessories
®
This manual is to be used by qualified, professionally trained HVAC technicians only. Goodman does not assume any
responsibility for property damage or personal injury due to improper service procedures or services performed by
an unqualified person.
The material in this manual does not supercede manufacturer’s installation and operation instructions.
®
®
is a registered trademark of Maytag Corporation or its related companies and is used under license.
All rights reserved.
Copyright © 2013 Goodman Manufacturing Company, L.P.
RS6612008r2
December 2013
TABLE OF CONTENTS
IMPORTANT INFORMATION ............................... 3
SYSTEM OPERATION COMFORTNET™ ... 57 - 62
PRODUCT IDENTIFICATION ........................ 4 - 9
POLARIZATION AND PHASING ......................... 63
ACCESSORIES ..........................................10 - 11
MAINTENANCE ........................................... 64 - 66
OPERATING INSTRUCTIONS .................... 12 -14
SERVICING .................................................67 - 84
PRODUCT DESIGN .................................... 15 -39
SERVICING TABLE OF CONTENTS ................ 67
SYSTEM OPERATION ...............................40 - 44
ACCESSORY WIRING DIAGRAMS ............ 85 - 86
TROUBLESHOOTING ................................45 - 56
IMPORTANT INFORMATION
Pride and workmanship go into every product to provide our customers with quality products. It is possible, however,
that during its lifetime a product may require service. Products should be serviced only by a qualified service technician
who is familiar with the safety procedures required in the repair and who is equipped with the proper tools, parts, testing
instruments and the appropriate service manual. REVIEW ALL SERVICE INFORMATION IN THE APPROPRIATE
SERVICE MANUAL BEFORE BEGINNING REPAIRS.
IMPORTANT NOTICES FOR CONSUMERS AND SERVICERS
RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS
WARNING
TO PREVENT
THE RISK OF PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH,
DO NOT STORE COMBUSTIBLE MATERIALS OR USE GASOLINE OR OTHER
FLAMMABLE LIQUIDS OR VAPORS IN THE VICINITY OF THIS APPLIANCE.
WARNING
G OODMAN W ILL NOT BE R ESPONSIBLE FOR A NY INJURY OR PROPERTY DAM AGE ARISING FROM IMPROPER SER VICE OR SERVICE PROCEDURES.
I F YOU INSTA LL OR PERFORM SERVICE ON THIS UNIT, YOU ASSUME RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROPERTY DAMAGE WHICH
MAY RESU LT. M ANY JURISDICTIONS REQUIRE A LICENSE TO IN STALL OR SERVICE HEATING AN D A IR CONDITIONING EQUIPMENT.
WARNING
HIGH VOLTAGE
DISCONNECT ALL POWER BEFORE SERVICING OR
INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY
BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY
DAMAGE, PERSONAL INJURY OR DEATH.
2
IMPORTANT INFORMATION
Special Warning for Installation of Furnace or Air Handling Units in
Enclosed Areas such as Garages, Utility Rooms or Parking Areas
Carbon monoxide producing devices (such as an automobile, space
heater, gas water heater, etc.) should not be operated in enclosed areas
such as unventilated garages, utility rooms or parking areas because of
the danger of carbon monoxide (CO) poisoning resulting from the exhaust
emissions. If a furnace or air handler is installed in an enclosed area such
as a garage, utility room or parking area and a carbon monoxide producing
device is operated therein, there must be adequate, direct outside
ventilation.
This ventilation is necessary to avoid the danger of CO poisoning which
can occur if a carbon monoxide producing device continues to operate in
the enclosed area. Carbon monoxide emissions can be (re)circulated
throughout the structure if the furnace or air handler is operating in any
mode.
CO can cause serious illness including permanent brain damage or death.
To locate an authorized servicer, please consult your telephone book or the dealer from whom you purchased this
product. For further assistance, please contact:
CONSUMER INFORMATION LINE
GOODMAN® BRAND PRODUCTS
TOLL FREE
1-877-254-4729 (U.S. only)
email us at:
customerservice@goodmanmfg.com
fax us at: (731) 856-1821
(Not a technical assistance line for dealers.)
CONSUMER INFORMATION LINE
AMANA® BRAND PRODUCTS
TOLL FREE
1-877-254-4729 (U.S. only)
email us at:
hac.consumer.affairs@amanahvac.com
fax us at: (731) 856-1821
(Not a technical assistance line for dealers.)
Outside the U.S., call 1-713-861-2500.
(Not a technical assistance line for dealers.) Your telephone company will bill you for the call.
3
PRODUCT IDENTIFICATION
The model and manufacturing number are used for positive identification of component parts used in manufacturing.
Please use these numbers when requesting service or parts information.
G
1
M
2
V
3
C
4
8
5
0
6
0
7
6
8
0
9
3
10
B
11
N
12
A
13
A
14
Brand
G- Goodman
Minor Revision
A - Initial Release
B - 1st Revision
Configuration
M - Upflow/Horizontal
C - Downflow/Horizontal
Major Revision
A - Initial Release
B - 1st Revision
Motor
V - Variable Speed/ComfortNet
Nox
N - Natural Gas
X - Low NOx
Gas Valve
M - Modulating
C - 2 Stage
Cabinet Width
A - 14"
B - 17.5"
C - 21"
D - 24.5"
AFUE
97 - 97% AFUE
80 - 80% AFUE
MBTU/h
40 - 40,000
60 - 60,000
80 - 80,000
100 - 100,000
120 - 120,000
Maximum CFM
3 - 1200 CFM
4 - 1600 CFM
5 - 2000 CFM
A
1
Brand
A- Amana
Configuration
M - Upflow/Horizontal
C - Downflow/ Horizontal
K - Dedicated Upflow
D - Dedicated Downflow
Motor
V - Variable Speed/ComfortNet
E - High Efficiency
S - Single S peed
Gas V alve
M - Modulating
C - 2 Stage
H - Convertible 2 Stage
S - Single S tage
AFUE
97 - 97% AFUE
80 - 80% AFUE
MBTU/ h
40 - 40,000
60 - 60,000
80 - 80,000
100 - 100,000
120 - 120,000
4
M
2
V
3
C
4
8
5
0
6
0
7
6
8
0
9
3
10
B
11
N
12
A
13
A
14
Minor Revision
A - Initial Release
B - 1st Revision
Major Revision
A - Initial Release
B - 1st Revision
Nox
N - Natural Gas
X - Low N Ox
Cabinet Width
A - 14"
B - 17.5"
C - 21"
D - 24.5"
Maximum CFM
3 - 1200 CFM
4 - 1600 CFM
5 - 2000 CFM
PRODUCT IDENTIFICATION
MODEL#
MFG.#
DESCRIPTION
GMVC8***AA
GMVC80704B*AA Goodman® Brand 80% communicating capable furnace, 33 3/8" tall, upflow / horizontal installation
GMVC80905C*AA positions, 2 stage gas heat, supports 2 stage cooling, induced draft. 4 wire serially communicating ECM
GMVC81155C*AA motor. 120 volt silicon carbide hot surface ignition. Left or right gas pipe entry. Aluminized steel tubular
heat exchanger. "X" models are low NOx. Available cabinet widths are 17.5"and 21"
GMVC8***AB
Goodman® Brand 80% communicating capable furnace, 33 3/8" tall, upflow / horizontal installation
GMVC80704B*AB
positions, 2 stage gas heat, supports 2 stage cooling, induced draft. 4 wire serially communicating ECM
GMVC80905C*AB
motor. 120 volt silicon carbide hot surface ignition. Left or right gas pipe entry. "X" models are low NOx.
GMVC81155C*AB
Aluminized steel tubular heat exchanger. Available cabinet widths are 17.5"and 21". AB revision went
to a Honeywell gas valve
GMVC8***AA
GMVC80604B*AA Goodman Brand 80% communicating capable furnace, New model nomencalture, firing at 23,000
BTUH per burner, 33 3/8" tall, upflow / horizontal installation positions, 2 stage gas heat, supports 2
GMVC80805C*AA
stage cooling, induced draft. 4 wire serially communicating ECM motor. 120 volt silicon carbide hot
GMVC81005C*AA
surface ignition. Left or right gas pipe entry. "X" models are low NOx. Aluminized steel tubular heat
exchanger. Available cabinet widths are 17.5"and 21".
GMVC8***BA
Goodman® Brand 80% communicating capable furnace, firing at 20,000 BTUH per burner, 33 3/8" tall,
GMVC80604B*BA
upflow
/ horizontal installation positions, 2 stage gas heat, supports 2 stage cooling, induced draft. 4
GMVC80805C*BA
wire serially communicating ECM motor. 120 volt silicon carbide hot surface ignition. Left or right gas
GMVC81005C*BA
pipe entry. "X" models are low NOx. Aluminized steel tubular heat exchanger. Available cabinet widths
are 17.5"and 21".
GMVC8***BB
Goodman® Brand 80% communicating capable furnace, firing at 20,000 BTUH per burner, 33 3/8" tall,
GMVC80604B*BB
upflow / horizontal installation positions, 2 stage gas heat, supports 2 stage cooling, induced draft. 4
GMVC80805C*BB
wire serially communicating ECM motor. 120 volt silicon carbide hot surface ignition. Left or right gas
GMVC81005C*BB
pipe entry. "X" models are low NOx. Aluminized steel tubular heat exchanger. Available cabinet widths
are 17.5"and 21". BB revision went to 2nd generation communicating control board - PCBKF103
GMVC8***BC
Goodman® Brand 80% communicating capable furnace, firing at 20,000 BTUH per burner, 33 3/8" tall,
GMVC80604B*BC
upflow / horizontal installation positions, 2 stage gas heat, supports 2 stage cooling, induced draft. 4
GMVC80805C*BC
GMVC81005C*BC wire serially communicating ECM motor. 120 volt silicon carbide hot surface ignition. Left or right gas
pipe entry. "X" models are low NOx. Aluminized steel tubular heat exchanger. Available cabinet widths
are 17.5"and 21". BC revision meets <2% cabinet low leakage.
®
5
PRODUCT IDENTIFICATION
MODEL#
AMVC8***AA
AMVC8***AB
MFG.#
DESCRIPTION
AMVC80704BXAA Ama na® Brand 80% communicating capable furnace, 33 3/8" tall, upflow / horizontal installation
AMVC80905CXAA positions, 2 stage gas heat, supports 2 stage cooling, induced draft. 4 wire serially communicating ECM
AMVC81155CXAA moto r. 120 volt silicon carbide hot surface ignition. L eft or right gas pipe entry. Stainless steel tubular
heat exchanger. Low NOx. Available cabinet widths are 17.5"and 21"
AMVC80704BXAB Ama na® Brand 80% communicating capable furnace, 33 3/8" tall, upflow / horizontal installation positions, 2
AMVC80905CXAB stage gas heat, supports 2 stage cooling, induced draft. 4 wire serially communicating ECM motor. 120 volt silicon
AMVC81155CXAB carbi de hot surface ignition. Left or right gas pipe entry. Low NOx. Stainless steel tubular heat exchanger. Available
cabinet widths are 17.5"and 21". AB revision went to a Honeywell gas valve
®
AMVC8***AA
AMVC8***BA
Ama na Brand 80% communicating capable furnace, New model nomencalture, firing at 23,000 BTUH per
AMVC80604B*AA
burner, 33 3/8" tall, upflow / horizontal installation positions, 2 stage gas heat, supports 2 stage cooling, induced
AMVC80805C*AA
draft. 4 wire serially communicating ECM motor. 120 volt silicon carbide hot surface ignition. Left or right gas
AMVC81005C*AA
pipe entry. "X" models are low NOx. Stainless steel tubular heat exchanger. Available cabinet widths are
17.5"and 21".
AMVC80604B*BA Ama na® Brand 80% communicating capable furnace, firing at 20,000 BTUH per burner, 33 3/8" tall, upflow /
AMVC80805C*BA horizontal installation positions, 2 stage gas heat, supports 2 stage cooling, induced draft. 4 wire serially
AMVC81005C*BA communicating ECM motor. 120 volt silicon carbide hot surface ignition. Left or right gas pipe entry. "X" models are
low N Ox. Stainless steel tubular heat exchanger. Available cabinet widths are 17.5"and 21".
®
AMVC8***BB
AMVC80604B*BB Ama na Brand 80% communicating capable furnace, firing at 20,000 BTUH per burner, 33 3/8" tall, upflow /
AMVC80805C*BB horizontal installation positions, 2 stage gas heat, supports 2 stage cooling, induced draft. 4 wire serially
AMVC81005C*BB communicating ECM motor. 120 volt silicon carbide hot surface ignition. Left or right gas pipe entry. "X" models are
low N Ox. Stainless steel tubular heat exchanger. Available cabinet widths are 17.5"and 21". BB revision went to
2nd generation communicating control board - PCBKF103.
®
AMVC8***BC
AMVC80604B*BC Ama na Brand 80% communicating capable furnace, firing at 20,000 BTUH per burner, 33 3/8" tall, upflow /
AMVC80805C*BC horizontal installation positions, 2 stage gas heat, supports 2 stage cooling, induced draft. 4 wire serially
AMVC81005C*BC communicating ECM motor. 120 volt silicon carbide hot surface ignition. Left or right gas pipe entry. "X" models are
low N Ox. Stainless steel tubular heat exchanger. Available cabinet widths are 17.5"and 21". BC revision meets
<2% cabinet low leakage.
6
PRODUCT IDENTIFICATION
MODEL#
ADVC8***AA
ADVC8***AB
ADVC8***AA
ADVC8***BA
MFG.#
DESCRIPTION
ADVC80703BXAA
ADVC80905CXAA
ADVC81155CXAA
Amana ® Brand 80% communicating capable furnace, 33 3/8" tall, dedicated down flow installation, 2 stage gas
heat, supports 2 stage cooli ng, induced draft. 4 wire serially communicating ECM motor. 120 volt silicon carbide hot
surface ignition. Left or right gas pipe entry. Stainless s teel tubular heat exchanger. Low NOx. Available cabinet
widths are 17.5"and 21"
ADVC80703BXAB
ADVC80905CXAB
ADVC81155CXAB
Amana Brand 80% communicating capable furnace, 33 3/8" tall, dedicated down flow stallation, 2 stage gas heat,
supports 2 stage cooling, induced draft. 4 wire serially communicating ECM motor. 120 volt silicon carbide hot surface
ignition. Left or right gas pipe entry. Low NOx. Stainless steel tubular heat exchanger. Available cabinet widths are 17.5"and
21". AB revision had shared data upgrade
ADVC80603B*AA
ADVC80805C*AA
ADVC81005C*AA
Amana ® Brand 80% communicating capable furnace, New model nomencalture, firing at 23,000 BTUH per burner, 33
3/8" tall, dedicated down flow installation, 2 stage gas heat, supports 2 stage cooling, induced draft. 4 wire serially
communicating ECM motor. 120 volt silicon carbide hot surface ignition. Left or right gas pipe entry. "X " models are low NOx.
Stainless steel tubular heat exchanger. Available cabinet widths are 17.5"and 21".
ADVC80603B*BA
ADVC80805C*BA
ADVC81005C*BA
Amana ® Brand 80% communicating capable furnace, firing at 20,000 BTUH per burner, 33 3/8" tall, dedicated
down flow installation, 2 stage gas heat, supports 2 stage cooling, induced draft. 4 wire serially communicating
ECM motor. 120 volt silicon carbide hot surface ignition. Left or right gas pipe entry. "X" models are low NOx.
Stainless steel tubular heat exchanger. Available cabinet widths are 17.5"and 21".
®
®
ADVC8***BB
ADVC80603B*BB
ADVC80805C*BB
ADVC81005C*BB
Amana Brand 80% communicating capable furnace, firing at 20,000 BTUH per burner, 33 3/8" tall, dedicated down
flow installation, 2 stage gas heat, supports 2 stage cooling, induced draft. 4 wire serially communicating ECM motor. 120
volt silicon carbide hot surface ignition. Left or right gas pipe entry. "X" models are low NOx. Stainless steel tubular heat
exchanger. Available cabinet widths are 17.5"and 21". BB revision went to 2nd generation communicating control board PCBKF103
7
PRODUCT IDENTIFICATION
MODEL #
AFE18 -60 A
CTK01 AA
CTK01 BA
CTK02**
CTK03 AA
CTK03 AB
8
MFG #
DESCRIPTION
N/A
Foss il Fue l Kit. Th e AFE18 -60 A co ntrol is d es igned fo r us e w here the in door co il is located
above /dow ns tream o f a g as or fos s il fue l furnace w hen us e d w ith a h eat pum p. It w ill
operate with s ingle a nd tw o s tage he at pum ps and s ingle and tw o s tag e furnaces . The
AFE18-60A control wi ll tu rn the heat pu m p un it off wh en the furn ace is tu rn ed o n. An antis hort cycle feature initiate s a 3 m inu te tim ed off dela y w hen the com p res s or go es off.
CTK01A A
Com m unica ting Therm os tat Kit- D ig itally co m m u nica ting touch s creen the rm os tat, a
nece s s ary pa rt o f any co m m u nica ting s ys te m . D es igne d for us e w ith com patible Air
Ha ndlers or Furnaces and ou tdo or s plit AC or H eat Pum p u nits . This the rm os tat s upports
up to thre e s tag es o f of hea t, two s tages of coo ling, du al fu el applica tions ,
dehu m idification , filter m ainte nance rem in ders , outdoor tem pe ra rture d is p lay and
advan ced m e nus including diagnos tics . The C TK01 AA kit inclu des a com m unicating
to uchs creen therm os tat and s ub bas e, 230 V-2 4V 40va trans form er, term in al blocks (2), wi
re jum pers , m ou nting s crews , ins talla tion m a nual an d h om eow ner g uide .
CTK01BA
Com m unica ting Therm os tat Kit-Digitally com m unicating to uchs creen therm os tat, a
nece s s ary pa rt o f any co m m u nica ting s ys te m . D es igne d for us e w ith com patible Air
Ha ndlers or Furnaces and ou tdo or s plit AC or H eat Pum p u nits . This the rm os tat s upports
up to thre e s tag es o f heat, tw o s ta ges of coolin g, dua l fuel applicatio ns , de hum id ificatio n,
filter m aintenan ce rem inders , ou tdoo r te m peratu re dis play an d a dvanced m enu s
in clud ing diagno s tics . The C TK0 1BA kit includes a com m unicating to uchs creen
th erm o s ta t and s ub bas e , term inal blocks (2), in s talla tion m anual a nd hom eow ner g uid e.
CTK02**
Com m unica ting Therm os tat Kit- D ig itally co m m u nica ting therm os tat, a n eces s ary part of
any com m unicating s ys tem . De s ign ed for us e with com pa tible Air Ha ndlers or Furnaces
and outdoo r s plit AC or He at Pu m p un its . The C TK02 ** the rm os tat features a full colo r
high definition dis pla y, a dvanced program m ing options inclu din g hu m idification control &
heat and cool m axim um tem perature s e tting s , a USB p lug allow ing d ealers the ability to
in s ert preprogram m ed operatin g pa ra m e ters and dea ler inform ation by us e o f an online
data entry s ys te m .
CTK03A A
Com m unica ting Therm os tat Kit- D ig itally co m m u nica ting touch s creen the rm os tat from
Ho neywe ll. Des ign ed for u s e with com patible Air Ha ndlers or Furnaces an d ou tdo or s plit
AC or Hea t Pum p units . The CTK03AA therm os tat fea tures full co lor h igh de finitio n
dis play an d can be us ed w ith Re dLIN K wirele s s acces s o ries .
CTK03A B
Com m unica ting Therm os tat Kit- D ig itally co m m u nica ting touch s creen the rm os tat from
Ho neywe ll. Des ign ed for u s e with com patible Am ana ® Bra nd o r Go odm an ® Brand Air
Ha ndlers or Furnaces and ou tdo or s plit AC or H eat Pum p u nits . The CTK03AB
th erm o s ta t Features full color high definition dis pla y and can be us e d w ith Red Lin k
wirele s s a cces s o ries and adde d ca pability to control th e H UM IN - H UM OU T relay on the
PC BKF103 and PC BKF104 con trol boa rd.
PRODUCT IDENTIFICATION
MODEL #
MFG #
DESCRIPTION
DEHUM1
P1227801F
Dehumidistat. Wall mou nted, 24 volt humidity control available as a Dehumidistat used to
reduce the airflow in th e air conditioning mode to lower the humidity in an occupied home. This
control features a moisture-sensitive nylon element and also provides positive On-Off settings
for manual operation. The control i s a normally cl osed switch that opens on humidity rise
causing the blower to switch to a lower spe ed to control the humidity within the structure.
EFR01
P1221001
P1221002F
External Filter Rack Kit. For u se with upflow gas fu rnace models. This kit is i ntended to provi de
a location, external to the furnace casing, for installation of a permanent filter. The rack is
mounted over the ind oor air blower compartment area of either side panel, and p rovide filter
retention as well as l ocation for attaching return air ductwork.
HA02
P1129112F
High Altitude Kit. The kit is desi gned to convert 80% gas furnace models at higher alti tudes.
This ki t is required when installing these furnaces above their maximum rated altitude. This kit
contains # 43-49, 55-58 gas orfices. The orfice s in the kit have been sele cted as a result of
testing with the American Gas Association. they will provide appropriate derating at the altitude
liste d in the High Altitude Charts as shown in the i nstallation instructions of the kit.
MODEL #
MFG #
DESCRIPTION
LPLP03
N/A
LP Gas Low Pressure Kit.For use with furnaces converted to LP gas. This ki t includes h arness
adaptors to work with White-Rod gers single & two stage gas valves, Honeywell single and twostag e gas valves, as well as modulating gas valves.
LPM-06
N/A
LP Conversion Kit. For use with 2-stage models using a White-Rodgers 36G54 2-stage gas
valve kit or a Honeywell VR9205 2-stage gas valve kit. Includes regulator springs, #55 orifices,
instructions and lable to show the furnace has been converted to L.P.
SBT17
SBT21
N/A
Dow nflow Subbas e. For use with 80% dedicated downflow furnace mode ls. These kits are
available for the fol lowing furnace widths: 17.5" wide (SBT17), 21" wide (SBT21)
9
ACCESSORIES
EXTERNAL FILTER RACK KIT
( EFR01 )
SLOTS IN FILTER
CLEAR SCREWS
ON UNIT
BLOWER DECK
SCREWS
UNIT SIDE
PANEL
FRONT
OF UNIT
FILTER RACK ASSEMBLY
(FACE FILTER OPENING
TOWARDS FRONT
OF UNIT)
BASE
OF UNIT
RETURN AIR
CUTOUT AREA
LOWER EDGE
SCREW
EFR01 EXTERNAL FILTER RACK KIT
Used on Models
80% Upflow Model Furnaces
10
ACCESSORIES
®
®
A/ GMVC80604B**
A/ GMVC800805C**
A/ GMVC81005C**
ADVC80603B**
ADVC80805C**
ADVC81005C**
AMU / GMU
ASASD / GSASD
SBT17
SBT21
CTK0*
LPM06
LPLP03
HA-02
Media Air Cleaner
Electronic Air Cleaner
Downflow Subbase
17.5"
Downflow Subbase
21"
Communicating
Thermostat
Propane Gas
Conversion Kit
LP Low Pressure Shut Off
Kit
High Al titude Natural Gas
Orifices
·
(1)
(1)
(1)
(1)
(1)
(1)
·
·
·
·
·
·
(2)
(2)
(2)
(2)
(2)
(2)
DEHUM1
EFR01
EFR External Fi lter Rack
· · · ·
·
· · · ·
·
· · · ·
·
·
· · ·
·
·
· ·
· ·
·
· ·
· ·
Dehumidistat
AFE180-60A
Description
MODEL
NUMBER
Dual Fuel Board
Goodman & Amana Brand Model Furnace Accessories
·
·
·
·
·
·
Not Approved for this model
Approved for this model
(1) W/R & HW 2 stg valve
(2) 7,000 - 11,000 ft altitude
11
OPERATING INSTRUCTIONS
FOR YOUR SAFETY READ BEFORE OPERATING
If you do not follow these instructions exactly,
a fire or explosion may result causing property
damage, personal injury or loss of life.
A. This appliance does not have a pilot. It
is equipped with an ignition device which
automatically lights the burners. Do not
try to light the burners by hand.
B. BEFORE OPERATING smell around
the appliance area for gas. Be sure to
smell next to the floor because some gas
is heavier than air and will settle on the
floor.
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance.
Do not touch any electric switch;
do not use any telephone in your
building.
Immediately call your supplier
from a neighbor's phone. Follow
the gas suppliers instructions.
If you cannot reach your gas supplier,
call the fire department.
C. Use only your hand to move the gas
control switch or knob. Never use
tools. If the gas control switch or knob
will not operate, don't try to repair it,
call a qualified service technician.
Force or attempted repair may result in
a fire or explosion.
D. Do not use this appliance if any part
has been under water. Immediately call
a qualified service technician to inspect
the appliance and to replace any part of
the control system and any gas control
which has been under water.
WARNING: Improper
alteration, service or
maintenance can
cause injury or
property damage.
Refer to the user's
information manual
provided with this
consult a qualified
or the gas supplier.
This furnace must be
instructions and local
codes. In the absence
of local codes, follow
the National Fuel Gas
Code, ANSI Z223.1.
OPERATING INSTRUCTIONS
1. STOP! Read the safety information
above on this label.
2. Set the thermostat to lowest setting.
3. Turn off all electric power to the
appliance.
4. This appliance is equipped with an
automatic ignition system which
automatically lights the burners. Do not
try to light the burners by hand.
5. Remove control access panel.
6. Move the gas control switch or knob
to "OFF".
7. Wait five (5) minutes to clear out any
gas. If you then smell gas, STOP!
Follow "B" in the safety information
above on this label. If you don't smell
gas, go to the next step.
8. Move the gas control switch or knob
to "ON".
9. Replace control access panel.
10. Turn on all electric power to the
appliance.
11. Set the thermostat to the desired
setting.
12. If the appliance will not operate,
follow the instructions "To Turn Off Gas
To Appliance" and call your service
technician or gas supplier.
GAS CONTROL
SW ITCH SHOWN
IN "ON" POSITION
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to its lowest setting.
2. Turn off all electric power to the
appliance if service is to be performed.
3. Remove control access panel.
4. Move the gas control switch or knob
to "OFF". Do not force.
5. Replace control access panel.
For indoor installation.
PGB & PGJ
For outdoor
installation only.
WARNING: If not
installed, operated
and maintained in
accordance with the
manufacturer's
instructions, this
product could expose
you to substances
in fuel combustion
which can cause
death or serious
illness and which
are known to the
State of California to
cause cancer, birth
defects or other
reproductive harm.
This product contains
fiberglass insulation.
Fiberglass insulation
contains a chemical
California to cause
cancer.
FOR YOUR SAFETY Do not store or use gasoline or
other flammable vapors and liquids in the vicinity of this
or any other appliance.
0140F00001P
12
OPERATING INSTRUCTIONS
CONSIGNES DE SECURITE - LIRE
AVANT D'ALLUMER L'APPAREIL
INSTRUCTIONS DE SERVICE
AVERTISSEMENT: Le non-respect des instructions qui suivent peut
^
entrainer
un risque d'incendie ou d'explosion causant des dommages,
des blessures ou la mort.
A. Cet appareil comporte pas de veilleuse. Il est muni d'un mecanisme qui allume
^
^
manuellement.
automatiquement le bruleur.
N'allumez paz le bruleur
B. Sentir tout autour de l'appariel AVANT D'ALLUMER afin de deceler toute fuite de gaz.
Assurez-vous de sentir tout pres du plancher car certains gaz sont plus lourds que l'air
et se deposeront sur le plancher.
SI VOUS SENTEZ UNE ODEUR DE GAZ:
Ne tentez d'allumer aucun appariel.
Ne touchez pas aux interrupteurs electriques; n'utiliser aucun telephone
dans l'edifice ou vous vous trouvez.
Appelez immediatement votre fournisseur de gaz en utilisant le telephone
d'un voisin et suivez les instructions du fournisseur.
Appelez les pompiers si vous ne parvenez pas a rejoindre votre fournisseur
de gaz.
C. N'utiliser que votre main pour pousser ou tourner le commande du gaz. N'utilisez
jamais d'outils. Si vous ne parvenez pas a pousser ou a tourner la commande, ne tentez
pas de la reparer; appelez un reparateur qualifie. Forcer la commande ou essayer de la
^
reparer peut entrainer
un risque d'incendie ou d'explosion.
D. N'utilisez pas cet appareil si l'une de ses parties a ete dans l'eau. Si cela se produit,
demandez immediatement a un reparateur qualifie d'inspecter l'appareil et de remplacer
^
toute piece du systeme de controle
et toute commande de gaz ayant ete dans l'eau.
0140F00002P
1. UN INSTANT! Lisez d'abord les consignes
de securite ci-dessus.
2. Reglez le thermostat a son point le plus bas.
3. Coupez l'alimentation electrique de l'appareil.
4. Cet appareil est muni d'un mecanisme qui
^
allume automatiquement le bruleur.
Ne tentez
^
pas d'allumer le bruleur
manuellement.
5. Retirez le panneau d'acces de la commande.
6. Mettez la commande de gaz a la position
^
ARRET
("OFF").
7. Attendez cinq (5) minutes afin de permettre a
^
tout gaz present d'etre
evacue. Si vous sentez
^
une odeur de gaz a ce moment, ARRETEZ!
et
suivez les consignes de securite donnees au
paragraphe B ci-dessus. Si vous ne sentez pas
de gaz, passez a l'etape suivante.
8. Mettez la commande de gaz a la position
MARCHE ("ON").
9. Remettez la panneau d'acces de la commande
en place.
10. Retablissez l'alimenation electrique de l'appareil.
11. Reglez le thermostat a le temperature desiree.
12. Si l'appareil ne fonctionne pas, suivez les
^
instructions intitulees "Arret
du gaz" et appelez un
reparateur qualifie ou votre fournisseur de gaz.
^
Commande de
gaz en position
"MARCHE"
ARRET DU GAZ
1.
2.
3.
4.
5.
Reglez le thermostat a son point le plus bas.
Coupez l'alimentation electrique de l'appareil si vous devez effectuer un entretien.
Retirez le panneau d'acces de la commande.
^
Mettez la commande de gaz a la position ARRET
("OFF").
Remettez le panneau d'acces de la commande en place.
13
OPERATING INSTRUCTIONS
ROBINET A GAZ
MANUEL, EN POS
"ON/MARCHE"
GAS
INLET
ARRIVEE
DU GAZ
MANUAL GAS
LEVER SHOWN
IN "ON" POS
14
PRODUCT DESIGN
Safety
Please adhere to the following warnings and cautions when
installing, adjusting, altering, servicing, or operating the furnace.
WARNING
TO PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION,
ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE, REFER TO THIS
MANUAL.
FOR ADDITIONAL ASSISTANCE OR INFORMATION, CONSULT A
QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.
Product Application
This product is designed for use as a residential home gas
furnace. It is not designed or certified for use in mobile home,
trailer, or recreational vehicle applications.
This furnace can be used in the following non-industrial
commercial applications: Schools, Office buildings, Churches,
Retail stores, Nursing homes, Hotels/motels, Common or
office areas. In such applications, the furnace must be installed
with the installation instructions.
Goodman & Amana® 80% furnaces are ETL certified appliances and are appropriate for use with natural or propane
gas. (NOTE: If using propane gas, a propane conversion kit
is required).
WARNING
THIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS WHICH
MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE KNOWN TO THE
STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER
REPRODUCTIVE HARM.
WARNING
IMPORTANT NOTE: The 80% furnace cannot be installed
as a direct vent (i.e.., sealed combustion) furnace. The
burner box is present only to help reduce sound transmission from the burners to the occupied space.
To ensure proper installation, operation and servicing, thoroughly read the installation and service manuals for specifics pertaining to the installation, servicing and application of
this product.
TO PREVENT POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH
DUE TO ELECTRICAL SHOCK, THE FURNACE MUST BE LOCATED TO PROTECT
WARNING
THE ELECTRICAL COMPONENTS FROM WATER.
Charge (ESD) Precautions
NOTE: Discharge body’s static electricity before touching
unit. An electrostatic discharge can adversely affect electrical components.
Use the following precautions during furnace installation and
servicing to protect the integrated control module from damage. By putting the furnace, the control, and the person at
the same electrostatic potential, these steps will help avoid
exposing the integrated control module to electrostatic discharge. This procedure is applicable to both installed and
uninstalled (ungrounded) furnaces.
1. Disconnect all power to the furnace. Do not touch the
integrated control module or any wire connected to the
control prior to discharging your body’s electrostatic
charge to ground.
2. Firmly touch a clean, unpainted, metal surface of the
furnace near the control. Any tools held in a person’s
hand during grounding will be discharged.
3. Service integrated control module or connecting wiring
following the discharge process in Step 2. Use caution
not to recharge your body with static electricity; (i.e., do
not move or shuffle your feet, do not touch ungrounded
objects, etc.). If you come in contact with an ungrounded
object, repeat Step 2 before touching control or wires.
4. Discharge any static electricity from your body to ground
before removing a new control from its container. Follow
Steps 1 through 3 if installing the control on a furnace.
Return any old or new controls to their containers before
touching any ungrounded object.
POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE,
EXPLOSION, SMOKE, SOOT, CONDENSTAION, ELECTRICAL SHOCK OR CARBON
MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION, REPAIR, OPERATION,
OR MAINTENANCE OF THIS PRODUCT.
WARNING
TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE,
DO NOT INSTALL THIS FURNACE IN A MOBILE HOME, TRAILER, OR RECREATIONAL
VEHICLE.
To ensure proper furnace operation, install, operate, maintain and service the furnace in accordance with the installation, operation and service instructions, all local building
codes and ordinances. In their absence, follow the latest
edition of the National Fuel Gas Code (NFPA 54/ANSI
Z223.1), and/or CAN/CGA B149 Installation Codes, local
plumbing or waste water codes, and other applicable codes.
A copy of the National Fuel Gas Code (NFPA 54/ANSI
Z223.1) can be obtained from any of the following:
American National Standards Institute
1430 Broadway
New York, NY 10018
National Fire Protection Association
1 Batterymarch Park
Quincy, MA 02269
15
PRODUCT DESIGN
CSA International
8501 East Pleasant Valley
Cleveland, OH 44131
•
A copy of the CAN/CGA B149 Installation Codes can be
obtained from:
CSA International
178 Rexdale Boulevard
Etobicoke, Ontario, Canada M9W, 1R3
The rated heating capacity of the furnace should be greater
than or equal to the total heat loss of the area to be heated.
The total heat loss should be calculated by an approved
method or in accordance with “ASHRAE Guide” or “Manual
J-Load Calculations” published by the Air Conditioning Contractors of America.
Location Requirements and Considerations
WARNING
TO PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE, PERSONAL
INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE OBSERVED
•
WHEN INSTALLING THE UNIT.
Follow the instructions listed below when selecting a furnace location. Refer also to the guidelines provided in the
Combustion and Ventilation Air Requirements section in this
manual or the installation instructions for details.
•
Centrally locate the furnace with respect to the proposed or existing air distribution system.
•
Ensure the temperature of the return air entering the
furnace is between 55°F and 100°F when the furnace
is heating.
•
If the furnace is installed in an application where the
typical operating sound level of a furnace is deemed
objectionable, an optional sound reduction kit is available. Consult your local distributor for more details.
•
Provide provisions for venting combustion products
outdoors through a proper venting system. Special
consideration should be given to vent/flue pipe routing
and combustion air intake pipe when applicable.
80% Furnaces: All installations must be vented in
accordance with National Fuel Gas Code, NFPA 54/
ANSI Z223.1 - lateset edition. In Canada the furnaces
must be vented in accordance with the National Standard of Canada, CAN/CGA B149.
•
Ensure upflow or horizontal furnaces are not installed
directly on carpeting, or any other combustible material. The only combustible material allowed is wood.
•
A special accessory subbase must be used for upright counterflow unit installations over any combustible material (including wood). Refer to subbase instructions for installation details. (NOTE: A subbase
will not be required if an air conditioning coil is located
16
•
•
•
beneath the furnace between the supply air opening
and the combustible floor.
Exposure to contaminated combustion air will result
in safety and performance-related problems. Do not
install the furnace where the combustion air is exposed to the following substances:
chlorinated waxes or cleaners
chlorine-based swimming pool chemicals
water softening chemicals
deicing salts or chemicals
carbon tetrachloride
halogen type refrigerants
cleaning solutions (such as perchloroethylene)
printing inks
paint removers
varnishes
hydrochloric acid
cements and glues
antistatic fabric softeners for clothes dryers
and masonry acid washing materials
To ensure that the enclosed non-direct vent furnace
has an adequate supply of combustion air, vent from
a nearby uncontaminated room or from outdoors. Refer to the Combustion and Ventilation Air Requirements section in this manual or the installation instructions for details.
If the furnace is used in connection with a cooling
unit, install the furnace upstream or in parallel with
the cooling unit coil. Premature heat exchanger failure will result if the cooling unit coil is placed ahead of
the furnace.
If the furnace is installed in a residential garage, position the furnace so that the burners and ignition source
are located not less than 18 inches (457 mm) above
the floor. Protect the furnace from physical damage
by vehicles.
If the furnace is installed horizontally, the furnace access doors must be vertical so that the burners fire
horizontally into the heat exchanger. Do not install
the unit with the access doors on the “up/top” or “down/
bottom” side of the furnace.
Clearances and Accessibility
Installations must adhere to the clearances to combustible
materials to which this furnace has been design certified.
The minimum clearance information for this furnace is provided on the unit’s clearance label. These clearances must
be permanently maintained. Refer to Specification Sheet for
minimum clearances to combustible materials. Clearances
must also accommodate an installation’s gas, electrical,
and drain trap and drain line connections. NOTE: In addition
to the required clearances to combustible materials, a minimum of 24 inches service clearance must be available in
front of the unit.
PRODUCT DESIGN
A furnace installed in a confined space (i.e., a closet or
utility room) must have two ventilation openings with a total
minimum free area of 0.25 square inches per 1,000 BTU/hr
of furnace input rating. One of the ventilation openings must
be within 12 inches of the top; the other opening must be
within 12 inches of the bottom of the confined space. In a
typical construction, the clearance between the door and
door frame is usually adequate to satisfy this ventilation requirement.
Furnace Suspension
If suspending the furnace from rafters or joist, use 3/8"
threaded rod and 2”x2”x1/8” angle iron as shown in the following figure. If the furnace is installed in a crawl space it
must also be suspended from the floor joist or supported by
a concrete pad. Never install the furnace on the ground or
allow it to be exposed to water. The length of rod will depend
on the application and the clearances necessary.
PROVIDE 8" MINIMUM CLEARANCE BETWEEN
CENTER ROD AND FURNACE CABINET
TO ALLOW FOR CIRCULATOR BLOWER REMOVAL.
3/8" DIAMETER
ALTERNATE
THREADED ROD
GAS PIPING
ASSURE FURNACE IS LEVEL FROM
END TO END.
ON 90% FURNACES MAKE SURE
(6 PLACES)
THE UNIT HAS A SLIGHT
FORWARD TILT WITH THE FRONT
OF THE FURNACE 0"-3/4"
HOLD DOWN
BELOW THE BACK OF THE FURNACE.
NUTS
SUPPORT
NUTS
CONDENSATE
DRAIN
GAS PIPING
2" X2"X1/8" ANGLE IRON
(3 PLACES)
POSITION AS CLOSE AS POSSIBLE
TILT OUTWARD TO ALLOW FOR
DOOR AND CIRCULATOR BLOWER
TO BLOWER DECK TO ALLOW FOR
REMOVAL.
CIRCULATOR BLOWER REMOVAL.
90% Suspended Furnace Shown
(80% Furnace Similar)
EXISTING FURNACE REMOVAL
NOTE: When an existing furnace is removed from a venting
system serving other appliances, the venting system may
be too large to properly vent the remaining attached appliances.
The following vent testing procedure is reproduced from the
American National Standard/National Standard of Canada for
Gas-Fired Central Furnaces ANSI Z21.47, latest edition,
CSA-2.3b, latest edition Section 1.23.1.
The following steps shall be followed with each appliance connected to
the venting system placed in operation, while any other appliances
connected to the venting system are not in operation:
a. Seal any unused openings in the venting system;
b. Inspect the venting system for proper size and horizontal pitch,
as required by the National Fuel Gas Code, ANSI Z223.1 or the
CSA B149 Installation Codes and these instructions. Determine
that there is no blockage or restriction, leakage, corrosion and other
deficiencies which could cause an unsafe condition;
c. In so far as practical, close all building doors and windows and all
doors between the space in which the appliance(s) connected to
the venting system are located and other spaces of the building.
d.
e.
f.
g.
Turn on clothes dryers and any appliance not connected to the
venting system. Turn on any exhaust fans, such as range hoods
and bathroom exhausts, so they shall operate at maximum speed.
Do not operate a summer exhaust fan. Close fireplace dampers;
Follow the lighting instructions. Place the appliance being inspected in operation. Adjust thermostat so appliance shall operate continuously;
Test for draft hood equipped spillage at the draft hood relief
opening after 5 minutes of main burner operation. Use the flame
of a match or candle;
After it has been determined that each appliance connected to the
venting system properly vents when tested as outlined above,
return doors, windows, exhaust fans, fireplace dampers and any
other gas burning appliance to their previous conditions of use;
If improper venting is observed during any of the above tests, the
common venting system must be corrected.
Corrections must be in accordance with the latest edition of
the National Fuel Gas Code NFPA 54/ANSI Z223.1 and/or
CSA B149 Installation Codes.
If resizing is required on any portion of the venting system,
use the appropriate table in Appendix G in the latest edition
of the National Fuel Gas Code ANSI Z223.1 and/or CSA B149
Installation Codes.
Thermostat Requirements
NOTE: A single-stage thermostat with only one heating stage
may be used to control ComfortNet™ compatible furnaces.
The application of a single-stage thermostat does not offer
“true” thermostat-driven two-stage operation, but provides a
timed transition from low to high fire. The furnace will run on
low stage for a fixed period of time before stepping up to
high stage to satisfy the thermostat’s call for heat. The
delay period prior to stepping up can be set at either a fixed
5 minute time delay or a load based variable time between 1
and 12 minutes (AUTO mode). If the AUTOmode is selected,
the control averages the cycle times of the previous three
cycles and uses the average to determine the time to transition from low stage to high stage.
To use a single-stage thermostat, turn off power to the furnace, move the thermostat selection DIP switch to the OFF
position. Set the desired transition time by setting the transition delay DIP switch to the desired ON/OFF position. Turn
power back on. Refer to the following figure.
OFF
ON
Move to the ON position
to select two-stage
thermostat or OFF to
select single stage
thermostat
Heat OFF Delay
DIP Switches
3
Thermostat
4
Stage Delay
S1
Move to the ON position
to select Auto transition
delay or OFF for 5 minute
transition delay
Dehumidistat Requirements
A dehumidistat can be used in conjunction with the twostage variable speed furnace to lower the humidity in the
conditioned space. The dehumidistat will improve dehumidification of the conditioned air by prompting the furnace to
17
PRODUCT DESIGN
reduce the speed of the circulator blower during operation in
the cooling mode. To be compatible with these furnaces, a
dehumidistat must operate on 24 VAC and utilize a switch
which opens on humidity rise. Refer to Electrical Connections - 24 Volt Dehumidistat Wiring section in this manual
or the installation instructions for correct installation procedure.
Thermostat and Dehumidistat Location
In an area having good air circulation, locate the thermostat
and dehumidistat (if applicable) about five feet high on a vibration-free inside wall. Do not install the thermostat or dehumidistat where it may be influenced by any of the following:
•
•
•
•
•
•
•
Drafts, or dead spots behind doors, in corners, or under cabinets.
Hot or cold air from registers.
Radiant heat from the sun.
Light fixtures or other appliances.
Radiant heat from a fireplace.
Concealed hot or cold water pipes, or chimneys.
Unconditioned areas behind the thermostat and dehumidistat, such as an outside wall.
and other fuel burning appliances. Appliances that pull air
out of the house (clothes dryers, exhaust fans, fireplaces,
etc.) increase the problem by starving appliances for air.
If this furnace is to be installed in the same space with other
gas appliances, such as a water heater, ensure there is an
adequate supply of combustion and ventilation air for the
other appliances. Refer to the latest edition of the National
Fuel Gas Code NFPA 54/ANSI Z223.1 (Section 9.3), or CAN/
CGA B149 Installation Codes (Sections 7.2, 7.3, or 7.4), or
applicable provisions of the local building codes for determining the combustion air requirements for the appliances.
Most homes will require outside air be supplied to the furnace area by means of ventilation grilles or ducts connecting directly to the outdoors or spaces open to the outdoors
such as attics or crawl spaces.
The following information on air for combustion and ventilation
is reproduced from the National Fuel Gas Code NFPA 54/ANSI
Z223.1 Section 9.3.
9.3* Air for Combustion and Ventilation.
9.3.1 General.
9.3.1.1 Air for combustion, ventilation, and dilution of flue gases for
appliances installed in buildings shall be obtained by application of one
of the methods covered in 9.3.2 through 9.3.6. Where the requirements
of 9.3.2 are not met, outdoor air shall be introduced in accordance with
methods covered in 9.3.3 through 9.3.6.
Exception No. 1: This provision shall not apply to direct vent appliances.
DRAFTS OR DEAD SPOTS
-BEHIND DOORS
-IN CORNERS
-UNDER CABINETS
HOT
COLD
9.3.1.2 Appliances of other than natural draft design and other than
Category 1 vented appliances shall be provided with combustion, ventilation, and dilution air in accordance with the appliance manufacturer’s
instructions.
9.3.1.3 Appliances shall be located so as not to interfere with proper
circulation of combustion, ventilation, and dilution air.
Thermostat Influences
Consult the instructions packaged with the thermostat and
dehumidistat for mounting instructions and further precautions.
COMBUSTION AND VENTILATION AIR
REQUIREMENTS
WARNING
POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR
IF THE FURNACE IS NOT PROVIDED WITH ENOUGH FRESH AIR FOR PROPER
COMBUSTION AND VENTILATION OF FLUE GASES. MOST HOMES REQUIRE
OUTSIDE AIR BE SUPPLIED TO THE FURNACE AREA.
Improved construction and additional insulation in buildings
have reduced heat loss by reducing air infiltration and escape around doors and windows. These changes have helped
in reducing heating/cooling costs but have created a problem supplying combustion and ventilation air for gas fired
18
9.3.1.4 Where used, a draft hood or a barometric draft regulator shall be
installed in the same room or enclosure as the appliance served so as to
prevent any difference in pressure between the hood or regulator and the
combustion air supply.
9.3.1.5 Makeup air requirements for the operation of exhaust fans, kitchen
ventilation systems, clothes dryers, and fireplaces shall be considered in
determining the adequacy of a space to provide combustion air requirements.
9.3.2 Indoor Combustion Air. The required volume of indoor air shall
be determined in accordance with the method in 9.3.2.1 or 9.3.2.2 except that where the air infiltration rate is known to be less than 0.40
ACH, the method in 9.3.2.2 shall be used. The total required volume
shall be the sum of the required volume calculated for all appliances
located within the space. Rooms communicating directly with the space
in which the appliances are installed through openings not furnished
with doors, and through combustion air openings sized and located in
accordance with 9.3.2.3, are considered a part of the required volume.
9.3.2.1* Standard Method. The minimum required volume shall be 50
ft 3 per 1,000/Btu/hour (4.8m3/kW).
PRODUCT DESIGN
9.3.2.2* Known Air Infiltration Rate Method. Where the air infiltration rate of a structure is known, the minimum required volume shall be
determined as follows:
(1) For appliances other than fan-assisted, calculate using the following
equation:
21 ft3
I other
Required Volume other > ________ _________
ACH
1000 Btu/hr
)
(
(2) For fan-assisted appliances, calculate using the following equation:
15 ft3
I fan
Required Volume fan > ________ _________
ACH
1000 Btu/hr
)
(
where:
I other
=
I
all appliances other than fan-assisted input in Btu per
hour
fan
=
fan-assisted appliances input in Btu per hour
ACH
=
air change per hour (percent of volume of space exchanged
per hour, expressed as a decimal)
9.3.3 Outdoor Combustion Air. Outdoor combustion air shall be provided through opening(s) to the outdoors in accordance with the methods in 9.3.3.1 or 9.3.3.2. The minimum dimension of air openings shall
not be less than 3 in. (80 mm).
9.3.3.1 Two Permanent Openings Method. Two permanent openings, one commencing within 12 in. (300 mm) of the top and one commencing within 12 in. (300 mm) of the bottom, of the enclosure shall be
provided. The openings shall communicate directly, or by ducts, with
the outdoors or spaces that freely communicate with the outdoors, as
follows:
(1)* Where directly communicating with the outdoors or where communicating to the outdoors through vertical ducts, each opening shall
have a minimum free area of 1 in.2/4000 Btu/hr (550 min2/kW) of
total input rating of all appliances in the enclosure. [See Figure
A.9.3.3.1(1)(a) and Figure A.9.3.3.1(1)(b).]
Chimney or Gas Vent
Ventilation louvers
(each end of attic)
NOTE: The inlet and outlet air
openings must each have a free
area of not less than one square
inch per 4000 BTU of the
total input rating of all equipment
in the enclosure.
(3) For purposes of this calculation, an infiltration rate greater than
0.60 ACH shall not be used in the equations in 9.3.2.2(1) and
9.3.2.2(2).
9.3.2.3 Indoor Opening Size and Location. Openings used to connect
indoor spaces shall be sized and located in accordance with the following:
Outlet Air
Water
Heater
Furnace
(1)*Combining spaces on the same story. Each opening shall have a
minimum free area of 1 in.2/1000Btu/hr (2200 mm2/kW) of the total
input rating of all appliances in the space but not less than 100 in.2
(0.60m2). One opening shall commence within 12 in. (300 mm) of
the top, and one opening shall commence within 12 in. (300 mm) of
the bottom, of the enclosure [see Figure A.9.3.2.3(1)]. The minimum dimension of air openings shall be not less than 3 in. (80 mm).
Inlet Air
Alternate
air inlet
Ventilation louvers for
unheated crawl space
Figure A.9.3.3.1(1)(a) All Combustion Air From Outdoors Inlet Air from Ventilated Crawl Space and Outlet Air
to Ventilated Attic.
Chimney or Gas Vent
NOTE: Each opening must have
a free area of not less than one
square inch per 1000 BTU of
the total input rating of all equipment in the enclosure, but not
less than 100 square inches.
Chimney or Gas Vent
Ventilation louvers
(each end of attic)
NOTE: The inlet and outlet air
openings must each have a free
area of not less than one square
inch per 4000 BTU of the
total input rating of all equipment
in the enclosure.
Opening
Furnace
Water
Heater
Outlet Air
Opening
Furnace
Water
Heater
Inlet air duct
[ends 1 ft (300 mm)
above floor]
Figure A.9.2.3.3.(1) All Combustion Air from Adjacent
Indoor Spaces through Indoor Combustion Air Openings.
(2) Combining spaces in different stories. The volumes of spaces in
different stories shall be considered as communicating spaces where
such spaces are connected by one or more openings in doors or
floors having a total minimum free area of 2 in.2/1000 Btu/hr (4400
mm2/kW) of total input rating of all appliances.
Figure A.9.3.3.1(1)(b) All Combustion Air
From Outdoors through Ventilated Attic.
(2)* Where communicating with the outdoors through horizontal ducts,
each opening shall have a minimum free area of 1 in.2/2000 Btu/hr
(1100 min2/kW) of total input rating of all appliances in the enclosure. [See Figure A.9.3.3.1(2).]
19
PRODUCT DESIGN
(c) The minimum size of outdoor opening(s) shall be the full size
of outdoor opening(s) calculated in accordance with 9.3.3,
multiplied by the reduction factor. The minimum dimension
of air openings shall not be less than 3 in. (80 mm).
Chimney or Gas Vent
Outlet air duct
Furnace
NOTE: The air duct openings
must have a free area of not
less than one square inch per
2000 BTU of the total input
rating of all equipment in the
enclosure*.
9.3.5 Engineered Installations. Engineered combustion air installations shall provide an adequate supply of combustion, ventilation, and
dilution air and shall be approved by the authority having jurisdiction.
Water
Heater
9.3.6 Mechanical Combustion Air Supply. Where all combustion air
is provided by a mechanical air supply system, the combustion air shall
be supplied form outdoors at the minimum rate of 0.35 ft3/min per 1000
Btu/hr (0.034 m3/min per kW) for all appliances located within the
space.
Inlet air duct
Figure A.9.3.3.1(2) All Combustion Air From Outdoors
through Horizontal Ducts.
9.3.3.2* One Permanent Opening Method. One permanent openings, commencing within 12 in. (300 mm) of the top of the enclosure,
shall be provided. The appliance shall have clearances of at least 1 in.
(25 mm) from the sides and back and 6 in. (150 mm) from the front of
the appliance. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the
outdoors or spaces that freely communicate with the outdoors (see
Figure A.9.3.3.2) and shall have a minimum free area of the following:
(1) 1 in.2/3000 Btu/hr (700 mm2 per kW) of the total input rating of all
appliances located in the enclosure, and
(2) Not less than the sum of the areas of all vent connectors in the
space.
NOTE: The single opening must have
a free area of not less than one
square inch per 3000 BTU of
the total input rating of all equipment in the enclosure, but not less than
the sum of the areas of all vent
connectors in the confined space.
Chimney or Gas Vent
Opening
Furnace
Water
Heater
Alternate
Opening
Location
Figure A.9.3.3.2 All Combustion Air
From Outdoors through Single Combustion Air Opening.
9.3.4 Combination Indoor and Outdoor Combustion Air. The use of
a combination of indoor and outdoor combustion air shall be in accordance with (1) through (3) (see example calculation in Annex J]:
(1) Indoor Openings: Where used, openings connecting the interior
spaces shall comply with 9.3.2.3.
(2) Outdoor Opening(s) Location. Outdoor opening(s) shall be located
in accordance with 9.3.3.
(3) Outdoor Opening(s) Size. The outdoor opening(s) size shall be
calculated in accordance with the following:
(a) The ratio of the interior spaces shall be the available volume
of all communicating spaces divided by the required volume.
(b) The outdoor size reduction factor shall be 1 minus the ratio of
interior spaces.
20
9.3.6.1 Where exhaust fans are installed, additional air shall be provided
to replace the exhausted air.
9.3.6.2 Each of the appliances served shall be interlocked to the mechanical air supply system to prevent main burner operation where the
mechanical air supply system is not in operation.
9.3.6.3 Where combustion air is provided by the building’s mechanical
ventilation system, the system shall provide the specified combustion
air rate in addition to the required ventilation air.
9.3.7 Louvers, Grilles, and Screens.
9.3.7.1 Louvers and Grilles. The required size of openings for combustion, ventilation, and dilution air shall be based on the net free area of
each opening. Where the free area through a design of louver or grille or
screen is known, it shall be used in calculating the size opening required
to provide the free area specified. Where the louver and grille design and
free area are not known, it shall be assumed that wood louvers will have
25 percent free area, and metal louvers and grilles will have 75 percent
free area. Nonmotorized louvers and grilles shall be fixed in the open
position.
9.3.7.2 Minimum Scree Mesh Size. Screens shall not be smaller than
1/4 in. mesh.
9.3.7.3 Motorized Louvers. Motorized louvers shall be interlocked
with the appliance so they are proven in the full open position prior to
main burner ignition and during main burner operation. Means shall be
provided to prevent the main burner form igniting should the louver fail
to open during burner startup and to shut down the main burner if the
louvers close during burner operation.
9.3.8 Combustion Air Ducts. Combustion air ducts shall comply with
9.3.8.1 through 9.3.8.8.
9.3.8.1 Ducts shall be constructed of galvanized steel or a material having equivalent corrosion resistance, strength, and rigidity.
Exception: Within dwellings units, unobstructed stud and joist spaces
shall not be prohibited from conveying combustion air, provided that not
more than one fireblock is removed.
9.3.8.2 Ducts shall terminate in an unobstructed space, allowing free
movement of combustion air to the appliances.
9.3.8.3 Ducts shall serve a single space.
PRODUCT DESIGN
9.3.8.4 Ducts shall not serve both upper and lower combustion air
openings where both such openings are used. The separation between
ducts servicing upper and lower combustion air openings shall be maintained to the source of combustion air.
9.3.8.5 Ducts shall not be screened where terminating in an attic space.
9.3.8.6 Horizontal upper combustion air ducts shall not slope downward toward the source of combustion air.
9.3.8.7 The remaining space surrounding a chimney liner, gas vent, special gas vent, or plastic piping installed within a masonry, metal, or
factory built chimney shall not be used to supply combustion air.
Exception: Direct vent appliances designed for installation in a solid
fuel-burning fireplace where installed in accordance with the
manufacture’s installation instructions.
9.3.8.8 Combustion air intake openings located on the exterior of the
building shall have the lowest side of the combustion air intake openings
located at least 12 in. (300 mm) vertically from the adjoining grade level.
Category I Venting (Vertical Venting)
(80% Furnaces Only)
WARNING
TO PREVENT POSSIBLE PERSONAL INJURY OR DEATH DUE TO
ASPHYXIATION, NON-CONDENSING GAS FIRED WARM AIR FURNACES MUST
BE CATEGORY I VENTED. DO NOT VENT ANY OF THESE FURNACES USING
CATEGORY III VENTING.
Category I Venting is venting at a non-positive pressure. A
furnace vented as Category I is considered a fan-assisted
appliance and does not have to be "gas tight." NOTE: SingleStage and Two-Stage gas furnaces with induced draft blowers draw products of combustion through a heat exchanger
allowing in some instances common venting with natural
draft appliances (i.e. water heaters).
All installations must be vented in accordance with National
Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition. In
Canada, the furnaces must be vented in accordance with
the National Standard of Canada, CAN/CGA B149.1 and
CAN/CGA B149.2 - latest editions and amendments.
NOTE: The vertical height of the Category I venting system
must be at least as great as the horizontal length of the
venting system.
MODEL
060
080
100
MINIMUM VENT
UPFLOW
COUNTERFLOW
4 Inch
4 Inch
4 Inch
4 Inch
5 Inch
5 Inch
Under some conditions, larger vents than those shown above
may be required or allowed.
When an existing furnace is removed from a venting system
serving other appliances, the venting system may be too
large to properly vent the remaining attached appliances.
For complete details refer to Existing Furnace Removal section of this manual.
When resizing any portion of the common venting system,
use the appropriate table in Appendix G in the latest edition
of the National Fuel Gas Code NFPA 54/ANSI Z223.1.
Upflow or Horizontal units are shipped with the induced
draft blower discharging from the top of the furnace ("Top" is
as viewed for an upflow installation). The induced draft blower
can be rotated 90 degrees for Category I venting. Refer to
the following figure. For horizontal installations, a four inch
single wall pipe can be used to extend the induced draft
blower outlet 1/2” beyond the furnace cabinet. Vent the furnace in accordance with the National Fuel Gas Code NFPA
54/ANSI Z223.1 - latest edition. In Canada, vent the furnace
in accordance with the National Standard of Canada, CAN/
CGA B149.1 and CAN/CGA B149.2 - latest editions and
amendments.
NOTE: This furnace is not design certified to be horizontally
vented.
WARNING
TO PREVENT DEATH OR SERIOUS ILLNESS TO BUILDING OCCUPANTS DUE
TO FLUE PRODUCTS LEAKING INTO THE BUILDING, PROPER INSTALLATION OF
GASKETS AND SCREWS IS ESSENTIAL FOR PROVIDING A GAS TIGHT SEAL
BETWEEN THE PARTITION PANEL AND THE INDUCED DRAFT BLOWER.
Make sure all wires are at least one inch from flue pipe.
Relocate junction box to right side of cabinet if necessary.
Refer to Electrical Connections section of this manual for
instructions.
WARNING
TO PREVENT POSSIBLE DEATH OR PERSONAL INJURY DUE TO
ASPHYXIATION, COMMON VENTING WITH OTHER MANUFACTURER'S
INDUCED DRAFT APPLIANCES IS NOT ALLOWED.
The minimum vent diameter for the Category I venting system is as shown in the following chart:
21
PRODUCT DESIGN
Masonry Chimneys
Proper Chimney
Termination?
(Check 1)
No
Line, terminate with
listed vent cap
(Fix 1)
No
Change venting
arrangements
(Fix 2)
No
Rebuild crown
(Fix 3)
and/or Reline
(Fix 4)
No
Reline
(Fix 4)
No
Reline
(Fix 4)
No
Reline
(Fix 4)
Yes
Chimney channel
free of solid and
liquid fuel
appliances?
(Check 2)
Yes
Crown in good
condition
(Check 3)
Yes
Crown
Wash
Roof Line
Clay Tile Size Generally
12" x 12" (24" Length)
Cleanout free of
debris?
(Check 4)
Yes
Clay Tile Size: 8" x 8" x12"
(Each x 24" Length)
Attic Floor
Liner in good
condition?
(Check 5)
1/2" to 1" Air Space
Yes
Second Floor
Dilution air
available?
(Check 6)
Throat
Damper
First Floor
Breech
Clean Out
F.A.F. Vent
Connector
Fan Assisted
Forced Air
Furnace
Yes
Water Heater
Vent Connector
Natural Draft
Water Heater
Complete the
installation.
(Check 7)
Basement Floor
Typical Multiple Flue Clay Tile Chimney
Checklist Summary
This checklist serves as a summary of the items to be
checked before venting an 80% furnace into a masonry chimney. In addition, we recommend that a qualified serviceman
use this checklist to perform a yearly inspection of the furnace venting system.
This checklist is only a summary. For detailed information
on each of the procedures mentioned, see the paragraph
referenced with each item.
This inspection is based upon a draft topical report, "Masonry Chimney Inspection and Relining", issued by the Gas
Research Institute. While not yet finalized, we believe this
report represents the best information on this subject which
is currently available.
22
Check 1 - Proper chimney termination.
A masonry chimney used as a vent for gas fired equipment
must extend at least three feet above the highest point where
it passes through the roof. It must extend at least two feet
higher than any portion of a building within a horizontal distance of 10 feet. In addition, the chimney must terminate at
least 3 feet above any forced air inlet located within 10 feet.
The chimney must extend at least five feet above the highest connected equipment draft hood outlet or flue collar.
If the chimney does not meet these termination requirements,
but all other requirements in the checklist can be met, it
may be possible for a mason to extend the chimney. If this
will not be practical, see Fix 1.
PRODUCT DESIGN
10' or Less
2' Min.
2' Min.
3' Min.
Wall or
Parapet
Chimney
10' or Less
2' Min.
Ridge
3' Min.
Chimney
Termination 10 Feet Or Less From Ridge, Wall or
Parapet
More than 10'
3' Min.
Wall or
Parapet
NOTE: No Height
above parapet
required when distance
from walls or parapet is
more than 10 feet.
Height above any
roof surface within
10 feet horizontally.
More than 10'
Ridge
Chimney
10'
2' Min.
3' Min.
Chimney
Termination More Than 10 Feet From Ridge, Wall or
Parapet
Check 2 - Any solid or liquid fuel appliances vented
into this chimney channel.
Solid fuel appliances include fireplaces, wood stoves, coal
furnaces, and incinerators.
Liquid fuel appliances include oil furnaces, oil-fired boilers
and oil-fired water heaters.
Appliances which burn propane (sometimes referred to as
LP (liquefied petroleum)) gas are considered gas-fired appliances.
Check 3 - Chimney Crown Condition.
Damage from condensate usually shows up first in the crown.
If any of the following trouble signs are present, the condition of the crown is not satisfactory:
a) Crown leaning
b) Bricks missing
c) Mortar missing
d) Tile liner cracked
e) No tile liner
f) Salt staining at mortar joints. (White stains, and mortar becomes sandy and/or erodes.)
For problems a, b, or c, see Fix 3. If problems d, e, or f are
present, see Fix 4. IMPORTANT: It may be necessary to
follow both Fix 3 and Fix 4.
Check 4 - Debris in Cleanout
A cleanout (dropleg) must be present such that the upper
edge of the cleanout cover is at least 12 inches below the
lower edge of the lowest chimney inlet opening.
A chimney without a cleanout could become partially blocked
by debris. If no cleanout is present, the chimney must be
relined (Fix 4).
Remove the cleanout cover, and examine the cleanout for
debris. If significant amounts of any of the following are found:
•
Fuel oil residue
•
Bricks
•
Mortar or sand
•
Pieces of the tile liner
•
Rusted pieces of the metallic liner
reline the chimney (Fix 4).
Check 5 - Liner Condition.
If a metal liner is present, it must be checked. It cannot be
assumed that all existing metal liners are correctly installed
and in good condition.
Remove the lowest existing vent connector, and examine
the inside of the elbow or tee at the base of the liner. A small
amount of soot may be considered acceptable, provided the
installer vacuums it away. If rusted pieces of the liner have
collected here, the metal liner must be removed and replaced
(Fix 4).
Next, gently tap the inside of the liner with a Phillips screwdriver. If the screwdriver perforates the liner, or if the tapping
does not sound like metal hitting metal, the liner must be
removed and replaced (Fix 4).
Remember that all appliances must be vented inside the
liner. Venting one appliance inside the liner and another appliance outside the liner is not acceptable.
Next, use a flashlight and small mirror to sight up the liner.
B vent must be supported so as to not come into direct
contact with the chimney walls or tile liner. If it is not, it can
probably be rehung so as to be acceptable. A thimble or fire
stop may be helpful here.
23
PRODUCT DESIGN
Flexible liners should be hung straight or nearly straight. If it
is spiraled in the chimney and in good condition, it should
be rehung. To do this, break the top seal; pull up and cut off
the excess liner length, and refit the top seal. Use caution
when doing this, as the cut edges of flexible liners may be
sharp.
The surfaces of the liner must be physically sound. If gaps
or holes are present, the metal liner must be removed and
replaced (Fix 4).
Finally, confirm that the metal liner is the correct size for the
appliances to be installed. Use the GAMA tables and rules.
If a metal liner is not present, a clay tile liner must be present,
or the chimney must be lined (Fix 4).
Use a flashlight and small mirror at the cleanout or vent
connector to inspect the clay tile liner. If any of the following
problems are present:
•
Tile sections misaligned
•
Tile sections missing
•
Gaps between tile sections
•
Signs of condensate drainage at the cleanout or vent
connectors
•
Mortar protruding from between tile sections
•
Use of sewer pipe or drainage pipe rather than an approved fire clay tile
reline the chimney (Fix 4).
Next, measure the size of the liner. It may be possible to do
this from the cleanout. The liner must be at least as large as
the minimum size established by the tables in National Fuel
Gas Code NFPA 54/ANSI Z223.1 - latest edition and in the
National Standard of Canada, CAN/CGA B149.1 and CAN/
CGA B149.2 - latest editions and amendments. If the liner
is too small or too large, then the chimney must be relined
(Fix 4).
Check 6 - Dilution Air.
If gas-fired appliances are to be vented into a clay tile liner,
a source of dilution air is required.
Dilution air cannot be obtained through:
•
Induced draft appliances
•
Natural draft appliances with vent dampers
Sufficient dilution air can ordinarily be obtained through the
draft hood of a natural draft appliance only if the appliance’s
vent connector does not include a vent damper.
If dilution air will not be available, the chimney must be relined (Fix 4).
Check 7 - Complete the Installation.
If Checks 1 through 6 have been satisfactory, and the liner
is an acceptable size as determined by the tables in National Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition
and in the National Standard of Canada, CAN/CGA B149.1
and CAN/CGA B149.2 - latest editions and amendments,
then the clay tile liner can probably be used as a vent for the
24
gas appliances. However, the installer must keep in mind
the following factors which may render the tile liner unsuitable for use as a vent:
•
Extremely cold weather
•
Long vent connectors
•
Masonry chimneys with no air gap between the liner
and the bricks. (In practice, this can be difficult to
detect.)
•
Exterior chimneys (The tables in National Fuel Gas
Code NFPA 54/ANSI Z223.1 - latest edition and in
the National Standard of Canada, CAN/CGA B149.1
and CAN/CGA B149.2 - latest editions and amendments assume interior chimneys.)
If, in the judgment of the local gas utility, installer, and/or
local codes; one or more of the above factors is likely to
present a problem, the chimney must be relined (Fix 4).
Fix 1 - Liner Termination.
Any cap or roof assembly used with a liner must be approved by the liner manufacturer for such use. The liner and
cap/roof assembly must then terminate above the roof in
accordance with the manufacturer’s instructions.
In some cases, a shorter extension above the roof may be
possible with a liner than would be required with a masonry
chimney.
For further information on relining, see Fix 4.
Fix 2 - Change Venting Arrangements
If the masonry chimney has more than one channel, it may
be possible to vent the gas appliances into one channel and
vent the solid or liquid fuel appliance(s) into another
channel(s). Do not vent an 80% furnace inside of a metal
liner with other appliances vented outside the liner.
Alternatively, the homeowner may agree to discontinue use
of the fireplace (solid fuel appliance). If so, the tile liner must
be cleaned to remove creosote buildup. The fireplace opening must then be permanently sealed.
If oil-fired appliance(s) are being replaced by gas-fired
appliance(s), the tile liner must first be cleaned to remove
the fuel oil residue.
If none of the above options are practical, the 80% furnace
may need to be vented vertically with B vent.
Under some conditions a 90%+ furnace could be installed
rather than an 80%. The 90% furnace can be vented horizontally or vertically through PVC pipe.
Fix 3 - Rebuild the Crown.
If the chimney crown is damaged, a qualified mason must
repair it in accordance with nationally recognized building
codes or standards. One such standard which may be referenced is the Standard for Chimneys, Fireplaces, Vents, and
Solid Fuel Burning Appliances, ANSI/NFPA 211.
Fix 4 - Relining.
Relining options include B vent and flexible liners.
If the chimney has diagonal offsets, B vent probably cannot
be used.
PRODUCT DESIGN
If B vent is to be used, it must be supported adequately.
Supports (such as fire stops or thimbles) must be used to
prevent the B vent from coming into direct contact with the
tile liner or chimney walls. Direct contact would result in
higher heat loss, with an increased possibility of poor venting system performance.
It is not acceptable to vent one appliance inside the B vent
and other appliances outside. The excess space between
the B vent and the chimney walls must be covered at the top
of the chimney by a weatherproof, corrosion resistant flashing.
The B vent should then be topped with a listed vent cap. The
listed vent cap will, when installed per the manufacturer’s
instructions, prevent problems due to rain, birds, or wind
effects.
A B vent installed as described in this section is considered
to be an enclosed vent system, and the sizing tables in
National Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition and in the National Standard of Canada, CAN/CGA
B149.1 and CAN/CGA B149.2 - latest editions and amendments may be used.
If a flexible liner is to be used, it must be made of the proper
materials:
•
For most residential applications, an aluminum liner
should be acceptable.
•
If the combustion air supplied to the furnace will be
contaminated with compounds containing chlorine or
fluorine, a liner of AL29-4C stainless steel should be
used. Common sources of chlorine and fluorine compounds include indoor swimming pools and chlorine
bleaches, paint strippers, adhesives, paints, varnishes,
sealers, waxes (which are not yet dried) and solvents
used during construction and remodeling. Various commercial and industrial processes may also be sources
of chlorine/fluorine compounds.
•
Heavier gauge 300 and 400 series stainless steel liners were developed for use with oil or solid fuel appliances. They are not suitable for use with gas-fired
appliances. Flexible liners specifically intended and
tested for gas applications are listed in the UL "Gas
and Oil Equipment Directory". (UL Standard 1777).
For sizing of flexible liners, see Note 22 and the tables in
the National Fuel Gas Code NFPA 54/ANSI Z223.1 - latest
edition and in the National Standard of Canada, CAN/CGA
B149.1 and CAN/CGA B149.2 - latest editions and amendments.
To install the liner, read and follow the liner manufacturer’s
instructions and your local codes. Excess liner length should
be pulled out of the chimney and cut off. Use caution when
doing this, as the cut edges of flexible liners may be sharp.
Do not spiral excess liner inside of the chimney. Support
the liner as recommended by the liner manufacturer.
Some manufacturers of flexible liners offer an insulation sleeve
designed to be added to the liner before it is installed in the
chimney. (Poured insulation, either vermiculite or other materials, is no longer recommended.) Insulation will need to
be added to the flexible liner if:
•
•
It is required by the liner manufacturer’s instructions.
The previous liner was properly sized and installed,
and suffered from condensation damage.
•
It is required by your local building codes.
Even if none of those three conditions exist which require
additional liner insulation, the installer may wish to consider
it if:
•
The local climate is very cold.
•
The chimney is very tall.
•
The vent connectors used are very long or have a large
number of elbows.
•
Local experience indicates that flexible liners installed
without insulation are likely to have condensation problems.
Insulation must be selected and installed in accordance with
the liner manufacturer’s instructions.
Finally, cap the chimney and terminate the liner in accordance with the liner manufacturer’s instructions.
Horizontal Applications and Considerations
Horizontal applications, in particular, may dictate many of
the installation’s specifics such as airflow direction, ductwork connections, flue and/or combustion air pipe connections, etc. Never install a furnace on its back. Furnace and
coil must be adequately supported.
Alternate Electrical and Gas Line Connections
Furnaces have provisions allowing for electrical and gas line
connections through either side panel. In horizontal applications the connections can be made either through the “top”
or “bottom” of the furnace.
Propane Gas and/or High Altitude Installations
WARNING
POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR IF
THE CORRECT CONVERSION KITS ARE NOT INSTALLED. THE APPROPRIATE KITS
MUST BE APPLIED TO INSURE SAFE AND PROPER FURNACE OPERATION. ALL
CONVERSIONS MUST BE PERFORMED BY A QUALIFIED INSTALLER OR SERVICE
AGENCY.
25
PRODUCT DESIGN
This furnace is shipped from the factory configured for natural gas at standard altitude. Propane gas installations require an orifice change to compensate for the energy content difference between natural and propane gas.
High altitude installations may require both a pressure switch
and an orifice change. These changes are necessary to compensate for the natural reduction in the density of both the
gas fuel and the combustion air at higher altitude.
Refer to the Accessories Charts in this manual or product
Specification Sheet for a tabular listing of appropriate
manufacturer’s kits for propane gas and/or high altitude installations. The indicated kits must be used to insure safe
and proper furnace operation. All conversions must be performed by a qualified installer, or service agency.
WARNING
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN BODILY INJURY OR
CAREFULLY READ AND FOLLOW ALL INSTRUCTIONS GIVEN IN THIS
DEATH.
SECTION.
WARNING
UPON COMPLETION OF THE FURNACE INSTALLATION, CAREFULLY INSPECT THE
ENTIRE FLUE SYSTEM BOTH INSIDE AND OUTSIDE THE FURNACE TO ASSURE IT
IS PROPERLY SEALED.
LEAKS IN THE FLUE SYSTEM CAN RESULT IN SERIOUS
PERSONAL INJURY OR DEATH DUE TO EXPOSURE TO FLUE PRODUCTS,
INCLUDING CARBON MONOXIDE.
It is the responsibility of the installer to follow the manufacturers’ recommendations and to verify that all vent/flue piping and connectors are compatible with furnace flue products. Additionally, it is the responsibility of the installer to
ensure that all piping and connections possess adequate
structural integrity and support to prevent flue pipe separation, shifting, or sagging during furnace operation.
GAS SUPPLY AND PIPING
The furnace rating plate includes the approved furnace gas
input rating and gas types. The furnace must be equipped to
operate on the type of gas applied. This includes any conversion kits required for alternate fuels and/or high altitude.
INLET GAS SUPPLY PRESSURE
Natural Gas
Minimum: 4.5" w.c. Maximum: 10.0" w.c.
Propane Gas
Minimum: 11.0" w.c.
Maximum: 13.0" w.c.
HIGH ALTITUDE DERATE
When this furnace is installed at high altitude, the appropriate High Altitude orifice kit must be applied. This is required
due to the natural reduction in the density of both the gas
fuel and combustion air as altitude increases. The kit will
provide the proper design certified input rate within the specified altitude range.
High altitude kits are purchased according to the installation altitude and usage of either natural or propane gas. Refer
to the product Specification Sheet or Technical Manual for a
tabular listing of appropriate altitude ranges and corresponding manufacturer’s high altitude (Natural, Propane gas, and/
or Pressure Switch) kits.
Do not derate the furnace by adjusting the manifold pressure to a lower pressure than specified on the furnace rating
plate. The combination of the lower air density and a lower
manifold pressure will prohibit the burner orifice from drawing the proper amount of air into the burner. This may cause
incomplete combustion, flashback, and possible yellow tipping.
In some areas the gas supplier may artificially derate the
gas in an effort to compensate for the effects of altitude. If
the gas is artificially derated, the appropriate orifice size
must be determined based upon the BTU/ft3 content of the
derated gas and the altitude. Refer to the National Fuel Gas
Code, NFPA 54/ANSI Z223.1, and information provided by
the gas supplier to determine the proper orifice size.
A different pressure switch may be required at high altitude
regardless of the BTU/ft3 content of the fuel used. Refer to
the product Specification Sheet or Technical Manual for a
tabular listing of appropriate altitude ranges and corresponding manufacturer’s pressure switch kits.
PROPANE GAS CONVERSION
CAUTION
TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE INLET
GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE
WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING.
Inlet gas supply pressures must be maintained within the
ranges specified below. The supply pressure must be constant and available with all other household gas fired appliances operating. The minimum gas supply pressure must
be maintained to prevent unreliable ignition. The maximum
must not be exceeded to prevent unit overfiring.
26
This unit is configured for natural gas. The appropriate
manufacturer’s propane gas conversion kit, must be applied
for propane gas installations.
• Two-stage furnace models using a White-Rodgers
36G54 two-stage valve require an LPM-05 or LPM-06
LP conversion kit.
• Two-stage furnace models using a Honeywell VR9205
two-stage valve require an LPM-06 LP conversion kit.
Refer to the specification sheet for the model you are servicing. Refer to the “propane gas and/or High Altitude Installations” section for details.
PRODUCT DESIGN
GAS VALVE
This unit is equipped with a 24 volt gas valve controlled during furnace operation by the integrated control module. As
shipped, the valve is configured for natural gas. The valve is
field convertible for use with propane gas by using the appropriate propane gas conversion kit. Taps for measuring
the gas supply pressure and manifold pressure are provided
on the valve.
NOTE: The gas supply pressure on White-Rodgers "G"
model gas valve, used on single stage furnaces, can
be checked with a gas pressure test kit (Part
#0151K00000S) available through our authorized distributors.
The gas valve has a manual ON/OFF control located on the
valve itself. This control may be set only to the “ON” or “OFF”
position. Refer to the Lighting Instructions Label or the “Putting the Furnace Into Operation” section of this manual or
the installation instructions for use of this control during start
up and shut down periods.
GAS PIPING CONNECTIONS
CAUTION
TO AVOID
POSSIBLE UNSATISFACTORY OPERATION OR EQUIPMENT DAMAGE
DUE TO UNDERFIRING OF EQUIPMENT, USE THE PROPER SIZE OF
NATURAL/PROPANE GAS PIPING NEEDED WHEN RUNNING PIPE FROM THE
The gas piping supplying the furnace must be properly sized
based on the gas flow required, specific gravity of the gas,
and length of the run. The gas line installation must comply
with local codes, or in their absence, with the latest edition
of the National Fuel Gas Code, NFPA 54/ANSI Z223.1.
Length of
Pipe in Feet
10
20
30
40
50
60
70
80
90
100
1. Use black iron or steel pipe and fittings for the building piping.
2. Use pipe joint compound on male threads only. Pipe
joint compound must be resistant to the action of the
fuel used.
3. Use ground joint unions.
4. Install a drip leg to trap dirt and moisture before it can
enter the gas valve. The drip leg must be a minimum
of three inches long.
5. Install a 1/8" NPT pipe plug fitting, accessible for test
gage connection, immediately upstream of the gas
supply connection to the furnace.
6. Use two pipe wrenches when making connection to
the gas valve to keep it from turning. The orientation of
the gas valve on the manifold must be maintained as
shipped from the factory.
7. Install a manual shutoff valve between the gas meter
and unit within six feet of the unit. If a union is installed, the union must be downstream of the manual
shutoff valve, between the shutoff valve and the furnace.
8. Tighten all joints securely.
METER/TANK TO THE FURNACE.
Natural Gas Capacity of Pipe
In Cubic Feet of Gas Per Hour (CFH)
Nominal Black Pipe Size
1/2"
3/4"
1"
1 1/4"
132
278
520
1050
92
190
350
730
73
152
285
590
63
130
245
500
56
115
215
440
50
105
195
400
46
96
180
370
43
90
170
350
40
84
160
320
38
79
150
305
The following stipulations apply when connecting gas piping. Refer to the following figures for typical gas line connections to the furnace.
1 1/2"
1600
1100
980
760
670
610
560
530
490
460
(Pressure 0.5 psig or less and pressure drop of 0.3" W.C.; Based on 0.60 Specific
Gravity Gas)
CFH = BTUH Furnace Input
9. Connect the furnace to the building piping by one of
the following methods:
– Rigid metallic pipe and fittings.
– Semi-rigid metallic tubing and metallic fittings. Aluminum alloy tubing must not be used in exterior locations. In order to seal the grommet cabinet penetration, rigid pipe must be used to reach the outside
of the cabinet. A semi-rigid connector to
the gas piping may be used from there.
10. Use listed gas appliance connectors in accordance with
their instructions. Connectors must be fully in the same
room as the furnace.
11. Protect connectors and semi-rigid tubing against physical and thermal damage when installed. Ensure aluminum-alloy tubing and connectors are coated to protect
against external corrosion when in contact with masonry,
plaster, or insulation, or subjected to repeated wetting
by liquids such as water (except rain water), detergents,
or sewage.
Heating Value of Gas (BTU/Cubic Foot)
To connect the furnace to the building’s gas piping, the installer must supply a ground joint union, drip leg, manual
shutoff valve, and line and fittings to connect to gas valve. In
some cases, the installer may also need to supply a transition piece from 1/2" pipe to a larger pipe size.
CAUTION
EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES A PRECAUTION
WHEN REMOVING HOLE PLUGS.
27
PRODUCT DESIGN
DIRECT/STANDARD INLET PIPING
When gas piping enters directly to the gas valve through the
standard inlet hole (upflow through the right side panel), the
installer must supply straight pipe with a ground joint union
to reach the exterior of the furnace. NOTE: The rigid pipe
must be long enough to reach the outside of the cabinet. A
semi-rigid connector to the gas piping can be used outside
the cabinet per local codes.
INDIRECT/ALTERNATE INLET PIPING
When gas piping enters indirectly to the gas valve through
the alternate gas inlet hole the installer must supply the
following fittings (starting from the gas valve) to reach the
outside of the cabinet.
•
Coupling.
•
90 degree elbow.
•
2 inch close nipple.
•
90 degree elbow.
•
Straight pipe, with a ground joint union, to reach the
exterior of the furnace.
GAS PIPING CHECKS
Before placing unit in operation, leak test the unit and gas
connections.
WARNING
TO AVOID THE POSSIBLITY OF EXPLOSION OR FIRE, NEVER USE A MATCH
smell. Contact a local propane gas supplier about installing
a gas detecting warning system. If the presence of gas is
suspected, follow the instructions on Page 3 of this manual.
All propane gas equipment must conform to the safety standards of the National Board of Fire Underwriters, NBFU
Manual 58.
For satisfactory operation, propane gas pressure must be
11 inch WC at the furnace manifold with all gas appliances
in operation. Maintaining proper gas pressure depends on
three main factors:
1. Vaporization rate, depending on temperature of the liquid, and “wetted surface” area of the container or containers.
2. Proper pressure regulation. (Two-stage regulation is recommended for both cost and efficiency).
3. Pressure drop in lines between regulators, and between
second stage regulator and the appliance. Pipe size will
depend on length of pipe run and total load of all appliances.
Complete information regarding tank sizing for vaporization,
recommended regulator settings, and pipe sizing is available from most regulator manufacturers and propane gas
suppliers. Use a pipe thread sealant approved for natural
gas and LP gas.
Refer to the following illustration for typical propane gas installations and piping.
OR OPEN FLAME TO TEST FOR LEAKS.
5 to 15 PSIG
(20 PSIG Max.)
First Stage
Regulator
Check for leaks using an approved chloride-free soap and
water solution, an electronic combustible gas detector, or
other approved testing methods.
NOTE: Never exceed specified pressures for testing. Higher
pressure may damage the gas valve and cause subsequent
overfiring, resulting in heat exchanger failure. Disconnect this
unit and shutoff valve from the gas supply piping system
before pressure testing the supply piping system with pressures in excess of 1/2 psig (3.48 kPa). Isolate this unit from
the gas supply piping system by closing its external manual
gas shutoff valve before pressure testing supply piping system with test pressures equal to or less than 1/2 psig (3.48
kPa).
200 PSIG
Maximum
Continuous
11" W.C.
Second Stage
Regulator
Typical Propane Gas Installation
WARNING
PROPANE GAS TANKS AND PIPING
IF THE GAS FURNACE IS INSTALLED IN A BASEMENT, AN EXCAVATED
WARNING
AREA OR A CONFINED SPACE, IT IS STRONGLY RECOMMENDED TO
CONTACT A PROPANE SUPPLIER TO INSTALL A GAS DETECTING
PROPANE GAS IS HEAVIER THAN AIR AND ANY LEAKING GAS CAN SETTLE IN
TO PREVENT PROPERTY DAMAGE,
ANY LOW AREAS OR CONFINED SPACES.
WARNING DEVICE IN CASE OF A GAS LEAK.
•
SINCE PROPANE GAS IS HEAVIER THAN AIR, ANY LEAKING GAS CAN
•
PROPANE GAS ODORANT MAY FADE, MAKING THE GAS UNDETECTABLE
SETTLE IN ANY LOW AREAS OR CONFINED SPACES.
PERSONAL INJURY, OR DEATH DUE TO FIRE OR EXPLOSION CAUSED BY A
PROPANE GAS LEAK, INSTALL A GAS DETECTION WARNING DEVICE.
EXCEPT WITH A WARNING DEVICE.
A gas detecting warning system is the only reliable way to
detect a propane gas leak. Iron oxide (rust) can reduce the
level of odorant in propane gas. Do not rely on your sense of
28
PRODUCT DESIGN
ELECTRICAL CONNECTIONS
WARNING
AN UNDETECTED GAS LEAK WILL CREATE A DANGER OF EXPLOSION
OR FIRE. IF THE PRESENCE OF GAS IS SUSPECTED, FOLLOW THE
INSTRUCTIONS ON THE COVER OF THIS MANUAL. FAILURE TO DO SO
COULD RESULT IN SERIOUS PERSONAL INJURY OR DEATH.
WARNING
TO AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO THE UNIT MUST BE
PROPERLY POLARIZED AND GROUNDED.
Sizing Between First and Second Stage Regulator*
Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting.
Capacities in 1,000 BTU/hour.
Pipe or
Tubing
Length
Feet
10
20
30
40
50
60
80
100
125
150
175
200
Tubing Size, O.D. Type L
3/8"
730
500
400
370
330
300
260
220
200
190
170
160
1/2"
1,700
1,100
920
850
770
700
610
540
490
430
400
380
5/8"
3,200
220
2,000
1,700
1,500
1,300
1,200
1,000
900
830
780
730
3/4"
5,300
3,700
2,900
2,700
2,400
2,200
1,900
1,700
1,400
1,300
1,200
1,100
WARNING
Nominal Pipe Size
Schedule 40
7/8"
8,300
5,800
4,700
4,100
3,700
3,300
2,900
2,600
2,300
2,100
1,900
1,800
1/2"
3,200
2,200
1,800
1,600
1,500
1,300
1,200
1,000
900
830
770
720
3/4"
7,500
4,200
4,000
3,700
3,400
3,100
2,600
2,300
2,100
1,900
1,700
1,500
To convert to capacities at 15 psig settings - multiply by 1.130
To convert to capacities at 5 psig settings - multiply by 0.879
Sizing Between Second or Second Stage Regulator & Appliance*
Maximum Propane Capacities listed are based on 1/2" W.C. pressure drop at 11" W.C. setting.
Capacities in 1,000 BTU/hour.
Pipe or
Tubing
Length
Feet
10
20
30
40
50
60
80
100
125
150
200
250
Nominal Pipe Size
Schedule 40
Tubing Size, O.D. Type L
3/8"
39
26
21
19
18
16
13
11
10
9
8
8
1/2"
92
62
50
41
37
35
29
26
24
21
19
17
5/8"
199
131
107
90
79
72
62
55
48
43
39
36
3/4"
329
216
181
145
131
1,211
104
90
81
72
66
60
7/8"
501
346
277
233
198
187
155
138
122
109
100
93
1/2"
275
189
152
129
114
103
89
78
69
63
54
48
3/4"
567
393
315
267
237
217
185
162
146
132
112
100
1"
1,071
732
590
504
448
409
346
307
275
252
209
185
1-1/4"
2,205
1,496
1,212
1,039
913
834
724
630
567
511
439
390
1-1/2"
3,307
2,299
1,858
1,559
1,417
1,275
1,066
976
866
787
665
590
*Data in accordance with NFPA pamphlet No. 54
Propane Gas Piping Charts
When installing a propane storage tank, the contractor must
consider proper tank sizing, safety, efficiency, ground characteristics and aesthetics. For a residential customer, the
size may range from 100-1,000 gallons, depending on household use. Typically, a 500 gallon tank is ample for an average four-bedroom home. However, it is best to consult your
local propane supplier to ensure the proper sizing for propane storage requirements. Determining the correct tank
size for each household is a function of demand, economy,
efficiency and convenience. It is a process that requires cooperation between the propane supplier and customer.
HIGH VOLTAGE
DISCONNECT ALL POWER BEFORE SERVICING OR
INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY
BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY
DAMAGE, PERSONAL INJURY OR DEATH.
CAUTION
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS.
WIRING ERRORS CAN COUSE IMPROPER AND DANGEROUS OPERATION.
VERIFY PROPER OPERATION AFTER SERVICING.
WIRING HARNESS
The wiring harness is an integral part of this furnace. Field
alteration to comply with electrical codes should not be required. Wires are color coded for identification purposes.
Refer to the wiring diagram for wire routings. If any of the
original wire as supplied with the furnace must be replaced,
it must be replaced with wiring material having a temperature rating of at least 105° C. Any replacement wiring must
be copper conductor.
115 VOLT LINE CONNECTIONS
Before proceeding with electrical connections, ensure that
the supply voltage, frequency, and phase correspond to that
specified on the unit rating plate. Power supply to the furnace must be N.E.C. Class 1, and must comply with all
applicable codes. The furnace must be electrically grounded
in accordance with local codes or, in their absence, with
the latest edition of The National Electric Code, ANSI NFPA
70 and/or The Canadian Electric Code CSA C22.1.
Use a separate fused branch electrical circuit containing
properly sized wire, and fuse or circuit breaker. The fuse or
circuit breaker must be sized in accordance with the maximum overcurrent protection specified on the unit rating plate.
An electrical disconnect must be provided at the furnace
location.
NOTE: Line polarity must be observed when making field
connections.
Connect hot, neutral, and ground wires as shown in the
wiring diagram located on the unit’s blower door. Line polarity must be observed when making field connections. Line
voltage connections can be made through either the right or
left side panel.
29
PRODUCT DESIGN
CAUTION
OPTIONAL
ACCESORIES
ELECTRO NIC
AIR C LEANER
EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES A PRECAUTION
WHEN REMOVING HOLE PLUGS.
WARNING
120 VAC
NEUTR AL
TERMINALS
TO AVOID THE RISK OF ELECTRICAL SHOCK, INJURY, OR DEATH, THE
FURNACE MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH LOCAL
NEUTRAL
120 VAC
HO T AND
PARK
TERMINALS
HUM-H
NOTE: Wire routing must not interfere with circulator blower
operation, filter removal, or routine maintenance.
EAC-H
HUMIDIFIER
INTEGRATED
CONTROL
M ODULE
12 PIN
CO NNECTOR
CODES OR, IN THEIR ABSENCE, WITH THE LATEST EDITION OF THE
NATIONAL ELECTRIC CODE.
Wiring to Single HUM Terminal
HIGH VOLTAGE
DISCONNECT ALL POWER BEFORE SERVICING OR
CHANGING ANY ELECTRICAL WIRING. MULTIPLE POWER
SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE
NEUTRAL
HUM-IN
WARNING
HUM-OUT
115 VOLT LINE CONNECTION OF ACCESSORIES
(HUMIDIFIER AND ELECTRONIC AIR CLEANER)
PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
Furnaces have an integrated ignition control that is equipped
with line voltage accessory terminals for controlling power
to an optional field-supplied humidifier and/or electronic air
cleaner.
Accessory Load Specifications
Humidifier
1.0 Amp maximum at 120 VAC
Electronic Air Cleaner 1.0 Amp maximum at 120 VAC
Turn OFF power to the furnace before installing any accessories. Follow the humidifier or air cleaner manufacturers’
instructions for locating, mounting, grounding, and controlling these accessories.
HUMIDIFIER WIRING
Accessory wiring connections are to be made through the
1/4" quick connect terminals provided on the furnace integrated control module. The Humidifier and Electronic Air
Cleaner hot and neutral terminals are identified as HUM and
EAC. All field wiring must conform to applicable codes. Connections should be made as in the following figure.
Wiring Using HUM IN - HUM OUT Terminals
If it is necessary for the installer to supply additional line
voltage wiring to the inside of the furnace, the wiring must
conform to all local codes, and have a minimum temperature rating of 105°C. All line voltage wire splices must be
made inside the furnace junction box.
Humidifier Wiring
There are several options for connecting humidifier wiring to
the current communicating furnace control board
(PCBKF103, PCBKF104)
Single HUM terminal The single HUM terminal is energized
with 115 volts whenever the draft inducer is running. This
function is present regardless of thermostat type. This terminal may be used to power a humidifier transformer. A field
supplied humidistat must be provided with this option.
HUM IN – HUM OUT Terminals Present on communicating
furnace models built with a PCBKF103 or PCBKF104 control board. These terminals may be used when a CTK02** or
CTK03AB communicating thermostat is used. These thermostats are capable of initiating a call for humidity.The HUM
IN – HUM OUT terminals are not energized by factory wiring
and must be field wired.Typical wiring would be to supply
the HUM IN contact with 115 volts from the furnace L1 terminal and connect a line voltage humidifier / transformer
between HUM OUT and the control board nuetral.
30
PRODUCT DESIGN
Options for control:
With the CTK02 thermostat. From the Main Menu > Clock
& Display > Hum Display > (On). Enter the Advanced menu
by pressing left and right arrows for three seconds > Com
Devices > Furnace > Setup > Humidity > (On or Independent) If “On” is selected, the HUM IN – HUM OUT contacts
will close during a call for heat if the room humidty is below
the humidity set point selected on the CTK02**. The control
board also runs the furnace blower on constant fan speed to
support the call for humidification. If “IND” is selected, the
HUM IN – HUM OUT contacts will close with or without a
call for heat if the room humidity is below the humidity setpoint
selected on the CTK02**. The control board also runs the
furnace blower on constant fan speed to support the call for
humidification.
With the CTK03AB thermostat. From the Main Menu > Installer Options (enter 4 digit passcode from the Dealer Information Menu) > View / Edit Current Setup > Humidification
> Humidifier Type (Steam or Bypass / fan powered) > Modes
Allowing Humidification (Heat, Off) > Humidification Control
> (Humidify only when fan is on, Humidify on demand –
thermostat controls fan, Humidify on demand – equipment
controls fan)
24 VOLT THERMOSTAT WIRING
NOTE: Low voltage connections can be made through either the right or left side panel. Wire routing must not interfere with circulator blower operation, filter removal, or routine
maintenance.
A 40 V.A. transformer and an integrated electronic control
are built into the furnace to allow use with most cooling equipment. Consult the wiring diagram, located in the Technical
Manual or on the blower door for further details of 115 Volt
and 24 Volt wiring.
NOTE: For single stage cooling applications, a jumper may
be required between Y1 and Y2 at the furnace control in
order to achieve the desired single stage cooling airflow.
Consult the blower performance tables to determine if the
required single stage cooling airflow can be delivered at low
stage (Y1 input) or high stage (Y2 input). Additionally, use
of ramping profile features require a jumper between Y1 and
O when used with a straight cooling unit.
NOTE: Thermostat “R” required if outdoor unit is equipped
with a Comfort Alert™ module or if the out door unit is a part
of the ComfortNet family of equipment AND is wired as a
legacy system.
Place Jumper Between Y1
and O For Proper
Dehumidification Operation
and Proper Ramping
Profile Operation
Thermostat
Single Stage Heating with
Single Stage Cooling
Y
R
Furnace Integrated
Control Module
R
NEU
Y
Dehumidistat
[Optional]
C
Remote
Condensing Unit
(Single-Stage Cooling)
Single Stage Heating with Single Stage Cooling
NOTE: To apply a single-stage Heating Thermostat,
the thermostat selector switch on the
Integrated Control Module must be set on
single-stage.
Place Jumper Between Y1
and O For Proper
Dehumidification Operation
and Proper Ramping
Profile Operation
Thermostat
Two-Stage Heating
with
Single-Stage Cooling
Y
R
Furnace Integrated
Control Module
R
Low voltage connections can be made through either the
right or left side panel. Thermostat wiring entrance holes are
located in the blower compartment. The following figure
shows connections for a “heat only” system and “heat/cool
system”.
NEU
Y
C
Dehumidistat
[Optional]
Remote
Condensing Unit
(Single-Stage Cooling)
Two-Stage Heating with Single-Stage Cooling
As a two-stage non-communicating furnace, the furnace integrated control module provides terminals for both “W1” and
“W2”, and “Y1” and “Y2” thermostat connections. This allows the furnace to support the following system applications: ‘Two-Stage Heating Only’, ‘Two-Stage Heating with
Single Stage Cooling’, and ‘Two-Stage Heating with TwoStage Cooling’. Refer to the following figures for proper connections to the integrated control module.
Low voltage connections can be made through either the
right or left side panel. Thermostat wiring entrance holes are
located in the blower compartment. The following figure
shows connections for a “heat/cool system”.
This furnace is equipped with a 40 VA transformer to facilitate use with most cooling equipment. Consult the wiring
diagram, located on the blower compartment door, for further details of 115 Volt and 24 Volt wiring.
Place Jumper Between Y1
and O For Proper
Dehumidification Operation
and Proper Ramping
Profile Operation
Y2
(
W2
W1
Y2
W1
Thermostat
Two-Stage Heating
with
Two-Stage Cooling
)
Furnace Integrated
Control Module
W2
NEU
Y2
Dehumidistat
[Optional]
Remote
Condensing Unit
(Two-Stage Cooling)
Two-Stage Heating with Two-Stage Cooling
Thermostat Wiring Diagrams
31
PRODUCT DESIGN
Single-Stage Thermostat Application
A single-stage thermostat with only one heating stage may
be used to control this furnace. The application of a singlestage thermostat does not offer “true” thermostat-driven twostage operation, but provides a timed transition from low to
high fire. The furnace will run on low stage for a fixed period
of time before stepping up to high stage to satisfy the
thermostat’s call for heat. The delay period prior to stepping up can be set at either a fixed 5 minute time delay or a
load based variable time between 1 and 12 minutes (AUTO
mode). If the AUTOmode is selected, the control averages
the cycle times of the previous three cycles and uses the
average to determine the time to transition from low stage to
high stage.
To use a single-stage thermostat, turn off power to the furnace, move the thermostat selection DIP switch to the OFF
position. Set the desired transition time by setting the transition delay DIP switch to the desired ON/OFF position.
Turn power back on. Refer to the following figure.
OFF
ON
Move to the ON position
to select two-stage
thermostat or OFF to
select single stage
thermostat
Heat OFF Delay
DIP Switches
3
Thermostat
4
Stage Delay
S1
Move to the ON position
to select Auto transition
delay or OFF for 5 minute
transition delay
PCBKF103 / PCBKF104
32
PRODUCT DESIGN
Models Equipped with PCBKF101 or PCBKF102 Control Board
Speed Selection Dip Switches
Cool
Selection
Switches
Adjust
Selection
Switches
TAP
1
A
OFF
OFF OFF OFF
OFF
B
ON
C
OFF
D
ON
Profiles
2
3
Profile
Selection
Switches
4
5
Model
Heat
Selection
Switches
6
OFF OFF
*DVC80603B***
7
8
OFF
OFF
ON
OFF
ON
OFF
ON
OFF
ON OFF
ON
OFF
ON
OFF
ON
ON
ON
ON
ON
ON
ON
ON
Tap
Pre-Run
Short-Run
OFF Delay
A
- ---- --
- -- - -- --
60 sec/100%
B
- -- -- --
30 sec/50%
60 sec/100%
C
- -- - -- -
7.5 min/82%
60 sec/100%
D
30 sec/50%
7.5 min/82%
30 sec/50%
To set airflow: (1) Select model and desired
high stage cooling airflow. Determine the corresponding tap
( A, B, C, or D ). Set dip switches 1and 2 to the appropriate
ON / OFF positions. (2) Select model and desired high stage
heating airflow. Determine the corresponding tap ( A, B, C, or
D ). Set dip switches 7 and 8 to the appropriate ON / OFF
positions. (3) Select the airflow adjustment factor taps A and
D are 1; Tap B is +10%; Tap C -10%. Set dip switches 3 and 4
to the appropriate ON / OFF positions.
To set Comfort Mode: Select desired Comfort Mode profile
(see profiles above). Set switches 5 and 6 to the appropriate
ON / OFF positions.
*DVC80805C***
*DVC81005C***
*MVC80604B***
*MVC80805C***
*MVC81005C***
Low Stage High Stage Low Stage High Stage
Cool
Cool
Heat
Heat
A
B
C
D
A
B
C
D
390
520
650
780
520
715
910
1170
600
800
1000
1200
800
1100
1400
1800
735
805
875
935
945
1015
1085
1155
1050
1150
1250
1350
1350
1450
1550
1650
A
B
C
D
553
748
943
1203
850
1150
1450
1850
1085
1155
1225
1260
1550
1650
1750
1800
A
B
C
D
A
B
C
D
390
520
715
910
520
715
910
1170
600
800
1100
1400
800
1100
1400
1800
875
945
1015
1085
1050
1120
1190
1260
1250
1350
1450
1550
1500
1600
1700
1800
A
B
C
D
520
715
910
1175
800
1100
1400
1800
1210
1225
1245
1260
1725
1750
1775
1800
NOTE: Airflow data shown applies to legacy mode operation only. For a fully communicating system,
please see the outdoor unit’s installation instructions for cooling and pump heating airflow data. See
ComfortNet™ System - Airflow Consideration section for details.
Models Equipped with PCBKF103 and PCBKF104 Control Board
Speed Selection Dip Switches
Cool
Selection
Switches
TAP
Adjust
Selection
Switches
Profile
Selection
Switches
Model
Heat
Selection
Switches
735
805
875
945
1050
1150
1250
1350
*DVC80805C***
A
B
C
D
520
715
910
1170
800
1100
1400
1800
945
1015
1085
1155
1350
1450
1550
1650
60 sec/100% *DVC81005C***
A
B
C
D
553
748
943
1203
850
1150
1450
1850
1085
1155
1225
1260
1550
1650
1750
1800
*MVC80604B***
A
B
C
D
390
520
715
910
600
800
1100
1400
875
945
1015
1085
1250
1350
1450
1550
*MVC80805C***
A
B
C
D
520
715
910
1170
800
1100
1400
1800
1050
1120
1190
1260
1500
1600
1700
1800
*MVC81005C***
A
B
C
D
520
715
910
1170
800
1100
1400
1800
1210
1225
1245
1260
1725
1750
1775
1800
S4- 3 S4- 4
OFF OFF
OFF
OFF
B
ON
OFF
ON
ON
OFF
C
OFF
ON OFF
ON
OFF
ON
OFF
ON
D
ON
ON
ON
ON
ON
ON
ON
Profiles
A
Pre-Run
Short- Run
-- -- ---
-- -- ----
B
-- ---- -
C
--- -- --
7.5 min/82%
30 sec/50%
D
30 sec/50%
7.5 min/82%
High Stage
Heat
600
800
1000
1200
OFF OFF OFF
ON
Low Stage
Heat
390
520
650
780
S3- 1 S3- 2 S3- 3 S3- 4 S4-1 S4-2
OFF
High Stage
Cool
A
B
C
D
OFF
OFF
Low Stage
Cool
*DVC80603B***
A
ON
Tap
OFF Delay
60 sec/100%
60 sec/100%
30 sec/50%
To Set Airflow: (1) Select model and desired High Stage Cooling Airflow. Determine
the corresponding tap (A, B, C, or D). Set dip switches S3-1* and S3-2* to the
appropriate ON / OFF positions. (2) Select model and desired High Stage Heating
Airflow. Determine the corresponding tap (A, B, C, or D). Set dip switches S4-3* and
S4-4* to the appropriate ON / OFF positions. (3) Selecting Airflow Adjustment Factor:
For 0% trim set S5-2* to OFF (trim disabled). If trim is desired set S5-2* to ON (trim
enabled) and set S3-3* and S3-4* to appropriate ON / OFF positions. Tap A is +5%,
Tap B is -5%, Tap C is +10%, Tap D is -10%.
To Set Comfort Mode: Select Desired Comfort Mode profile (see profiles above). Set
dip switches S4-1* and S4-2* to the appropriate ON / OFF positions.
Dehumidification: To enable, set switch S5-1* to ON. Cooling airflow will be reduced
to 85% of nominal value during cool call. To disable, set switch S5-1* to OFF.
Continuous Fan Speed: Set dip switches S5-3* and S5-4* to select one of 4
continuous fan speeds (25%, 50%, 75%, or 100%). " See installation manual
for details"
*the “S” number refers to one of four labeled dip switch section each containing 4
individual dip switches. The following number refers to the individual labeled dip
switch within that section
0140F01170
NOTE: Airflow data shown applies to legacy mode operation only. For a fully communicating system, please
see the outdoor unit’s installation instructions for cooling and pump heating airflow data. See ComfortNet™
System - Airflow Consideration section for details.
33
PRODUCT DESIGN
24 Volt Dehumidistat Wiring
The optional usage of a dehumidistat allows the furnace’s
circulator blower to operate at a slightly lower speed (85%
of desired speed) during a combined thermostat call for cooling and dehumidistat call for dehumidification. This can be
done through an independent dehumidistat or through a
thermostat’s DEHUM terminal (if available). This lower blower
speed enhances dehumidification of the conditioned air as
it passes through the AC coil. For proper function, a dehumidistat applied to this furnace must operate on 24 VAC
and utilize a switch which opens on humidity rise.
To install/connect a dehumidistat:
1. Turn OFF power to furnace.
2. Secure the dehumidistat neutral wire (typically the white
lead) to the terminal marked “DEHUM” on the furnace
integrated control module.
3. Secure the dehumidistat hot wire (typically the black
lead) to the terminal marked “R” on the furnace integrated control module.
4. Secure the dehumidistat ground wire (typically the green
lead) to the ground screw on the furnace junction box.
NOTE: Ground wire may not be present on all
dehumidistats.
5. Turn ON power to furnace.
To enable the dehumidify function on the integrated control
module, set the dehumidification ENABLE dipswitch from
OFF to ON.
Once the switch is set, the dehumidify function is enabled
during a combination call for cooling (T-Stat) and dehumidification (DEHUM-Stat).
CONTINUOUS FAN OPERATION
The two stage furnace control will energize ECM blower motor when the fan switch on the thermostat is turned to the
"ON" position. Continuous fan speed will be of the furnaces
maximum airflow capability. 25%, 50%, 75%, or 100% selectable by DIP switch setting or communicating thermostat.
Example: If the furnace’s maximum airflow capability
is 2000 CFM, the continuous fan speed will be 0.30 x
2000 CFM = 600 CFM.
For the PCBKF103 and PCBKF104, continuous fan speeds
that provide 25, 50, 75 and 100% of the furnace’s maximum
airflow capability are selectable via dip switches S5- 3, 4.
Example: If the furnace’s maximum airflow capability is
2000 CFM and 25% continuous fan speed
is selected, the continuous fan speed will be
0.25 x 2000 CFM = 500 CFM.
S5
Continuous Fan
Once the switch is set, the dehumidify function is enabled
during a combination call for cooling (T-Stat) and dehumidification (DEHUM-Stat).
S5
S5
Dehum
SWITCH
1
Disabled
Off
Enabled
On
PCBKF103 / PCBKF104
Fossil Fuel Applications
Two-Stage furnaces can be used in conjunction with a heat
pump in a fossil fuel application. A fossil fuel application is
where an outdoor temperature sensor determines the most
cost efficient means of heating (heat pump, gas furnace, or
both).
A heat pump thermostat with two stages of heat is required
to properly use the single-stage furnace with a heat pump.
A heat pump thermostat with three stages of heat is required to properly use the two-stage furnace with a heat
pump. Refer to dual fuel, AFE-18-60A installation manual
(IO-627) for additional wiring instructions.
34
25%
50%
75%
100%
SWITCH
3
4
Off
Off
On
Off
Off
On
On
On
Dehum
SWITCH
1
Disabled
Off
Enabled
On
PCBKF103 / PCBKF104
Fossil Fuel Applications
Two-Stage furnaces can be used in conjunction with a heat
pump in a fossil fuel application. A fossil fuel application is
where an outdoor temperature sensor determines the most
cost efficient means of heating (heat pump, gas furnace, or
both).
A heat pump thermostat with two stages of heat is required
to properly use the single-stage furnace with a heat pump.
A heat pump thermostat with three stages of heat is required to properly use the two-stage furnace with a heat
pump. Refer to dual fuel, AFE-18-60A installation manual
(IO-627) for additional wiring instructions.
CONTINUOUS FAN OPERATION
The two stage furnace control will energize ECM blower motor when the fan switch on the thermostat is turned to the
"ON" position. Continuous fan speed will be of the furnaces
maximum airflow capability. 25%, 50%, 75%, or 100% selectable by DIP switch setting or communicating thermostat.
PRODUCT DESIGN
Example: If the furnace’s maximum airflow capability
is 2000 CFM, the continuous fan speed will be 0.30 x
2000 CFM = 600 CFM.
For the PCBKF103 and PCBKF104, continuous fan speeds
that provide 25, 50, 75 and 100% of the furnace’s maximum
airflow capability are selectable via dip switches S5- 3, 4.
Example: If the furnace’s maximum airflow capability is
2000 CFM and 25% continuous fan speed
is selected, the continuous fan speed will be
0.25 x 2000 CFM = 500 CFM.
S5
Continuous Fan
25%
50%
75%
100%
SWITCH
3
4
Off
Off
On
Off
Off
On
On
On
CIRCULATOR BLOWER SPEED ADJUSTMENT
WARNING
HIGH VOLTAGE
DISCONNECT ALL POWER BEFOR CHANGING SPEED TAPS.
MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO
SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
In general lower heating speeds will: reduce electrical consumption, lower operating sound levels of the blower, and
increase the outlet air temperature delivered to the home.
The speeds available allow the blower performance to be
optimized for the particular homeowner’s needs.
This furnace is equipped with a multi-speed circulator blower.
This blower provides ease in adjusting blower speeds. The
Specification Sheet applicable to your model provides an
airflow table, showing the relationship between airflow (CFM)
and external static pressure (E.S.P.), for the proper selection of heating and cooling speeds. The heating blower speed
is shipped set at “B”, and the cooling blower speed is set at
“D”. These blower speeds should be adjusted by the installer to match the installation requirements so as to provide the correct heating temperature rise and correct cooling CFM.
Use the dual 7-segment LED display adjacent to the
dipswitches to obtain the approximate airflow quantity. The
airflow quantity is displayed as a number on the display,
rounded to the nearest 100 CFM. The display alternates
airflow delivery indication and the operating mode indication.
Example: Cooling Capacity of 30,000 BTU/hr.
30,000/12,000 = 2.5 Tons
2. Determine the proper air flow for the cooling system.
Most cooling systems are designed to work with air flows
between 350 and 450 CFM per ton. Most manufacturers
recommend an air flow of about 400 CFM per ton.
Example: 2.5 tons X 400 CFM per ton = 1000 CFM
The cooling system manufacturer’s instructions must be
checked for required air flow. Any electronic air cleaners or
other devices may require specific air flows; consult installation instructions of those devices for requirements.
3. Knowing the furnace model, locate the high stage cooling air flow charts in the Specification Sheet applicable
to your model. Look up the cooling air flow determined
in step 2 and find the required cooling speed and adjustment setting.
Example: A GMVC80604B furnace installed with a
2.5 ton air conditioning system. The air flow needed is
1000 CFM. Looking at the cooling speed chart for
GMVC80604B, find the air flow closest to 1000 CFM. A
cooling airflow of 990 CFM can be attained by setting
the cooling speed to “C” and the adjustment to -10%
trim.
4. Continuous fan speeds that provide 25, 50, 75 and 100%
of the furnace’s maximum airflow capability are selectable via dip switches S5- 3, 4.
Example: If the furnace’s maximum airflow capability
is 2000 CFM and 25% continuous fan speed is selected,
the continuous fan speed will be 0.25 x 2000 CFM = 500
CFM.
5. Locate the blower speed selection DIP switches on the
integrated control module. Select the desired “cooling”
speed tap by positioning switches 1 and 2 appropriately.
Select the desired “adjust” tap by positioning switches
3 and 4 appropriately. To enable adjustments and select -5, 5, -10 or 10% trim, you must set dipswitch S5-2
to ON. If S5-2 is in the OFF position, you will receive
0% trim. Refer to the following figure for switch positions and their corresponding taps. Verify CFM by noting the number displayed on the dual 7-segment LED
display.
Example: The airflow being delivered is 1225 CFM. The
display indicates 12. If the airflow being delivered is 1275,
the display indicates 13.
1. Determine the tonnage of the cooling system installed
with the furnace. If the cooling capacity is in BTU/hr
divide it by 12,000 to convert capacity to TONs.
35
PRODUCT DESIGN
6. The multi-speed circulator blower also offers several custom ON/OFF ramping profiles. These profiles may be
used to enhance cooling performance and increase comfort level. The ramping profiles are selected using DIP
switches S4- 1, 2. Refer to the following figure for switch
positions and their corresponding taps. Refer to the bullet points below for a description of each ramping profile. Verify CFM by noting the number displayed on the
dual 7-segment LED display.
•
Profile A provides only an OFF delay of one (1) minute
at 100% of the cooling demand airflow.
100% CFM
OFF
1 min
•
Profile B ramps up to full cooling demand airflow by
first stepping up to 50% of the full demand for 30 seconds. The motor then ramps to 100% of the required
airflow. A one (1) minute OFF delay at 100% of the
cooling airflow is provided.
Switch Bank: S4
Ramping
Profiles
A*
B
DIP Switch No.
1
2
OFF
ON
OFF
OFF
C
OFF
ON
D
ON
ON
(*Indicates factory setting)
7. Select the heating speed for your model from the heating speed chart in the Specification Sheet. The adjust
setting (already established by the cooling speed selection) determines which set of speeds are available.
The selected speed must provide a temperature rise
within the rise range listed with the particular model.
Example: If the GMVC80604B is set for 1210 CFM
on cooling, the “ADJUST” is set to “+”
(plus). The four heating speeds available
are “A Plus”, “B Plus”, “C Plus”, and “D
Plus”. “A Plus” has a rise of 38°F for both
stages which is within the 20-50°F rise
range for the GMVC80604B. This setting
will keep electrical consumption to a minimum. Set the “Heat” speed DIP switches
to “A”.
8. Select the desired “heating” speed tap by positioning
switches S4- 3, 4 appropriately. Refer to figure above.
Verify CFM by noting the number displayed on the dual
7-segment LED display.
In general lower heating speeds will: reduce electrical consumption, lower operating sound levels of the blower, and
increase the outlet air temperature delivered to the home.
The speeds available allow the blower performance to be
optimized for the particular homeowner’s needs.
Sw itch Ba nk: S 4
Heating
CFM
DIP S witch No.
3
4
OFF
OFF
B*
ON
OFF
C
OFF
ON
D
ON
ON
A
(*Indicates factory setting)
PCBKF103 / PCBKF104
36
100% CFM
OFF
100% CFM
OFF
OFF
1/2 min
•
100% CFM
50% CFM
1 min
Profile C ramps up to 85% of the full cooling demand
airflow and operates there for approximately 7 1/2 minutes. The motor then steps up to the full demand
airflow. Profile C also has a one (1) minute 100% OFF
delay.
100% CFM
OFF
S3
Trim Amount
Add 5%
Minus 5%
Add 10%
Minus10%
S5
Trim Enable
OFF
SWITC H
3
4
OF F
OFF
ON
OFF
OF F
ON
ON
ON
SWITCH 2
DISABLE
ENABLE
OFF
ON
•Profile D ramps up to 50% of the demand for 1/2 minute,
then ramps to 85% of the full cooling demand airflow
and operates there for approximately 7 1/2 minutes.
The motor then steps up to the full demand airflow.
Profile D has a 1/2 minute at 50% airflow OFF delay.
PRODUCT DESIGN
OFF
OFF
CIRCULATING AIR AND FILTERS
DUCTWORK - AIRFLOW
Duct systems and register sizes must be properly designed
for the C.F.M. and external static pressure rating of the furnace. Ductwork should be designed in accordance with the
recommended methods of "Air Condition Contractors of
America" manual D.
A duct system should be installed in accordance with Standards of the National Board of Fire Underwriters for the Installation of Air Conditioning, Warm Air Heating and Ventilating Systems, Pamphlets No. 90A and 90B.
A return air filter is not supplied with the furnace. The installer must supply a means of filtering all of the return air.
Filter(s) shall comply with UL900 or CAN/ULC-S111 Standards. If the furnace is installed without filters, the warranty
will be voided.
The following two charts show the bottom and side return
filter sizes available for each size furnace. Larger sizes are
also acceptable.
SIDE RETURN
BOTTOM RETURN
Cabinet
Width
(In.)
Nominal
Filter
Size (In.)
Approx.
Flow Area
(In.)
All
16x25x1
400
Cabinet
Width
(In.)
Nominal Approx.
Filter
Flow Area
Size (In.)
(In.)
14"
14X25X1
350
17-1/2
21
24-1/2
14X25X1
16x25x1
20X25X1
350
400
500
Refer to Minimum Filter Area tables to determine filter area
requirement. NOTE: Filters can also be installed elsewhere
in the duct system such as a central return.
GMVC8, AMVC8, ADVC8
MINIMUM FILTER SIZES
FURNACE INPUT
60M / 70M
FILT ER SIZE
241 in2
T YPE
permanent
80M / 90M
320 in2
permanent
100M / 115M
400 in2
permanent
60M / 70M
483 in2
disposable
80M / 90M
640 in2
disposable
100M / 115M
800 in2
disposable
PERMANENT NOMINAL 600 F.M. FACE VELOCITY
DISPOSABLE NOMINAL 300 F.M. FACE VELOCITY
One inch throwaway filters should be sized for a face velocity of 300 feet per minute or less (14x25x1 throwaway = 730
CFM maximum, 16x25x1 throwaway = 830 CFM maximum,
18x25x1 throwaway = 940 CFM maximum, 20x25x1 throwaway = 1040 CFM maximum) All other filters should be
sized according to their manufacturer's instructions.
To find the minimum filter requirement (in2) for either permanent or disposable filters divide the required airflow (CFM)
by the rated velocity of the filter, either 300ft/min for disposable filter or 600ft/min for permanent filter. Multiply the number by 144 in.2 to obtain the minimum filter requirement (in2).
EXAMPLE:
Filter Size (in2) =
1400 CFM x 144 in2
600 ft./min. (Permanent)
Filter Size (in2) =
1400 CFM x 144 in2
300 (Disposable) ft./min.
Filter Size
= 672in2 Disposable
Filter Size
= 336in2 Permanent
Upflow furnaces with air delivery of less than 1800 CFM:
Use one side return or one bottom return ductwork connection.
Upflow furnaces with air delivery of 1800 CFM or higher:
Use two side returns or one bottom return connection or a
combination of both.
Guide dimples locate the side and bottom return cutout locations. Use a straight edge to scribe lines connecting the
dimples. Cut out the opening on these lines. An undersized
opening will cause reduced airflow. For bottom return connection, remove the bottom of the cabinet before setting the
furnace on the raised platform or return air duct.
A closed return duct system must be used, with the return
duct connected to the furnace. NOTE: Ductwork must never
be attached to the back of the furnace. Supply and return
connections to the furnace may be made with flexible joints
to reduce noise transmission, if desired. If a central return is
used, a connecting duct must be installed between the unit
and the utility room wall so the blower will not interfere with
combustion air or draft. The room, closet, or alcove must
not be used as a return air chamber.
When the furnace is used in connection with a cooling unit,
the furnace should be installed in parallel with or on the upstream side of the cooling unit to avoid condensation in the
heating element. With a parallel flow arrangement, the dampers or other means used to control the flow of air must be
adequate to prevent chilled air from entering the furnace and,
if manually operated, must be equipped with means to prevent operation of either unit unless the damper is in the full
heat or cool position.
When the furnace is heating, the temperature of the return
air entering the furnace must be between 55°F and 100°F.
37
PRODUCT DESIGN
UPRIGHT FILTER INSTALLATIONS
Depending on the installation and/or customer preference,
differing filter arrangements can be applied. Filters can be
installed in the central return register and a side panel external filter rack kit (upflow filter kit # EFR01). As an alternative a media air filter or electronic air cleaner can be
used as the requested filter. Refer to the following minimum filter requirement charts for determination of the minimum filter area to ensure proper unit performance. The following figures show possible filter locations. NOTE: A ductwork access door must be used in counterflow applications to allow filter removal. If the filter rack is used, the
side of the plenum must be at least as tall as dimension
"A" shown in the following illustration. For dimension of "A"
refer to the following chart.
COUNTERFLOW FILTER INSTALLATION
This furnace has provisions for the installation of return air
filters at the counterflow top return. The furnace will
accommodate the following filter sizes depending on cabinet size:
Return Air
Optional
Access
Door
"A"
Min
COUNTERFLOW TOP RETURN
Cabinet
Width
14
17 1/2
21
24 1/2
14
17 1/2
21
24 1/2
14
17 1/2
21
24 1/2
Filter Area
2
(in )
Qty.
Filter Size
(in)
600
2
15x20x1
800
2
20x20x1
1000
2
25x20x1
Dimension "A:
(in)
15.1
14.2
13.0
11.3
20.4
19.7
18.8
17.7
25.5
25.0
24.3
23.4
Refer to Minimum Filter Area tables to determine filter area
requirement. NOTE: Filters can also be installed elsewhere
in the duct system such as a central return.
38
Horizontal Installations
Filter(s) must be installed external to the furnace casing for
horizontal installations. For most installations it is preferable to use a central return with filters installed in the duct
behind the return air grille. In this way filter replacement is
relatively simple by merely removing the grille, rather than
going into the attic or crawl space.
ADDITIONAL FILTERING ACCESSORIES
External Filter Rack Kit (EFR01)
The external filter rack kit is intended to provide a location
external to the furnace casing, for installation of a permanent filter on upflow model furnaces. The rack is designed to
mount over the indoor blower compartment area of either
side panel, and provide filter retention as well as a location
for attaching return air ductwork.
PRODUCT DESIGN
DIP SWITCHES - FURNACES EQUIPPED WITH PCBFK103 / PCBKF104
Dip Switch
Switch Bank
Purpose
Function
1
2
3
90
Off
Off
120
On
Off
Heating Off Delay
150
Off
On
180
On
On
S1
2 Stage Stat
On
Thermostat
2 Stage Stat
On
Setup
1 Stg Stat 5 min delay
Off
1 Stg Stat auto delay
Off
A
Off
Off
B
On
Off
Cooling Airflow
C
Off
On
D
On
On
S3
Add 5%
Off
Minus 5%
On
Trim
Add 10%
Off
Minus 10%
On
A
Off
Off
B
On
Off
Ramping Profile
C
Off
On
D
On
On
S4
A
Off
B
On
Heating Airflow
C
Off
D
On
Disabled
Off
Dehum
Enabled
On
Disabled
Off
Trim
Enabled
On
S5
25%
Off
50%
On
Continuous Fan
75%
Off
100%
On
4
On
Off
Off
On
Off
Off
On
On
Off
Off
On
On
Off
Off
On
On
* = Factory Setting
39
SYSTEM OPERATION
NORMAL SEQUENCE OF OPERATION
POWER UP
The normal power up sequence is as follows:
•
115 VAC power applied to furnace. Integrated control
module performs internal checks.
•
Integrated control module displays 8 8 on dual 7-segment display LED’s.
•
Integrated control module monitors safety circuits continuously.
•
Furnace awaits call from thermostat. Dual 7-segment
LED’s display 0P or 0N while awaiting call from thermostat.
HEATING MODE
The normal operational sequence in heating mode is as follows:
•
R and W1 (or R and W1/W2) thermostat contacts
close, initiating a call for heat.
•
Integrated control module performs safety circuit
checks.
•
Induced draft blower is energized on high speed for a
15-second prepurge. Humidifier terminal is energized
with induced draft blower.
•
Induced draft blower steps to low speed following
prepurge. Low stage pressure switch contacts are
closed.
•
Igniter warm up begins upon step to low speed and
presence of closed low stage pressure switch contacts.
•
Gas valve opens at end of igniter warm up period, delivering gas to burners and establishing flame.
•
Integrated control module monitors flame presence.
Gas valve will remain open only if flame is detected.
•
If the thermostat call is for low heat, gas valve and
induced draft blower will continue on low stage. If the
call is for high heat, the gas valve and induced draft
blower will change to high stage.
•
Circulator blower is energized on heat speed following a thirty (30) second blower on delay. The circulator blower requires thirty seconds to ramp up to full
speed. Electronic air cleaner terminal is energized with
circulator blower.
•
Furnace is now operating on the specified stage called
for by the two-stage thermostat.
•
Furnace runs, integrated control module monitors
safety circuits continuously. If the two-stage thermostat changes the call from low heat to high heat, the
integrated control module will immediately switch the
induced draft blower, gas valve, and circulator blower
to their high stage settings.
40
• If the two-stage thermostat changes the call from high
heat to low heat, the control will immediately switch
the induced draft blower and gas valve to their low
stage settings. The circulator blower will remain on
high heating speed for thirty (30) seconds before
switching to the low heat circulating speed.
•
R and W1 (or R and W1/W2) thermostat contacts
open, completing the call for heat.
•
Gas valve closes, extinguishing flame.
•
Induced draft blower is de-energized following a fifteen second post purge. Humidifier terminals are deenergized.
•
Circulator blower continues running for the selected
heat off delay period (90, 120, 150 or 180 seconds).
The speed run during this period depends on the last
heat call provided by the thermostat.
If the last call for heat was a call for low heat, the air
circulator motor will run on low heat speed for the duration of the heat off delay period (90, 120, 150 or 180
seconds).
If the last call for heat was a call for high heat, the air
circulating motor will run on the high heating speed
for thirty (30) seconds and then switch to the low heating speed for the balance of the heat off delay period
(60, 90, 120 or 150 seconds).
•
Circulator blower and electronic air cleaner terminal
is de-energized.
•
Circulator blower ramps down to OFF during the 30
seconds following the heat off delay period.
•
Furnace awaits next call from thermostat.
COOLING MODE
The normal operational sequence in cooling mode is as follows:
•
R and Y1/G or Y2/G thermostat contacts close, initiating a call for cool.
•
Integrated control module performs safety circuit
checks.
•
Outdoor fan and compressor are energized to their
appropriate speed.
•
Circulator blower is energized on the appropriate cool
speed at the level and time determined by the selected ramping profile. Electronic air cleaner terminal
is energized with circulator blower.
•
Furnace circulator blower and outdoor cooling unit run
their appropriate speeds, integrated control module
monitors safety circuits continuously.
•
R and Y1/G or Y2/G thermostat contacts open, completing the call for cool.
•
Outdoor fan and compressor are de-energized.
•
Circulator blower continues running during a cool off
delay period. The OFF delay time and airflow level
are determined by the selected ramping profile.
SYSTEM OPERATION
•
•
Electronic air cleaner terminal and circulator blower
are de-energized.
Furnace awaits next call from thermostat.
FAN ONLY MODE
The normal operational sequence in fan only mode is as
follows:
•
R and G thermostat contacts close, initiating a call
for fan.
•
Integrated control module performs safety circuit
checks.
•
Circulator blower is energized on continuous fan speed
(25, 50, 75, 100% of the furnace’s maximum airflow
capability) following a five (5) second delay. Electronic air cleaner terminal is de-energized.
•
R and G thermostat contacts open, completing the
call for fan.
•
Circulator blower is de-energized. Electronic air
cleaner terminal is de-energized.
•
Furnace awaits next call from thermostat.
HEATING - Abnormal Operation
The following presents the probable causes of questionable
furnace operation and how to fix them. Look through the
observation window in the blower access door and make a
note of the error code displayed on the dual 7-segment display. Next, refer to the Troubleshooting Chart - ComfortNet™
on the following pages for an interpretation of the code displayed on the LED's for a description of the problem.
NOTE: Use caution when reading the diagnostic codes from
the furnace control's dual, 7-segment LED's. The position
of the control within the furnace can lead to a misinterpretation of the error codes. With the control in an orientation as
shown below, codes on the dual, 7-segment LED's are read
left to right.
DEHUMIDIFICATION MODE
The normal operational sequence in dehumidification
mode is as follows:
1. R and Y1/G or Y1+Y2/G thermostat contacts close,
initiating a call for cool.
2. Integrated control module performs safety circuit checks.
3. Outdoor fan and compressor are energized to their appropriate speed.
4. Circulator blower is energized on the appropriate cool
speed at the level and time determined by the selected
ramping profile. Electronic air cleaner terminals are energized with circulator blower.
5. Furnace circulator blower and outdoor cooling unit run
their appropriate speed, integrated control module monitors safety circuits continuously.
6. Dehumidistat opens on humidity rise allowing the furnace circulator blower to operate at 85% of the cooling
speed during combined thermostat call for cooling and
dehumidistat call for dehumidification.
7. Humidistat opens on humidity fall allowing furnace circulator blower to switch back to normal cooling speed.
8. R and Y1/G or Y1+Y2/G thermostat contacts open, completing the call for cool.
9. Outdoor fan and compressor are de-energized.
10. Circulator blower continues running during a cool off delay period. The OFF delay time and airflow level are determined by the selected ramping profile.
11. Electronic air cleaner terminals and circulator blower
are de-energized.
1 2 R C G W1 W2 Y1 Y2 O
DE
HUM
Memory Card Connector
Dual 7-Segment LED’s
1. Internal Control Failure with Integrated Ignition Control. Check for voltage to the furnace and low voltage at
the control board. Check for blown fuse on the control
board. If the control determines it has an internal fault, it
enters a locked-out state. Any of the situations mentioned will cause the dual, 7-segment LED's to be off.
The control board should only be replaced only after all
other checks from the Troubleshooting Chart ComfortNet™ have been verified.
12. Furnace awaits next call from thermostat.
41
SYSTEM OPERATION
2. System Lockout. If a flame is not sensed during the
first seven (4) seconds after the gas valve is energized,
the control turns off the gas. There will then be a 30
second delay while the induced draft blower is energized
to purge the heat exchanger. The ignitor will again be
energized and preheated for an additional (1) second.
The gas valve will then be energized. If flame is not sensed
the gas valve will be de-energized and another purge will
occur and a third ignitor warm up for an additional (2)
seconds will occur. The control will cycle the gas valve a
total of three (3) times before it determines it cannot
establish measurable combustion and enters a locked
out state. The diagnostic error code for this problem is
E0. The control can be reset and brought out of lockout
mode by turning the thermostat off for more than (5) seconds and less then (20) seconds and then back on. It
can also be reset by turning off the electrical disconnect
switch to the furnace for a minimum of 5 seconds.
NOTE: The control board will automatically reset one hour
after lockout occurs. If the furnace frequently has to be reset, it means that a problem exists that should be corrected.
Refer to Troubleshooting Chart - ComfortNet™ on the following pages for aid in determining the cause.
3. Low Stage Pressure Switch Stuck Closed. If the control senses the low stage pressure switch is closed when
the induced draft blower is off, it waits until the fault is
corrected. The diagnostic error code for this problem is
E1. The probable cause is either a faulty pressure switch
or wiring.
4. Low Stage Pressure Switch Stuck Open. If, after the
induced draft blower is energized, the low stage pressure switch does not close within 5 minutes, the control
will go into a 1-hour lockout. The control will automatically reset from lockout and restart the ignition sequence.
The diagnostic error code for this problem is E2. The
probable causes are either disconnected hose to the
pressure switch, faulty pressure switch or wiring, restricted air intake or flue piping.
5. Open Primary, Auxiliary, or Rollout Limit. If the limit
control opens, the air circulator blower and induced draft
blower will be turned on until the limit closes. The diagnostic error code for this problem is E3. The probable
cause is either low conditioned air flow due to dirty filter
or resistance in duct work, faulty limit, faulty blower,
blower speed set to low, misaligned burners, faulty induced draft blower, or blocked flue.
6. Flame Sensed with No Call for Heat. If the control
senses a flame when the gas valve is de-energized, it
will run the air circulation blower and the induced draft
blower continuously with no further furnace operation.
The diagnostic error code for this condition is E4. The
probable causes are either a short to ground in flame
sense circuit, miswiring, lingering burner flame or a slow
closing gas valve.
42
7. Open Fuse. If the control detects an open fuse, it will
inhibit all furnace operation, except the display of the
error code. The diagnostic error code for this condition
is E5. The probable cause is a short in the low voltage
wiring, either internal to the furnace or external to the
furnace.
8. Low Flame Sense Signal. If the furnace continues to
operate and the micro-amp signal from the flame sensor
falls below specified level. The diagnostic error code for
this problem is E6. The probable cause is either a coated/
oxidized sensor, incorrectly positioned sensor in burner
flame or lazy burner flame due to improper gas pressure
or combustion air.
9. Check Igniter or No Ground Condition. Check for
broken or improperly connected igniter. Check for proper
ground and correct. The diagnostic error code for this
problem is E7.
10. High Stage Pressure Switch Stuck Closed. If the control fails to operate at high stage heat when commanded
to do so, the high stage pressure switch is stuck closed.
For this condition, the furnace will operate at low stage
only, regardless of the thermostat demand. The diagnostic error code for this condition is E8. The probable
cause is sticking high stage pressure switch contacts
or a short in the high stage pressure switch wiring.
11. High Stage Pressure Switch Stuck Open. This condition can occur if the pressure switch hose is blocked
or pinched. Check for blocked flue and/or inlet air pipe.
Blocked drain, weak induced draft blower and malfunctioning pressure switch are possible. The diagnostic
error code for this problem is E9 followed by a pause.
12. Reversed Polarity. If the 115V or 24V AC power leads
are reversed, the furnace will fail to operate. The diagnostic error code for this problem is EA. The probable
cause is either the 115V AC power to furnace or integrated control module is reversed, the 24V AC wires to
transformer are reversed, or poor unit ground.
13. No Shared Data. The control does not contain any
shared data. Shared data sets contain all the information required to drive the variable speed motor as well as
calculate airflow demands. The furnace cannot function
without the appropriate shared data set. The diagnostic
error code for the this condition is d0. A memory card
must be used to populate shared data to the control.
Contact your distributor to obtain the appropriate memory
card for your particular furnace model.
NOTE: Turn off power to the furnace prior to inserting memory
card onto the control. With memory card inserted onto control, turn power to furnace on. Control has accepted memory
card data once control displays OP on the dual, 7-segment
display. Memory card may be left on control or removed
and used on another furnace of the same model. Turn power
off to furnace prior to removing memory card.
SYSTEM OPERATION
14. Invalid Memory Card Data. This condition occurs if
the control rejects the shared data set on a memory
card. Memory cards are model specific. The diagnostic
error code for this condition is d4.
15. ECM Blower Motor Not Running. This condition occurs if the control fails to detect the ECM blower motor
running when it should be running. The furnace will not
operate if the control detects the blower motor is not
running when it should be running. The diagnostic error
code for this condition is b0. The probable cause loose
or disconnected wiring between the motor and control,
an open inductor (3/4 Hp and 1 Hp motors only), or a
failed ECM blower motor (see section S-16C in Servicing).
16. ECM Motor Communications Lost. This condition occurs if the furnace control cannot communicate with the
ECM blower motor. The furnace will not operate if the
control cannot communicate with the blower motor. The
diagnostic error code for this condition is b1. The probable cause loose or disconnected wiring between the
motor and control, a failed ECM blower motor (see section S-16C in Servicing), or a failed control.
17. Motor Horsepower Mismatch. This condition occurs
if the horsepower of the motor connected to the control
does not match the motor horsepower specified in the
shared data set. The furnace will not operate is there is
a motor horsepower mismatch. The diagnostic error
code for this condition is b2.
Verify that the installed motor is the correct motor for
the furnace model. Obtain the correct motor for the furnace model. Verify the shared data set is correct for the
furnace. The shared data set may be corrected using
the appropriate memory card. Contact your distributor
for the correct memory card. See preceding # 13 and 14
for additional memory card information.
18. ECM Motor Operating in a Limiting Condition. This
condition will occur if the ECM operates in a power,
speed, or temperature limiting condition. The furnace
will continue operating at reduced performance. The diagnostic error code for the this condition is b3.
Power Limit. In attempting to deliver the airflow demand,
the motor may exceed its rated output power. The motor will reduce its output to prevent exceeding its power
limit. This will result in lower than demanded airflow.
This will occur under high loading conditions. High loading conditions could be due to blocked/clogged filters,
blocked or restrictive ductwork, or undersized ductwork.
Temperature Limit. In attempting to deliver the airflow demand, the motor may exceed its temperature limit. The
motor will reduce its output in an attempt to reduce its
temperature. This will result in lower than demanded
airflow. A high ambient temperature at a high loading
condition is the most probable cause. Reduce the ambient temperature and/or motor loading/demand.
19. Motor Trips. This condition occurs if the ECM motor
senses a loss of control or becomes overloaded. The
furnace may halt operation if the motor shuts down for a
trip condition. The diagnostic error code for this condition is b4.
Loss of Control (Lost Rotor Trip). This occurs if a sudden change in speed or torque is detected. The motor
will shut down and restart if this condition is encountered. Possible causes are abnormal loading conditions
due to sudden blockages of the duct system or sudden
high increases in the loading on the motor.
Overload (Current Trip). This occurs if the motor becomes overloaded due to high loading conditions. The
motor will shut down and restart if this condition is encountered. High loading conditions could be due to
blocked/clogged filters, blocked or restrictive ductwork,
or undersized ductwork.
20. Motor Locked Rotor. This condition occurs if the motor fails to start after (10) consecutive attempts. The
furnace will not operate if the ECM blower motor fails to
start. The diagnostic error code for this condition is b5.
The probable cause is an obstruction in the blower housing or wheel, seized motor bearings, or a failed blower
motor.
21. Motor Volts. This condition occurs if the line voltage is
too low or too high, or if the motors power module gets
too hot. The ECM motor will shut down while the abnormal condition is present. If the abnormal condition is
cleared, the motor will restart. The furnace will be inoperable while the motor is off.
Over Voltage. If the line voltage exceeds 140VAC, the
motor will shut down due to an over voltage condition.
Verify the line voltage to the furnace is within the range
specified on the rating plate.
Under Voltage. If the line voltage is less than 70VAC,
the motor will shut down due to an under voltage condition. Verify the line voltage to the furnace is within the
range specified on the rating plate.
Over Temperature. A high ambient temperature or a
high loading condition is the most probable cause. Reduce the ambient temperature and/or motor loading/demand.
43
SYSTEM OPERATION
22. Motor Parameters. This condition occurs if the motor
does not receive all the information is requires to operate or an event occurs that prevents the motor from
running, or the motor fails to start for (40) consecutive
attempts. The diagnostic error code for the this condition is b7. Probable causes are intermittent wiring connection between the control and motor, an error with
the furnace control, or any of the conditions described
in 19, 20, or 21 above.
44
23. Low Indoor Airflow. This condition occurs if the indoor airflow falls below a calculated minimum value. The
minimum airflow value is calculated from factors defined
in the shared data set. If the airflow falls below the calculated minimum, the furnace will continue to operate
with the reduce airflow. If the furnace was operating at
stage, it will stage back to low in an effort to remedy the
condition. The furnace will halt operation if the airflow
falls to 0 CFM.
The diagnostic error code for the this condition is b9.
Probable causes are blocked/clogged filters, blocked
or restrictive ductwork, or undersized ductwork.
TROUBLESHOOTING
Symptoms of Abnormal Diagnostic/
Operation (Legacy &
Status LED
ComfortNet™ Thermostat)
Codes
Fault Description
PCBKF103
ComfortNet™
Thermostat Only
Message
Code
INTERNAL
FAULT
EE
Possible Causes
AND
PCBKF104
Corrective Actions
• Furnace fails to operate
• Integrated control module
LED display provides no
signal.
• ComfortNet™ thermostat
“Call for Service” icon
illuminated
• ComfortNet™ thermostat
scrolls “Check Furnace”
message
None
• LED display indicates On
On
• Normal operation
None
None
• Furnace fails to operate
• Integrated control module
LED display provides E0
error code.
• ComfortNet™ thermostat
“Call for Service” icon
illuminated.
• ComfortNet™ thermostat
scrolls “Check Furnace”
message.
E0
• Furnace lockout
due to an excessive
number of ignition
“retries” (3 total)
LOCKOUT
E0
• Furnace fails to operate.
• Integrated control module
LED display provides E1
error code.
• ComfortNet™ thermostat
“Call for Service” icon
illuminated.
• ComfortNet™ thermostat
scrolls “Check Furnace”
message.
E1
• Low stage pressure
switch circuit is
closed at start of
heating cycle.
PS1
CLOSED
E1
• Low stage pressure switch • Replace low stage
contacts sticking.
pressure switch.
• Shorts in pressure switch • Repair short in wiring.
circuit wiring.
• No 115 power to
furnace or no 24 volt
power to integrated
control module
• Blown fuse or circuit
breaker
• Integrated control
module has an
internal fault
Notes & Cautions
• Manual disconnect switch
OFF, door switch open or
24 volt wire improperly
connected or loose
• Blown fuse or circuit
breaker
• Integrated control module
has an internal fault
• Assure 115 and 24
volt power to furnace
and integrated control
module.
• Check integrated control
module fuse (3A).
Replace if necessary.
• Check for possible
shorts in 115 and 24
volt circuits. Repair as
necessary.
• Replace bad integrated
control module.
• Turn power OFF prior
to repair.
• Replace integrated
control module fuse
with 3A automotive
fuse.
• Read precautions
in “Electrostatic
Discharge” section of
manual.
• Replace control with
correct replacement
part
• Normal operation
• None
• Normal operation
• Failure to establish fame.
Cause may be no gas
to burners, front cover
pressure switch stuck
open, bad igniter or igniter
alignment, improper
orifces, or coated/oxidized
or improperly connected
fame sensor.
• Loss of fame after
establishment. Cause
may be interrupted gas
supply, lazy burner fames
(improper gas pressure
or restriction in fue and/
or combustion air piping),
front cover pressure switch
opening, or improper
induced draft blower
performance.
• Locate and correct gas
interruption.
• Check front cover
pressure switch operation
(hose, wiring, contact
operation). Correct if
necessary.
• Replace or realign igniter.
• Check fame sense
signal. Sand sensor if
coated and/or oxidized.
• Check fue piping for
blockage, proper length,
elbows, and termination.
• Verify proper induced
draft blower performance.
• Turn power OFF prior
to repair.
• Igniter is fragile,
handle with care.
• Sand fame sensor
with emery cloth.
• See “Vent/Flue Pipe”
section for piping
details.
• Turn power OFF prior
to repair.
• Replace pressure
switch with proper
replacement part.
45
PCBKF103
TROUBLESHOOTING
Symptoms of Abnormal
Operation (Legacy
& ComfortNet™
Thermostat)
Diagnostic/
Status LED
Codes
Fault Description
ComfortNet™
Thermostat Only
Message
Code
AND
PCBKF104
Possible Causes
Corrective Actions
Notes & Cautions
• Induced draft blower
runs continuously with no
further furnace operation.
• Integrated control module
LED display provides E2
error code.
• ComfortNet™ thermostat
“Call for Service” icon
illuminated.
• ComfortNet™ thermostat
scrolls “Check Furnace”
message.
E2
• Low stage
pressure switch
circuit is not
closed.
PS1 OPEN
E2
• Pressure switch hose
blocked pinched, or
connected improperly.
• Blocked fue and/or inlet
air pipe, blocked drain
system or weak induced
draft blower.
• Incorrect pressure
switch set point or
malfunctioning switch
contacts.
• Loose or improperly
connected wiring.
• Inspect pressure switch
hose. Repair/replace if
necessary.
• Inspect fue and/or inlet
air piping for blockage,
proper length, elbows,
and termination. Check
drain system. Correct as
necessary.
• Check induced draft
blower performance.
Correct as necessary.
• Correct pressure switch
set point or contact
motion.
• Tighten or correct wiring
connection.
• Turn power OFF prior
to repair.
• Replace pressure
switch with proper
replacement part.
• Replace induced draft
blower with proper
replacement part.
• Circulator blower
runs continuously. No
furnace operation.
• Integrated control
module LED display
provides E3 error code.
• ComfortNet™
thermostat “Call
for Service” icon
illuminated.
• ComfortNet™
thermostat scrolls
“Check Furnace”
message.
E3
• Primary limit or
auxiliary limit
circuit is open.
• Rollout limit
circuit is open.
HIGH LIMIT
OPEN
E3
• Insuffcient conditioned
air over the heat
exchanger. Blocked
flters, restrictive
ductwork, improper
circulator blower
speed, or failed
circulator blower motor.
• Flame rollout.
• Misaligned burners,
blocked fue and/or
air inlet pipe, or failed
induced draft blower.
• Loose or improperly
connected wiring.
• Check flters and
ductwork for blockage.
Clean flters or remove
obstruction.
• Check circulator
blower speed and
performance. Correct
speed or replace blower
motor if necessary.
• Check burners for
proper alignment.
• Check fue and air inlet
piping for blockage,
proper length, elbows,
and termination.
Correct as necessary.
• Check induced draft
blower for proper
performance. Replace if
necessary.
• Tighten or correct
wiring connection.
• Turn power OFF
prior to repair.
• See Specifcation
Sheet applicable
to your model* for
allowable rise range
and proper circulator
speed.
• See "Vent/Flue Pipe"
section for piping
details.
• Induced draft blower
and circulator blower
runs continuously. No
furnace operation.
• Integrated control
module LED display
provides E4 error code.
• ComfortNet™
thermostat “Call
for Service” icon
illuminated.
• ComfortNet™
thermostat scrolls
“Check Furnace”
message.
E4
• Flame sensed
with no call for
heat.
IMPROPER
FLAME
E4
• Short to ground in
fame sense circuit.
• Lingering burner fame.
• Slow closing gas valve.
• Correct short at fame
sensor or in fame
sensor wiring.
• Check for lingering
fame.
• Verify proper operation
of gas valve.
• Turn power OFF
prior to repair.
• No furnace operation.
• Integrated control
module LED display
provides E5 error code.
• ComfortNet™
thermostat displays
“Battery Power”
E5
• Open Fuse
• Locate and correct
short in low voltage
wiring
• Turn power OFF
prior to repair.
• Replace fuse with
3-amp automotive
type
• Normal furnace
operation.
• Integrated control
module LED display
provides E6 error code.
E6
• Flame sense
micro amp signal
is low
• Sand fame sensor if
coated/oxidized.
• Inspect for proper
sensor alignment.
• Check inlet air piping
for blockage, proper
length, elbows, and
termination.
• Compare current gas
pressure to rating plate.
Adjust as needed.
• Turn power OFF
prior to repair.
• Sand fame sensor
with emery cloth.
• See "Vent/Flue Pipe"
section for piping
details.
• See rating plate for
proper gas pressure.
46
Not
Displayed
WEAK
FLAME
Not
• Short in low voltage
Displayed
wiring
E6
• Flame sensor is
coated/oxidized.
• Flame sensor
incorrectly positioned
in burner fame.
• Lazy burner fame
due to improper gas
pressure or combustion
air.
PCBKF103
TROUBLESHOOTING
Symptoms of Abnormal
Operation (Legacy
& ComfortNet™
Thermostat)
Diagnostic/
Status LED
Codes
Fault Description
ComfortNet™
Thermostat Only
Possible Causes
Message
Code
IGNITER
FAULT
E7
• Improperly connected
igniter.
• Shorted igniter.
• Poor unit ground.
• Igniter relay fault on
integrated control
module.
AND
PCBKF104
Corrective Actions
• Check and correct
wiring from integrated
control module to
igniter.
• Replace shorted igniter.
• Check and correct unit
ground wiring.
• Check igniter output
from control. Replace if
necessary.
Notes & Cautions
• Turn power OFF
prior to repair.
• Replace igniter with
correct replacement
part.
• Replace control with
correct replacement
part.
• Furnace fails to operate.
• Integrated control
module LED display
provides E7 error code.
• ComfortNet™
thermostat “Call
for Service” icon
illuminated.
• ComfortNet™
thermostat scrolls
“Check Furnace”
message.
E7
• Problem with
igniter circuit.
• Furnace fails to operate
on high stage; furnace
operates normally on low
stage.
• Integrated control module
LED display provides E8
error code.
E8
• High stage
pressure switch
circuit is closed
at start of heating
cycle.
• Induced draft
blower is
operating.
• Furnace is
operating on low
stage only
PS2 CLOSED
E8
• High stage pressure
• Replace high stage
switch contacts sticking.
pressure switch.
• Shorts in pressure
• Repair short in wiring
switch circuit wiring.
• Furnace fails to operate
on high stage; furnace
operates normally on low
stage.
• Integrated control module
LED display provides E9
error code.
E9
• High stage
pressure switch
circuit is not
closed.
• Induced draft
blower is
operating.
• Furnace is
operating on low
stage only
PS2 OPEN
E9
• Pressure switch hose
blocked pinched, or
connected improperly.
• Blocked fue and/or inlet
air pipe, blocked drain
system or weak induced
draft blower.
• Incorrect pressure
switch set point or
malfunctioning switch
contacts.
• Loose or improperly
connected wiring.
• Inspect pressure switch
hose. Repair/replace if
necessary.
• Inspect fue and/or inlet
air piping for blockage,
proper length, elbows,
and termination. Check
drain system. Correct as
necessary.
• Check induced draft
blower performance.
Correct as necessary.
• Correct pressure switch
set point or contact
motion.
• Tighten or correct wiring
connection.
• Furnace fails to operate.
• Integrated control module
LED display provides EA
error code.
• ComfortNet™ thermostat
“Call for Service” icon
illuminated.
• ComfortNet™ thermostat
scrolls “Check Furnace”
message.
EA
• Polarity of 115 volt
AC is reversed
REVERSED
PLTY
EA
• Polarity of 115 volt AC
power to furnace or
integrated module is
revered.
• Poor unit ground
• Review wiring diagram to • Turn power OFF prior
correct polarity.
to repair.
• Verify proper ground.
Correct if necessary.
• Check and correct
wiring.
• Integrated control
module LED display EF
error code.
• ComfortNet™ thermostat
“Call for Service” .
EF
• Aux switch open
Aux Alarm
Fault
EF
• High water level in the
evaporation coil.
• Check overfow pan and
service.
• Turn power OFF prior
to service.
• Furnace fails to operate.
• Integrated control module
LED display provides d0
error code.
• ComfortNet™ thermostat
“Call for Service” icon
illuminated.
• ComfortNet™ thermostat
scrolls “Check Furnace”
message.
d0
• Data not yet on
network.
NO NET
DATA
d0
• Furnace does not
• Populate shared data
contain any shared data.
set using memory card.
• Turn power OFF prior
to repair
• Use memory card for
the specifc model.
• Insert memory card
BEFORE turning
power ON. Memory
card may be removed
after data is loaded
and power is turned
off.
• Error code will be
cleared once data is
• Turn power OFF prior
to repair.
• Replace pressure
switch with proper
replacement part.
• Turn power OFF prior
to repair.
• Replace pressure
switch with proper
replacement part.
• Replace induced draft
blower with proper
replacement part.
47
PCBKF103
TROUBLESHOOTING
Symptoms of Abnormal
Diagnostic/
Operation (Legacy
Status LED Fault Description
& ComfortNet™
Codes
Thermostat)
ComfortNet™
Thermostat Only
Message
Code
Possible Causes
AND
PCBKF104
Corrective Actions
Notes & Cautions
• Verify shared data set is • Turn power OFF prior
to repair
correct for the specifc
model. Re-populate data • Use memory card for
using correct memory
the specifc model.
card if required.
• Insert memory card
BEFORE turning
power ON. Memory
card may be removed
after data is loaded
and power is turned
off.
• Error code will be
cleared once data is
loaded and power is
turned off.
• Operation different than
expected or no operation.
• Integrated control
module LED display
provides d4 error code.
• ComfortNet™ thermostat
“Call for Service” icon
illuminated.
• ComfortNet™ thermostat
scrolls “Check Furnace”
message.
d4
• Invalid memory
card data.
INVALID MC
DATA
d4
• Shared data set on
memory card has been
rejected by integrated
control module
• Furnace fails to operate.
• Integrated control
module LED display
provides b0 error code.
• ComfortNet™ thermostat
“Call for Service” icon
illuminated.
• ComfortNet™ thermostat
scrolls “Check Furnace”
message.
b0
MOTOR NOT
• Circulator blower
RUN
motor is not
running when it
should be running.
b0
• Loose wiring connection • Tighten or correct wiring
connection.
at circulator motor
power leads or
• Verify continuous
circulator motor power
circuit through inductor.
leads disconnected.
Replace if open or short
circuit.
• Open circuit in inductor
or loose wiring
• Check circulator blower
connection at inductor
motor. Replace if
(3/4 Hp and 1 Hp
necessary.
models only).
• Failed circulator blower
motor.
• Furnace fails to operate.
• Integrated control
module LED display
provides b1 error code.
• ComfortNet™ thermostat
“Call for Service” icon
illuminated.
• ComfortNet™ thermostat
scrolls “Check Furnace”
message.
b1
• Integrated control
module has lost
communications
with circulator
blower motor.
MOTOR
COMM
b1
• Loose wiring connection • Tighten or correct wiring • Turn power OFF prior
at circulator motor
connection.
to repair
control leads.
• Check circulator blower • Replace circulator
• Failed circulator blower
motor with correct
motor. Replace if
motor.
replacement part.
necessary.
• Failed integrated control • Check integrated control • Replace integrated
module.
control module with
module. Replace if
correct replacement
necessary.
part.
• Furnace fails to operate.
• Integrated control
module LED display
provides b2 error code.
• ComfortNet™ thermostat
“Call for Service” icon
illuminated.
• ComfortNet™ thermostat
scrolls “Check Furnace”
message.
b2
• Circulator blower
motor horse
power in shared
data set does not
match circulator
blower motor
horse power.
MOTOR
MISMATCH
b2
• Incorrect circulator
• Verify circulator blower if
blower motor in furnace.
motor horse power is the
same specifed for the
• Incorrect shared data
specifc furnace model.
set in integrated control
Replace if necessary.
module.
• Verify shared data set is
correct for the specifc
model. Re-populate data
using correct memory
card if required.
• Turn power OFF prior
to repair
• Replace motor with
correct replacement
part.
• Use memory card for
the specifc model
• Insert memory card
BEFORE turning
power ON. Memory
card may be removed
after data is loaded
and power is turned
off.
• Error code will be
cleared once shared
data and motor horse
power match.
• Furnace operates at
reduced performance.
• Airfow delivered is less
than expected.
• Integrated control
module LED display
provides b3 error code.
b3
• Circulator blower
motor is operating
in a power,
temperature, or
speed limiting
condition.
MOTOR
LIMITS
b3
•
•
•
•
• Turn power OFF prior
to repair.
48
Blocked flters.
Restrictive ductwork.
Undersized ductwork.
High ambient
temperatures.
• Check flters for
blockage. Clean flters
or remove obstruction.
• Check ductwork for
blockage. Remove
obstruction. Verify all
registers are fully open.
• Verify ductwork is
appropriately sized for
system. Resize/replace
ductwork if necessary.
• See "III. Product
Description" and "IV.
Location Requirements
& Considerations"
furnace installation
requirements.
• Turn power OFF prior
to repair
• Replace inductor with
correct replacement
part.
• Replace circulator
motor with correct
replacement part.
TROUBLESHOOTING
Symptoms of Abnormal
Diagnostic/
Operation (Legacy
Status LED Fault Description
& ComfortNet™
Codes
Thermostat)
• Furnace fails to operate.
• Integrated control
module LED display
provides b4 error code.
• ComfortNet™ thermostat
“Call for Service” icon
illuminated.
• ComfortNet™ thermostat
scrolls “Check Furnace”
message.
b4
• Furnace fails to operate.
• Integrated control
module LED display
provides b5 error code.
• ComfortNet™ thermostat
“Call for Service” icon
illuminated.
• ComfortNet™ thermostat
scrolls “Check Furnace”
message.
b5
• Furnace fails to operate.
• Integrated control
module LED display
provides b6 error code.
• ComfortNet™ thermostat
“Call for Service” icon
illuminated.
• ComfortNet™ thermostat
scrolls “Check Furnace”
message.
b6
• Furnace fails to operate.
• Integrated control
module LED display
provides b7 error code.
• ComfortNet™ thermostat
“Call for Service” icon
illuminated.
• ComfortNet™ thermostat
scrolls “Check Furnace”
message.
b7
• Furnace operates at
reduced performance or
operates on low stage
when high stage is
expected.
• Integrated control
module LED display
provides b9 error code.
b9
• Circulator blower
motor senses
a loss of rotor
control.
PCBKF103
ComfortNet™
Thermostat Only
Possible Causes
AND
PCBKF104
Corrective Actions
Notes & Cautions
Message
Code
MOTOR
TRIPS
b4
• Turn power OFF prior
to repair
b5
• Turn power OFF prior
to repair.
• Replace motor with
correct replacement
part.
• Replace wheel with
correct replacement
part.
• Circulator blower
motor senses
high current.
• Circulator blower MOTOR LCKD
ROTOR
motor fails to start
10 consecutive
times.
•
• Circulator blower
motor shuts down
for over or under
voltage condition.
• Circulator blower
motor shuts
down due to
over temperature
condition on
power module.
• Circulator blower
motor does not
have enough
information to
operate properly.
Motor fails to start
40 consecutive
times.
• Airflow is lower
than demanded.
MOTOR
VOLTS
b6
• Turn power OFF prior
to repair
•
•
•
MOTOR
PARAMS
b7
•
•
•
LOW ID
AIRFLOW
B9
• Blocked filters.
• Restrictive ductwork.
• Undersized ductwork.
• Check filters for
blockage. Clean filters
or remove obstruction.
• Check ductwork for
blockage. Remove
obstruction. Verify all
registers are fully open.
• Verify ductwork is
appropriately sized for
system. Resize/replace
ductwork if necessary.
• Turn power OFF prior
to repair.
49
50
OP
E0
x LED display indicates OP
x Low stage pressure
switch circuit is closed at
start of heating cycle.
x Low stage pressure
switch circuit is not
closed.
E1
E2
x Induced draft blower runs continuously
with no further furnace operation.
x Integrated control module LED display
provides E2 error code.
x ComfortNet™ thermostat “Call for
Service” icon illuminated.
x ComfortNet™ thermostat scrolls “Check
Furnace” message.
x Furnace lockout due to
an excessive number of
ignition “retries” (3 total)
x Normal operation
x No 115 power to furnace
or no 24 volt power to
integrated control
module
x Blown fuse or circuit
breaker
x Integrated control
module has an internal
fault
Fault Description
x Furnace fails to operate.
x Integrated control module LED display
provides E1 error code.
x ComfortNet™ thermostat “Call for
Service” icon illuminated.
x ComfortNet™ thermostat scrolls “Check
Furnace” message.
x Furnace fails to operate
x Integrated control module LED display
provides E0 error code.
x ComfortNet™ thermostat “Call for
Service” icon illuminated.
x ComfortNet™ thermostat scrolls “Check
Furnace” message.
None
Diagnostic/Status
LED Codes
x Furnace fails to operate
x Integrated control module LED display
provides no signal.
x ComfortNet™ thermostat “Call for
Service” icon illuminated
x ComfortNet™ thermostat scrolls “Check
Furnace” message
Symptoms of Abnormal Operation (Legacy
& ComfortNet™ Thermostat)
PS1 OPEN
E2
E1
E0
PS1
CLOSED
None
None
LOCKOUT
ComfortNet™
Thermostat Only
Message
Code
INTERNAL
EE
FAULT
x Pressure switch hose blocked
pinched, or connected improperly.
x Blocked flue and/or inlet air pipe,
blocked drain system or weak
induced draft blower.
x Incorrect pressure switch set point
or malfunctioning switch
contacts.
x Loose or improperly connected
wiring.
x Failure to establish flame. Cause
may be no gas to burners, front
cover pressure switch stuck open,
bad igniter or igniter alignment,
improper orifices, or
coated/oxidized or improperly
connected flame sensor.
x Loss of flame after establishment.
Cause may be interrupted gas
supply, lazy burner flames
(improper gas pressure or
restriction in flue and/or
combustion air piping), front
cover pressure switch opening, or
improper induced draft blower
performance.
x Low stage pressure switch
contacts sticking.
x Shorts in pressure switch circuit
wiring.
x Board timing with PCBKF101
control will detect a closed
pressure switch after a failed
ignition attempt and before the
next attempt and may display a
misleading E1 code.
x Normal operation
x Manual disconnect switch OFF,
door switch open or 24 volt wire
improperly connected or loose
x Blown fuse or circuit breaker
x Integrated control module has an
internal fault
Possible Causes
x Inspect pressure switch hose.
Repair/replace if necessary.
x Inspect flue and/or inlet air
piping for blockage, proper
length, elbows, and termination.
x Check drain system. Correct as
necessary.
x Check induced draft blower
performance. Correct as
necessary.
x Correct pressure switch set point
or contact motion.
x Tighten or correct wiring
connection.
x Replace low stage pressure
switch.
x Repair short in wiring.
x Disregard E1 code shown
between ignition attempts if
furnace is equipped with
PCBKF101 control board. Look
for cause of no ignition – gas
supply, gas valve switch off,
improper gas manifold pressure,
improper L.P. conversion.
x Locate and correct gas
interruption.
x Check front cover pressure
switch operation (hose, wiring,
contact operation). Correct if
necessary.
x Replace or realign igniter.
x Check flame sense signal. Sand
sensor if coated and/or oxidized.
x Check flue piping for blockage,
proper length, elbows, and
termination.
x Verify proper induced draft
blower performance.
x None
x Assure 115 and 24 volt power to
furnace and integrated control
module.
x Check integrated control module
fuse (3A). Replace if necessary.
x Check for possible shorts in 115
and 24 volt circuits. Repair as
necessary.
x Replace bad integrated control
module.
Corrective Actions
x Turn power OFF prior to
repair.
x Replace pressure switch
with correct replacement
part.
x The board checks for an
open pressure switch when
a call for heat is received.
It will only power the
inducer and proceed with
the call for heat if the
pressure switch is open.
x Turn power OFF prior to
repair.
x Replace pressure switch
with correct replacement
part.
x Replace induced draft
blower with correct
replacement part.
x Turn power OFF prior to
repair.
x Igniter is fragile, handle
with care.
x Sand flame sensor with
emery cloth.
x See “Vent/Flue Pipe”
section for piping details.
x Turn power OFF prior to
repair.
x Replace integrated control
module fuse with 3A
automotive fuse.
x Read precautions in
“Electrostatic Discharge”
section of manual.
x Replace integrated control
module with current
replacement parts.
x Normal operation
Notes & Cautions
TROUBLESHOOTING
PCBKF101/2
EA
d0
REVERSED
PLTY
NO NET
DATA
x Polarity of 115 volt AC
is reversed
x Data not yet on network.
EA
d0
E9
x Furnace fails to operate.
x Integrated control module LED display
provides EA error code.
x ComfortNet™ thermostat “Call for
Service” icon illuminated.
x ComfortNet™ thermostat scrolls “Check
Furnace” message.
x Furnace fails to operate.
x Integrated control module LED display
provides d0 error code.
x ComfortNet™ thermostat “Call for
Service” icon illuminated.
x ComfortNet™ thermostat scrolls “Check
Furnace” message.
PS2 OPEN
E9
x Furnace fails to operate on high stage;
furnace operates normally on low stage.
x Integrated control module LED display
provides E9 error code.
ComfortNet™
Thermostat Only
Message
Code
PS2
E8
CLOSED
x High stage pressure
switch circuit is closed at
start of heating cycle.
x Induced draft blower is
operating.
x Furnace is operating on
low stage only
x High stage pressure
switch circuit is not
closed.
x Induced draft blower is
operating.
x Furnace is operating on
low stage only
Fault Description
E8
Diagnostic/Status
LED Codes
x Furnace fails to operate on high stage;
furnace operates normally on low stage.
x Integrated control module LED display
provides E8 error code.
Symptoms of Abnormal Operation
(Legacy & ComfortNet™ Thermostat)
x Furnace does not contain any
shared data.
x Polarity of 115 volt AC power to
furnace or integrated module is
revered.
x Poor unit ground
x Pressure switch hose blocked
pinched, or connected
improperly.
x Blocked flue and/or inlet air pipe,
blocked drain system or weak
induced draft blower.
x Incorrect pressure switch set
point or malfunctioning switch
contacts.
x Loose or improperly connected
wiring.
x High stage pressure switch
contacts sticking.
x Shorts in pressure switch circuit
wiring.
Possible Causes
x Populate shared data set using
memory card.
x Inspect pressure switch hose.
Repair/replace if necessary.
x Inspect flue and/or inlet air
piping for blockage, proper
length, elbows, and termination.
Check drain system. Correct as
necessary.
x Check induced draft blower
performance. Correct as
necessary.
x Correct pressure switch set point
or contact motion.
x Tighten or correct wiring
connection.
x Review wiring diagram to
correct polarity.
x Verify proper ground. Correct if
necessary.
x Check and correct wiring.
x Replace high stage pressure
switch.
x Repair short in wiring
Corrective Actions
x Turn power OFF prior to
repair
x Use memory card for the
specific model.
x Insert memory card
BEFORE turning power
ON. Memory card may be
removed after data is
loaded.
x Turn power OFF before
removing memory card.
x Error code will be cleared
once data is loaded.
x Turn power OFF prior to
repair.
x Turn power OFF prior to
repair.
x Replace pressure switch
with correct replacement
part.
x Replace induced draft
blower with correct
replacement part.
x Turn power OFF prior to
repair.
x Replace pressure switch
with correct replacement
part.
Notes & Cautions
TROUBLESHOOTING
PCBKF101/2
51
52
x Flame sensed with no
call for heat.
x Open Fuse
x Flame sense micro amp
signal is low
x Problem with igniter
circuit.
E4
E5
E6
E7
x Induced draft blower and circulator blower
runs continuously. No furnace operation.
x Integrated control module LED display
provides E4 error code.
x ComfortNet™ thermostat “Call for
Service” icon illuminated.
x ComfortNet™ thermostat scrolls “Check
Furnace” message.
x No furnace operation.
x Integrated control module LED display
provides E5 error code.
x ComfortNet™ thermostat displays
“Battery Power”.
x Normal furnace operation.
x Integrated control module LED display
provides E6 error code.
x Furnace fails to operate.
x Integrated control module LED display
provides E7 error code.
x ComfortNet™ thermostat “Call for
Service” icon illuminated.
x ComfortNet™ thermostat scrolls “Check
Furnace” message.
x Primary limit or
auxiliary limit circuit is
open.
x Rollout limit circuit is
open.
Fault Description
E3
Diagnostic/Status
LED Codes
x Circulator blower runs continuously. No
furnace operation.
x Integrated control module LED display
provides E3 error code.
x ComfortNet™ thermostat “Call for
Service” icon illuminated.
x ComfortNet™ thermostat scrolls “Check
Furnace” message.
Symptoms of Abnormal Operation
(Legacy & ComfortNet™ Thermostat)
IGNITER
FAULT
WEAK
FLAME
Not
Displayed
IMPROPER
FLAME
E7
E6
Not
Displayed
E4
ComfortNet™
Thermostat Only
Message
Code
HIGH
E3
LIMIT
OPEN
x
x
x
x
Improperly connected igniter.
Shorted igniter.
Poor unit ground.
Igniter relay fault on integrated
control module.
x Flame sensor is coated/oxidized.
x Flame sensor incorrectly
positioned in burner flame.
x Lazy burner flame due to
improper gas pressure or
combustion air.
x Short in low voltage wiring
x Short to ground in flame sense
circuit.
x Lingering burner flame.
x Slow closing gas valve.
x Insufficient conditioned air over
the heat exchanger. Blocked
filters, restrictive ductwork,
improper circulator blower speed,
or failed circulator blower motor.
x Flame rollout.
x Misaligned burners, blocked flue
and/or air inlet pipe, or failed
induced draft blower.
x Loose or improperly connected
wiring.
Possible Causes
x Sand flame sensor if
coated/oxidized.
x Inspect for proper sensor
alignment.
x Check inlet air piping for
blockage, proper length, elbows,
and termination.
x Compare current gas pressure to
rating plate. Adjust as needed.
x Check and correct wiring from
integrated control module to
igniter.
x Replace shorted igniter.
x Check and correct unit ground
wiring.
x Check igniter output from
control. Replace if necessary.
x Locate and correct short in low
voltage wiring
x Check filters and ductwork for
blockage. Clean filters or
remove obstruction.
x Check circulator blower speed
and performance. Correct speed
or replace blower motor if
necessary.
x Check burners for proper
alignment.
x Check flue and air inlet piping
for blockage, proper length,
elbows, and termination. Correct
as necessary.
x Check induced draft blower for
proper performance. Replace if
necessary.
x Tighten or correct wiring
connection.
x Correct short at flame sensor or
in flame sensor wiring.
x Check for lingering flame.
x Verify proper operation of gas
valve.
Corrective Actions
x Turn power OFF prior to
repair.
x Replace igniter with
correct replacement part.
x Replace control with
correct replacement part.
x Turn power OFF prior to
repair.
x Sand flame sensor with
emery cloth.
x See "Vent/Flue Pipe"
section for piping details.
x See rating plate for proper
gas pressure.
x Turn power OFF prior to
repair.
x Replace fuse with 3-amp
automotive type
x Turn power OFF prior to
repair.
x Turn power OFF prior to
repair.
x See Specification Sheet
applicable to your model
for allowable rise range
and proper circulator
speed.
x See "Vent/Flue Pipe"
section for piping details.
Notes & Cautions
TROUBLESHOOTING
PCBKF101/2
d4
b0
b1
b2
b3
x Furnace fails to operate.
x Integrated control module LED display
provides b0 error code.
x ComfortNet™ thermostat “Call for
Service” icon illuminated.
x ComfortNet™ thermostat scrolls “Check
Furnace” message.
x Furnace fails to operate.
x Integrated control module LED display
provides b1 error code.
x ComfortNet™ thermostat “Call for
Service” icon illuminated.
x ComfortNet™ thermostat scrolls “Check
Furnace” message.
x Furnace fails to operate.
x Integrated control module LED display
provides b2 error code.
x ComfortNet™ thermostat “Call for
Service” icon illuminated.
x ComfortNet™ thermostat scrolls “Check
Furnace” message.
x Furnace operates at reduced performance.
x Airflow delivered is less than expected.
x Integrated control module LED display
provides b3 error code.
Diagnostic/Status
LED Codes
x Operation different than expected or no
operation.
x Integrated control module LED display
provides d4 error code.
x ComfortNet™ thermostat “Call for
Service” icon illuminated.
x ComfortNet™ thermostat scrolls “Check
Furnace” message.
Symptoms of Abnormal Operation
(Legacy & ComfortNet™ Thermostat)
b0
b1
b2
b3
MOTOR
NOT RUN
MOTOR
COMM
MOTOR
MISMATCH
MOTOR
LIMITS
x Integrated control
module has lost
communications with
circulator blower motor.
x Circulator blower motor
horse power in shared
data set does not match
circulator blower motor
horse power.
x Circulator blower motor
is operating in a power,
temperature, or speed
limiting condition.
ComfortNet™
Thermostat Only
Message
Code
INVALID
d4
MC DATA
x Circulator blower motor
is not running when it
should be running.
x Invalid memory card
data.
Fault Description
x
x
x
x
Blocked filters.
Restrictive ductwork.
Undersized ductwork.
High ambient temperatures.
x Incorrect circulator blower motor
in furnace.
x Incorrect shared data set in
integrated control module.
x Loose wiring connection at
circulator motor control leads.
x Failed circulator blower motor.
x Failed integrated control module.
x Loose wiring connection at
circulator motor power leads or
circulator motor power leads
disconnected.
x Open circuit in inductor or loose
wiring connection at inductor (3/4
Hp and 1 Hp models only).
x Failed circulator blower motor.
x Shared data set on memory card
has been rejected by integrated
control module
Possible Causes
x Check filters for blockage.
Clean filters or remove
obstruction.
x Check ductwork for blockage.
Remove obstruction. Verify all
registers are fully open.
x Verify ductwork is appropriately
sized for system. Resize/replace
ductwork if necessary.
x See "Product Description" and
"Location Requirements &
Considerations" for furnace
installation requirements.
x Verify circulator blower motor
horse power is the same
specified for the specific furnace
model. Replace if necessary.
x Verify shared data set is correct
for the specific model. Repopulate data using correct
memory card if required.
x Tighten or correct wiring
connection.
x Check circulator blower motor.
Replace if necessary.
x Check integrated control module.
Replace if necessary.
x Tighten or correct wiring
connection.
x Verify continuous circuit
through inductor. Replace if
open or short circuit.
x Check circulator blower motor.
Replace if necessary.
x Verify shared data set is correct
for the specific model. Repopulate data using correct
memory card if required.
Corrective Actions
x Turn power OFF prior to
repair
x Replace circulator motor
with correct replacement
part.
x Replace integrated control
module with correct
replacement part.
x Turn power OFF prior to
repair
x Replace motor with correct
replacement part.
x Use memory card for the
specific model
x Insert memory card
BEFORE turning power
ON. Memory card may be
removed after data is
loaded.
x Turn power OFF before
removing memory card.
x Error code will be cleared
once shared data and
motor horse power match.
x Turn power OFF prior to
repair.
x Turn power OFF prior to
repair
x Use memory card for the
specific model.
x Insert memory card
BEFORE turning power
ON. Memory card may be
removed after data is
loaded.
x Turn power OFF before
removing memory card.
x Error code will be cleared
once data is loaded.
x Turn power OFF prior to
repair
x Replace inductor with
correct replacement part.
x Replace circulator motor
with correct replacement
part.
Notes & Cautions
TROUBLESHOOTING
PCBKF101/2
53
54
b6
b7
b9
MOTOR
VOLTS
MOTOR
PARAMS
LOW ID
AIRFLOW
x Circulator blower motor
shuts down for over or
under voltage condition.
x Circulator blower motor
shuts down due to over
temperature condition on
power module.
x Circulator blower motor
does not have enough
information to operate
properly.
x Motor fails to start 40
consecutive times.
x Airflow is lower than
demanded.
b6
b7
b9
x Furnace fails to operate.
x Integrated control module LED display
provides b7 error code.
x ComfortNet™ thermostat “Call for
Service” icon illuminated.
x ComfortNet™ thermostat scrolls “Check
Furnace” message.
x Furnace operates at reduced performance
or operates on low stage when high stage is
expected.
x Integrated control module LED display
provides b9 error code.
b5
MTR LCKD
ROTOR
x Circulator blower motor
fails to start 10
consecutive times.
b5
ComfortNet™
Thermostat Only
Message
Code
MOTOR
b4
TRIPS
x Furnace fails to operate.
x Integrated control module LED display
provides b5 error code.
x ComfortNet™ thermostat “Call for
Service” icon illuminated.
x ComfortNet™ thermostat scrolls “Check
Furnace” message.
x Furnace fails to operate.
x Integrated control module LED display
provides b6 error code.
x ComfortNet™ thermostat “Call for
Service” icon illuminated.
x ComfortNet™ thermostat scrolls “Check
Furnace” message.
x Circulator blower motor
senses a loss of rotor
control.
x Circulator blower motor
senses high current.
Fault Description
b4
Diagnostic/Status
LED Codes
x Furnace fails to operate.
x Integrated control module LED display
provides b4 error code.
x ComfortNet™ thermostat “Call for
Service” icon illuminated.
x ComfortNet™ thermostat scrolls “Check
Furnace” message.
Symptoms of Abnormal Operation
(Legacy & ComfortNet™ Thermostat)
x Blocked filters.
x Restrictive ductwork.
x Undersized ductwork.
x Error with integrated control
module.
x Motor has a locked rotor
condition.
x High AC line voltage to furnace.
x Low AC line voltage to furnace.
x High ambient temperatures.
x Check filters for blockage.
Clean filters or remove
obstruction.
x Check ductwork for blockage.
Remove obstruction. Verify all
registers are fully open.
x Verify ductwork is appropriately
sized for system. Resize/replace
ductwork if necessary.
x Check power to furnace. Verify
line voltage to furnace is within
the range specified on the
furnace rating plate.
x See "Product Description" and
"Location Requirements &
Considerations" for furnace
installation requirements.
x Check integrated control module.
Verify control is populated with
correct shared data set. See data
errors above for details.
x Check for locked rotor condition
(see error code above for
details).
x Check circulator blower for
obstructions. Remove and
repair/replace wheel/motor if
necessary.
x Check circulator blower motor
shaft rotation and motor.
Replace motor if necessary.
x Turn power OFF prior to
repair.
x Turn power OFF prior to
repair.
x Replace with correct
replacement part(s).
x Use memory card for the
specific model.
x Turn power OFF prior to
repair.
x Turn power OFF prior to
repair
x Replace motor with correct
replacement part.
x Replace wheel with correct
replacement part.
x Turn power OFF prior to
repair.
x Check filters, filter
grills/registers, duct system, and
furnace air inlet/outlet for
blockages.
x Abnormal motor loading, sudden
change in speed or torque, sudden
blockage of furnace air inlet or
outlet.
x High loading conditions, blocked
filters, very restrictive ductwork,
blockage of furnace air inlet or
outlet.
x Obstruction in circulator blower
housing.
x Seized circulator blower motor
bearings.
x Failed circulator blower motor.
Notes & Cautions
Corrective Actions
Possible Causes
TROUBLESHOOTING
PCBKF101/2
PCBKF103
TROUBLESHOOTING
AND
PCBKF104
INTERNAL CONTROL FAULT/NO POWER
O n
E 0
E 1
NORMAL OPERATION
E 2
LOW STAGE PRESSURE SWI TCH STUCK OPEN
E 3
E 4
OPEN HIGH LIMIT SWITCH
E 5
OPEN FUSE
E 6
LOW FLAME SIGNAL
E 7
IGNITER FAULT OR IMPROPER GROUNDING
E 8
HIGH STAGE PRESSURE SWITCH STUCK CLOSED AT START OF HEATING CYCLE
E 9
E A
E F
d 0
d 4
HIGH STAGE PRESSURE SWITCH STUCK OPEN
b
b
b
b
0
1
2
3
b 4
b 5
b 6
LOCKOUT DUE TO EXCESSIVE RETRIES
LOW STAGE PRESSURE SWITCH STUCK CLOSED AT START OF HEATING CYCLE
FLAME DETECTED WHEN NO FLAME SHOULD BE PRESENT
REVERSED 115 VAC POLARITY
AUXILIARY SWITCH OPEN
DATA NOT YET ON NETWORK
INVALID MEMORY CARD DATA
BLOWER MOTOR NOT RUNNING
BLOWER COMMUNICATION ERROR
BLOWER HP MIS-MATCH
BLOWER MOTOR OPERATING IN POWER, TEMPERATURE, OR SPEED LIMIT
BLOWER MOTOR CURRENT TRIP OR LOST ROTOR
BLOWER MOTOR LOCKED ROTOR
OVER/UNDER VOLTAGE TRIP OR OVER TEMPERATURE TRIP
b 7
b 9
C 1
C 2
P 1
P 2
HIGH STAGE HEAT PUMP HEAT
L 0
LOW STAGE GAS HEAT
H I
HIGH STAGE GAS HEAT
F
1 2
CONTINUOUS FAN
INCOMPLETE PARAMETERS SENT TO MOTOR
LOW INDOOR AIRFLOW
LOW STAGE COOL
HIGH STAGE COOL
LOW STAGE HEAT PUMP HEAT
CFM/100; ALTERNATES WITH
C 1 , C 2, L O , H I
P 1,P 2
,
F
0140F01169REV A
55
PCBKF101/2
TROUBLESHOOTING
INTERNAL CONTROL FAULT/NO POWER
56
O n
NORMAL OPERATION (PCBBF102)
O P
NORMAL OPERATION (PCBKF101)
E
E
E
E
E
E
E
E
E
E
E
d
d
b
b
b
b
b
b
b
b
b
C
C
LOCKOUT DUE TO EXCESSIVE RETRIES
0
1
2
3
4
5
6
7
8
9
A
0
4
0
1
2
3
4
5
6
7
9
1
2
LOW STAGE PRESSURE SWITCH STUCK CLOSED AT START OF HEATING CYCLE
LOW STAGE PRESSURE SWITCH STUCK OPEN
OPEN HIGH LIMIT SWITCH
FLAME DETECTED WHEN NO FLAME SHOULD BE PRESENT
OPEN FUSE
LOW FLAME SIGNAL
IGNITER FAULT OR IMPROPER GROUNDING
HIGH STAGE PRESSURE SWITCH STUCK CLOSED AT START OF HEATING CYCLE
HIGH STAGE PRESSURE SWITCH STUCK OPEN
REVERSED 115 VAC POLARITY
DATA NOT YET ON NETWORK
INVALID MEMORY CARD DATA
BLOWER MOTOR NOT RUNNING
BLOWER COMMUNICATION ERROR
BLOWER HP MIS-MATCH
BLOWER MOTOR OPERATING IN POWER, TEMPERATURE, OR SPEED LIMIT
BLOWER MOTOR CURRENT TRIP OR LOST ROTOR
BLOWER MOTOR LOCKED ROTOR
OVER/UNDER VOLTAGE TRIP OR OVER TEMPERATURE TRIP
INCOMPLETE PARAMETERS SENT TO MOTOR
LOW INDOOR AIRFLOW
LOW STAGE COOL
HIGH STAGE COOL
L 0
H I
F
LOW STAGE HEAT
1 2
CFM/100; ALTERNATES WITH
HIGH STAGE HEAT
CONTINUOUS FAN
C 1
,
C 2
,
L O, H I
,
F
SYSTEM OPERATION
ComfortNet™ System
OVERVIEW
The ComfortNet system is a system that includes a
ComfortNet compatible furnace and air conditioner or heat
pump with a CTK0*** thermostat. A valid ComfortNet system could also be a compatible furnace, CTK0*** thermostat and non-compatible, single stage air conditioner. Any
other system configurations are considered invalid
ComfortNet systems and must be connected as a traditional (or legacy) system (see Electrical Connections for
wiring connections).
A ComfortNet heating/air conditioning system differs from
a legacy/traditional system in the manner in which the indoor unit, outdoor unit and thermostat interact with one
another. In a traditional system, the thermostat sends commands to the indoor and outdoor units via analog 24 VAC
signals. It is a one-way communication path in that the
indoor and outdoor units typically do not return information
to the thermostat.
On the other hand, the indoor unit, outdoor unit, and thermostat comprising a ComfortNet system “communicate”
digitally with one another. It is now a two-way communications path. The thermostat still sends commands to the
indoor and outdoor units. However, the thermostat may
also request and receive information from both the indoor
and outdoor units. This information may be displayed on
the ComfortNet thermostat. The indoor and outdoor units
also interact with one another. The outdoor unit may send
commands to or request information from the indoor unit.
This two-way digital communications between the thermostat and subsystems (indoor/outdoor unit) and between subsystems is the key to unlocking the benefits and features
of the ComfortNet system.
Two-way digital communications is accomplished using
only two wires. The thermostat and subsystem controls
are power with 24 VAC. Thus, a maximum of 4 wires between the equipment and thermostat is all that is required
to operate the system.
ComfortNet™ System
4. Dehumidification (lowering of CFM to 85%) only happens
during low stage cooling operation. The dehumidification
feature is not active during high stage cool. The CTK03A*
can be set up to overcool the home in order to reach the
RH set point.
CTK0*** WIRING
NOTE: Refer to Electrical Connections for 115 volt line
connections to the furnace.
NOTE: A removable plug connector is provided with the
control to make thermostat wire connections. This plug may
be removed, wire connections made to the plug, and replaced.
It is strongly recommended that multiple wires into a single
terminal be twisted together prior to inserting into the plug
connector. Failure to do so may result in intermittent
operation.
Typical 18 AWG thermostat wire may be used to wire the
system components. However, communications reliability
may be improved by using a high quality, shielded, twisted
pair cable for the data transmission lines. In either case,
100 feet is the maximum length of wire between indoor unit
and outdoor unit, or between indoor unit and thermostat.
FOUR-WIRE INDOOR AND OUTDOOR WIRING
Typical wiring will consist of four wires between the indoor
unit and outdoor unit and between the indoor unit and thermostat. The required wires are: (a) data lines, 1 and 2; (b)
thermostat “R” (24 VAC hot) and “C” (24 VAC common).
1
C
2 R
CTK0***
Thermostat
1
2
ComfortNet Compatible Furnace
R C Integrated Control Module
1
2
R C
OPERATIONS WITH CTK03A*
1. Humidification Options are ON / OFF with the CTK03AB.
When “On” is selected, the humidification relay on the
furnace control board will function during a heat call if a
humidity demand exists. Selecting “Off” means the
humidification relay will not function.
2. If the CTK03A* is set up so the compressor off delay is
0 min, it will display a cool / heat call immediately regardless of the delay built into the outdoor unit control
board. This means the CTK03A* could show COOL ON
when the outdoor unit is still in a delay period. The recommendation is to set up the compressor delay to at
least 3 minutes
3. Dual Fuel – When the CTK03A* calls for gas heat, the
heat pump will shut off, after a delay of approximately 3
minutes it will then turn on gas heat.
ComfortNet Compatible AC/HP
Integrated Control Module
TWO-WIRE OUTDOOR, FOUR-WIRE INDOOR WIRING
Two wires only may be utilized between the indoor and outdoor units. For this wiring scheme, only the data lines, 1
and 2, are required between the indoor and outdoor units. A
40VA, 208/230 VAC to 24VAC transformer must be installed
in the outdoor unit to provide 24VAC power to the outdoor
unit’s electronic control. The transformer is included with
the CTK01A* kit. See kit instructions for mounting and wiring instructions. Four wires are required between the indoor
unit and thermostat.
57
ComfortNet™ System
SYSTEM OPERATION
NOTE: Use of an accessory transformer is recommended if
installing a dual fuel system. Failure to use the transformer
in the outdoor unit could result in over loading of the furnace
transformer.
If your communicating thermostat kit does not include a
transformer, an accessory kit is available by ordering part
TFK01.
SYSTEM WIRING BETWEEN FURNACE AND NON-COMFORTNET
COMPATIBLE SINGLE STAGE AIR CONDITIONER
COMFORTNET SYSTEM ADVANCED FEATURES
The ComfortNet system permits access to additional system information, advanced setup features, and advanced diagnostic/troubleshooting features. These advanced features
are organized into a menu structure. The menus are accessed and navigated as described in the following section.
ACCESSING AND NAVIGATING THE ADVANCED FEATURES
MENUS FOR THE CTK01* THERMOSTAT
1
C
2 R
40VA Transformer
208/230 VAC
CTK0***
Thermostat
1
2
ComfortNet Compatible
R C Furnace Integrated
Control Module
1
2
R C
ComfortNet Compatible
AC/HP Integrated
Control Module
24 VAC
The advanced system features are accessed using the
ComfortNet thermostat. These advanced features are accessed as follows:
•
On the ComfortNet thermostat Home Screen Display,
touch the Menu key to display additional key choices.
•
Touch and hold the Installer Config key for approximately 3 seconds to enter the Thermostat Options
Configuration menu.
•
Touch and hold the Installer Config key again for
approximately 3 seconds to enter the Advanced Installer Configuration menu.
SYSTEM WIRING USING TWO-WIRES BETWEEN FURNACE AND
CTKO2* Thermostat: From the Home screen, press and hold
FOUR-WIRES BETWEEN FURNACE AND THERMOSTAT
the left and right arrow keys for 3 seconds.
COMFORTNET COMPATIBLE FURNACE WITH NON-COMFORTNET
CTKO3* Thermostat: From the Home screen, press menu >
COMPATIBLE SINGLE STAGE AIR CONDITIONER
installer options (you will need to enter the 4 digit date code
Four wires are required between the furnace and thermostat.
Two wires are required between the furnace control and single
stage air conditioner. For this system configuration, the
“Y1” terminal on the integrated furnace control becomes an
output rather than an input.
1
C
2 R
1
2
R C G
C
58
CTK0***
Thermostat
W1 W2 Y1
Y
Y2
O
ComfortNet
Compatible
Furnace Integrated
Control Module
Non-ComfortNet Compatible
Single Stage AC
which can be found in menu > dealer info)
For the ComfortNet menu: From the Home screen press
menu > ComfortNet user menu (you will need to enter the 4
digit date code which can be found in menu > dealer info).
SYSTEM OPERATION
ComfortNet™ System
FURNACE ADVANCED FEATURES MENUS
CONFIGURATION
Submenu Item
Indication (for Display Only; not User Modifiable)
Number of Heat Stages (HT STG)
Displays the number of furnace heating stages
Input Rate (BTU/HR)
Displays the furnace input rate in kBtu/hr
Motor HP (1/2, ¾, or 1 MTR HP)
Displays the furnace indoor blower motor horsepower
DIAGNOSTICS
Submenu Item
Indication/User Modifiable Options
Comments
Fault 1 (FAULT #1)
Most recent furnace fault
For display only
Fault 2 (FAULT #2)
Next most recent furnace fault
For display only
Fault 3 (FAULT #3)
Next most recent furnace fault
For display only
Fault 4 (FAULT #4)
Next most recent furnace fault
For display only
Fault 5 (FAULT #5)
Next most recent furnace fault
For display only
Fault 6 (FAULT #6)
Least recent furnace fault
For display only
Clear Fault History (CLEAR)
NO or YES
Selecting “YES” clears the
fault history
NOTE: Consecutively repeated faults are shown a maximum of 3 times.
IDENTIFICATION
Submenu Item
Indication (for Display Only; not User Modifiable)
Model Number (MOD NUM)
Displays the furnace model number
Serial Number (SER NUM)
Displays the furnace serial number (Optional)
Software (SOFTWARE)
Displays the application software revision
SET-UP
Submenu Item
User Modifiable Options
Comments
Heat Airflow Trim (HT
TRM)
Heat ON Delay (HT ON
-10% to +10% in 2% increments,
default is 0%
5, 10, 15, 20, 25, or 30 seconds,
default is 30 seconds
30, 60, 90, 120, 150, or 180
seconds, default is 150 seconds
1, 2, 3, or 4
Trims the heating airflow by the selected
amount.
Selects the indoor blower heat ON delay
Heat OFF Delay (HT OFF)
Heat Airflow (HT ADJ)
Selects the indoor blower heat OFF delay
Selects the nominal heating airflow (see
Startup Procedure and Adjustment –
Circulator Blower Speeds for additional
information)
STATUS
Submenu Item
Indication (for Display Only; not User Modifiable)
Mode (MODE)
Displays the current furnace operating mode
CFM (CFM)
Displays the airflow for the current operating mode
59
SYSTEM OPERATION
ComfortNet™ System
NON-COMM (APPLIES ONLY TO A COMMUNICATING COMPATIBLE FURNACE MATCHED
WITH A NON-COMMUNICATING COMPATIBLE SINGLE STAGE AIR CONDITIONER)
Submenu Item
User Modifiable Options
Comments
Cool Airflow (CL CFM)
18, 24, 30, 36, 42, 48, or 60, default
is 18
Selects the airflow for the non-CT
compatible single stage AC unit
Cool Airflow Trim (CL TRM)
-10% to +10% in 2% increments,
default is 0%
Cool Airflow Profile (CL PRFL)
A, B, C, or D, default is A
Cool ON Delay (CL ON)
5, 10, 20, or 30 seconds, default is
5 seconds
Cool OFF Delay (CL OFF)
30, 60, 90, or 120 seconds, default
is 30 seconds
Selects the airflow trim amount for the noncommunicating compatible single stage AC
unit
Selects the airflow profile for the noncommunicating compatible single stage AC
unit
Selects the indoor blower ON delay for the
non-communicating compatible single
stage AC unit
Selects the indoor blower OFF delay for the
non-communicating compatible single
stage AC unit
The integrated furnace control has some on-board tools that may be used to trouble-shoot the network. These
tools are; red communications LED, green receive (Rx) LED, and learn button.
•
Red communications LED – Indicates the status of the network. The table below indicates the LED
status and the corresponding potential problem.
•
Green receive LED – Indicates network traffic. The table below indicates the LED status and the corresponding potential problem.
•
Learn button – Used to reset the network. Depress the button for approximately 2 seconds to reset the
network.
60
ComfortNet™ System
SYSTEM OPERATION
SYSTEM TROUBLESHOOTING
NOTE: Refer to the instructions accompanying the ComfortNet compatible outdoor AC/HP unit for troubleshooting information.
Refer to the Troubleshooting Chart for a listing of possible furnace error codes, possible causes and corrective actions.
LED
LED
Status
Off
1 Flash
Indication
Possible Causes
Corrective Action(s)
Notes & Cautions
x None
x Depress once
quickly for a powerup reset
x Depress and hold
for 2 seconds for
an out-of-box reset
x None
x Normal condition
x Communications
Failure
x None
x Communications
Failure
x None
x Depress Learn Button
x Verify that bus BIAS
and TERM
dipswitches are in the
ON position.
2 Flashes
x Out-of-box reset
x None
Off
x No power
x Communications
error
x Control power up
x Learn button
depressed
x No power to furnace
x Open fuse
x Communications error
1 Steady
Flash
x No network found
x Broken/ disconnected
data wire(s)
x Furnace is installed as
a legacy/ traditional
system
Rapid
Flashing
On Solid
x Normal network
traffic
x Data 1/ Data 2
miss-wire
x Control is “talking” on
network as expected
x Data 1 and data 2
wires reversed at
furnace, thermostat,
or CT™ compatible
outdoor AC/HP
x Short between data 1
and data 2 wires
x Short between data 1
or data 2 wires and R
(24VAC) or C (24VAC
common)
Red
Communications
LED
Green Receive
LED
x Check fuses and
circuit breakers;
replace/reset
x Replace blown fuse
x Check for shorts in
low voltage wiring in
furnace/system
x Reset network by
depressing learn
button
x Check data 1/ data 2
voltages
x Check
communications
wiring (data 1/ data 2
wires)
x Check wire
connections at
terminal block
x Verify furnace
installation type
(legacy/ traditional or
communicating)
x Check data 1/ data 2
voltages
x None
x Check
communications
wiring (data 1/ data 2
wires)
x Check wire
connections at
terminal block
x Check data 1/ data 2
voltages
x Turn power OFF
prior to repair
x Turn power OFF
prior to repair
x Verify wires at
terminal blocks are
securely twisted
together prior to
inserting into
terminal block
x Verify data1 and
data voltages as
described above
x None
x Turn power OFF
prior to repair
x Verify wires at
terminal blocks are
securely twisted
together prior to
inserting into
terminal block
x Verify data1 and
data voltages as
described above
61
SYSTEM OPERATION
TROUBLESHOOTING
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
NOTE: Discharge body’s static electricity before touching
unit. An electrostatic discharge can adversely affect electrical
components.
Use the following precautions during furnace installation and
servicing to protect the integrated control module from damage. By putting the furnace, the control, and the person at
the same electrostatic potential, these steps will help avoid
exposing the integrated control module to electrostatic discharge. This procedure is applicable to both installed and
uninstalled (ungrounded) furnaces.
1. Disconnect all power to the furnace. Do not touch the
integrated control module or any wire connected to
the control prior to discharging your body’s electrostatic charge to ground.
2. Firmly touch a clean, unpainted, metal surface of the
furnace away from the control. Any tools held in a
person’s hand during grounding will be discharged.
3. Service integrated control module or connecting wiring
following the discharge process in step 2. Use caution not to recharge your body with static electricity;
(i.e., do not move or shuffle your feet, do not touch ungrounded objects, etc.). If you come in contact with
an ungrounded object, repeat step 2 before touching
control or wires.
4. Discharge your body to ground before removing a new
control from its container. Follow steps 1 through 3 if
installing the control on a furnace. Return any old or
new controls to their containers before touching any
ungrounded object.
FOUR WIRE MOTOR TROUBLESHOOTING
Any manual testing of the 4 wire seriallY communicating
motor should only be done with the ULTRACHECK-EZ diagnostic tool. All other methods may not be reliable or cause
damage to the 4 wire motor. See section S-16C for additional details.
COMFORTNET SYSTEM TROUBLESHOOTING
At system power-up, the CTK0*** thermostat will begin
searching for any connected compatible equipment. The
thermostat will scroll "SEARCHING". The thermostat will
scroll <equipment> FOUND once it identifies that piece of
equipment. In a typical installation, an indoor unit and outdoor unit will be identified.
If the thermostat scrolls "SEARCHING" for several minutes,
then it has failed to identify any connected equipment. The
thermostat may identify one piece of equipment, but not the
other. Broken or improper wiring is the most likely cause for
the thermostat to fail to identify any equipment. If an outdoor unit is not identified, the thermostat will scroll "CHECK
SYSTEM", indicating that no indoor unit was found.
62
ComfortNet™ System
Wiring issues may be confirmed (or eliminated) by using
the CTK0*** thermostat and sub base, a 4-position connector (included with the kit), and a short section (~ 2ft) of thermostat wire. Connect the wire between the connector and
thermostat sub base. Connect the thermostat to the indoor
unit and apply power. If the thermostat identifies the indoor
unit, then a wiring problem exists between the indoor unit
and the permanent thermostat location. Repair or replace
wiring.
Connect the thermostat to the outdoor unit. If the thermostat identifies the outdoor unit, then a wiring problem exists
between the indoor and outdoor units. Repair or replace
wiring.
NOTE: A 24VAC source will be needed to power the thermostat and outdoor unit control.
DIAGNOSTIC CHART
WARNING
HIGH VOLTAGE !
TO AVOID PERSONAL INJURY OR DEATH DUE TO
ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER
BEFORE PERFORMING ANY SERVICE OR MAINTENANCE.
Refer to the Troubleshooting Chart in the Appendix for assistance in determining the source of unit operational problems. The dual 7-segment LED display will display an error
code that may contain a letter and number. The error code
may be used to assist in troubleshooting the unit.
RESETTING FROM LOCKOUT
Furnace lockout results when a furnace is unable to achieve
ignition after three attempts during a single call for heat. It
is characterized by a non-functioning furnace and a E 0 code
displayed on the dual 7-segment display. If the furnace is in
“lockout”, it will (or can be) reset in any of the following ways.
1. Automatic reset. The integrated control module will
automatically reset itself and attempt to resume normal
operations following a one hour lockout period.
2. Manual power interruption. Interrupt 115 volt power to
the furnace.
3. Manual thermostat cycle. Lower the thermostat so
that there is no longer a call for heat for 1 -20 seconds
then reset to previous setting.
NOTE: If the condition which originally caused the lockout
still exists, the control will return to lockout. Refer to the
Diagnostic Chart for aid in determining the cause.
POLARIZATION AND PHASING
As more and more electronic's are introduced to the Heating Trade, Polarization of incoming power and phasing of
primary to secondary voltage on transformers becomes
more important.
INCOMING POWER
METER READS
METER READS
120 VOLTS
0 VOLTS
Polarization has been apparent in the Appliance industry
since the introduction of the three prong plug, however,
the Heating Industry does not use a plug for incoming
power, but is hard wired.
VOLT / OHM
METER
VOLT / OHM
METER
GND
GND
Some of the electronic boards being used today, with flame
rectification, will not function properly and/or at all without
polarization of incoming power. Some also require phasing between the primary and secondary sides of step-down
transformers.
THIS IS THE COMMON
OR NEUTRAL LEG
THIS IS L1 OR THE
HOT POWER LEG
These then should be wired to the furnace accordingly.
CHECKING FOR PHASING - PRIMARY TO SECONDARY OF UNMARKED TRANSFORMERS*
METER READS
120 VOLTS
METER READS
24 VOLTS
.
.
.
.
.
C
G
D
N
N
R
L1
.
VOLT / OHM
METER
VOLT / OHM
METER
TRANSFORMER
G
R
LINE VOLTAGE
(NEUTRAL)
PRIMARY
SECONDARY
C
ND
LINE VOLTAGE
L1 (HOT)
VOLT / OHM
METER
READS 96 VOLTS - IN PHASE
C
G
ND
N
L1
R
VOLT / OHM
METER
VOLT / OHM
METER
READS 144 VOLTS - OUT OF PHASE
If meter reads approximately 96 volts - the primary to secondary are in phase - if reads approximately 144 volts out of
phase - reverse low voltage wires.
*NOTE: For flame rectification the common side of the secondary voltage (24 V) is cabinet grounded. If you were to bench
test a transformer the primary neutral and secondary common must be connected together for testing purposes.
C
ND
G
24 V
NEUTRAL
120 V
R
L1
PHASING SYMBOL
Some transformers will display phasing symbols as shown
in the illustration to the left to assist in determining proper
transformer phasing.
Checking for polarization and phasing should become a habit
in servicing. Let's start now.
NOTE: Newer integrated ignition controls have a diagnostic
flash code for reversed polarity (Refer to TroubleshootingDiagnostic Chart for LED
63
MAINTENANCE
WARNING
HIGH VOLTAGE
DISCONNECT ALL POWER BEFORE SERVICING OR
C
.o
d
e
)sINSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY
BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY
DAMAGE, PERSONAL INJURY OR DEATH.
CAUTION
IF
YOU MUST HANDLE THE ITNITOR, HANDLE WITH CARE.
T OUCHING
THE IGNITOR BODY WITH BARE FINGERS, ROUGH HANDLING, OR
VIBRATION COULD RESULT IN EARLY IGNITOR FAILURE.
O NLY
A
QUALIFIED SERVICER SHOULD EVER HANDLE THE IGNITOR.
ANNUAL INSPECTION
The furnace should be inspected by a qualified installer, or
service agency at least once per year. This check should
be performed at the beginning of the heating season. This
will ensure that all furnace components are in proper working order and that the heating system functions appropriately. Pay particular attention to the following items. Repair
or service as necessary.
•
Flue pipe system. Check for blockage and/or leakage. Check the outside termination and the connections at and internal to the furnace.
•
Combustion air intake pipe system (where applicable).
Check for blockage and/or leakage. Check the outside termination and the connection at the furnace.
•
Heat exchanger. Check for corrosion and/or buildup
within the heat exchanger passageways.
•
Burners. Check for proper ignition, burner flame, and
flame sense.
•
Drainage system. Check for blockage and/or leakage. Check hose connections at and internal to furnace.
•
Wiring. Check electrical connections for tightness
and/or corrosion. Check wires for damage.
•
Filters.
AIR FILTER
WARNING
Maintenance
Improper filter maintenance is the most common cause of
inadequate heating or cooling performance. Filters should
be cleaned (permanent) or replaced (disposable) every two
months or as required. It is the owner's responsibility to
keep air filters clean. When replacing a filter, it must be
replaced with a filter of the same type and size.
Filter Removal
Depending on the installation, differing filter arrangements
can be applied. Filters can be installed in the central return
register, the bottom of the blower compartment (upflow only),
a side panel external filter rack kit (upflow only), or the
ductwork above a counterflow furnace. A media air filter or
electronic air cleaner can be used as an alternate filter.
The filter sizes given in the Product Design section of this
manual or the product Specification Sheet must be followed
to ensure proper unit performance. Refer to the following
information for removal and installation of filters.
FILTER REMOVAL PROCEDURE
Media Air Filter or Electronic Air Cleaner Removal
Follow the manufacturer’s directions for service.
Upright Counterflow Filter Removal
To remove filters from the ductwork above an upright counterflow installation:
1. Turn off electrical power to furnace.
2. Remove access door in ductwork above furnace.
3. Remove filters.
4. Remove blower compartment door. Vacuum compartment. Replace blower compartment door.
5. Replace filters opposite of removal.
6. Replace access door in ductwork.
NEVER
OPERATE FURNACE WIHTOUT A FILTER INSTALLED AS DUST
AND LINT WILL BUILD UP ON INTERNAL PARTS RESULTING IN LOSS OF
EFFICIENCY, EQUIPMENT DAMAMGE, AND POSSIBLE FIRE.
Filters must be used with this furnace. Filters do not ship
with these furnaces but must be provided by the installer for
proper furnace operation.
Remember that dirty filters are the most common cause of
inadequate heating or cooling performance.
64
Horizontal Unit Filter Removal
Filters in horizontal installations are located in the central
return register.
INDUCED DRAFT AND CIRCULATION BLOWERS
The bearings in the induced draft blower and circulator blower
motors are permanently lubricated by the manufacturer.
No further lubrication is required. Check motor windings for
accumulation of dust which may cause overheating. Clean
as necessary.
MAINTENANCE
FLUE PASSAGES (QUALIFIED SERVICER ONLY)
At the start of each heating season, inspect and, if necessary, clean the furnace flue passages.
3. Volt-Ohm Meter - testing continuity, capacitors, and
motor windings.
FLAME SENSOR (QUALIFIED SERVICER ONLY)
Under some conditions, the fuel or air supply can create a
nearly invisible coating on the flame sensor. This coating
acts as an insulator, causing a drop in the flame sensing
signal. If this occurs, a qualified servicer must carefully clean
the flame sensor with steel wool. After cleaning, the flame
sensor output should be as listed on the specification sheet.
5. Water Manometer (12") - to test gas inlet and manifold pressure.
BURNERS
HEATING PERFORMANCE TEST
Before attempting to diagnose an operating fault, run a heating performance test and apply the results to the Service
Problem Analysis Guide.
To conduct a heating performance test, the BTU input to
the furnace must be calculated.
After the heating cycle has been in operation for at least
fifteen minutes and with all other gas appliances turned off,
the gas meter should be clocked.
To find the BTU input, multiply the number of cubic feet of
gas consumed per hour by the heating value of the gas
being used. (The calorific value of the gas being used is
found by contacting your local utility.)
EXAMPLE: It is found by the gas meter, that it takes forty
(40) seconds for the hand on the cubic foot dial to make
one complete revolution, with all appliances off, except the
furnace. Take this information and locate it on the gas rate
chart. Observe the forty (40) seconds, locate and read across
to the one (1) cubic foot dial column. There we find the
number 90, which shows that ninety (90) cubic feet of gas
will be consumed in one (1) hour.
Let's assume the local gas utility has stated that the calorific value of the gas is 1,025 BTU per cubic foot.
Multiplying the ninety (90) cubic feet by 1,025 BTU per cubic foot gives us an input of 92,250 BTUH.
Checking the BTU input on the rating plate of the furnace
being tested.
EXAMPLE:
INPUT: 92,000 BTU/HR
OUTPUT CAP: 84,000
Should the figure you calculated not fall within five (5) percent of the nameplate rating of the unit, adjust the gas valve
pressure regulator or resize orifices.
WARNING
HIGH VOLTAGE
ELECTRICAL COMPONENTS ARE CONTAINED IN BOTH
COMPARTMENTS. TO AVOID ELECTRICAL SHOCK, INJURY OR
DEATH, DO NOT REMOVE ANY INTERNAL COMPARTMENT COVERS
OR ATTEMPT ANY ADJUSTMENT.
CONTACT
A QUALIFIED
SERVICE AGENT AT ONCE IF AN ABNORMAL FLAME
APPEARANCE SHOULD DEVELOP.
Periodically during the heating season make a visual check
of the burner flames. Turn the furnace on at the thermostat.
Wait a few minutes since any dislodged dust will alter the
normal flame appearance. Flames should be stable, quiet,
soft and blue with slightly orange tips. They should not be
yellow. They should extend directly outward from the burner
ports without curling downward, floating or lifting off the ports.
Check the burner flames for:
1. Stable, soft and blue
2. Not curling, floating, or lifting off.
Burner Flame
TEST EQUIPMENT
Proper test equipment for accurate diagnosis is as essential as regular hand tools.
The following is a must for every service technician and service shop.
1. Dial type thermometers or thermocouple meter (optional) - to measure dry bulb temperature.
4. Inclined Manometer - to measure static pressure,
pressure drop across coils, filters, and draft.
Other recording type instruments can be essential in solving abnormal problems, however, in many instances they
may be rented from local sources.
Proper equipment promotes faster, more efficient service
and accurate repairs resulting in fewer call backs.
2. Amprobe - to measure amperage and voltage.
65
MAINTENANCE
CAUTION
ALWAYS CONNECT A MONOMETER TO THE OUTLET TAP AT THE GAS
VALVE BEFORE ADJUSTING THE PRESSURE REGULATOR. IN NO CASE
SHOULD THE FINAL MANIFOLD PRESSURE VARY MORE THAN PLUS OR
MINUS .3 INCHES WATER COLUMN FROM 3.5 INCHES WATER COLUMN
FOR NATURAL GAS OR 10 INCHES WATER COLUMN FOR PROPANE GAS.
To adjust the pressure regulator on the gas valve, turn down
(clockwise) to increase pressure and input, and out (counterclockwise) to decrease pressure and input.
Since normally propane gas is not installed with a gas meter,
clocking will be virtually impossible. The gas orifices used
with propane are calculated for 2500 BTU per cubic foot gas
and with proper inlet pressures and correct piping size, full
capacity will be obtained.
With propane gas, no unit gas valve regulator is used; however, the second stage supply line pressure regulator should
be adjusted to give 11" water column with all other gas consuming appliances running.
The dissipation of the heat transferred to the heat exchanger
is now controlled by the amount of air circulated over its
surface.
66
The amount (CFM) of air circulated is governed by the external static pressure in inches of water column of duct work,
cooling coil, registers, etc., applied externally to the unit
versus the motor speed tap (direct drive) or pulley adjustments of the motor and blower (belt drive).
A properly operating unit must have the BTU per hour input
and CFM of air, within the limits shown to prevent short cycling of the equipment. As the external static pressure goes
up, the temperature rise will also increase. Consult the proper
tables for temperature rise limitation.
SERVICING
TABLE OF CONTENTS
S-1
CHECKING VOLTAGE ............................................................................................................................................. 69
S-2
CHECKING WIRING ............................................................................................................................................... 69
S-3A
THERMOSTAT AND WIRING ................................................................................................................................... 69
S-3B
HEATING ANTICIPATOR ......................................................................................................................................... 69
S-4
CHECKING TRANSFORMER AND Control CIRCUIT ............................................................................................ 70
S-16A
CHECKING AIR CIRCULATOR BLOWER MOTOR (ECM) ..................................................................................... 70
S-200
CHECKING DUCT STATIC ....................................................................................................................................... 73
S-201
CHECKING TEMPERATURE RISE ........................................................................................................................ 74
S-300
CHECKING PRIMARY LIMIT CONTROL ................................................................................................................ 74
S-301
CHECKING AUXILIARY LIMIT CONTROL .............................................................................................................. 75
S-302
CHECKING FLAME ROLLOUT CONTROL ............................................................................................................ 76
S-303
INDUCED DRAFT BLOWER Motor ........................................................................................................................ 77
S-304
CHECKING GAS VALVE (Redundant) .................................................................................................................... 77
S-305
CHECKING MAIN BURNERS ................................................................................................................................. 77
S-306
CHECKING ORIFICES ........................................................................................................................................... 77
S-307
CHECKING GAS PRESSURE ................................................................................................................................ 78
S-308
CHECKING HOT SURFACE IGNITOR ................................................................................................................... 80
S-309
CHECKING FOR FLASHBACK ............................................................................................................................... 81
S-310
CHECKING PRESSURE SWITCH ......................................................................................................................... 81
S-311
HIGH ALTITUDE APPLICATION (USA) .................................................................................................................... 81
S-312
CHECKING FOR DELAYED IGNITION ................................................................................................................... 82
S-313
CHECKING INTEGRATED IGNITION CONTROL BOARDS ................................................................................ 82
S-314
CHECKING FLAME SENSOR ............................................................................................................................... 83
67
SERVICING
1
1
CUBIC
FEET
One
GAS RATE -- CUBIC FEET PER HOUR
Seconds for
One
Revolution
1/4
cu/ft
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
90
82
75
69
64
60
56
53
50
47
45
43
41
39
37
36
34
33
32
31
30
-28
-26
--
68
Size of Test Dial
1/2
1
2
cu/ft
cu/ft
cu/ft
5
cu/ft
180
164
150
138
129
120
113
106
100
95
90
86
82
78
75
72
69
67
64
62
60
-56
-53
--
1800
1636
1500
1385
1286
1200
1125
1059
1000
947
900
857
818
783
750
720
692
667
643
621
600
581
563
545
529
514
360
327
300
277
257
240
225
212
200
189
180
171
164
157
150
144
138
133
129
124
120
116
113
109
106
103
720
655
600
555
514
480
450
424
400
379
360
343
327
313
300
288
277
265
257
248
240
232
225
218
212
206
Seconds for
One
Revolution
1/4
cu/ft
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
25
-23
-22
-21
--20
-19
--18
--17
--16
---15
Size of Test Dial
1/2
1
2
cu/ft
cu/ft
cu/ft
50
-47
-45
-43
-41
40
-38
--36
--34
--32
-31
-30
100
97
95
92
90
-86
-82
80
78
76
75
-72
-69
-67
-64
-62
-60
200
195
189
185
180
176
172
167
164
160
157
153
150
147
144
141
138
136
133
131
129
126
124
122
120
5
cu/ft
500
486
474
462
450
439
429
419
409
400
391
383
375
367
360
355
346
340
333
327
321
316
310
305
300
SERVICING
Power Failure
Blown Fuse
Loose Connection
Shorted or Broken Wires
No Low Voltage
Faulty Thermostat
Faulty Transformer
Poor or High Resistance Ground
•
•
•
•
•
•
•
•
Faulty Ignition Control
Gas Valve or Gas Supply Shut Off
Faulty Induced Draft Blower
Faulty Blower Motor (PSC & ECM)
Broken or Shorted Ignitor
Dirty Flame Sensor, Low UA
Stuck Gas Valve
Faulty Gas Valve
Open Auxiliary Limit
Improper Air Flow or Distribution
Cycling on Limit
Delayed Ignition
•
•
•
• • •
•
•
• •
•
•
•
•
• •
•
• •
Orifice Size
Cracked Heat Exchanger
•
Furnace Undersized
Furnace Oversized
Faulty Pressure Switch
Blocked or Restricted Flue
Open Roll Out Switch
Bouncing On Pressure Switch
• • •
• •
•
•
• •
• •
•
Test Voltage
S-1
Test Voltage
S-4
Check Wiring
S-2
Check Wiring
S-3A
Check Transformer
S-4
Check Thermostat
S-3A
Check Transformer
•
•
• • •
• • •
•
•
•
•
S-3B
Relocate Thermostat
S-316
Test Control
S-300 / S-302
Test Flame Sensor
S-314
Test Control
S-313
Turn Valves to On Position
S-317
Test Blower Motor (PSC & ECM)
•
•
S-4
S-17B
Adjust Heat Anticipator Setting
Test Induced Draft Motor
• •
• •
See Service Procedure Reference
Not Enough Heat
Too Much Heat
Long Cycles
• •
• •
Flashback
Gas Pressure
• •
Test Method
Remedy
Measure Ground Resistance
Improper Thermostat Location
Faulty Flame Sensor
Soot and /or Fumes
• •
Improper Heat Anticipator Setting
Faulty Limit or Roll Out Switch
Short Cycles
Unsatisfactory Heat
Burner Shuts Off prior to T'Stat being Satisfied
Burner Ignites-Locks Out
DOTS IN ANALYSIS
GUIDE INDICATE
"POSSIBLE CAUSE"
SYMPTOM
POSSIBLE CAUSE
Burner Won't Ignite
No Heat
System Will Not Start
Service Problem
S-303
S-16A,B,C
Test Ignitor
S-308
Clean Flame Sensor
S-314
Replace Gas Valve
S-304
Replace Gas Valve
S-304
Reset Control
S-301
Check Duct Static
Check Controls & Temperature Rise
Test for Delayed Ignition
S-200
S-201 / S-300
S-312
Test for Flashback
S-309 / S-311
Check Orifices
S-306 / S-311
Check Gas Pressure
S-307
Check Burner Flames
S-305
Replace with Proper Size Furnace
S-318
Replace with Proper Size Furnace
S-318
Test Pressure Switch
S-310
Check Flue/Drawdown Pressure
S-310
Test Flame Roll Out Control
S-302
Test Negative Pressure
S-310
69
SERVICING
S-1 CHECKING VOLTAGE
CHECKING THERMOSTAT, WIRING
AND ANTICIPATOR
WARNING
HIGH VOLTAGE
DISCONNECT ALL POWER BEFORE SERVICING OR
CHANGING ANY ELECTRICAL WIRING. MULTIPLE POWER
SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE
S-3A THERMOSTAT AND WIRING
WARNING
D ISCONNECT ALL
POWER BEFORE SERVICING.
PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
1. Remove the burner door to gain entry to the Junction
Box.
2. Remove cover from the Junction Box and gain access to
incoming power lines.
With Power ON:
WARNING
LINE VOLTAGE
1. Remove the blower compartment door to gain access
to the thermostat low voltage wires located at the furnace integrated control module terminals.
2. Remove the thermostat low voltage wires at the furnace
control panel terminal board.
3. Jumper terminals R to W (or W1 and W2 for two-stage
models) on the integrated ignition control.
With Power On (and Door Interlock Switch closed):
NOW PRESENT
3. Using a voltmeter, measure the voltage across the hot
and neutral connections.
NOTE: To energize the furnace, the Door Interlock Switch
must be engaged at this point.
4. No reading - indicates open wiring, open fuse, no
power, or faulty Door Interlock Switch from unit to
fused disconnect service. Repair as needed.
5. With ample voltage at line voltage connectors, energize the furnace blower motor by jumpering terminals
R to G on the integrated ignition control.
WARNING
LINE VOLTAGE NOW
PRESENT
4. Induced Draft Motor must run and pull in pressure
switch.
5. If the hot surface ignitor heats and at the end of the
ignitor warm-up period the gas valve opens and the
burners ignite, the trouble is in the thermostat or wiring.
6. With power off, check the continuity of the thermostat and wiring. Repair or replace as necessary.
6. With the blower motor in operation, the voltage should
be 115 volts ± 10 percent.
If checking the furnace in the air conditioning mode, proceed as follows.
7. If the reading falls below the minimum voltage, check
the line wire size. Long runs of undersized wire can
cause low voltage. If wire size is adequate, notify the
local power company of the condition.
7. With power off, Jumper terminals R to Y (or Y1 or Y2
for two-stage models) to G.
8. After completing check and/or repair, replace Junction
Box cover and reinstall the service panel doors.
9. If the furnace blower motor starts and the condensing
unit runs, then the trouble is in the thermostat or wiring. Repair or replace as necessary.
9. Turn on electrical power and verify proper unit operation.
S-2 CHECKING WIRING
WARNING
D ISCONNECT ALL
POWER BEFORE SERVICING.
1. Check wiring visually for signs of overheating, damaged
insulation and loose connections.
2. Use an ohmmeter to check continuity of any suspected
open wires.
3. If any wires must be replaced, replace with AWM, 105°C.
2/64 thick insulation of the same gauge or its equivalent.
70
8. Turn on the power.
10. After completing check and/or repair of wiring and
check and/or replacement of thermostat, reinstall
blower compartment door.
11. Turn on electrical power and verify proper unit operation.
S-3B HEATING ANTICIPATOR
On older thermostats the heating anticipator is a wire wound
adjustable heater which is energized during the "ON" cycle
to help prevent overheating of the conditioned space. Most
modern thermostats have a cycle rate adjustment switch.
The anticipator is a part of the thermostat and if it should
fail for any reason, the thermostat must be replaced.
The heating anticipator setting for furnaces covered in this
manual is 0.70 Amps.
SERVICING
If the anticipator current draw is unknown, then a current
amp draw should be measured to determine the anticipator
setting. Use an amprobe as shown in the following drawing.
10 TURNS OF
THERMOSTAT WIRE
(From "W" on thermostat)
STATIONARY JAW
OF AMPROBE
3. Use a voltmeter, check voltage across terminals R
and C. Must read 24 VAC.
4. No voltage indicates faulty transformer, open fuse,
bad wiring, bad splice, or open door interlock switch.
5. Check transformer primary voltage at incoming line
voltage connections, fuse, splices, and blower door
interlock switch.
6. If line voltage is available to the primary side of transformer and not at secondary side, the transformer is
inoperative. Replace.
7. After completing check and/or replacement of transformer and check and/or repair of control circuit, reinstall blower compartment door.
READS 4 AMPS
CURRENT DRAW
WOULD BE .4 AMPS
Checking Heating Anticipator Current (Amp) Draw
Cooling Anticipator
The cooling anticipator is a small heater (resistor) in the
thermostat. During the "OFF" cycle it heats the bimetal element helping the thermostat call for the next cooling cycle.
This prevents the room temperature from rising too high before the system is restarted. A properly sized anticipator
should maintain room temperature within 1 1/2 to 2 degrees.
The anticipator is fixed in the subbase and is not to be replaced. If the anticipator should fail for any reason, the subbase must be changed.
S-4 CHECKING TRANSFORMER AND Control
CIRCUIT
A step-down transformer 120 volt primary to 24 volt secondary, 40 VA (Heating and Cooling Models) supplies ample
capacity of power for either operation.
WARNING
HIGH VOLTAGE
DISCONNECT ALL POWER BEFORE SERVICING OR
CHANGING ANY ELECTRICAL WIRING. MULTIPLE POWER
SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE
PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
1. Remove blower compartment door to gain access to the
thermostat low voltage wires located at the furnace integrated control module.
2. Remove the thermostat low voltage wires at the furnace
integrated control module terminals.
With Power On (and Door Interlock Switch closed):
8. Turn on electrical power and verify proper unit operation.
S-16A CHECKING AIR CIRCULATOR BLOWER
MOTOR (ECM)
Description
These models utilize an Emerson, 4-wire variable speed
ECM blower motor. The ECM blower motor provides constant CFM.
The motor is a serially communicating variable speed motor. Only four wires are required to control the motor: +Vdc,
Common, Receive, and Transmit.
The +Vdc and Common wires provide power to the motor's
low voltage control circuits. Typical supply voltage is 9-15
volts DC.
ECM Control Connections
ECM control connections are made through the integrated
ignition control. No other control connections are needed.
NOTE: An inductor (Factor Power Choke Correction) is required when powering the 3/4 and 1 horsepower motors
with 115 volts (inductor pictured below). The operation of
this inductor is to reduce the line current by storing the
electrical energy in a magnetic field, such that the voltage
AC waveform leads the current AC waveform. In other words,
the inductor reduces line current which extends the life of
the 3/4 and 1 horsepower motors.
IMPORTANT: If the inductor fails, there will be no motor
operation since this is the "LINE" power supply, black wire,
from the integrated ignition control to the motor. To determine if the inductor is at fault, you can bypass by the inductor by disconnecting the black wire from the inductor
and connecting it directly to the motor. If the motor operates then the inductor will need to be replaced.
WARNING
LINE VOLTAGE NOW PRESENT
71
SERVICING
Checking ECM Motors
ECM motors connect directly to the AC Line Voltage. DO
NOT insert contactors in series with the ECM Motor AC
Line. The control is powered continuously to insure reliable
start-up. The connector plug is polarized, verify and reverify
correct connector orientation before applying power. DO
NOT force plug into motor and make sure power is off before inserting power connector. DO NOT apply voltage to
terminals 1 or 2.
General Checks/Considerations
1. Check power supply to the furnace. Ensure power supply is within the range specified on rating plate. See
section S-1.
2. Check motor power harness. Ensure wires are continuous and make good contact when seated in the connectors. Repair or replace as needed.
3. Check motor control harness. Ensure wires are continuous and make good contact when seated in the connectors. Repair or replace as needed.
4. Check thermostat and thermostat wiring. Ensure thermostat is providing proper cooling/heating/continuous fan
demands. Repair or replace as needed.
5. Check blower wheel. Confirm wheel is properly seated
on motor shaft. Set screw must be on shaft flat and
torqued to 165 in-lbs minimum. Confirm wheel has no
broken or loose blades. Repair or replace as needed.
6. Ensure motor and wheel turn freely. Check for interference between wheel and housing or wheel and motor.
Repair or replace as needed.
7. Check housing for cracks and/or corrosion. Repair or
replace as needed.
8. Check motor mounting bracket. Ensure mounting bracket
is tightly secured to the housing. Ensure bracket is not
cracked or broken.
Emerson UltraCheck-EZTM Diagnostic Tool
The Emerson UltraCheck-EZTM diagnostic tool may be used
to diagnose the ECM motor.
HIGH VOLTAGE!
Disconnect ALL power before servicing
or installing. Multiple power sources
may be present. Failure to do so may
cause property damage, personal injury
or death.
To use the diagnostic tool, perform the following steps:
1. Disconnect power to the furnace.
2. Disconnect the 4-circuit control harness from the motor.
3. Plug the 4-circuit connector from the diagnostic tool into
the motor control connector.
72
4. Connect one alligator clip from the diagnostic tool to a
ground source.
5. Connect the other alligator clip to a 24VAC source.
NOTE: The alligator clips are NOT polarized.
NOTE: The UltraCheck-EZTM diagnostic tool is equipped with
a nonreplaceable fuse. Connecting the tool to a source
other than 24VAC could damage the tool and cause the
fuse to open. Doing so will render the diagnostic tool
inoperable.
6. Turn on power to the furnace.
WARNING
Line Voltage now present.
7. Depress the orange power button on the diagnostic tool
to send a run signal to the motor. Allow up to 5 seconds
for the motor to start.
NOTE: If the orange power button does not illuminate when
depressed, the tool either has an open fuse or is not properly connected to a 24VAC source.
8. The green LED on the diagnostic tool will blink indicating
communications between the tool and motor. See table
below for indications of tool indicators and motor actions.
Replace or repair as needed.
Pow e r
Bu tto n
G re e n
L ED
M oto r
Actio n
OFF
OFF
Not
Rotating
ON
B link ing
Rotating
ON
OFF
Rotating
ON
B link ing
Not
Rotating
ON
OFF
Not
Rotating
Ind ica tio n (s)
Confirm 24V A C to
UltraChec k -E ZTM tool.
If 24V A C is c onfirm ed,
diagnos tic tool is
inoperable.
M otor and c ontrol/end
bell are func tioning
properly .
Replac e m otor
c ontrol/end bell.
Chec k m otor (s ee
Motor Chec k s below).
Replac e m otor
c ontrol/end bell; verify
m otor (s ee Motor
Chec k s below).
9. Depress the orange power button to turn off motor.
10. Disconnect power. Disconnect diagnostic tool.
11. Reconnect the 4-wire harness from control board to
motor.
SERVICING
Electrical Checks - High Voltage Power Circuits
HIGH VOLTAGE!
Disconnect ALL power before servicing
or installing. Multiple power sources
may be present. Failure to do so may
cause property damage, personal injury
or death.
1. Disconnect power to the furnace.
2. Disconnect the 5-circuit power connector to the ECM
motor.
3. Turn on power to the furnace.
WARNING
7. If no voltage is present, check supply voltage to the
furnace. See section S-1.
8. Disconnect power to the furnace. Reconnect the 5circuit power harness disconnected in step 2.
Electrical Checks - Low Voltage Control Circuits
1. Turn on power to the furnace.
WARNING
Line Voltage now present.
2. Check voltage between pins 1 and 4 on the 4-wire motor
control harness between the motor and control board.
Voltage should be between 9 and 15 VDC.
3. If no voltage is present, check control board. See section S-313.
Line Voltage now present.
Motor Control/End Bell Checks
4. Measure voltage between pins 4 and 5 on the 5-circuit
connector. Measured voltage should be the same as the
supply voltage to the furnace.
5
AC Line Hot Connection
4
AC Line Neutral Connection
3
Gnd
2
}
1
Lines 1 and 2 will be connected
for 120VAC Power Connector
applications only
POWER CONNECTOR
(1/2 HP MOTORS)
"Motor Half“
(Viewed from Plug End)
inductor
AC Line Hot Connection
5
4
AC Line Neutral Connection
3
Gnd
2
}
1
Lines 1 and 2 will be connected
for 120VAC Power Connector
applications only
HIGH VOLTAGE!
Disconnect ALL power before servicing
or installing. Multiple power sources
may be present. Failure to do so may
cause property damage, personal injury
or death.
1. Disconnect power to the furnace.
NOTE: Motor contains capacitors that can hold a charge
for several minutes after disconnecting power. Wait 5
minutes after removing power to allow capacitors to discharge.
2. Disconnect the motor control harness and motor power
harness.
3. Remove the blower assembly from the furnace.
4. Remove the (3) screws securing the control/end bell to
the motor. Separate the control/end bell. Disconnect
the 3-circuit harness from the control/end bell to remove
the control/end bell from the motor.
5. Inspect the NTC thermistor inside the control/end bell
(see figure below). Replace control/end bell if thermistor
is cracked or broken.
POWER CONNECTOR
(3/4 & 1 HP MOTORS)
"Motor Half“
(Viewed from Plug End)
5. Measure voltage between pins 4 and 3. Voltage should
be approximately zero.
6. Measure voltage between pins 5 and 3. Voltage should
be the same as the supply voltage to the furnace.
73
SERVICING
6. Inspect the large capacitors inside the control/end bell
(see figure below). Replace the control/end bell if any of
the capacitors are bulging or swollen.
7. Locate the 3-circuit connector in the control/end bell.
Using an ohmmeter, check the resistance between each
terminal in the connector. If the resistance is 100kΩ or
greater, the control/end bell is functioning properly. Replace the control/end bell if the resistance is lower than
100kΩ.
8. Reassemble motor and control/end bell in reverse of disassembly. Replace blower assembly into the furnace.
Motor Checks
HIGH VOLTAGE!
Disconnect ALL power before servicing
or installing. Multiple power sources
may be present. Failure to do so may
cause property damage, personal injury
or death.
74
1. Disconnect power to the furnace.
NOTE: Motor contains capacitors that can hold a charge
for several minutes after disconnecting power. Wait 5 minutes after removing power to allow capacitors to discharge.
2. Disassemble motor as described in steps 2 through 4
above.
3. Locate the 3-circuit harness from the motor. Using an
ohmmeter, measure the resistance between each motor
phase winding. The resistance levels should be equal.
Replace the motor if the resistance levels are unequal,
open circuited or short circuited.
4. Measure the resistance between each motor phase winding and the motor shell. Replace the motor if any phase
winding is short circuited to the motor shell.
5. Reassemble motor and control/end bell in reverse of disassembly. Replace blower assembly into the furnace.
S-200
CHECKING DUCT STATIC
The maximum and minimum allowable external static pressures are found in the specification section. These tables
also show the amount of air being delivered at a given static
by a given motor speed or pulley adjustment.
The furnace motor cannot deliver proper air quantities (CFM)
against statics other than those listed.
Too great of an external static pressure will result in insufficient air that can cause excessive temperature rise, resulting in limit tripping, etc. Whereas not enough static may
result in motor overloading.
To determine proper air movement, proceed as follows:
1. With clean filters in the furnace, use a draft gauge (inclined manometer) to measure the static pressure of
the return duct at the inlet of the furnace. (Negative Pressure)
2. Measure the static pressure of the supply duct. (Positive Pressure)
3. Add the two (2) readings together for total external static
pressure.
NOTE: Both readings may be taken simultaneously and
read directly on the manometer if so desired. If an air conditioner coil or Electronic Air Cleaner is used in conjunction
with the furnace, the readings must also include theses components, as shown in the following drawing.
4. Consult proper tables for the quantity of air.
If the total external static pressure exceeds the minimum or
maximum allowable statics, check for closed dampers, registers, undersized and/or oversized poorly laid out duct work.
SERVICING
SUPPLY
AIR
CUTAWAY OF DUCTWORK
TO EXPOSE COIL
SUPPLY
AIR
INCLINED
MANOMETER
Amana
Elec tronic Ai r Cleaner
Ca ution
High Voltage
To a void per sonal in u
j ry, wait 15
secon ds afte r de -ene rgizing u nit
b efore touch n
i g unit n
i terior .
RETURN
AIR
RETURN
AIR
Checking Temperature Rise
Checking Static Pressure
(80% Furnace Shown, 90% Similar)
S-201
CHECKING TEMPERATURE RISE
The more air (CFM) being delivered through a given furnace,
the less the rise will be; so the less air (CFM) being delivered, the greater the rise. The temperature rise should be
adjusted in accordance to a given furnace specifications
and its external static pressure. An incorrect temperature
rise may result in condensing in or overheating of the heat
exchanger. An airflow and temperature rise table is provided in the blower performance specification section. Determine and adjust temperature rise as follows:
1. Operate furnace with burners firing for approximately
ten minutes. Check BTU input to furnace - do not exceed input rating stamped on rating plate. Ensure all
registers are open and all duct dampers are in their final
(fully or partially open) position.
2. Place thermometers in the return and supply ducts as
close to the furnace as possible. Thermometers must
not be influenced by radiant heat by being able to “see”
the heat exchanger.
3. Subtract the return air temperature from the supply air
temperature to determine the air temperature rise. Allow adequate time for thermometer readings to stabilize.
4. Adjust temperature rise by adjusting the circulator blower
speed. Increase blower speed to reduce temperature
rise. Decrease blower speed to increase temperature
rise. Refer to Circulator Blower Speed section in the
Product Design section of this manual for speed changing details. Temperature rise is related to the BTUH
output of the furnace and the amount of air (CFM) circulated over the heat exchanger. Measure motor current draw to determine that the motor is not overloaded
during adjustments.
S-300 CHECKING PRIMARY LIMIT CONTROL
All use a nonadjustable, automatic reset, bi-metal type
limit control. Refer to the following drawing for the location
of the primary limit.
Location of Primary Limit
Primary Limit Control Location
(80% Upflow Furnace Shown, Counterflow Similar)
75
SERVICING
Style 1 drawing illustrates the Primary Limit used on the
80% furnaces.
S-301 CHECKING AUXILIARY LIMIT CONTROL
Auxiliary Limit Control Location
Style 1
WARNING
The 80% two-stage furnaces use an auxiliary limit (automatic reset) control connected in series with the primary
limit control and rollout limit controls connected to the integrated ignition control. If its temperature should be exceeded, it will open, interrupting the voltage to the gas valve
causing it to close. The auxiliary limit is located on the front
side of the blower housing, near the center, as shown in the
following illustration.
HIGH VOLTAGE
DISCONNECT ALL POWER BEFORE SERVICING OR
CHANGING ANY ELECTRICAL WIRING. MULTIPLE POWER
SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE
PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
1. Remove burner compartment door to gain access to
the primary limit.
2. Remove low voltage wires at limit control terminals.
BLOWER HOUSING
3. With an ohmmeter, test between these two terminals
as shown in the following drawing. The ohmmeter
should read continuous unless heat exchanger temperature is above limit control setting. If not as above,
replace the control.
AUXILIARY LIMIT CONTROL
Auxiliary Limit Control Location
(80% Single-Stage Furnaces)
VOLT / OHM
METER
WARNING
HIGH VOLTAGE
DISCONNECT ALL POWER BEFORE SERVICING OR
INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY
BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY
DAMAGE, PERSONAL INJURY OR DEATH.
Testing Primary Limit Control
(80% Furnaces)
4. After completing check and/or replacement of primary
limit control, reinstall burner compartment door.
5. Turn on electrical power and verify proper unit operation.
To aid in identifying these controls, refer to the Primary Limit
Charts in furnace Technical Manual for part number, temperature setting and color(s) code.
76
SERVICING
On two-stage models the ignition control the diagnostic light
will flash (4) four times indicating a trip of the rollout switch.
These symptoms are identical to a trip of the primary limit
control.
To aid in identifying these controls, color coded labels have
been affixed to the back of these controls. Refer to the
Rollout Limit Charts in furnace Technical Manual for temperature settings and color codes.
The circuit between the ignition control and gas valve will be
interrupted when the rollout switch opens up.
VOLT / OHM
METER
RED
RESET
BUTTON
WARNING
LINE VOLTAGE
COLOR
IDENTIFYING
TAB
Testing Auxiliary Limit Control
(80% & 90% Furnaces)
WARNING
TO AVOID POSSIBLE FIRE, ONLY RESET THE AUXILIARY LIMIT CONTROL
ONCE. I F IT SHOULD OPEN A SECOND TIME, A QUALIFIED SERVICER
NOW PRESENT
1. Remove the burner compartment door to gain access to the
rollout switch(es) mounted to burner bracket.
The servicer should reset the ignition control by opening and
closing the thermostat circuit. Then look for the ignitor glowing
which indicates there is power to the ignition control. Measure
the voltage between each side of the rollout control and ground
while the ignition control tries to power the gas valve.
2. Measure the voltage between each side of the rollout
control and ground during the ignition attempt. Refer to
the following figure.
MUST DETERMINE WHY THE AUXILIARY LIMIT OPENED BEFORE
RESETTING AGAIN.
S-302 CHECKING FLAME ROLLOUT CONTROL
A temperature activated manual reset control is mounted to
the manifold assembly on 80% furnaces, as shown in the
following illustrations.
VOLT / OHM
METER
N
G
ROLLOUT
SWITCH
Flame Rollout Switch Location
(80% Upflow Furnace Shown, Downflow Similar)
The control is designed to open should a flame roll out occur. An over firing condition or flame impingement on the
heat shield may also cause the control to open. If the rollout
control opens, the air circulation blower will run continuously.
D
RED
RESET
BUTTON
COLOR
IDENTIFYING
TAB
Checking Flame Rollout Switch
a. If no voltage is measured on either side of control it
indicates ignition control or wiring to control problem.
b. If voltage is measured on one side of the control and
not the other it indicates the control is open.
c. If voltage is measured on both sides of the control
the wiring to gas valve or valve is at fault.
3. After check and/or replacement of rollout switch, reinstall burner compartment door and verify proper unit operation.
77
SERVICING
S-303 INDUCED DRAFT BLOWER Motor
WARNING
HIGH VOLTAGE
DISCONNECT ALL POWER BEFORE SERVICING OR
INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY
BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY
.023" - .027"
DAMAGE, PERSONAL INJURY OR DEATH.
1. Remove burner compartment door to gain access to
the induced draft blower motor.
2. Disconnect the motor wire leads from its connection
point at the induced draft motor.
3. Using a ohmmeter, test for continuity between each
of the motor leads.
4. Touch one probe of the ohmmeter to the motor frame
(ground) and the other probe in turn to each lead.
If the windings do not test continuous or a reading is
obtained to ground, replace the motor.
5. If the windings have a continuity reading, reconnect
wires. Turn power on to the furnace and turn the
thermostat on in the heating mode. Check voltage
for 115V at the induced draft motor terminals during
the trial for ignition. If you have 115V and the motor
does not run, replace the induced draft motor.
6. After completing check and/or replacement of induced draft motor, reinstall burner compartment door.
7. Turn on electrical power and verify proper unit operation.
S-304 CHECKING GAS VALVE (Redundant)
A combination redundant operator type gas valve which provides all manual and automatic control functions required
for gas fired heating equipment is used.
The valve provides control of main burner gas flow, pressure regulation, and 100 percent safety shut-off. Gas valves
must be checked by confirming that 24 vac is present between C and Low (main) while proper gas pressure is supplied to the valve.
Beckett Burner
WARNING
DISCONNECT ALL GAS AND ELECTRICAL POWER SUPPLY.
In checking main burners, look for signs of rust, oversized
and undersized carry over ports restricted with foreign material, etc, refer to previous drawing. Burner slots must not
be altered in size.
S-306
CHECKING ORIFICES
A predetermined fixed gas orifice is used in all of these furnaces. That is an orifice which has a fixed bore and position
as shown in the following drawing.
No resizing should be attempted until all factors are taken
into consideration such as inlet and manifold gas pressure,
alignment, and positioning, specific gravity and BTU content of the gas being consumed.
The only time resizing is required is when a reduction in
firing rate is required for an increase in altitude.
Orifices should be treated with care in order to prevent damage. They should be removed and installed with a box-end
wrench in order to prevent distortion. In no instance should
an orifice be peened over and redrilled. This will change the
angle or deflection of the vacuum effect or entraining of primary air, which will make it difficult to adjust the flame properly. This same problem can occur if an orifice spud of a
different length is substituted.
WARNING
WARNING
DISCONNECT ALL POWER BEFORE SERVICING
S-305
CHECKING MAIN BURNERS
The main burners are used to provide complete combustion of various fuels in a limited space, and transfer this
heat of the burning process to the heat exchanger.
Proper ignition, combustion, and extinction are primarily
due to burner design, orifice sizing, gas pressure, primary
and secondary air, vent and proper seating of burners.
78
DISCONNECT ALL GAS AND ELECTRICAL POWER SUPPLY.
1. Check orifice visually for distortion and/or burrs.
2. Check orifice size with orifice sizing drills.
3. If resizing is required, a new orifice of the same physical
size and angle with proper drill size opening should be
SERVICING
NOTE: At either location, a hose fitting must be installed
prior to making the hose connection.
NOTE: Use adapter kit #0151K00000S to measure gas pressure on White-Rodgers 36G22 and 36G54 gas valves.
A
installed.
GAS
STREAM B
GAS LINE
GAS SHUTOFF VALVE
The length of Dimension "A" determines the angle of Gas
Stream "B".
GAS LINE
TO FURNACE
DENT OR
BURR
GAS
STREAM B
OPEN TO
ATMOSPHERE
DRIP LEG CAP
WITH FITTING
A dent or burr will cause a severe deflection of the gas
stream.
MANOMETER HOSE
S-307 CHECKING GAS PRESSURE
Gas Supply Pressure Measurement
CAUTION
TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE
INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT
RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES
OPERATING.
Gas inlet and manifold pressures should be checked and
adjusted in accordance to the type of fuel being consumed.
The line pressure supplied to the gas valve must be within
the range specified below. The supply pressure can be measured at the gas valve inlet pressure tap or at a hose fitting
installed in the gas piping drip leg. The supply pressure
must be measured with the burners operating. To measure
the gas supply pressure, use the following procedure.
WARNING
DISCONNECT
ELECTRICAL POWER AND SHUT OFF GAS SUPPLY.
1. After turning off gas to furnace at the manual gas shutoff
valve external to the furnace, remove burner compartment door to gain access to the gas valve.
2. Connect a calibrated water manometer (or appropriate
gas pressure gauge) at either the gas valve inlet pressure tap or the gas piping drip leg as shown in the following figures. Refer to Measuring Gas Pressure: Single
Stage Valves figure for single stage valve inlet pressure
tap connections. Refer to Measuring Gas Pressure:
Two-Stage Valves figure for two-stage gas valve inlet
pressure tap connections.
MANOMETER
Measuring Inlet Gas Pressure
(Alternate Method)
3. Turn ON the gas and electrical power supply and operate the furnace and all other gas consuming appliances
on the same gas supply line.
4. Measure furnace gas supply pressure with burners firing. Supply pressure must be within the range specified
in the following table.
INLET GAS SUPPLY PRESSURE
Natural Gas
Minimum: 4.5" w.c. Maximum: 10.0" w.c.
Propane Gas
Minimum: 11.0" w.c.
Maximum: 13.0" w.c.
If supply pressure differs from above, make necessary adjustments to pressure regulator, gas piping size, etc., and/
or consult with local gas utility.
WARNING
HIGH VOLTAGE
DISCONNECT ALL ELECTRICAL POWER AND SHUT OFF GAS
SUPPLY BEFORE SERVICING OR INSTALLING THIS UNIT.
MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO
DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
5. Disconnect manometer after turning off gas at manual
shutoff valve. Reinstall plug before turning on gas to furnace.
6. Turn OFF any unnecessary gas appliances started in
step 3.
7. Turn on gas to furnace and check for leaks. If leaks are
found, repair and then reinstall burner compartment door.
79
SERVICING
8. Turn on electrical power and verify proper unit operation.
WARNING
HIGH VOLTAGE
DISCONNECT ALL ELECTRICAL POWER AND SHUT OFF GAS
SUPPLY BEFORE SERVICING OR INSTALLING THIS UNIT.
MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO
DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
Gas Manifold Pressure Measurement and Adjustment
Natural Gas Adjustments
WARNING
HIGH VOLTAGE
D ISCONNECT ALL ELECTRICAL
POWER AND SHUT OFF GAS SUPPLY
BEFORE SERVICING OR INSTALLING.
NOTE: Use adapter kit #0151K00000S to measure gas
pressure on White-Rodgers 36G54 gas valves.
Only small variations in gas pressure should be made by
adjusting the gas valve pressure regulator. The manifold
pressure must be measured with the burners operating. To
measure and adjust the manifold pressure, use the following procedure.
1. After turning off gas to furnace at the manual gas shutoff valve external to the furnace, remove burner compartment door to gain access to the gas valve.
2. Connect a calibrated water manometer (or appropriate
gas pressure gauge) at the gas valve outlet pressure
tap. Refer to Measuring Gas Pressure: Two-Stage
Valves figure for two-stage gas valve outlet pressure
tap connections.
d. Turn on power and close thermostat “R” and “W1”
contacts to provide a call for low stage heat.
e. Measure the gas manifold pressure with burners firing. Adjust manifold pressure using the Manifold Gas
Pressure table shown below.
f. Remove regulator cover screw from the low (LO) outlet pressure regulator adjust tower and turn screw
clockwise to increase pressure or counterclockwise
to decrease pressure. Replace regulator cover screw.
g. Close thermostat “R” and “W2” contacts to provide a
call for high stage heat.
h. Remove regulator cover screw from the high (HI) outlet pressure regulator adjust tower and turn screw
clockwise to increase pressure or counterclockwise
to decrease pressure. Replace regulator cover screw.
i. Turn off all electrical power and gas supply to the
system.
j. Remove the manometer hose from the hose barb fitting or outlet pressure boss.
k. Turn outlet pressure test screw in to seal pressure
port (clockwise, 7 in-lb minimum).
5. Honeywell VR8215 Valve:
a. Remove the outlet pressure boss plug. Install an 1/
8" NPT hose barb fitting into the outlet pressure tap.
b. Attach a hose and manometer to the outlet pressure
barb fitting.
c. Turn ON the gas supply.
d. Turn on power and close thermostat “R” and “W1”
contacts to provide a call for low stage heat.
e. Measure the gas manifold pressure with burners firing. Adjust manifold pressure using the Manifold Gas
Pressure table shown below.
Manometer
Hose
High Fire Regulator
Adjust
Regulator
Vent
WARNING
LINE VOLTAGE NOW PRESENT
3. Turn ON the gas and electrical power supply and operate the furnace.
4. White-Rodgers 36G54 Valves:
a. Back outlet pressure test screw (inlet/outlet pressure boss) out one turn (counterclockwise, not more
than one turn).
b. Attach a hose and manometer to the outlet pressure
outlet pressure boss.
c. Turn ON the gas supply.
80
Manometer
Measuring Manifold Gas Pressure
(36G54 Valve)
SERVICING
Regulator
Vent
High Fire
Regulator
Adjust
WARNING
HIGH VOLTAGE
DISCONNECT ALL ELECTRICAL
POWER AND SHUT OFF GAS SUPPLY
BEFORE SERVICING OR INSTALLING.
Gas Valve On/Off
Selector Switch
Low Fire
Regulator
Adjust
Honeywell Model VR9205 (Two-Stage)
Measuring Gas Pressure: Two-Stage Valves
Cont'd
Open to
Atmosphere
Manometer
Hose
7. Turn on gas to furnace and check for leaks. If leaks are
found, repair and then reinstall burner compartment door.
8. Turn on electrical power and verify proper unit operation.
Make sure furnace operates at the proper manifold pressure at both high and low stage outputs.
Gas
i
Nominal
Natural Gas High Stage 3.2 to 3.8" w.c. 3.5" w.c.
Low Stage 1.6 to 2.2" w.c. 1.9" w.c.
Common
Terminal(C)
High Fire Coil
Terminal (HI)
Low Fire Coil
Terminal (LO)
Manifold Gas Pressure
Rate
Range
WARNING
HIGH VOLTAGE
DISCONNECT ALL ELECTRICAL POWER AND SHUT OFF GAS
SUPPLY BEFORE SERVICING OR INSTALLING THIS UNIT.
MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO
Inlet Pressure Tap
1/8 NPT
DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
WARNING
Manometer
HIGH VOLTAGE
DISCONNECT ALL ELECTRICAL POWER AND SHUT OFF GAS SUPPLY
BEFORE SERVICING OR INSTALLING.
Outlet Pressure Tap
1/8 NPT
Honeywell Model VR9205 Connected to Manometer
f. Remove regulator cover screw from the low (LO) outlet pressure regulator adjust tower and turn screw
clockwise to increase pressure or counterclockwise
to decrease pressure. Replace regulator cover screw.
g. Close thermostat R + W1 + W2 contacts to provide a
call for high stage heat.
h. Remove regulator cover screw from the high (HI) outlet pressure regulator adjust tower and turn screw
clockwise to increase pressure or counterclockwise
to decrease pressure. Replace regulator cover screw.
i. Turn off all electrical power and gas supply to the system.
j. Remove the manometer hose from the hose barb fitting or outlet pressure boss.
k. Remove the 1/8" NPT hose barb fitting from the outlet
pressure tap. Replace the outlet pressure boss plug
and seal with a high quality thread sealer.
Manifold Gas Pressure
Rate
Range
Nominal
High Stage 9.7 to 10.3" w.c. 10.0" w.c.
Propane Gas
Low Stage 5.7 to 6.3" w.c. 6.0" w.c.
Gas
S-308 CHECKING HOT SURFACE IGNITOR
120V Silicon Nitride Igniter - furnaces use a 120V silicon
nitride igniter for ignition. The normal operating temperature
is approximately 2156°F - 2678°F.
WARNING
D ISCONNECT ALL
POWER BEFORE SERVICING.
1. Remove burner compartment door to gain access to the
ignitor.
81
SERVICING
2. Ignitor cool - approximately 70 - 77°F.
3. Disconnect the ignitor from the Ignition Control.
4. Using an ohmmeter measure the resistance of the ignitor:
120 Volt Silicon Nitride : 120V Nitride Igniter should read
between 37 to 68 ohms.
5. Reconnect ignitor.
WARNING
2. Remove wires from the pressure switch(es) electrical
terminals.
3. Using a VOM check from common terminal to NC (Normally Closed) - should read open.
If switch reads as above proceed to Step 4, otherwise replace control.
4. Remove the pressure control hose from the control and
interconnect with an inclined manometer as shown in
the following figures.
LINE VOLTAGE NOW PRESENT
6. Place unit in heating cycle, measure current draw of
ignitor during preheat cycle.
7. After checking and/or replacing of hot surface ignitor,
reinstall burner compartment door and verify proper unit
operation.
S-309 CHECKING FOR FLASHBACK
Flashback will also cause burning in the burner venturi, but
is caused by the burning speed being greater than the gasair flow velocity coming from a burner port.
Flashback may occur at the moment of ignition, after a burner
heats up or when the burner turns off. The latter is known as
extinction pop.
Since the end results of flashback and delayed ignition can
be the same (burning in the burner venturi) a definite attempt should be made to determine which has occurred.
If flashback should occur, check for the following:
1. Improper gas pressure - adjust to proper pressure (See
S-307 CHECKING GAS PRESSURE)..
2. Check burner for proper alignment and/or replace burner.
3. Improper orifice size - check orifice for obstruction.
Induced Draft Blower
Pressure Switch
Pressure Switch
Hose
1/4" Tee
Inclined Manometer
Hose to Induced
Draft Blower Tap
S-310 CHECKING PRESSURE SWITCH
The pressure control is a safety device to prevent the combustion cycle from occurring with inadequate venting caused
by a restricted or blocked vent pipe on the 80% and 90%
furnaces. Also on the 90% furnaces there is a pressure
control that will prevent the combustion cycle from occurring with inadequate condensate drainage due to a partial or
blocked recuperator coil or drain.
WARNING
HIGH VOLTAGE
DISCONNECT ALL POWER BEFORE SERVICING OR
INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY
BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY
DAMAGE, PERSONAL INJURY OR DEATH.
1. Remove burner compartment door to gain access to pressure switch(es).
82
S-311 HIGH ALTITUDE APPLICATION (USA)
The furnace as shipped requires no change to run between
0 - 4500 feet. Do not attempt to increase the firing rate by
changing orifices or increasing the manifold pressure below 4500 feet. This can cause poor combustion and equipment failure. High altitude installations above 4500 feet may
require both a pressure switch and an orifice change. These
changes are necessary to compensate for the natural reduction in the density of both the gas fuel and the combustion air at higher altitude.
SERVICING
For installations above 4500 feet, please refer to your distributor for required kit(s). Contact the distributor for a tabular listing of appropriate manufacturer’s kits for propane gas
and/or high altitude installations. The indicated kits must
be used to insure safe and proper furnace operation. All
conversions must be performed by a qualified installer, or
service agency.
In some areas the gas supplier may artificially derate the
gas in an effort to compensate for the effects of altitude. If
the gas is artificially derated the appropriate orifice size must
be determined based on the BTU/ft3 content of the derated
gas and the altitude. Refer to the National Fuel Gas Code,
NFPA 54/ANSI Z223.1, and information provided by the gas
supplier to determine the proper orifice size.
S-312 CHECKING FOR DELAYED IGNITION
Delayed ignition is a delay in lighting a combustible mixture
of gas and air which has accumulated in the combustion
chamber.
When the mixture does ignite, it may explode and/or rollout
causing burning in the burner venturi.
If delayed ignition should occur, the following should be
checked:
1. Improper gas pressure - adjust to proper pressure (See
S-307 CHECKING GAS PRESSURE).
2. Improper burner positioning - burners should be in locating slots, level front to rear and left to right.
3. Carry over (lighter tube or cross lighter) obstructed clean.
4. Main burner orifice(s) deformed, or out of alignment to
burner - replace.
S-313 CHECKING INTEGRATED IGNITION
CONTROL BOARDS
This section discusses various integrated ignition boards
used on models listed in this manual. You will be guided
though some common diagnostic procedures.
NOTE: Failure to earth ground the furnace, reversing the
neutral and hot wire connection to the line (polarity), or a
high resistance connection in the neutral line may cause
the control to lockout due to failure to sense flame.
WARNING
TO AVOID THE RISK OF
ELECTRICAL SHOCK, WIRING TO THE UNIT
MUST BE PROPERLY POLARIZED AND GROUNDED.
DISCONNECT POWER
BEFORE PERFORMING SERVICE LISTED BELOW.
The ignition control is a combination electronic and electromechanical device and is not field repairable. Complete unit
must be replaced.
WARNING
LINE VOLTAGE NOW PRESENT
These tests must be completed within a given time frame
due to the operation of the ignition control.
The ignition control is capable of diagnosing many furnace
failures to help in troubleshooting. A flashing red or green
diagnostic indicator light on the control flashes a code for
any detected failures. The control utilizes a dual, 7-segment LED display to indicate diagnostic codes.
When the control is powered up normally the light will be on
continuously. The display will indicate "ON" when powered and in standby mode. This can be used to test for 120
volts and 24 volts to the control since both must be present
for the light to be on. If this step fails, check for 120 volts to
the control and check the transformer and its associated
wiring. If this step is successful give the control a call for
heat and wait five (5) seconds or until the furnace goes into
lockout. If the control detects a failure it will now be shown
on the diagnostic indicator light/display. Refer to the Abnormal Operation section in the Sequence of Operation section of this manual for more detail on failure codes.
PCBKF103 / PCBKF104 Control Board
1. Check for 120 volts from Line 1 (Hot) to Line 2 (Neutral)
at the ignition control. No voltage, check the door switch
connections and wire harness for continuity.
2. Check for 24 volts from W1 to C terminal on the ignition
control. No voltage. Check transformer, room thermostat, and wiring.
If you have 24 volts coming off the transformer but receive approximately 13 volts on the terminal board between (C) and (R), check for blown fuse.
3. Check for 120 volts to the induced draft blower (low-stage)
by measuring voltage between Pin 3 and Pin 4 (on the 5pin connector) located on circuit board. No voltage, check
for loose connection in the 5-pin connector or replace
ignition control.
Check for 120 volts to the induced draft blower (highstage) by measuring voltage between Pin 2 and Pin 4
(on the 5-pin connector) located on circuit board. No voltage, check for loose connection in the 5-pin connector,
no call for high stage heat or replace ignition control.
The ground wire must run from the furnace all the way back
to the electrical panel. Proper grounding can be confirmed
by disconnecting the electrical power and measuring resistance between the neutral (white) connection and the burner
closest to the flame sensor. Resistance should be less than
10 ohms.
83
SERVICING
S-314 CHECKING FLAME SENSOR
A flame sensing device is used in conjunction with the ignition control module to prove combustion. If proof of flame is
not present the control will de-energize the gas valve and
"retry" for ignition or lockout.
WARNING
HIGH VOLTAGE
DISCONNECT ALL POWER BEFORE SERVICING OR
INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY
BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY
DAMAGE, PERSONAL INJURY OR DEATH.
1. Connect a micro-amp meter in series with this wire and
the sensor terminal.
WARNING
LINE VOLTAGE NOW PRESENT
1 2 R C G W1 W2 Y1 Y2 O
DE
HUM
4. If voltage is present in Steps 1 through 3 and the induced draft blower is operating, check for 120 volts to
the ignitor during the preheat cycle. Measure voltage
between Pin 1 and Pin 5 (on the 5-pin connector) located on ignition control. No voltage, check low stage
and high stage pressure switches or replace the ignition control board.
5. After the ignitor warmup time, begin checking for 24
volts to the gas valve. Voltage will be present for seven
seconds only if proof of flame has been established.
6. If proof of flame was established voltage will be provided
to the air circulation blower following the heat on delay
period.
a. BEFORE replacing the ECM motor assembly or the
end bell, first check the motor with an Emerson
UltraCheck-EZTM diagnostic tool . If the motor runs
with the diagnostic tool, the motor is good. To check
the end bell, see the previous variable speed testing
section of this manual before replacing the end bell.
b. The two-stage variable speed furnaces should have
120 Volts at the motor at all times, even without a
call for cooling or heating. These motors receive their
operational signals (5 Volts dc) through the 4-pin wiring harness, connected between the motor and integrated control board. NOTE: For complete troubleshooting information on units using the ECM blower
motors, refer to the servicing section - Checking Air
Circulator Blowers (S-16B) in this service manual.
84
2. Place the unit into a heating cycle.
3. As soon as flame is established a micro-amp reading
should be evident once proof of flame (micro-amp reading) is established, the hot surface ignitor will be deenergized.
4. The Integrated Ignition controls will have 1 to 4 microamps. If the micro-amp reading is less than the minimum specified, check for high resistance wiring connections, sensor to burner gap, dirty flame sensor, or
poor grounding.
5. If absolutely no reading, check for continuity on all components and if good - replace ignition control module.
NOTE: Contaminated fuel or combustion air can create a
nearly invisible coating on the flame sensor. This coating
works as an insulator causing a loss in the flame sense
signal. If this situation occurs the flame sensor must be
cleaned with steel wool.
ACCESSORY WIRING DIAGRAMS
HIGH VOLTAGE!
DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS
UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO
DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
ALL FUEL SYSTEM CONTROL BOARD - AFE1860A
24VAC
F1
3A
P1-8
POWER SUPPLY
INPUT
FURNACE DEMAND
OUTPUT
BLOWER FAN DEMAND
OUTPUT
POWER SUPPLY INPUT
(COMMON)
SECOND STAGE FURNACE
DEMAND OUTPUT
COMPRESSOR OUTPUT
+VD C
R
POWER
SUPPLY
P1-7
F
U
R
N
A
C
E
SECOND STAGE
COMPRESSOR OUTPUT
REVERSING VALVE
OUTPUT
W1
+5VDC
W1-FURN
W2-HP
P1-4
+VD C
G
24VAC
P1-6
C
G-STAT
C
K1
P1-5
G-FURN
W2
P1-2
Y
P1-3
K2
Y2-HP
Y2
P1-1
+VDC
O
Y2-STAT
Y2-FURN
24VAC
P2-2
POWER SUPPLY OUT
TO THERMOSTAT
CALL FOR
REVERSING VALVE
CALL FOR
COMPRESSOR
CALL FOR
EMERGENCY HEAT
CALL FOR
BLOWER FAN
CALL FOR
FURNACE HEAT
POWER SUPPLY COMMON
OUT TO THERMOSTAT
CALL FOR 2ND STAGE
FURNACE HEAT
CALL FOR 2ND STAGE
COMPRESSOR
T
H
E
R
M
O
S
T
A
T
K4
R
Y-STAT
Y-FURN
Q1
P2-1
O
P2-7
Y-HP
Y
P2-8
K3
E
P2-5
G
Q2
+5VDC
P2-9
W1
P2-3
C
E/W1
C
P2-4
1. 0K
W2
P2-6
Y2
24VAC
O
MICROPROCESSOR
P3-9
POWER SUPPLY OUT
TO HP CONTROL
HP CALL FOR FURNACE
(DURING DEFROST)
REVERSING
VALVE OUTPUT
COMPRESSOR
CONTACTOR OUTPUT
POWER SUPPLY COMMON
OUT TO HP CONTROL
R
6. 8K
P3-8
H
E
A
T
W2
P3-7
Y
O
P3-2
Y
6. 8K
P3-6
C
P
U
M
P
ODT (OUTDOOR
THERMOSTAT)
2ND STAGE COMPRESSOR
DEMAND OUTPUT
C
P3-3
OT-NO
P3-1
OT-NC
P3-4
OT-C
P3-5
2
Y2
1
BREAK FOR ODT
ALL FUEL SYSTEM CONTROL BOARD - AFE18-60A
This wiring diagram is for reference only. Not all wiring is as shown above.
Refer to the appropriate wiring diagram for the unit being serviced.
(For use with Heat Pumps in conjunction with 80% or 90% Single-Stage or Two-Stage Furnaces)
85
ACCESSORY WIRING DIAGRAMS
HIGH VOLTAGE!
DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS
UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO
DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
INTEGRATED IGNITION CONTROL
1 2 R C G W1 W2 Y1 Y2 O
DE
HUM
WHITE
BLACK
GREEN
70
80
60
50
40
DE-HUMIDISTAT
DE-HUMIDISTAT - DEHUM1
86
ON
30