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INSTALLATION INSTRUCTIONS
FOR UPFLOW CONDENSING MODULATING,
COMMUNICATING GAS FURNACES W/ECM BLOWER
(-)98V SERIES
IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED
EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY
DAMAGE, PERSONAL INJURY OR DEATH.
THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED
SERVICE PERSONNEL FOR PROPER INSTALLATION, ADJUSTMENT
AND OPERATION OF THIS UNIT. READ THESE INSTRUCTIONS
THOROUGHLY BEFORE ATTEMPTING INSTALLATION OR OPERATION.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
IMPROPER INSTALLATION, ADJUSTMENT, SERVICE OR
MAINTENANCE, POSSIBLY RESULTING IN FIRE, ELECTRICAL SHOCK,
CARBON MONOXIDE POISONING, EXPLOSION, PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH.
CARBON-MONOXIDE POISONING HAZARD
FAILURE TO FOLLOW INSTRUCTIONS COULD RESULT IN SEVERE
PERSONAL INJURY OR DEATH DUE TO CARBON-MONOXIDE
POISONING, IF COMBUSTION PRODUCTS INFILTRATE INTO THE
BUILDING.
CHECK THAT ALL OPENINGS IN THE OUTSIDE WALL AROUND THE
VENT (AND AIR INTAKE) PIPE(S) ARE SEALED TO PREVENT
INFILTRATION OF COMBUSTION PRODUCTS INTO THE BUILDING.
CHECK THAT FURNACE VENT (AND AIR INTAKE) TERMINAL(S) ARE
NOT OBSTRUCTED IN ANY WAY DURING ALL SEASONS.
PROPOSITION 65 WARNING: THIS PRODUCT CONTAINS CHEMICALS
KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH
DEFECTS OR OTHER REPRODUCTIVE HARM.
— Do not store or use gasoline or other flammable vapors and liquids, or other combustible
materials in the vicinity of this or any other appliance.
— WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's
instructions.
• If you cannot reach your gas supplier, call the fire department.
• Do not return to your home until authorized by the gas supplier or fire department.
— DO NOT RELY ON SMELL ALONE TO DETECT LEAKS. DUE TO VARIOUS FACTORS,
YOU MAY NOT BE ABLE TO SMELL FUEL GASES.
• U.L. and/or C.S.A. recognized fuel gas and CO (carbon monoxide) detectors are rec-
ommended in all applications, and their installation should be in accordance with the
manufacturer's recommendations and/or local laws, rules, regulations, or customs.
— Improper installation, adjustment, alteration, service or maintenance can cause injury
property damage or death. Refer to this manual. Installation and service must be
performed by a qualified installer, service agency or the gas supplier. In the
commonwealth of Massachusetts, installation must be performed by a licensed plumber
or gas fitter for appropriate fuel.
92-24161-159-01
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Summary of Contents for AHRI (-)98VA060M317USA
- Page 1 INSTALLATION INSTRUCTIONS FOR UPFLOW CONDENSING MODULATING, COMMUNICATING GAS FURNACES W/ECM BLOWER (-)98V SERIES IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED SERVICE PERSONNEL FOR PROPER INSTALLATION, ADJUSTMENT AND OPERATION OF THIS UNIT.
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Page 2: Table Of Contents
TABLE OF CONTENTS 1 TABLE OF CONTENTS ..... . 2 8 CONDENSATE DRAIN AND DRAIN NEUTRALIzER ......42 2 GENERAL INFORMATION . -
Page 3: General Information
GENERAL INFORMATION NOTE: A heat loss calculation should be performed to 1. As non-direct vent central forced air furnaces taking properly determine the required furnace BTU size for the combustion air from the installation area or using air structure. Also, the duct must be properly designed and in- ducted from the outside. -
Page 4: Receiving
GENERAL INFORMATION (cont.) IMPORTANT: All manufacturer products meet current In Canada installations must comply with CSA B149.1. Federal OSHA Guidelines for safety. California Proposition Install units in Canada in accordance with CSA-B149, 65 warnings are required for certain products, which are local installation codes and authorities having jurisdiction. -
Page 5: Checklist
Installation Instructions remain with the furnace as a reference guide to the servicing contractor. We recommend that performance and installation data be recorded for future reference on this sheet to meet service and warranty obligations so that job site information is available when required. ______ no. -
Page 6: Safety Information
SAFETy INFORMATION WARNING WARNING DO NOT INSTALL THIS FURNACE IN A MOBILE HOME!! COMBUSTION AND VENTILATION AIR MUST BE PRO- THIS FURNACE IS NOT APPROVED FOR INSTALLATION VIDED TO THE FURNACE AS REqUIRED By THE NA- IN A MOBILE HOME. DOING SO COULD CAUSE FIRE, TIONAL FUEL-GAS CODE (U.S.) AND CSA B149.1 PROPERTy DAMAGE, PERSONAL INJURy OR DEATH. -
Page 7: Important Information About Efficiency And Quality
Consumption of Furnaces and Boilers) and the clarifying TAIN HAzARDOUS CARBON MONOxIDE) INTO THE HOME THAT COULD RESULT IN PERSONAL INJURy OR provisions provided in the AHRI Operations Manual for DEATH. Residential Furnaces that were applicable at the date of manufacture should be used for test set up and perform- ance. -
Page 8: Commonwealth Of Massachusetts Note
COMMONWEALTH OF MASSACHUSETTS NOTE IMPORTANT! THE COMMONWEALTH OF MASSACHU- 4. INSPECTION. The state or local gas inspector of the SETTS REqUIRES COMPLIANCE WITH REGULATION side wall horizontally vented gas fueled equipment shall 248 CMR 4.00 AND 5.00 FOR INSTALLATION OF not approve the installation unless, upon inspection, the THROUGH-THE-WALL VENTED GAS APPLIANCES AS inspector observes carbon monoxide detectors and sig-... -
Page 9: Location Requirements
LOCATION REqUIREMENTS GENERAL INFORMATION or CSA listed heat tape or UL or CSA approved heating cable with a rating of 3-6 watts per foot is acceptable pro- WARNING tection when installed and maintained in accordance with WHEN THIS FURNACE IS INSTALLED IN A RESI- the manufacturer’s instructions. -
Page 10: Clearance Accessibility
LOCATION REqUIREMENTS GENERAL INFORMATION (cont.) WARNING WARNING DO NOT LIFT THE UNIT By THE HEAT Ex- COMBUSTIBLE MATERIAL MUST NOT BE CHANGER TUBES. DOING SO CAN DAMAGE THE PLACED ON OR AGAINST THE FURNACE HEAT ExCHANGER ASSEMBLy. JACkET. THE AREA AROUND THE FURNACE MUST BE kEPT CLEAR AND FREE OF ALL COM- CLEARANCE –... -
Page 11: Clearance Table
FIGURE 5 UNIT DIMENSIONS (CLEARANCE TO COMBUSTIBLES – SOME MEASUREMENTS DO NOT APPLy TO UPFLOWS) -
Page 12: Field Conversions
FIELD CONVERSIONS... -
Page 13: Lists Of Materials For Parts Bag And Conversion Kits
FIELD CONVERSIONS SEE NExT PAGE FOR APPLICABLE CONFIGURATIONS... -
Page 14: Conversion Table Of Contents
FIELD CONVERSIONS FIELD CONVERSION TO VARIOUS CONFIGURATIONS Furnaces can be converted to two different upflow configurations as follows. There are two different venting options, includ- ing a zero-clearance option, to give the installer flexibility in locating the venting for this furnace. LISTS OF MATERIALS FOR PARTS BAGS AND CONVERSION KITS. - Page 16 ST-A1194-68-00...
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Page 19: Ducting
DUCTING External filter racks are available from the distributor. Use FIGURE 6 the following part numbers when ordering: RXGF-CA External Side Filter Rack Kit REMOVE SOLID BASE PANEL FROM THE RXGF-CB External Bottom Filter Rack Kit TOP BEFORE INSTALLING FURNACE Proper air flow is required for the correct operation of this furnace. - Page 20 DUCTING 6. If a filter is installed near the furnace, be sure to have adequate space for installation and removal of the WARNING unit filter. UPFLOW FURNACE: THE SOLID METAL BASE PLATE (SHIPPED WITH THE FURNACE) MUST BE 7. NOTE: Where the maximum airflow is 1800 CFM or INSTALLED IN THE FURNACE BOTTOM WHEN more, BOTH sides or the bottom must be used for the USING SIDE AIR RETURN.
- Page 21 DUCTING FIGURE 8 FIGURE 9 AS - SHIPPED FLAT INSTALLER BENT - UP ALTERNATE - BENT (DOWN) INSTALLER BENT - UP CUT - OUT USING EMBOSSED ANGLES AS A GUIDE FOR PROPER SIZE 23” x 14” ST-A1194-04-X0 NOTES: THIS VIEW IS REPRESENTATIVE OF BOTH SUPPLY AND RETURN OPEN- INGS.
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Page 22: Venting
GENERAL VENTING REqUIREMENTS AND GUIDELINES VENTING & COMBUSTION AIR REqUIREMENTS The following types of installations (but not limited to the following) may require outdoor air for combustion (direct vent) due to chemical exposures: WARNING READ AND FOLLOW ALL INSTRUCTIONS IN THIS Commercial buildings SECTION. -
Page 23: Piping Requirements
GENERAL VENTING REqUIREMENTS AND GUIDELINES VENTING & COMBUSTION AIR REqUIREMENTS (cont.) IMPORTANT: ONLy THE CURRENT VENT INSTRUC- edition of the National Fuel Gas Code, NFPA-54/ANSI TIONS APPLy. All 90 Plus Gas Furnaces cannot be com- Z223.1, CSA B149.1; Canadian Natural Gas and Propane mon-vented. - Page 24 GENERAL VENTING REqUIREMENTS AND GUIDELINES VENTING & COMBUSTION AIR REqUIREMENTS (cont.) JOINING PIPE AND FITTINGS and installed per the manufacturer’s instructions. NOTE: Never cover heat tape with insulation. All pipe, fittings, solvent cement, primers and procedures 5. The minimum vent pipe length is 5 feet [1.5m]. must be installed following the vent manufacturer’s instal- lation instructions and must conform to American National 6.
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Page 25: Vent Pipe Sizing And Maximum Lengths
GENERAL VENTING REqUIREMENTS AND GUIDELINES VENT PIPE SIzING AND MAxIMUM VENT LENGTHS EqUIVALENT VENT LENGTHS The concept of equivalent vent lengths is frequently used in piping systems to account for pressure drop of fittings, such as elbows. The equivalent length of a fitting is the length of a straight section of pipe that has an equivalent pressure drop in the application as the fitting used. - Page 26 GENERAL VENTING REqUIREMENTS AND GUIDELINES VENT PIPE SIzING AND MAxIMUM VENT LENGTHS (cont.) TABLE 3: MAXIMUM EQUIVALENT VENT LENGTH (-)98VA060M317USA (-)98VA070M317USA (-)98VA085M521USA (-)98VA100M521USA (-)98VA115M524USA * This is the recommended maximum number of long sweep elbows for either 2 or 3 inch pipe. Combinations of long sweep 90s, standard 90s, or 45s may be used, but the manufacturer recommends the use of long sweep 90s whenever possible because the use of the maximum number of standard 90 and 45 elbows only may result in nuisance furnace outages due to individual installation specifics.
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Page 27: Polypropylene Vent Products
GENERAL VENTING REqUIREMENTS AND GUIDELINES VENT PIPE SIzING AND MAxIMUM VENT LENGTHS (cont.) POLyPROPyLENE VENT PRODUCTS bles 4 and 5 below. These manufacturers have provisions for B-vent liners and chimney liners which can be used Centrotherm brand Innoflue and Duravent Polypro Single- with this furnace with non-direct venting applications only. -
Page 28: Termination Requirements
GENERAL VENTING REqUIREMENTS AND GUIDELINES TERMINATION REqUIREMENTS pliance or clothes dryer to prevent recirculation of the flue gases into the furnace combustion air inlet. The CAUTION only exception to this requirement is the case of multi- THE COMBUSTION PRODUCTS AND MOISTURE IN THE FLUE GASES WILL CONDENSE AS THEy venting two or more furnaces, which is covered in the LEAVE THE TERMINATION. -
Page 29: Non-Direct Venting
GENERAL VENTING REqUIREMENTS AND GUIDELINES NON-DIRECT VENT (VERTICAL TERMINATIONS ONLy) FURNACE LOCATED IN AN UNCON- FINED SPACE (U.S. INSTALLATIONS) USING INDOOR AIR FOR COMBUSTION: ALL FURNACE INSTALLATIONS MUST COMPLy WITH THE NATIONAL FUEL GAS CODE, NFPA 54, AND IN An unconfined space must have at least 50 cubic feet for each CANADA CSA B149.1;... - Page 30 GENERAL VENTING REqUIREMENTS AND GUIDELINES NON-DIRECT VENT (cont.) B. USING OUTDOOR AIR FOR COMBUSTION: A. Where directly communicating with the outdoors through an opening or where communicating to the outdoors through IMPORTANT: Do not take air from an attic space that is vertical ducts as shown in Figure 12, each opening shall have equipped with power ventilation.
- Page 31 GENERAL VENTING REqUIREMENTS AND GUIDELINES NON-DIRECT VENT (cont.) FIGURE 12 FIGURE 13 NON-DIRECT VENT AIR FROM NON-DIRECT VENT ATTIC OR CRAWL SPACE OUTSIDE AIR USING A HORIzONTAL DUCT OUTLET AIR 1 SQ. IN. (6.5 SQ. CM.) PER 2000 BTUH ST-A1194-19 INLET AIR 1 SQ.
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Page 32: Non-Direct Venting Terminations
GENERAL VENTING REqUIREMENTS AND GUIDELINES NON-DIRECT VENT (cont.) B. Not less than the sum of the areas of all vent connectors in the confined space. If the unit is installed where there is an exhaust fan, sufficient ALL VENTS INSTALLED THROUGH UNCONDI- ventilation must be provided to prevent the exhaust fan from TIONED SPACE WHERE BELOW-FREEzING TEM- creating negative pressure. -
Page 33: Direct Venting
GENERAL VENTING REqUIREMENTS AND GUIDELINES DIRECT VENT DIRECT-VENT (2-PIPE) INSTALLATIONS ALL FURNACE INSTALLATIONS MUST COMPLy The field-supplied vent system used for direct-vent instal- WITH THE NATIONAL FUEL GAS CODE OR, IN lations uses 2 pipes; one inlet pipe for supplying the com- CANADA, CSA B149.1;... - Page 34 GENERAL VENTING REqUIREMENTS AND GUIDELINES DIRECT VENT (cont.) Figure 17 below shows the necessary detail for the roof penetration on a standard direct-vent vertical termination. FIGURE 17 DIRECT VENT VERTICAL TERMINATION DETAIL Terminations more than 24” above roof penetration re- quire additional support.
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Page 35: Option 2: Standard Horizontal Direct Vent
GENERAL VENTING REqUIREMENTS AND GUIDELINES DIRECT VENT (cont.) OPTION 2: STANDARD HORIzONTAL DIRECT-VENT TERMINATION FIGURE 18 STANDARD HORIzONTAL DIRECT VENTING SEE DETAIL B FOR DIMENSION BETWEEN INTAKE AND EXHAUST SEE DETAIL A COUPLINGS: REQUIRED ON EXTERIOR, OPTIONAL ON INTERIOR 1) SUPPORT HORIZONTAL PIPE EVERY FOUR FEET. 2) WHEN 3”... -
Page 36: Termination
GENERAL VENTING REqUIREMENTS AND GUIDELINES DIRECT VENT (cont.) OPTION 4: ALTERNATE HORIzONTAL DIRECT-VENT TERMINATION FIGURE 20 NOTE: A TRAP MUST BE IN- TyPICAL HORIzONTAL VENTED 2 PIPE TERMINALS STALLED IN THIS OPTION TO PREVENT WATER FROM ENTERING THE FURNACE NOTE: THROUGH THE COMBUS- 1) FOR EXHAUST / INTAKE PENETRATION TION AIR PIPE. -
Page 37: Horizontal And Variant Of Alt. Horizontal Direct-Vent Terminations (Options 4 And 5)
GENERAL VENTING REqUIREMENTS AND GUIDELINES DIRECT VENT (cont.) OPTIONAL TERMINATION ANGLES FOR OPTION FOR ALT. HORIz. AND VARIANT OF ALT. HORIz. DIRECT-VENT TERMINATIONS (OPTIONS 4 &5) NOTE: These optional termination angles apply only to di- tical risers and final elbows before gluing into place to rect-vent termination options 4 and 5 above (alternate hor- ensure that the final angles are correct. -
Page 38: Option 6 & 7: Vertical And Horizontal Concentric Vent Termination (Rxgy-E02A And Rxgy-E03A)
GENERAL VENTING REqUIREMENTS AND GUIDELINES DIRECT VENT (cont.) OPTIONS 6 & 7: VERTICAL OR HORIzONTAL CONCENTRIC VENT TERMINATION FOR 2” PIPE: RxGy-EO2 (U.S. ONLy) OR RxGy-EO2A (U.S. AND CANADA) FOR 3” PIPE: RxGy-EO3 (U.S. ONLy) OR RxGy-EO3A (U.S. AND CANADA) CONCENTRIC TERMINATIONS 3”... - Page 39 GENERAL VENTING REqUIREMENTS AND GUIDELINES DIRECT VENT (cont.) OPTIONS 8 & 9: 2( & 3( SIDE WALL VENT TERMINATIONS (Figures 24 & 25) FOR 2( PIPE: RxGy-G02 FOR 3( PIPE: RxGy-G01 NOTE: With this option a trap on the inlet combustion This termination is for horizontal venting only.
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Page 40: Direct Venting Termination Clearances
GENERAL VENTING REqUIREMENTS AND GUIDELINES DIRECT VENT TERMINATION CLEARANCES Figure 26 shows minimum clearances that must be used for direct venting terminations. FIGURE 26 DIRECT VENT TERMINAL CLEARANCES ST-A1194-18-01 FIGURE A... -
Page 41: Multiventing Of Direct Vent Furnaces
GENERAL VENTING REqUIREMENTS AND GUIDELINES MULTIVENTING OF DIRECT-VENT FURNACES Figures 27 & 28: NOTE: WHEN VENTING MULTIPLE FURNACES IN CLOSE PROXIMITY, EACH FURNACE MUST BE INDIVIDUALLY VENTED – NO COMMON VENTING IS PERMITTED. See Figures 27 & 28 for positioning of the terminations. -
Page 42: Condensate Drain And Drain Neutralizer
CONDENSATE DRAIN CONDENSATE DRAIN & DRAIN NEUTRALIzER GENERAL INFORMATION B. FURNACE SHUTOFF – When the top of the vent tube is above the elevation of the LOWER condensate water level sensor (aka electronic water level sensor), the furnace will be shut off in the event of a blocked drain and no heat will be provided. - Page 43 CONDENSATE DRAIN CONDENSATE DRAIN & DRAIN NEUTRALIzER (cont.) FIGURE 29 ST-A1194-70-00...
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Page 44: Gas Supply And Piping
GAS SUPPLy GAS SUPPLy AND PIPING IMPORTANT SAFETy INFORMATION AND WILL RISE, POSSIBLy ACCUMULATING IN NATURAL GAS AND PROPANE HIGHER PORTIONS OF THE STRUCTURE. • IF A GAS LEAk IS PRESENT OR SUSPECTED: (LIqUEFIED PETROLEUM GAS / LPG) - DO NOT ATTEMPT TO FIND THE CAUSE yOUR- SAFETy SELF. -
Page 45: Gas Piping
FIGURE 30 THIS FURNACE IS EqUIPPED AT THE FACTORy GAS PIPING INSTALLATION UPFLOW FOR USE ON NATURAL GAS ONLy. CONVERSION TO LP GAS REqUIRES A SPECIAL kIT IS AVAIL- ABLE AT THE DISTRIBUTOR. FAILURE TO USE THE PROPER CONVERSION kIT CAN CAUSE FIRE, CARBON MONOxIDE POISONING, ExPLOSION, PROPERTy DAMAGE, PERSONAL INJURy OR DEATH. -
Page 46: Gas Pressure
GAS SUPPLy GAS PRESSURE ways use a pipe compound resistant to the action of lique- fied petroleum gases on all threaded connections. FIGURE 31 IMPORTANT: When making gas pipe connections, use a back-up wrench to prevent any twisting of the main gas valve and manifold. -
Page 47: Gas Valve
2. NOTE: Order the correct LP conversion kit from the furnace manufacturer. Furnace conversion to LP gas must be performed by a qualified installer, service NEVER PURGE A GAS LINE INTO THE COMBUS- agency or the gas supplier. TION CHAMBER. NEVER USE MATCHES, FLAME OR ANy IGNITION SOURCE FOR CHECkING LEAk- 3. - Page 48 WARNING FIGURE 34 TURN OFF ELECTRICAL POWER AND MAIN GAS LP JUMPER INSTALLED ON SERVO MODULATING GAS VALVE WITH PINS NOT CONNECTED. THIS IS INCORRECT. MAkE SURE THAT THE JUMPER SUPPLy BEFORE BEGINNING MODIFICATION. CONNECTS THE TWO PINS TOGETHER AND VERIFy MANIFOLD GAS FAILURE TO DO SO CAN RESULT IN ELECTRICAL PRESSURE AT HIGH FIRE TO MAkE SURE THE VALVE IS PROPERLy CON- SHOCk OR ExPLOSION CAUSING PROPERTy...
- Page 49 NOTE: 1.10 mm orifices provided in kit are used in all alti- FIGURE 36 tudes. These orifices comply with the 2% de-rate require- ments due to the natural de-rate related to lower barometric pressure. NOTE: Use a pipe compound resistant to the action of the liq- uefied petroleum gases at all threaded pipe connections.
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Page 50: Furnace Adjustments
FURNACE ADJUSTMENTS The following pages will cover in detail how to select the ft. All other elevations and heating values will require proper orifice, adjust the manifold pressures (at min and changing orifices and possibly input rate. max firing rates), verify the rate and set the proper temper- A. -
Page 51: Adjust The Gas Pressure
LP GAS ORIFICE SELECTION properly calibrated manometer is required for accurate gas pres sure measurements. For LP Orifice selection, refer to the “LP Conversion” sec- tion of this manual. If the supply gas line pressure is above these ranges, in - stall an in-line gas regulator to the furnace for natural gas E. - Page 52 FURNACE ADJUSTMENTS 2. Connect a manometer to the pressure tap. FIGURE 41 3. Turn on the gas supply and operate the furnace at SERVO CONTROLLED GAS VALVE PRESSURE ADJUSTMENT 100% and all other gas-fired units on the same gas line as the furnace. 4.
- Page 53 ADJUST MANIFOLD PRESSURE AT 10. After ignition, allow furnace to operate and complete the pressure switch calibration before checking maxi- MINIMUM FIRING RATE mum firing rate outlet/manifold pressure. 1. Set dip switch SW10 to the “ON” position and dip- Note: The manifold gas pressure to be: switch SW11 to the “OFF”...
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Page 54: Verify The Input Rate
FURNACE ADJUSTMENTS Example: while power is off, the outlet pressure of the valve will not be adjusted and will remain the same and will be The following information is determined: re-assigned to the new wheel selection. 1. Altitude-Adjusted Gas Heating Value = 975 BTU/ft 6. -
Page 55: Adjust The Gas Heat Temperature Rise
STEP 4: ADJUST GAS HEAT TEMPERATURE RISE TABLE 15 GAS RATE (FT /HOUR) COMFORT/EFFICIENCy SELECT: One dipswitch SW18 is provided to allow for selection be- tween Comfort and Efficiency mode as follows: SW18 = OFF = Comfort Mode, Target Temp Rise = +10°F above Nameplate Mid-Rise SW18 = ON = Efficiency Mode, Target Temp Rise = Mid- rise as specified on Nameplate Label... -
Page 56: Temperature Rise Verification
FURNACE ADJUSTMENTS Further, for communicating systems, the above selections ing (approximately 5 minutes), subtract the return air (made with dipswitches SW13, SW14, SW15, and SW16 temperature from the supply air temperature. The dif- in legacy mode) can be made via the Econet control cen- ference is the temperature rise. - Page 57 FIGURE 43 TyPICAL FURNACE NAME PLATE THE MEASURED TEMPERATURE RISE SHOULD BE AS CLOSE TO THE MIDDLE OF THE STATED RANGE AS POSSIBLE. FOR ExAMPLE, IF THE RISE RHEEM SALES COMPANY, INC. FORT SMITH, ARKANSAS CANADIAN ENERGY RANGE IS 40°F TO 70°F (4.5° - 21°C), THE MIDDLE PERFORMANCE VERIFIED RENDEMENT...
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Page 58: Electrical Wiring
CSA - International 5060 Spectrum Way Mississauga, Ontario TURN OFF ELECTRIC POWER AT FUSE BOx OR Canada L4W 5N6 SERVICE PANEL BEFORE MAkING ANy ELECTRI- online: www.csa.ca CAL CONNECTIONS. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCk RESULTING IN PER- SONAL INJURy OR DEATH. -
Page 59: Thermostat
ELECTRICAL WIRING REVERSING ELECTRICAL CONNECTION & THERMOSTAT NOTE: Do not use 24 volt control wiring smaller than No. 3. Remove the junction box from the furnace cabinet wall by removing the two screws that hold it to the cabinet. 18 AWG. Leave the wires connected to the junction box. -
Page 60: Accessories
ELECTRONIC AIR CLEANER HUMIDIFIER Line voltage power can be supplied from the terminal la- Humidifier output is a set of dry contacts. The logic control- beled “EAC” and a line voltage neutral terminal on the ling these contacts and the necessary wire diagrams for in- control board. - Page 61 FIELD INSTALLED OPTION ACCESSORIES (cont.) FIGURE 46 UPFLOW/HORIzONTAL FILTER LOCATIONS RXGF-CB ACCESSORY FILTER RACK RXGF-CB ACCESSORT FILTER RACK ST-A1194-10-X0 SIDE RETURN FLANGE WRAPS AROUND BACK AND SCREWS TO THE REAR OF THE FURNCE, AT THE LOCATIONS PROVIDED CUT - OUT USING EMBOSSED ANGLES AS A GUIDE FOR PROPER SIZE 23”...
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Page 62: Calibration Sequence Of Operations
Cold Calibration- Low Pressure Switch The IFC will energize the inducer at a low starting RPM WARNING SHOULD OVERHEATING OCCUR OR THE GAS and increase the inducer speed until the low pressure SUPPLy FAIL TO SHUT OFF, CLOSE THE MANUAL switch closes. -
Page 63: Start-Up And Sequence Of Operations
START-UP AND SEqUENCE OF OPERATIONS Note: If the calibration attempt fails or fault codes are Blower Off Delay present, see Table 18, R97V Fault Codes with Descrip- The blower off delay is to always begin after the gas valve tion and Solutions. is de-energized or when detected error conditions that Burner Ignition have been cleared require blower to be energized and... - Page 64 INTEGRATED FURNACE CONTROL FIGURE 47 FURNACE CONTROL BOARD OR IFC (INTEGRATED FURNACE CONTROL)
- Page 65 6. LINE VOLTAGE CONNECTIONS (120VAC, L1) Continuous fan speeds are selectable and some lower fan speeds may not deliver enough airflow to Four ¼” spade terminals are provided for internal operate an electronic air cleaner. The IFC determines connections and accessories. the minimum airflow necessary to operate an 7.
- Page 66 1.) There must be a call for heat and the blower must be diagram and method to use, select from the following engaged and configurations: A. HUMIDIFICATION CONTROL ONLy WITH NO 2.) The humidistat must determine that there is a need for DEHUMIDIFICATION (REqUIRES OPTIONAL humidification.
- Page 67 HUMIDIFICATION/DEHUMIDIFICATION B2. WITH NON-COMMUNICATING THERMOSTAT STAT”. A separate humidistat is not required for this (REqUIRES OPTIONAL HUMIDISTAT) configuration and the humidifier will turn on whenever there is a call for heat and the blower is running. Control of dehumidification only (no humidification)can be A2-2 CONTROLLED HUMIDIFIER OPERATION USING accomplished by installing an optional humidistat as A HUMIDISTAT (REqUIRES OPTIONAL HUMIDISTAT).
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Page 68: Integrated Furnace Control
HUMIDIFICATION/DEHUMIDIFICATION FIGURE 51 WIRING FOR OPTIONAL DE-HUMIDIFICATION AND HUMIDIFICATION (WITH OPTIONAL HUMIDIFIER) (HUMIDIFIER WITH INTERNAL POWER SUPPLy. NOTE: FOR USE WITH NON-COMMUNICATING SySTEMS. SWITCH #S2-8 MUST BE IN “ON” POSITION (NOTE: FACTORY SWITCH #S2-8 MUST BE IN “ON” POSITION POSITION IS “OFF”) TURNING THIS HUM STAT (NOTE: FACTORY POSITION IS ”OFF”). - Page 69 HUMIDIFICATION/DEHUMIDIFICATION FIGURE 52 HUMIDISTAT USED TO CONTROL DEHUMIDIFICATION IN COOLING ONLy (NO HUMIDIFIER) NOTE: FOR USE WITH NON-COMMUNICATING THERMOSTATS. HUMIDISTAT HUM STAT (24V) HUMIDISTAT (24V) (CONTACTS (CONTACTS OPEN WHEN HUMIDITY OPEN IS ABOVE SET POINT) WHEN HUMIDITY IS ABOVE SET POINT) OAT1 OAT2...
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Page 70: Dipswitches
DIPSWITCHES FIGURE 53 DIPSWITCH MAP... - Page 71 DIPSWITCHES OFF/OFF- NORMAL OPERATION – MODULATING OR OFF/ON- HIGH HEAT SINGLE RATE MODE TIMED STAGING HEAT When SW10 is “OFF” and SW11 is “ON”, the furnace will When both Mode dipswitches are set to the “OFF” posi- operate in the 100% heat mode with any legacy call for tion, the furnace operates as normal to a legacy modulat- heat (first stage, second stage or modulating).
- Page 72 INTEGRATED FURNACE CONTROL SW16 (“2F/4F”) is mapped as follows: without the correct furnace model data. When no furnace model data is present either on the model data card or on SW16 OFF = 2 Deg F Temperature Rise Adjustment* the furnace microprocessor a "d1 " (NO MODEL DATA) SW16 ON = 4 Deg F Temperature Rise Adjustment.
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Page 73: Dual 7-Segment Display
DUAL SEVEN SEGMENT DISPLAy numbers. Therefore, fault code priority 1 has the highest row, the control enters one-hour lockout and fault priority and shall be displayed when present regardless of codes “10” and “11” will be displayed alternately as any other fault that might also be present at the same described above (A-D). -
Page 74: Pushbutton
DUAL SEVEN SEGMENT DISPLAy switch make (close) RPM is greater than the high The fault and mode codes and fault priorities are listed pressure switch make (close) RPM or, if the low pres- below. Priority is to be used to determine which fault to dis- sure switch break (open) RPM is greater than the high play when two or more faults are present simultaneously. - Page 75 INTEGRATED FURNACE CONTROL PUSHBUTTON Step Info CFM- “1000's” & CFM- “ten’s” and “100’s” place “one’s” place delay delay Time (sec) Example (1246) “12” “46” Example (721) “7” (right segment) “21” Airflow display Displayed CFM range is between 100 and 9999 per fol- lowing sequence: The sequence repeats until the status menu is exited or the pushbutton is pressed again.
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Page 76: Supply & Outdoor Air Temp Sensors
INTEGRATED FURNACE CONTROL SUPPLy AND OUTDOOR AIR TEMPERATURE SENSORS the sensor was determined to be present and then is opened the control should display a fault "82". The fault is 17. AUxILIARy INPUTS (COMMUNICATING SySTEMS a level 1 fault and will not inhibit furnace operation. Also, if ONLy) (T5) (SEE FIGURE 55) the resistance between the terminals is determined to be Terminal T5 is provided for field installation of up to... -
Page 77: Auxiliary Inputs
INTEGRATED FURNACE CONTROL AUxILIARy INPUTS FIGURE 54 WIRING OF SUPPLy AIR (SA) AND OUTDOOR AIR (OAT) TEMPERATURE SENSORS. ST-A1194-63 (BOTTOM) NOTE: SUPPLY AIR SENSOR MUST NOT BE IN DIRECT LINE-OF-SIGHT TO ST-A1194-63-01 THE HEAT EXCHANGER. active furnace information at the thermostat and thermostat wire can be used to reduce or eliminate improved diagnostics and troubleshooting. -
Page 78: Thermostat Inputs
THERMOSTAT INPUTS FIGURE 55 WIRING OF AUxILIARy INPUTS (USE WITH COMMUNICATING SySTEMS ONLy). ST-A1194-63 (TOP) -
Page 79: Thermostat Wiring Diagrams-Communicating
INTEGRATED FURNACE CONTROL THERMOSTAT WIRING DIAGRAMS-COMMUNICATING FIGURE 56 WIRING DIAGRAM FOR A FULLy COMMUNICATING SySTEM. ST-A1217-01 A. WIRING OF FULLy COMMUNICATING SySTEMS. Additional EcoNet devices can be added to the system as shown in Figure 56. The approved wiring configuration is Figure 56 is the wiring diagram for connecting the furnace the daisy-chain configuration shown in Figure 56. -
Page 80: Non-Communicating
INTEGRATED FURNACE CONTROL THERMOSTAT WIRING DIAGRAMS-CONDENSING UNIT (NON-COMMUNICATING) FIGURE 57 WIRING DIAGRAM FOR NON-COMMUNICATING CONDENSER UNIT WITH COMMUNICATING FURNACE AND THERMOSTAT. A. WIRING DIAGRAM SPECIAL CONFIGURATION: COMMUNICATING THERMOSTAT AND FURNACE WITH NON-COMMUNICATING CONDENSER (SINGLE - STAGE ONLY CONDENSER) 125 FEET MAX. @ 18 GA. EcoNet COMMUNICATING THERMOSTAT (CONTROL CENTER) - Page 81 INTEGRATED FURNACE CONTROL THERMOSTAT WIRING DIAGRAMS-CONDENSING UNIT (NON-COMMUNICATING) FIGURE 58 WIRING DIAGRAM FOR LEGACy SINGLE-STAGE THERMOSTAT WITH AUTOSTAGING ST-A1194-61-04 C. CONDENSING SySTEMS W/LEGACy THERMOSTAT C1. WIRING OF A 1-STAGE LEGACY THERMOSTAT C2. WIRING OF A 2-STAGE LEGACY THERMOSTAT WITH AUTOSTAGING SELECTED (SEE FIGURE (SEE FIGURE 59).
- Page 82 INTEGRATED FURNACE CONTROL THERMOSTAT WIRING DIAGRAMS-CONDENSING UNIT (NON-COMMUNICATING) FIGURE 59 WIRING DIAGRAM FOR A LEGACy TWO-STAGE THERMOSTAT TWO-STAGE TWO-STAGE / MODULATING CONDENSER THERMOSTAT GAS FURNACE CONTROL UNIT (NON-COMMUNICATING) HUM STAT ST-A1194-62-04...
- Page 83 INTEGRATED FURNACE CONTROL THERMOSTAT WIRING DIAGRAMS-CONDENSING UNIT (NON-COMMUNICATING) D. SPECIAL CONFIGURATION – WIRING OF NON- COMMUNICATING HEAT-PUMPS WITH COMMUNICATING FURNACE AND THERMOSTAT (SEE FIGURE 60). FIGURE 60 WIRING DIAGRAM FOR NON-COMMUNICATING HEAT PUMPS WITH COMMUNICATING FURNACE AND THERMOSTAT ST-A1194-87-01...
- Page 84 INTEGRATED FURNACE CONTROL THERMOSTAT WIRING DIAGRAMS-CONDENSING UNIT (NON-COMMUNICATING) E. HEAT PUMP SySTEMS W/LEGACy THERMOSTATS E1. WIRING OF A SINGLE-STAGE LEGACY THERMOSTAT WITH AUTOSTAGING SELECTED (SEE FIGURE 61). FIGURE 61 WIRING DIAGRAM FOR A LEGACy SINGLE-STAGE THERMOSTAT WITH AUTOSTAGING. ST-A1194-92-01...
- Page 85 INTEGRATED FURNACE CONTROL THERMOSTAT WIRING DIAGRAMS-CONDENSING UNIT (NON-COMMUNICATING) E2. WIRING OF A TWO-STAGE LEGACY THERMO- STAT (SEE FIGURE 62) FIGURE 62 WIRING DIAGRAM FOR A LEGACy 2-STAGE THERMOSTAT TWO-STAGE / MODULATING GAS FURNACE CONTROL HUM STAT ST-A1194-93-01 19. 24VAC AND COMMON CONNECTIONS (E10/E11) 20.
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Page 86: Timing Diagram
TIMING DIAGRAM TABLE 16 TIMING DIAGRAM FOR A CALIBRATION GAS HEAT SEqUENCE... - Page 87 TIMING DIAGRAM TABLE 17 TIMING DIAGRAM FOR NON-CALIBRATION GAS HEAT SEqUENCE...
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Page 88: Maintenance
THESE INSTRUCTIONS ARE INTENDED AS AN AID TO FIRE, ELECTRICAL SHOCk, CARBON MONOxIDE POI- qUALIFIED SERVICE PERSONNEL FOR PROPER IN- SONING, ExPLOSION, PROPERTy DAMAGE, PER- STALLATION, ADJUSTMENT AND OPERATION OF THIS SONAL INJURy OR DEATH. UNIT. READ THESE INSTRUCTIONS THOROUGHLy BE- DISCONNECT MAIN ELECTRICAL POWER TO THE FORE ATTEMPTING INSTALLATION OR OPERATION. -
Page 89: System Operation Information
SySTEM OPERATION INFORMATION ADVISE THE CUSTOMER or radios to influence the thermostat operation. 6. Except for the mounting platform, keep all combustible 1. Keep the air filters clean. The heating system will op- articles 3 feet from the furnace and vent system. erate better, more efficiently and more economically. -
Page 90: Diagnostics And Troubleshooting
DETAILS OF BURNER FACE-IGNI- TOR ELECTRODE RELATIONSHIP (MODULATING FURNACE ONLy) The tip of the positive electrode must be inside the hatched area. .201 dimension from electrode to burner face must be maintained. Delayed ignitioin can result if these dimensions are not observed. FIGURE 63 FIGURE 64... -
Page 91: Normal Operation Codes
NOTE: Verify display orientation is correct before inter- Below are two lists; a list of standard operating codes and a list of fault codes. The fault code list provides diagnostic preting fault codes. Otherwise, the fault codes may be up- and troubleshooting information to help determine the side-down. - Page 92 TABLE 19 R98V FAULT CODES WITH DESCRIPTIONS AND SOLUTIONS...
- Page 93 TABLE 19 (continued) R98V FAULT CODES WITH DESCRIPTIONS AND SOLUTIONS...
- Page 94 TABLE 19 (continued) R98V FAULT CODES WITH DESCRIPTIONS AND SOLUTIONS...
- Page 95 TABLE 19 (continued) R98V FAULT CODES WITH DESCRIPTIONS AND SOLUTIONS...
- Page 96 TABLE 19 (continued) R98V FAULT CODES WITH DESCRIPTIONS AND SOLUTIONS...
- Page 97 TABLE 19 (continued) R98V FAULT CODES WITH DESCRIPTIONS AND SOLUTIONS...
- Page 98 TABLE 19 (continued) R98V FAULT CODES WITH DESCRIPTIONS AND SOLUTIONS...
- Page 99 TABLE 19 (continued) R98V FAULT CODES WITH DESCRIPTIONS AND SOLUTIONS...
- Page 100 TABLE 19 (continued) R98V FAULT CODES WITH DESCRIPTIONS AND SOLUTIONS...
- Page 101 TABLE 19 (continued) R98V FAULT CODES WITH DESCRIPTIONS AND SOLUTIONS...
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Page 102: Lockout
All lockout conditions can be cleared immediately pro- 3. The furnace control will declare that the blower motor is vided that the original fault causing the lockout is cleared inoperable (dead) if the main limit control has been open and power to the unit is cycled off and then back on again for more than 150 seconds. - Page 103 1. MOTOR POWER AND COMMUNICATIONS IS- B. Remove the motor control connector from the fur- SUES (FAULT CODE “68”) nace control at P5 and apply 24VAC to pins 3 & 4 (see photo). With the door switch closed (motor Is the motor communicating properly with the fur- powered) and 24VAC on pins 3 &...
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Page 104: Wiring Diagram
DIAGNOSING BLOWER MOTOR ISSUES B. Is the motor set-screw not tightened to the motor shaft? This may cause erratic motor operation and cause the furnace to display a “66” fault code. Further, airflow will be low or air may not be moving at all. - Page 108 CM 0717...
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