Daikin DM80VC Service Instructions Manual
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Daikin DM80VC Service Instructions Manual

Daikin DM80VC Service Instructions Manual

80% communicating gas furnaces
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Service Instructions

Daikin 80%
TM
Communicating
Gas Furnaces
DM80VC, DD80VC
This manual is to be used by qualified, professionally trained HVAC technicians only. Daikin does not
RSD6621001r6
assume any responsibility for property damage or personal injury due to improper service procedures
July 2016
or
services performed by an unqualified person.
Copyright © 2013 - 2014, 2016

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Summary of Contents for Daikin DM80VC

  • Page 1: Service Instructions

    Daikin 80% Communicating Gas Furnaces DM80VC, DD80VC This manual is to be used by qualified, professionally trained HVAC technicians only. Daikin does not RSD6621001r6 assume any responsibility for property damage or personal injury due to improper service procedures July 2016 services performed by an unqualified person.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS SYSTEM OPERATION COMFORTNET™ ...49 - 54 IMPORTANT INFORMATION ......3 - 4 PRODUCT IDENTIFICATION ......5 - 9 POLARIZATION AND PHASING ......55 MAINTENANCE ...........56 - 58 ACCESSORIES ..........10 SERVICING ..........59 - 77 OPERATING INSTRUCTIONS ....11 - 13 SERVICING TABLE OF CONTENTS ....

  • Page 3: Important Information

    IMPORTANT INFORMATION 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- DAIKIN BRAND PRODUCTS TOLL FREE 1-877-254-4729 (U.S. only) email us at: customerservice@daikincomfort.com fax us at: (713) 856-1821 (Not a technical assistance line for dealers.)

  • Page 4: Important Information

    IMPORTANT INFORMATION Advertencia especial para la instalación de calentadores ó manejadoras de aire en áreas cerradas como estacionamientos ó cuartos de servicio. Las emisiones de monóxido de carbono pueden circular a través del aparato cuando se opera en cualquier modo. CO can cause serious illness including permanent brain El monóxido de carbono puede causar enfermedades severas damage or death.

  • Page 5: Product Identification

    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.
  • Page 6 MODEL # MFG. # 80 % GAS FURNACES Daikin Brand 80% variable Speed Comunicating gas Furnace - 2 stage heat gas furnace, 33 3/8" DD80VC0603B* tall, Dedicated Downflow, 2-Stage induced Draft, Two-tone gray painted c abinet and front panels. Left...
  • Page 7 Communicating Thermostat Kit - Digitally communicating touchscreen thermostat from Honeywell. Designed for use with compatible Daikin® Brand Air Handlers or Furnaces and outdoor split AC or CTK03AA CTK03AA Heat Pump units.
  • Page 8 External Filter Rack Kit . For u se with Daikin upflow gas furnace models. This kit is intend ed to provide a location, externa l to the furnace casing, for installati on of a perma nent filter. The rack...

  • Page 9: Product Identification

    MODEL # MFG # DESCRIPTION LP Gas Low Pressure Kit. For use with Daikin furnaces converted to LP gas. This kit incl udes LPLP03 harne ss adaptors to wo rk with White-Rodgers single & two stage gas valves,Hone ywell single N/ A and two-stage gas valves, as well as modu lating gas valves.

  • Page 10: Accessories

    FRONT OF UNIT FILTER RACK ASSEMBLY (FACE FILTER OPENING BASE TOWARDS FRONT OF UNIT OF UNIT) RETURN AIR CUTOUT AREA LOWER EDGE SCREW Daikin DM80VC DD80VC Model Furnace Accessories MODEL NUMBER DM80VC0604B** ● ● ● ● ● DM80VC0805C** ● ●...

  • Page 11: Operating Instructions

    OPERATING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING WARNING: Improper If you do not follow these instructions exactly, alteration, service or a fire or explosion may result causing property maintenance can damage, personal injury or loss of life. cause injury or property damage.
  • Page 12 OPERATING INSTRUCTIONS CONSIGNES DE SECURITE - LIRE INSTRUCTIONS DE SERVICE AVANT D'ALLUMER L'APPAREIL 1. UN INSTANT! Lisez d'abord les consignes de securite ci-dessus. 2. Reglez le thermostat a son point le plus bas. AVERTISSEMENT: Le non-respect des instructions qui suivent peut 3.

  • Page 13: Operating Instructions

    OPERATING INSTRUCTIONS...

  • Page 14: Product Design

    O PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION, installation instructions. with the ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE, REFER TO THIS Daikin 80% furnaces are ETL certified appliances and are MANUAL. OR ADDITIONAL ASSISTANCE OR INFORMATION, CONSULT A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.
  • Page 15 PRODUCT DESIGN • Exposure to contaminated combustion air will result CSA International in safety and performance-related problems. Do not 8501 East Pleasant Valley install the furnace where the combustion air is ex- Cleveland, OH 44131 posed to the following substances: chlorinated waxes or cleaners A copy of the CAN/CGA B149 Installation Codes can be chlorine-based swimming pool chemicals...

  • Page 16: Furnace Suspension

    PRODUCT DESIGN A furnace installed in a confined space (i.e., a closet or Turn on clothes dryers and any appliance not connected to the utility room) must have two ventilation openings with a total venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum speed.
  • Page 17 PRODUCT DESIGN reduce the speed of the circulator blower during operation in and other fuel burning appliances. Appliances that pull air the cooling mode. To be compatible with these furnaces, a out of the house (clothes dryers, exhaust fans, fireplaces, dehumidistat must operate on 24 VAC and utilize a switch etc.) increase the problem by starving appliances for air.
  • Page 18 PRODUCT DESIGN 9.3.2.2* Known Air Infiltration Rate Method. Where the air infiltra- 9.3.3 Outdoor Combustion Air. Outdoor combustion air shall be pro- tion rate of a structure is known, the minimum required volume shall be vided through opening(s) to the outdoors in accordance with the meth- determined as follows: ods in 9.3.3.1 or 9.3.3.2.
  • Page 19 PRODUCT DESIGN (c) The minimum size of outdoor opening(s) shall be the full size Chimney or Gas Vent 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). NOTE: The air duct openings must have a free area of not less than one square inch per...
  • Page 20 PRODUCT DESIGN The minimum vent diameter for the Category I venting sys- 9.3.8.4 Ducts shall not serve both upper and lower combustion air tem is as shown in the following chart: openings where both such openings are used. The separation between ducts servicing upper and lower combustion air openings shall be main- MINIMUM VENT tained to the source of combustion air.

  • Page 21: Masonry Chimneys

    PRODUCT DESIGN Masonry Chimneys Proper Chimney Line, terminate with listed vent cap Termination? (Check 1) (Fix 1) Chimney channel free of solid and Change venting liquid fuel arrangements appliances? (Fix 2) (Check 2) Rebuild crown Crown in good (Fix 3) condition and/or Reline (Check 3)
  • Page 22 PRODUCT DESIGN 10' or Less 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 condi- 2' Min. 2' Min. 3' Min. tion of the crown is not satisfactory: a) Crown leaning b) Bricks missing Wall or...
  • Page 23 PRODUCT DESIGN • Extremely cold weather Flexible liners should be hung straight or nearly straight. If it is spiraled in the chimney and in good condition, it should • Long vent connectors be rehung. To do this, break the top seal; pull up and cut off •...
  • Page 24 PRODUCT DESIGN If B vent is to be used, it must be supported adequately. Some manufacturers of flexible liners offer an insulation sleeve Supports (such as fire stops or thimbles) must be used to designed to be added to the liner before it is installed in the prevent the B vent from coming into direct contact with the chimney.
  • Page 25 PRODUCT DESIGN Alternate Electrical and Gas Line Connections GAS SUPPLY AND PIPING Furnaces have provisions allowing for electrical and gas line The furnace rating plate includes the approved furnace gas connections through either side panel. In horizontal applica- input rating and gas types. The furnace must be equipped to tions the connections can be made either through the “top”...
  • Page 26 PRODUCT DESIGN PROPANE GAS CONVERSION Natural Gas Capacity of Pipe In Cubic Feet of Gas Per Hour (CFH) Length of Nominal Black Pipe Size Pipe in Feet 1/2" 3/4" 1" 1 1/4" 1 1/2" 1050 1600 1100 This unit is configured for natural gas. The appropriate manufacturer’s propane gas conversion kit, must be applied for propane gas installations.
  • Page 27 PRODUCT DESIGN NOTE: Never exceed specified pressures for testing. Higher – Semi-rigid metallic tubing and metallic fittings. Alu- minum alloy tubing must not be used in exterior loca- pressure may damage the gas valve and cause subsequent tions. In order to seal the grommet cabinet penetra- overfiring, resulting in heat exchanger failure.

  • Page 28: Propane Gas Piping Charts

    PRODUCT DESIGN Sizing Between Second or Second Stage Regulator & Appliance* 5 to 15 PSIG First Stage Maximum Propane Capacities listed are based on 1/2" W.C. pressure drop at 11" W.C. setting. (20 PSIG Max.) Regulator Continuous Capacities in 1,000 BTU/hour. 11"...
  • Page 29 PRODUCT DESIGN Refer to the wiring diagram for wire routings. If any of the Furnaces have an integrated ignition control that is original wire as supplied with the furnace must be replaced, equipped with line voltage accessory terminals for con- it must be replaced with wiring material having a tempera- trolling power to an optional field-supplied humidifier ture rating of at least 105°...
  • Page 30 PRODUCT DESIGN Humidifier Wiring Low voltage connections can be made through either the right or left side panel. Thermostat wiring entrance holes There are several options for connecting humidifier wiring to are located in the blower compartment. The following figure the current communicating furnace control board shows connections for a “heat only”...
  • Page 31 PRODUCT DESIGN Place Jumper Between Y1 Thermostat DEHUM and O For Proper Move to the ON position Two-Stage Heating Dehumidification Operation with and Proper Ramping to enable dehumidification Single-Stage Cooling TRIM ENABLE Profile Operation PCBKF103 / PCBKF104 / PCBKF105 Furnace Integrated Control Module 24 Volt Dehumidistat Wiring - Two-Stage Variable Speed ComfortNet™...
  • Page 32 PRODUCT DESIGN A heat pump thermostat with two stages of heat is required TWO STAGE 2-STAGE VARIABLE SPEED COMFORTNET™ FURNACES (WR50C51) to properly use the single-stage furnace with a heat pump. A heat pump thermostat with three stages of heat is re- This furnace is equipped with a multi-speed circulator blower.
  • Page 33 PRODUCT DESIGN 8. Select the desired “heating” speed tap by positioning 4. Continuous fan speeds that provide 25, 50, 75 and 100% switches S4- 3, 4 appropriately. Refer to figure above. of the furnace’s maximum airflow capability are select- Verify CFM by noting the number displayed on the dual able via dip switches S5- 3, 4.

  • Page 34: Air Flow Data

    PRODUCT DESIGN Profile D ramps up to 50% of the demand for 1/2 • SWITCH minute, then ramps to 85% of the full cooling demand airflow and operates there for approximately 7 1/2 min- Add 5% OF F utes. The motor then steps up to the full demand air- Minus 5% flow.
  • Page 35 PRODUCT DESIGN DIP SWITCHES Dip Switch Switch Bank Purpose Function Heating Off Delay 2 Stage Stat 2 Stage Stat Thermostat Setup 1 Stg Stat 5 min delay 1 Stg Stat auto delay Cooling Airflow Add 5% Minus 5% Trim Add 10% Minus 10% Ramping Profile Heating Airflow...
  • Page 36 PRODUCT DESIGN CIRCULATING AIR AND FILTERS When the furnace is used in connection with a cooling unit, DUCTWORK - AIR FLOW the furnace should be installed in parallel with or on the up- stream side of the cooling unit to avoid condensation in the Duct systems and register sizes must be properly designed heating element.
  • Page 37 PRODUCT DESIGN Horizontal Installations Filter(s) must be installed external to the furnace casing for horizontal installations. For most installations it is prefer- Return Air able to use a central return with filters installed in the duct behind the return air grill. In this way filter replacement is Optional relatively simple by merely removing the grille, rather than Access...

  • Page 38: System Operation

    SYSTEM OPERATION NORMAL SEQUENCE OF OPERATION the induced draft blower and gas valve to their low stage settings. The circulator blower will remain on OWER high heating speed for thirty (30) seconds before The normal power up sequence is as follows: switching to the low heat circulating speed.
  • Page 39 SYSTEM OPERATION 11. Electronic air cleaner terminals and circulator blower • Electronic air cleaner terminal and circulator blower are de-energized. are de-energized. • Furnace awaits next call from thermostat. 12. Furnace awaits next call from thermostat. HEATING - Abnormal Operation The normal operational sequence in fan only mode is as The following presents the probable causes of questionable follows:...
  • Page 40 SYSTEM OPERATION 7. Open Fuse. If the control detects an open fuse, it will Chart - ComfortNet™ have been verified. inhibit all furnace operation, except the display of the 2. System Lockout. If a flame is not sensed during the error code.
  • Page 41 SYSTEM OPERATION 14. Invalid Memory Card Data. This condition occurs if tor will reduce its output to prevent exceeding its power limit. This will result in lower than demanded airflow. the control rejects the shared data set on a memory This will occur under high loading conditions.

  • Page 42: System Operation

    SYSTEM OPERATION 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 abnor- mal condition is present. If the abnormal condition is cleared, the motor will restart.

  • Page 43: Troubleshooting

    TROUBLESHOOTING PCBKF103 / PCBKF104 / PCBKF105 ComfortNet™ Symptoms of Abnormal Diagnostic/ Thermostat Only Operation (Legacy & Status LED Fault Description Possible Causes Corrective Actions Notes & Cautions ComfortNet™ Thermostat) Codes Message Code • Furnace fails to operate None • No 115 power to INTERNAL •...
  • Page 44 TROUBLESHOOTING PCBKF103 / PCBKF104 / PCBKF105 Symptoms of Abnormal ComfortNet™ Diagnostic/ Operation (Legacy Thermostat Only Status LED Fault Description Possible Causes Corrective Actions Notes & Cautions & ComfortNet™ Codes Message Code Thermostat) • Induced draft blower • Low stage PS1 OPEN •...
  • Page 45 TROUBLESHOOTING PCBKF103 / PCBKF104 / PCBKF105 ComfortNet™ Symptoms of Abnormal Diagnostic/ Thermostat Only Operation (Legacy Status LED Fault Description Possible Causes Corrective Actions Notes & Cautions & ComfortNet™ Codes Message Code Thermostat) • Furnace fails to operate. • Problem with IGNITER •...
  • Page 46 TROUBLESHOOTING PCBKF103 / PCBKF104 / PCBKF105 ComfortNet™ Symptoms of Abnormal Diagnostic/ Thermostat Only Operation (Legacy Status LED Fault Description Possible Causes Corrective Actions Notes & Cautions & ComfortNet™ Codes Message Code Thermostat) • Operation different than • Invalid memory INVALID MC •...
  • Page 47 TROUBLESHOOTING PCBKF103 / PCBKF104 / PCBKF105 ComfortNet™ Symptoms of Abnormal Diagnostic/ Thermostat Only Operation (Legacy Status LED Fault Description Possible Causes Corrective Actions Notes & Cautions & ComfortNet™ Codes Message Code Thermostat) • Circulator blower MOTOR • Turn power OFF prior •...

  • Page 48: Troubleshooting

    TROUBLESHOOTING PCBKF103 / PCBKF104 / PCBKF105 INTERNAL CONTROL FAULT/NO POWER NORMAL OPERATION LOCKOUT DUE TO EXCESSIVE RETRIES 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...

  • Page 49: System Operation Comfortnet

    SYSTEM OPERATION ComfortNet™ System ComfortNet System 4. Dehumidification (lowering of CFM to 85%) only happens during low stage cooling operation. The dehumidification VERVIEW feature is not active during high stage cool. The CTK03A* The ComfortNet system is a system that includes a and the CTK04A* can be set up to overcool the home in ComfortNet compatible furnace and air conditioner or heat order to reach the RH set point.
  • Page 50 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. CTK0*** Thermostat If your communicating thermostat kit does not include a transformer, an accessory kit is available by ordering part ComfortNet TFK01.
  • Page 51 SYSTEM OPERATION ComfortNet™ System URNACE DVANCED EATURES ENUS 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)
  • Page 52 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 Selects the airflow for the non-CT is 18 compatible single stage AC unit...
  • Page 53 ComfortNet™ System SYSTEM OPERATION YSTEM ROUBLESHOOTING 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. 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.
  • Page 54 SYSTEM OPERATION ComfortNet™ System TROUBLESHOOTING Wiring issues may be confirmed (or eliminated) by using the CTK0*** thermostat and sub base, a 4-position connec- (ESD) P LECTROSTATIC ISCHARGE RECAUTIONS tor (included with the kit), and a short section (~ 2ft) of ther- mostat wire.

  • Page 55: Polarization And Phasing

    POLARIZATION AND PHASING As more and more electronic's are introduced to the Heat- INCOMING POWER METER READS METER READS ing Trade, Polarization of incoming power and phasing of 120 VOLTS 0 VOLTS primary to secondary voltage on transformers becomes more important. Polarization has been apparent in the Appliance industry VOLT / OHM VOLT / OHM...

  • Page 56: Maintenance

    MAINTENANCE WARNING HIGH VOLTAGE ISCONNECT POWER BEFORE SERVICING OR C o d e s ) . INSTALLING THIS UNIT. ULTIPLE POWER SOURCES MAY BE PRESENT. AILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. Maintenance CAUTION Improper filter maintenance is the most common cause of F YOU MUST HANDLE THE ITNITOR, HANDLE WITH CARE.
  • Page 57 MAINTENANCE FLUE PASSAGES (QUALIFIED SERVICER ONLY) 3. Volt-Ohm Meter - testing continuity, capacitors, and motor windings. At the start of each heating season, inspect and, if neces- sary, clean the furnace flue passages. 4. Inclined Manometer - to measure static pressure, pressure drop across coils, filters, and draft.
  • Page 58 MAINTENANCE With propane gas, no unit gas valve regulator is used; how- CAUTION ever, the second stage supply line pressure regulator should be adjusted to give 11" water column with all other gas con- LWAYS CONNECT A MONOMETER TO THE OUTLET TAP AT THE GAS suming appliances running.

  • Page 59: Servicing

    SERVICING SERVICING TABLE OF CONTENTS CHECKING VOLTAGE ..........................62 CHECKING WIRING ............................ 62 S-3A THERMOSTAT AND WIRING ........................62 S-3B HEATING ANTICIPATOR ..........................62 CHECKING TRANSFORMER AND CONTROL CIRCUIT ................63 S-16A CHECKING AIR CIRCULATOR BLOWER MOTOR (ECM) ................63 S-200 CHECKING DUCT STATIC ...........................
  • Page 60 SERVICING CUBIC FEET GAS RATE -- CUBIC FEET PER HOUR Size of Test Dial Size of Test Dial Seconds for Seconds for cu/ft cu/ft cu/ft cu/ft cu/ft cu/ft cu/ft cu/ft cu/ft cu/ft Revolution Revolution 1800 1636 1500 1385 1286 1200 1125 1059 1000...
  • Page 61 SERVICING Service Problem No Heat Unsatisfactory Heat POSSIBLE CAUSE Test Method DOTS IN ANALYSIS Remedy GUIDE INDICATE "POSSIBLE CAUSE" • Power Failure Test Voltage • Blown Fuse Test Voltage • Loose Connection Check Wiring • Shorted or Broken Wires Check Wiring S-3A •...

  • Page 62: Checking Voltage

    SERVICING CHECKING THERMOSTAT, WIRING S-1 CHECKING VOLTAGE AND ANTICIPATOR WARNING S-3A THERMOSTAT AND WIRING HIGH VOLTAGE WARNING ISCONNECT POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING. ULTIPLE POWER SOURCES MAY BE PRESENT. AILURE TO DO SO MAY CAUSE ISCONNECT POWER BEFORE SERVICING. PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

  • Page 63: Checking Transformer And Control Circuit

    SERVICING 3. Use a voltmeter, check voltage across terminals R If the anticipator current draw is unknown, then a current and C. Must read 24 VAC. amp draw should be measured to determine the anticipator setting. Use an amprobe as shown in the following drawing. 4.
  • Page 64 SERVICING correct connector orientation before applying power. DO NOT 5. Connect the other alligator clip to a 24VAC source. force plug into motor and make sure power is off before in- NOTE: The alligator clips are NOT polarized. serting power connector. DO NOT apply voltage to terminals NOTE: The UltraCheck-EZ diagnostic tool is equipped 1 or 2.
  • Page 65 SERVICING Electrical Checks - High Voltage Power Circuits 8. Disconnect power to the furnace. Reconnect the 5- circuit power harness disconnected in step 2. Electrical Checks - Low Voltage Control Circuits HIGH VOLTAGE! 1. Turn on power to the furnace. Disconnect ALL power before servicing or installing.

  • Page 66: Checking Duct Static

    SERVICING 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.

  • Page 67: Checking Temperature Rise

    SERVICING SUPPLY SUPPLY CUTAWAY OF DUCTWORK TO EXPOSE COIL INCLINED MANOMETER Amana Elec tr onic Ai r Cleaner Ca ution High Voltage T o a void per sonal in j u ry, wait 15 secon ds afte r de -ene rgizing u nit b efore touch i n g unit i n terior .

  • Page 68: Checking Auxiliary Limit Control

    SERVICING Location of Primary Limit VOLT / OHM METER Testing Primary Limit Control (80% Furnaces) Primary Limit Control Location 4. After completing check and/or replacement of primary (80% Upflow Furnace Shown, Counterflow Similar) limit control, reinstall burner compartment door. 5. Turn on electrical power and verify proper unit opera- Style 1 drawing illustrates the Primary Limit used on the tion.

  • Page 69: S-302 Checking Flame Rollout Control

    SERVICING 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. BLOWER HOUSING ROLLOUT SWITCH AUXILIARY LIMIT CONTROL Auxiliary Limit Control Location (80% Single-Stage Furnaces) Flame Rollout Switch Location (80% Upflow Furnace Shown, Downflow Similar) WARNING...

  • Page 70: Induced Draft Blower Motor

    SERVICING 7. Turn on electrical power and verify proper unit opera- tion. S-304 CHECKING GAS VALVE (Redundant) A combination redundant operator type gas valve which pro- vides all manual and automatic control functions required VOLT / OHM METER for gas fired heating equipment is used. The valve provides control of main burner gas flow, pres- sure regulation, and 100 percent safety shut-off.

  • Page 71: Checking Gas Pressure

    SERVICING The line pressure supplied to the gas valve must be within The only time resizing is required is when a reduction in the range specified below. The supply pressure can be mea- firing rate is required for an increase in altitude. sured at the gas valve inlet pressure tap or at a hose fitting Orifices should be treated with care in order to prevent dam- installed in the gas piping drip leg.
  • Page 72 SERVICING 2. Connect a calibrated water manometer (or appropriate INLET GAS SUPPLY PRESSURE gas pressure gauge) at the gas valve outlet pressure Natural Gas Minimum: 4.5" w.c. Maximum: 10.0" w.c. tap. Refer to Measuring Gas Pressure: Two-Stage Valves Propane Gas Minimum: 11.0"...
  • Page 73 SERVICING f. Remove regulator cover screw from the low (LO) outlet pressure regulator adjust tower and turn screw clock- High Fire Regulator wise to increase pressure or counterclockwise to de- Adjust Regulator Vent crease pressure. Replace regulator cover screw. g. Close thermostat R + W1 + W2 contacts to provide a call for high stage heat.

  • Page 74: Checking Hot Surface Ignitor

    SERVICING Manifold Gas Pressure S-310 CHECKING PRESSURE SWITCH Rate Range Nominal The pressure control is a safety device to prevent the com- High Stage 9.7 to 10.3" w.c. 10.0" w.c. bustion cycle from occurring with inadequate venting caused Propane Gas by a restricted or blocked vent pipe on the 80% and 90% Low Stage 5.7 to 6.3"...

  • Page 75: High Altitude Application (Usa)

    SERVICING S-312 CHECKING FOR DELAYED IGNITION Induced Draft Blower Pressure Switch Delayed ignition is a delay in lighting a combustible mix- Pressure Switch Hose ture of gas and air which has accumulated in the combus- tion chamber. 1/4" Tee When the mixture does ignite, it may explode and/or rollout causing burning in the burner venturi.
  • Page 76 SERVICING When the control is powered up normally the light will be on continuously. The display wil indicate "ON" when pow- ered 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.

  • Page 77: S-314 Checking Flame Sensor

    SERVICING S-314 CHECKING FLAME SENSOR A flame sensing device is used in conjunction with the igni- tion 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 ISCONNECT...

  • Page 78: Accessories Wiring Diagrams

    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 P1-8 +VDC POWER SUPPLY...
  • Page 79 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 WHITE BLACK GREEN DE-HUMIDISTAT DE-HUMIDISTAT - DEHUM1...
  • Page 80 SCHEMATICS 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 CONTROL MODULE LINE LOAD TRANSFORMER INDUCTOR COIL Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.
  • Page 81 SCHEMATICS 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. Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

  • Page 82: Wiring Diagrams

    WIRING DIAGRAMS DM80VC/DD80VC Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

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