Table of Contents
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F96CTN and G96CTN (Series A)
Two-Stage, Variable-Speed, Multipoise
35 in. (889 mm) Tall, Condensing Gas Furnace
NOTE: Read the entire instruction manual before starting the installation.
TABLE OF CONTENTS
IMPORTANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Table 1 - Minimum Clearances to Combustible Materials for All Units
5
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table 2 - Loose Parts Bag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CODES AND STANDARDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
AIR FOR COMBUSTION AND VENTILATION . . . . . . . . . . . . . . 7
Table 3 - Minimum Free Area Required for Each Combustion Air
Opening or Duct to Outdoors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Table 4 - Minimum Space Volumes for 100% Combustion, Ventila-
tion and Dilution Air from Outdoors . . . . . . . . . . . . . . . . . . . . . . . 9
CONDENSATE TRAP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Condensate Drain Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Table 5 - Opening Dimensions - In. (mm) . . . . . . . . . . . . . . . . . 16
Table 6 - Air Filter Selection and Duct Sizing - In. (mm) . . . . . 18
Table 7 - Filter Media Pressure Drop (Clean) Versus Airflow - In.
W.C. (Pa) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Table 8 - Filter Media Pressure Drop (Clean) Versus Face Velocity-
In. W.C. (Pa) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
AIR DUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
GAS PIPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Table 9 - Maximum Capacity of Pipe . . . . . . . . . . . . . . . . . . . . . 22
ELECTRICAL CONNECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
115-V Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Table 10 - Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
24-V Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
VENTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Table 11 - Vent Termination Kit for Direct Vent (2-pipe) Systems31
Table 12 - Maximum Allowable Exposed Vent Lengths Insulation Ta-
ble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Table 13 - Maximum Equivalent Vent Length - Ft. . . . . . . . . . . 42
Table 14 - Deductions from Maximum Equivalent Vent Length - Ft.
(M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Table 15 - Hanger Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Table 16 - Approved Combustion-Air and Vent Pipe, Fitting and Ce-
ment Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
START-UP, ADJUSTMENT, AND SAFETY CHECK . . . . . . . . . 50
Table 17 - Cooling4 and Heating Air Delivery - CFM (Bottom Re-
turn5 with Filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Table 18 - Altitude Derate Multiplier for U.S.A. . . . . . . . . . . . . 55
Portions of the text and tables are reprinted from NFPA 54/ANSI Z223.1E, with permission of National Fire Protection Association, Quincy, MA
02269 and American Gas Association, Washington DC 20001. This reprinted material is not the complete and official position of the NFPA or ANSI
Installation, Start-up, Operating,
Service and Maintenance Instructions
on the referenced subject, which is represented only by the standard in its entirety.
Table 19 - Blower Off Delay Setup Switch . . . . . . . . . . . . . . . . 58
Table 20 - Orifice Size and Manifold Pressure (In. W.C.) for Gas Input
Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Table 21 - Gas Rate (CU ft./hr). . . . . . . . . . . . . . . . . . . . . . . . . . 60
SERVICE AND MAINTENANCE PROCEDURES. . . . . . . . . . . . 60
WINTERIZATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
PARTS REPLACEMENT INFORMATION GUIDE . . . . . . . . . . . 75
MODEL NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
WARNING
!
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury and/or
death.
Carbon Monoxide (CO) is a colorless, odorless, and tasteless poisonous
gas that can be fatal when inhaled. Follow all installation, maintenance,
and service instructions. See additional information below regarding
the installation of a CO Alarm.
Most states in the USA and jurisdictions in Canada have laws that
require the use of Carbon Monoxide (CO) alarms with fuel burning
products. Examples of fuel burning products are furnaces, boilers, space
heaters, generators, water heaters, stoves/ranges, clothes dryers,
fireplaces, incinerators, automobiles, and other internal combustion
engines. Even if there are no laws in your jurisdiction requiring a CO
Alarm, it's highly recommended that whenever any fuel burning product
is used in or around the home or business that the dwelling be equipped
with a CO Alarm(s). The Consumer Product Safety Commission
recommends the use of CO Alarm(s). The CO Alarm(s) must be
installed, operated, and maintained according to the CO Alarm
manufacturer's instructions. For more information about Carbon
Monoxide, local laws, or to purchase a CO Alarm online, please visit the
following website. https://www.kidde.com.
Use of the AHRI Certified TM Mark indicates
a manufacturer's participation in the program.
For verification of certification for individual
products, go to www.ahridirectory.org .
A200326
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Page 1: Table Of Contents
F96CTN and G96CTN (Series A) Two-Stage, Variable-Speed, Multipoise 35 in. (889 mm) Tall, Condensing Gas Furnace Installation, Start-up, Operating, Service and Maintenance Instructions NOTE: Read the entire instruction manual before starting the installation. TABLE OF CONTENTS Table 19 – Blower Off Delay Setup Switch ....58 REQUIRED NOTICE FOR MASSACHUSETTS INSTALLATIONS2 Table 20 –... -
Page 2: Required Notice For Massachusetts Installations2
F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions REQUIRED NOTICE FOR MASSACHUSETTS INSTALLATIONS IMPORTANT The Commonwealth of Massachusetts requires compliance with regulation 248 CMR as follows: 5.08: Modifications to NFPA-54, Chapter 10 2) Revise 10.8.3 by adding the following additional requirements: a. -
Page 3: Safety Considerations
F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions NOTE: ALL DIMENSIONS IN INCH (MM) U.S. ECCN: Not Subject to Regulation (N.S.R.) SD5660-4 REV. - A210210 SHIP WT. FURNACE SIZE LB (KG) CABINET WIDTH OUTLET WIDTH BOTTOM INLET WIDTH AIR INTAKE 0601714 17-1/2 (445) - Page 4 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions exceed certain local codes and ordinances, especially those that may not WARNING have kept up with changing residential construction practices. We require these instructions as a minimum for a safe installation. FIRE, EXPLOSION, ELECTRICAL SHOCK, AND Follow all safety codes.
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Page 5: Introduction
F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions Table 1 – Minimum Clearances to Combustible Materials for All temperature limits may affect reliability of heat exchangers, motors, and Units controls. See Fig. POSITION CLEARANCE Rear 0 (0 mm) SUPPLY AIR Front (Combustion air openings in 1 in. -
Page 6: Codes And Standards
F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions Acoustical Lining and Fibrous Glass Duct WARNING • US and CANADA: Current edition of SMACNA, NFPA 90B as tested by UL Standard 181 for Class I Rigid Air Ducts FIRE, INJURY OR DEATH HAZARD Gas Piping and Gas Pipe Pressure Testing Failure to follow this warning could result in personal injury, death... -
Page 7: Accessories
F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions ACCESSORIES WARNING See Specification Sheet for a list of accessories for this product. LOCATION CARBON MONOXIDE POISONING / COMPONENT DAMAGE HAZARD CAUTION Failure to follow this warning could result in personal injury or death and unit component damage. - Page 8 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions Ventilated Combustion Air Applications (for U.S. Only) The requirements for combustion and ventilation air depend upon whether or not the furnace is located in a space having a volume of at When the furnace is installed using the ventilated combustion air option, least 50 cubic feet per 1,000 BTUh input rating for all gas appliances the attic or crawlspace must freely communicate with the outdoor to...
- Page 9 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions EXAMPLES: Determining Free Area FURNACE WATER HEATER TOTAL INPUT 100,000 30,000 (130,000 divided by 4,000) 32.5 Sq. In. for each two Vertical Ducts or Openings 60,000 40,000 (100,000 divided by 3,000) 33.3 Sq.
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Page 10: Condensate Trap
F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions 2. An attic or crawlspace may be considered a space that freely WARNING communicates with the outdoors provided there are adequate permanent ventilation openings directly to outdoors having free CARBON MONOXIDE POISONING HAZARD area of at least 1-in.2/4,000 BTUh of total input rating for all gas appliances in the space. - Page 11 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions Vent Pipe Clamp Condensate Trap Vent Elbow Clamp Relief Port Collector Box Plugs Vent Elbow Collector Box Plug Condensate Trap Relief Port Condensate Trap Pressure Switch Outlet Port UPFLOW TRAP CONFIGURATION 1 &...
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Page 12: Condensate Drain Connection
F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions NOTICE Evaporator Coil + + + + = Positive pressure The field-supplied, accessory horizontal drain trap grommet is ONLY < + = Pressure lower than areas with + = Negative pressure REQUIRED FOR DIRECT VENT APPLICATIONS. - Page 13 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions pad and replaces the factory-installed condensate trap. Refer to the Accessory section of the Specification Sheet for current kit number. A self-regulating, shielded and waterproof heat tape rated at 3 to 6 watt per foot (10 to 20 watt per meter) at 115 volt, 40°F (4°C) may be used to provide freeze protection of the remaining condensate drain line.
- Page 14 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions grommet at the opposite side of the furnace as necessary for proper fit and positioning. In both upflow and downflow orientations, the Z-pipe should NOT be resting on any sheet metal parts. 13.
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Page 15: Installation
F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions condensate and compatible with mineral and vegetable oils, such as UPFLOW DOWNFLOW HORIZONTAL canola oil. PERFORATED DISCHARGE DUCT 90° 90° FLANGE Allow at least 1/4-in. per foot (20 mm per meter) of slope down and away from the furnace in horizontal sections of drain line. - Page 16 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions HORIZONTAL TOP RETURN NOT PERMITTED FOR ANY MODEL BOTTOM CLOSURE SCREWS (2) Representative drawing. Models may vary. Lay furnace on the back or side Remove the two (2) screws that secure the bottom closure panel to the furnace casing and remove the panel A170123...
- Page 17 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions FURNACE FURNACE (OR COIL CASING WHEN USED) APPROVED COIL ASSEMBLY COIL BOX COMBUSTIBLE COMBUSTIBLE FLOORING FLOORING PLENUM OPENING DOWNFLOW SUBBASE SHEET METAL PLENUM FLOOR SHEET METAL PLENUM OPENING FLOOR FLOOR OPENING...
- Page 18 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions The furnace can be installed horizontally in an attic or crawlspace on A filter rack or any field supplied accessory air cleaner can also be either the left-hand (LH) or right-hand (RH) side. The furnace can be installed in the common return duct prior to entering the return air hung from floor joists, rafters or trusses or installed on a opening in any orientation.
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Page 19: Pa)
F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions Table 7 – Filter Media Pressure Drop (Clean) Versus Airflow - In. W.C. (Pa) Representative After-Market Filter Media 14 x 25 Filter Factory-Accessory (356 x 635 mm) Washable Fiberglass Pleated (1-in. -
Page 20: Air Ducts
F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions AIR DUCTS 5. Reinstall bottom closure panel if removed. ″ 5/ 16 NOTICE (8mm) (8mm) Many states, provinces and localities are considering or have ″ 5/ 16 implemented standards and/or restrictions on duct sizing practices, ductwork leakage, and/or ductwork thermal, airflow and electrical ″... -
Page 21: Gas Piping
F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions GAS PIPING COMBUSTION - AIR PIPE (SEE VENTING SECTION) WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury, death, and/or property damage. Never purge a gas line into a combustion chamber. - Page 22 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions PRESSURE TESTING ABOVE ½ psig: Left Side Gas Entry. Gas Pipe Gas Pipe Grommet Required Grommet Required For Direct The furnace and it’s individual shut-off valve must be disconnected from For Direct Vent Applications Vent Applications.
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Page 23: Electrical Connections
F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions supply pipe pressure test. After all connections have been made, purge WARNING lines and check for leakage at furnace prior to operating furnace. The gas supply pressure shall be within the maximum and minimum ELECTRICAL SHOCK AND FIRE HAZARD inlet supply pressures marked on the rating plate with the furnace burners ON and OFF. - Page 24 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions WARNING FIRE HAZARD Failure to follow this warning could result in personal injury, death, or property damage. Do not connect aluminum wire between disconnect switch and furnace. Use only copper wire. See Fig.
- Page 25 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions 1. Select and remove 7/8-in. (22 mm) knock-out on the desired side of the casing. Remove the knock-out from the casing. NOTE: If electrical entry through the furnace top panel is used, a 7/8-in. (22 mm) hole must be drilled through the top panel.
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Page 26: 24-V Wiring
F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions 3. Communication Connector (communication connection) WARNING This connection is used when the furnace is controlled by an optional communicating User Interface instead of a standard FIRE, EXPLOSION, ELECTRICAL SHOCK, AND thermostat. - Page 27 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions To HUM Terminal On To Humidifier Leads Furnace Control Board 24 V Coil To Humidifier Leads To Com/24V Screw Terminal on Thermostat Strip A11157 Fig. 37 – Field-supplied Isolation Relay for Humidifiers with Internal Power Supply MODEL PLUG SW1 SETUP OUTDOOR...
- Page 28 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions NOTE 9 L09F027 L09F025 L09F026 L09F028 Fig. 39 – Thermostat Wiring Diagrams NOTES FOR THERMOSTAT WIRING DIAGRAMS 1. Refer to outdoor equipment Installation Instructions for additional information and setup procedure. 2.
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Page 29: Venting
F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions VENTING utilisé avec les Royal Pipe. Système IPEX 636, apprêt PVC/CPVC, Purple pour évacuation des gaz de combustion et système IPEX 636(1)t, NOTE: Planning for the venting system should be done in conjunction ciment PVC pour évacuation des gaz de combustion, coté... - Page 30 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions General Venting Systems If this furnace replaces a furnace that was connected to a vent system or WARNING chimney, the vent or vent connectors of other remaining appliances may need to be re-sized.
- Page 31 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions Non-Direct Vent (1-pipe) System WARNING In a non direct-vent (1-pipe) system, all air for combustion is taken from the area adjacent to furnace, and all flue products are discharged to CARBON MONOXIDE POISONING HAZARD outdoor atmosphere.
- Page 32 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions Locating the Vent Termination NOTICE General NOTE: Termination Requirements for the Provinces of Alberta and RECOMMENDED SUPPORT FOR VENT Saskatchewan are located at the end of this section. TERMINATIONS Combustion-air inlet pipe (direct vent/2-pipe system only) and vent pipe It is recommended that sidewall vent terminations in excess of 24...
- Page 33 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions Direct Vent / 2-Pipe System WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow the instructions outlined below for each appliance being placed into operation could result in carbon monoxide poisoning or death.
- Page 34 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions A12326 Fig. 45 – Direct Vent Termination Clearance NOTE: The following is based upon National codes for gas appliances and is provided as a reference. Refer to local codes which may supersede these standards and/or recommendations. (1 ) (2 ) Canadian Installations...
- Page 35 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions A12325 Fig. 46 – Ventilated Combustion Air and Non-Direct Vent Termination Clearance NOTE: The following is based upon National codes for gas appliances and is provided as a reference. Refer to local codes which may supersede these standards and/or recommendations.
- Page 36 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions No operable windows, doors or Clearance distances for intakes of any type within the items greater than 3 feet shaded areas of Wall A and B. (1 meter ) away from the inside corner, refer to the For all other items, refer to the Inside Inside Corner Clearance...
- Page 37 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions Non-Direct Vent / 1-Pipe System There are no additional restrictions on unobstructed distances greater than 8 ft. (2.4 M). All single, two-pipe and concentric vents may be used, The vent pipe for a Non Direct Vent (1-pipe) system must terminate providing all other Code and manufacturer’s requirements in these outdoors.
- Page 38 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions TO CODE- - APPROVED DRAIN OR CONDENSATE PUMP Recommend “T” fitting with 4--inch minimum height standpipe (A) of same diameter or larger extending upward. Dry Well Dry Well (water tight Dry Well and removable)
- Page 39 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions vent terminations and flexible vent pipes, and for calculating total vent 6. Install the insulation per the insulation manufacturer’s installation lengths. instructions. To calculate the Total Equivalent Vent Length (TEVL) of the venting NOTE: Pipe length (ft.
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Page 40: Ble
F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions Ventilated Combustion Air intake pipe Pipe hangar 3” (76 mm) 12” (305 mm) Ventilated Combustion Air intake termination in crawl space CRAWL SPACE highest level of insulation ATTIC A10497 Fig. - Page 41 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions 80,000 BTUH Unit Size Uninsulated 3/8-in. Insulation 1/2-in. Insulation Winter Pipe Dia. 1 ½ 2 ½ 1 ½ 2 ½ 1 ½ 2 ½ Design Temp °F 100,000 BTUH Unit Size Uninsulated 3/8-in.
- Page 42 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions NOTE: Maximum Equivalent Vent Length (MEVL) includes standard and concentric vent termination and does NOT include elbows. Use Table 14 - Deductions from Maximum Equivalent Vent Length to determine allowable vent length for each application. Table 13 –...
- Page 43 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions Slope vent pipe back to the furnace at least ¼” per foot Use 45 deg. Elbows where Avoid short horizontal offsets with 90 possible, to ensure conden- deg. Elbows. Short offsets can be sate drainage.
- Page 44 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions Any other unused knockout may be used for combustion air connection. Requires Accessory Internal Vent Kit. A11310A See Product Data for current kit number. UPFLOW VERTICAL VENT A11313A Fig.
- Page 45 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions ALTERNATE COMBUSTION AIR CONNECTIONS Requires Accessory Vent Kit See Product Data for Current Kit Number A11335 A11329A HORIZONTAL RIGHT-RIGHT VENT CONFIGURATION HORIZONTAL LEFT-RIGHT VENT CONFIGURATION Fig. 57 – Horizontal Right (Appearance may vary) Fig.
- Page 46 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions 4. Slide the end of the rubber vent coupling with notches in it over the 6. Tighten the clamp around the outlet of the vent elbow. Torque the standoffs on the vent pipe adapter.
- Page 47 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions Table 15 – Hanger Spacing Material Diameter PVC Sch 40 SDR 21 & 26 CPVC Polypropylene 1 1/2-in. 3-ft. 2 1/2-ft. 3-ft. 3-ft. 3.25-ft. 38-mm 914-mm 762-mm 914-mm 914-mm 1000 mm 2-in.
- Page 48 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions It is recommended that the flashing be installed by a roofer or competent 1. Cut one 4-in. diameter hole for 2-in. kit, or one 5-in. diameter hole professional prior to installing the concentric vent. The terminations can for 3-in.
- Page 49 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions Table 16 – Approved Combustion-Air and Vent Pipe, Fitting and Cement Materials MATERIALS 1. All pipe*, fittings*, primers**, and solvents** must conform to American National Standards Institute (ANSI) standards and American Society for Testing and Materials (ASTM) standards 2.
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Page 50: Start-Up, Adjustment, And Safety Check
F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions Example 2 A direct-vent 60,000 BTUH furnace installed at 2100 ft. (640M). Venting system includes FOR EACH PIPE: 100 feet (30 M) of vent pipe, 95 feet (29 M) of combustion air inlet pipe, (3) 90º long-radius elbows, and a polypropylene concentric vent kit. Also includes 20 feet (6.1 M) of flexible polypropylene vent pipe, included within the 100 feet (30 M) of vent pipe. - Page 51 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions A190155 Fig. 60 – Furnace Setup Switches and Description Table 17 – Cooling and Heating Air Delivery - CFM (Bottom Return with Filter) (SW1-5 and SW4-3 set to OFF, except as indicated. See notes 1 and 2.) Unit Size: Clg/CF Switch settings External Static Pressure (ESP)
- Page 52 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions Table 17 – Cooling and Heating Air Delivery - CFM (Bottom Return with Filter) (Continued) (SW1-5 and SW4-3 set to OFF, except as indicated. See notes 1 and 2.) Unit Size: Clg/CF Switch settings External Static Pressure (ESP)
- Page 53 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions Table 17 – Cooling and Heating Air Delivery - CFM (Bottom Return with Filter) (Continued) (SW1-5 and SW4-3 set to OFF, except as indicated. See notes 1 and 2.) Unit size: Clg/CF Switch settings External Static Pressure (ESP)
- Page 54 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions Setup Switches Prime Condensate Trap with Water There are four sets of setup switches on the furnace control board. These WARNING switches configure the furnace for correct application requirement. They also select the airflow settings for Air Conditioning and Continuous Fan CARBON MONOXIDE POISONING HAZARD airflows.
- Page 55 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions NOTICE WARNING FIRE OR EXPLOSION HAZARD The NATURAL GAS manifold pressure adjustments in Table 20 compensate for BOTH altitude AND gas heating value. DO NOT apply Failure to follow this warning could result in personal injury, death, an additional derate factor to the pressures shown in Table 20.
- Page 56 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions Adjust Manifold Pressure NOTICE 1. Adjust manifold pressure to obtain low fire input rate. See Fig. a. Turn gas valve ON/OFF switch to OFF. If orifice hole appears damaged or it is suspected to have been redrilled, b.
- Page 57 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions Clocking the Meter CAUTION Verify natural gas input rate by clocking meter. NOTE: Contact your HVAC distributor or gas supplier for metric gas FURNACE DAMAGE HAZARD meter tables, if required. Failure to follow this caution may result in: 1.
- Page 58 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions 2. Wait until the blower off delay is completed. via SW3 at the control board. Refer to the section titled “continuous Blower Speed selection for Thermostat.” 3. Turn 115 VAC power off. Adjust Thermostat Heat Anticipator.
- Page 59 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions should NOT glow and control diagnostic light flashes a pressure Table 20 – Orifice Size and Manifold Pressure (In. W.C.) for Gas switch fault if hot surface igniter glows when inducer motor is Input Rate disconnected, shut down furnace immediately.
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Page 60: Service And Maintenance Procedures
F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions Table 21 – Gas Rate (CU ft./hr) SIZE OF TEST SIZE OF TEST DIAL DIAL SECONDS SECONDS FOR 1 REV FOR 1 REV 1 Cu 2 Cu 5 Cu 1 Cu 2 Cu 5 Cu... - Page 61 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions The electrical ground and polarity for 115-v wiring must be properly CAUTION maintained. Refer to Fig. 36 for field wiring information and to Fig. 73 for furnace wiring information. ENVIRONMENTAL HAZARD NOTE: If the polarity is not correct, the STATUS LED on the control will flash rapidly (Status Code 10) and prevent the furnace from heating.
- Page 62 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions WARNING WARNING ELECTRICAL SHOCK HAZARD ELECTRICAL SHOCK AND FIRE HAZARD Failure to follow this warning could result in personal injury, or death. Failure to follow this warning could result in personal injury, death, and/or property damage.
- Page 63 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions 7. If greasy residue is present on blower wheel, remove wheel from WARNING the blower housing and wash it with an appropriate degreaser. To remove wheel: ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD a.
- Page 64 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions 19. Turn on gas supply and cycle furnace through one complete heating 9. Support the manifold and remove the four screws that secure that cycle. Verify the furnace temperature rise as shown in Adjustments manifold assembly to the burner assembly and set aside.
- Page 65 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions a. Using a 1/4-in. driver, remove the two screws securing the igniter mounting bracket to the burner assembly. See Fig. b. Carefully withdraw the igniter and bracket assembly through the front of the burner assembly without striking the igniter on surrounding parts.
- Page 66 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions 5. Disconnect external drain from condensate drain elbow or drain replaced rather than trying to clean them thoroughly due to their intricate extension pipe inside the furnace and set aside. design.
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Page 67: Winterization
F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions 2. Turn off gas and electrical supplies to your furnace. 3. Remove furnace control door. 4. Remove the top unused rubber plug from the port on the collector box opposite the condensate trap. - Page 68 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions A190162 Fig. 72 – Troubleshooting Guide Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
- Page 69 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions A190163 Troubleshooting Guide (Continued) Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
- Page 70 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions A190164 Troubleshooting Guide (Continued) Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
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Page 71: Sequence Of Operation
F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions SEQUENCE OF OPERATION b. Igniter Warm-Up -At the end of the prepurge period, the Hot-Surface Igniter HSI is energized for a 17-sec igniter NOTE: Furnace control must be grounded for proper operation or else warm-up period. - Page 72 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions circuits always causes high-heat operation, regardless of the setting of furnace blower BLWM and electronic air cleaner terminal EAC-1 will the low-heat only switch. remain energized for an additional 90 sec. Jumper Y1 to DHUM to reduce the cooling off-delay to 5 sec.
- Page 73 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions shut OFF and remain OFF for the blower-ON delay (45 sec in low-heat, and 25 sec in high-heat), allowing the furnace heat exchangers to heat up more quickly, then restarts at the end of the blower-ON delay period at low-heat or high-heat airflow, respectively.
- Page 74 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions A190153 Fig. 73 – Wiring Diagram Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
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Page 75: Parts Replacement Information Guide
F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions PARTS REPLACEMENT INFORMATION GUIDE Casing Group Gas Control Group Blower door Burner Bottom plate Flame sensor Control door Gas valve Door knob assembly Hot surface igniter Top filler plate Manifold Electrical Group Orifice... - Page 76 F96CTN and G96CTN (Series A): Installation, Start-up, Operating, Service and Maintenance Instructions © 2022 Carrier. All rights reserved. Edition Date: 03/22 Catalog No: 440 014900 00 REV B A Carrier Company Replaces: 440 01 4900 00 REV A Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
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