Haier GE NF80XV Series Service Manual
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Haier GE NF80XV Series Service Manual

Haier GE NF80XV Series Service Manual

80% two stage variable speed ultra low nox gas furnace
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Service
NF80XV
80% Two Stage Variable Speed
Manual
Ultra Low NOx Gas Furnace
READ CAREFULLY.
.
KEEP THESE INSTRUCTIONS
31-5000734 Rev. 0 11-22 GEA

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Summary of Contents for Haier GE NF80XV Series

  • Page 1 Service NF80XV 80% Two Stage Variable Speed Manual Ultra Low NOx Gas Furnace READ CAREFULLY. KEEP THESE INSTRUCTIONS 31-5000734 Rev. 0 11-22 GEA...

  • Page 2: Table Of Contents

    SERVICE MANUAL NF80XV Gas Furnace This is a safety alert symbol and should never be ignored. When you see this symbol on labels or in manuals, be alert to the potential for personal injury or death. NF80XV series units are 80% efficiency gas furnaces used Table of Contents for upflow or horizontal applications only, manufactured with heat exchangers formed of aluminized steel.

  • Page 3: Technical Specifications

    Technical Specifications Physical and Electrical Data Max. Time Approx Nominal Volts/ Nominal Input Output AFUE Delay Trans Shipping Model Cooling Inlet Full Load (Btuh) (Btuh) (ICS) Breaker or (VA) Weight Capacity (in.) Phase Amps Fuse (lbs) NF80X060V3A 60,000 48,000 3 Tons 120-60-1 NF80X080V4B 80,000...

  • Page 4: Blower Performance

    Blower Performance NF80X060V3A BLOWER PERFORMANCE (less filter) BOTTOM RETURN AIR 0 through 0.8 in. w.g. (Heating) and 0 through 1.0 in. w.g. (Cooling) External Static Pressure Range HEATING Heating Speed DIP First Stage Heating Speed - cfm Second Stage Heating Speed - cfm Switch Settings +24% 1030...

  • Page 5: Blower Performance

    Blower Performance NF80X100V5C BLOWER PERFORMANCE (less filter) BOTTOM RETURN AIR, RETURN AIR FROM BOTH SIDES OR RETURN AIR FROM BOTTOM AND ONE SIDE 0 through 0.8 in. w.g. (Heating) and 0 through 1.0 in. w.g. (Cooling) External Static Pressure Range HEATING Heating Speed DIP First Stage Heating Speed - cfm...

  • Page 6: Parts Arrangement

    Parts Arrangement Heat Exchanger Combustion Air Inducer Gas Valve Air Intake Pipe Access Panel Control Box (includes two-stage integrated control, transformer and circuit breaker) Blower Assembly Figure 1. Page 6 31-5000734 Rev. 0...

  • Page 7: Unit Components

    Circuit Breaker (CB8) Unit Components A 24V circuit breaker is also located in the control box. The switch provides overcurrent protection to the transformer NF80XV unit components are shown in Figure 1. The gas (T1). The breaker is rated 3A at 32V. If the current exceeds valve, combustion air inducer and burners can be accessed this limit the breaker will trip and all unit operation will by removing the access panel.
  • Page 8 second stage prove switch closes during the first stage PIN# Function heat pre-purge, the control will allow second stage heat. Ignitor Once the first stage prove switch is determined to be open, Combustion Air Inducer High the combustion air inducer is energized on low (first stage) Speed heat speed.
  • Page 9 HS/ CAI LINE 1 NEUTRAL 7 SEGMENT LED FLAME SENSE INDOOR BLOWER DIAGNOSTIC CONNECTOR PUSH BUTTON DIP SWITCHES 12 PIN LOW OUTDOOR AIR VOLTAGE SENSOR CONNECTOR TERMINALS DISCHARGE AIR W915 Y1 TO Y2 SENSOR 2 STAGE COMPR TERMINALS W951 R TO O HEAT PUMP TB83 NOT USED...
  • Page 10 INTEGRATED CONTROL CONFIGURATION GUIDE CLG BLOWER SPEED ADJUSTMENT 2ND STAGE HEAT ON DELAY DEFAULT 7 MIN CONTINUOUS FAN MODE BLOWER SPEED UPSTAGE THERMOSTAT SELECTION DELAY + 10% MEDIUM−LOW SPEED TWO STAGE (38%) THERMOSTAT 12 MIN − 10% UPSTAGE MEDIUM−HIGH DELAY SPEED 1−STAGE (70%)
  • Page 11 Display Action (when button released) No change (idle)* Remain in idle mode Solid “E” Enter diagnostic recall mode Solid “D” Discharge Air Installed Solid “F” Enter flame signal mode Solid “P” (variable speed only) Program unit capacity/size (Unit Code) Two horizontal bars = Soft disable * No change implies the display will continue to show whatever is currently being displayed for normal operation (blinking decimal, active error code, heat state, etc..)

  • Page 12: Diagnostic Led Codes

    Diagnostic LED Codes Code Diagnostic Codes / Status of Equipment Action Required to Clear and Recover Idle mode (Decimal blinks at 1 Hertz - 0.5 • seconds ON, 0.5 seconds OFF). Cubic feet per minute (cfm) setting for indoor blower (1 second ON, 0.5 seconds OFF) / cfm setting for current mode displayed.
  • Page 13 Code Diagnostic Codes / Status of Equipment Action Required to Clear and Recover E200 Hard Lock out - Rollout circuit open or previously Correct cause of rollout trip or replace flame rollout open switch. Test furnace operation. Cleared after fault recovered.
  • Page 14 Code Diagnostic Codes / Status of Equipment Action Required to Clear and Recover E227 Low pressure switch open during trial for ignition Check operation of low pressure switch closing on heat or run mode. Refer to troubleshooting call. Measure operating pressure (inches w.c.). Inspect vent and combustion air inducer for correct operation and restriction.
  • Page 15 Code Diagnostic Codes / Status of Equipment Action Required to Clear and Recover E290 Ignitor circuit fault - Failed ignitor or triggering Measure resistance of hot surface igniter. Replace if circuitry. open or not within specifications. 1-hour soft lockout. Clears when flame has been proven stable. E291 Heat airflow restricted below the minimum.
  • Page 16 DIP Switch Settings Switches 5 and 6 set the blower cfm for secondstage cool. The integrated control automatically ramps down to 70% of Heating Operation DIP Switch Settings the second-stage cfm for first-stage cfm. Refer to tables for Switch 1 -- Thermostat Selection -- This unit may be corresponding cfm values.
  • Page 17 Ramping Option A (Factory Selection) Switches 11, 12 and 13 -- Heating Mode Blower Speed The switches are factory set to the OFF position which • Motor runs at 50% for 30 seconds. provides factory default heat speed. Refer to Table 9 for •...
  • Page 18 On-Board Links On-Board Link W951 Heat Pump (R to O) On-board link W951 is a clippable connection between terminals R and O on the integrated control. W951 must WARNING be cut when the furnace is installed in applications which include a heat pump unit and a thermostat which features Carefully review all configuration information provided.
  • Page 19 Operating Sequence System Demand System Response Blower Thermostat Demand Relative Humidity System Condition Step Compressor Comments Status (cool) NO CALL FOR DEHUMIDIFICATION Compressor and indoor Normal Operation Y1 Acceptable 24 VAC 70%* blower follow thermostat Normal Operation Y2 Acceptable 24 VAC High 100% demand...

  • Page 20: Indoor Blower Motor

    A solid-state controller is permanently attached to the Indoor Blower Motor motor. The controller is primarily an A.C. to D.C. converter. Converted D.C. power is used to drive the motor. The controller contains a microprocessor which monitors varying conditions inside the motor (such as motor workload).
  • Page 21 Motor Start-Up Troubleshooting Motor Operation When B3 begins start-up, the motor gently vibrates back To verify motor operation see steps below and Figure 8 and forth for a moment. This is normal. During this time and Figure 9. the electronic controller is determining the exact position of the rotor.
  • Page 22 BLOWER B3 HARNESS CONNECTORS BLOWER B3 HARNESS CONNECTORS P48 5 Pin P49 4 Pin P48 5 Pin SHAFT SHAFT P49 4 Pin MOTOR with INTEGRATED MOTOR with INTEGRATED CONTROLLER CONTROLLER J48 5 Pin P48 5 Pin J49 4 Pin P49 4 Pin J49 4 Pin Control Connector J48 5 Pin Line Voltage Connector J48 Connector...
  • Page 23 TEST A Troubleshooting Motor Windings Ensure that motor windings are not damaged by performing Measure the resistance between each of the three motor the following tests: leads (3-pin plug) and the unpainted part of the end shield. NOTE: If your ohm meter is not an auto-ranging type, set If the winding resistance to ground is <100k ohms, it to the highest ohm scale (100k ohms or greater) before replace the motor and control module.

  • Page 24: Heating Components

    Thermal Switch Heating Components The auto-reset switch is located on the front of the intake air elbow. The switch will safely shut the unit down if excessive temperatures are detected. See Figure 13. Ignitor When the switch senses excessive temperature, the circuit The ignitor is made of durable silicon nitride.
  • Page 25 HEATING COMPONENTS Air Gas Plenum Burner Gasket Gas Valve Sensor Ignitor Orifice Housing Gas Orifice Air Orifice Intake Air Screen Thermal Intake Air Switch Elbow (location) Figure 13. Page 25 31-5000734 Rev. 0...
  • Page 26 Ignitor Check Out (exploded view for clarity) Test 1 Remove 5-pin plug from control Check ohms reading across terminals 1and 5 Ohm value should be between 39 - 70. Meter (set to ohms) Integrated control detail Test 2 Seperate the 2-pin jack plug near the manifold and check resistance of the ignitor.

  • Page 27: Placement And Installation

    Combustion Air Inducer (B6) Placement and Installation All NF80XV units use a two-stage combustion air inducer to move air through the burners and heat exchanger during Make sure unit is installed in accordance with installation heating operation. The blower uses a 120VAC motor. instructions and applicable codes.

  • Page 28: Heating System Service Checks

    10. Is pressure switch closed? Obstructed flue will cause GAS VALVE unit to shut off at pressure switch. Check flue and outlet for blockages. MANIFOLD PRESSURE ADJUSTMENT (TURN CCW TO INCREASE PRESSURE) 11. Are flame rollout switches tripped? If flame rollout switches are tripped, call the service technician for NEGATIVE AIR POSITIVE AIR...
  • Page 29 Rate Check When pressure testing gas lines, the gas valve must be disconnected and isolated. Gas valves can be damaged Manifold Pressure Measurement if subjected to more than 0.5 psig (14” W.C.). See Figure To correctly measure manifold pressure, follow the steps 17.

  • Page 30: High Altitude

    Proper Gas Flow (Approximate) High Altitude Furnace should operate at least 5 minutes before checking Units may be installed at altitudes up to 7,500 ft. above gas flow. Determine time in seconds for two revolutions of sea level. See Table 17 for de-rate manifold values. 60K gas through the meter.

  • Page 31: Typical Operating Characteristics

    External Static Pressure Typical Operating Characteristics 1. Tap locations shown in Figure 19. Punch a 1/4” diameter hole in supply and return air Blower Operation and Adjustment plenums. Insert manometer hose flush with inside edge of hole or insulation. Seal around the hose with 1.

  • Page 32: Maintenance

    Check the cleanliness of blower assembly and Maintenance clean the housing, blower wheel and blower motor if necessary. The blower motors are prelubricated for Annual Furnace Maintenance extended bearing life. No further lubrication is needed. At the beginning of each heating season, and to comply Inspect the combustion air inducer and clean if with the Limited Warranty, your system should be checked necessary.
  • Page 33 Heat Exchanger and Burners Figure 21 15. Reconnect gas supply piping. Cleaning the Heat Exchanger and Burners 16. Turn on power and gas supply to unit. NOTE: Use papers or protective covering in front of the 17. Set thermostat and check for proper operation. furnace during cleaning.

  • Page 34: Wiring And Sequence Of Operation

    Heat Exchanger and Burner Assembly Removal * Re-install screws per the numbered sequence shown Air Fuel Plenum Heat Exchanger Gasket *Air Fuel Plenum Gas Valve Burner Gasket Gasket (replace) Debri Screen Air Intake Assembly Figure 21. Wiring and Sequence of Operation CAUTION NOTE: The ignition control thermostat selection DIP switch Failure to use properly sized wiring and circuit breaker...
  • Page 35 Figure 22. Schematic Wiring Diagram Page 35 31-5000734 Rev. 0...
  • Page 36 060*3A 080*4B 100*5C DISCHARGE AND OUTDOOR AIR TERMINALS NOT USED THERMOSTAT CONNECTIONS ARE FOR 24V SYSTEM ONLY DH TERMINAL NOT USED Figure 23. Page 36 31-5000734 Rev. 0...
  • Page 37 Applications Using a Two-Stage Thermostat Applications Using A Single-Stage Thermostat A - Heating Sequence -- Integrated Control Thermostat B - Heating Sequence -- Integrated Control Thermostat Selection DIP Switch 1 OFF in “Two-Stage” Position Selection DIP Switch 1 ON in “Single-Stage” Position (Factory Setting) NOTE: In these applications, two-stage heat will be 1.
  • Page 38 DIP Switch Settings and On-Board Links W915 W914 W951 Thermostat Wiring Connections (Y1 to Y2) DIP Switch 1 (DS to R) (Oto R) Two-Stage Dehumidification Heat Pumps Cooling FURNACE OUTDOOR T'STAT TERM. STRIP UNIT 1 Heat / 1 Cool NOTE: Use DIP switch 3 to set Intact...
  • Page 39 DIP Switch Settings and On-Board Links W915 W914 W951 Thermostat Wiring Connections (Y1 to Y2) DIP Switch 1 (DS to R) (Oto R) Two-Stage Dehumidification Heat Pumps Cooling FURNACE OUTDOOR T'STAT TERM. STRIP UNIT 2 Heat / 2 Cool Intact Intact *Not required on all units FURNACE...
  • Page 40 DIP Switch Settings and On-Board Links W915 W914 W951 Thermostat Wiring Connections (Y1 to Y2) DIP Switch 1 (DS to R) (Oto R) Two-Stage Dehumidification Heat Pumps Cooling FURNACE HEAT PUMP TERM. STRIP T'STAT 67M41* Dual Fuel Single- Stage Heat Pump Thermostat w/dual Intact Intact...
  • Page 41 DIP Switch Settings and On-Board Links W915 W914 W951 Thermostat Wiring Connections (Y1 to Y2) DIP Switch 1 (DS to R) (Oto R) Two-Stage Dehumidification Heat Pumps Cooling FURNACE HEAT PUMP TERM. STRIP T'STAT Dual Fuel Single- 67M41* Stage Heat Pump Thermostat w/dual fuel capabilities Intact...

  • Page 42: Program Unit Capacity Size Modes

    Program Unit Capacity Size Modes Power-Up - Number displayed represents by integrated control unit size code (furnace model and capacity). If three horizontal bars are displayed followed by continuous E203, furnace control does not recognize unit size code. Configure per the following: Furnace control in IDLE mode (No Heating, cooling,...

  • Page 43: Troubleshooting

    Troubleshooting CALL FOR FIRST-STAGE HEAT CALL FOR 1ST STAGE HEAT (LOW FIRE) INDOOR BLOWER OFF AFTER HEAT FAN OFF DELAY (LOW HEAT SPEED) INDOOR LIMIT BLOWER OFF HIGH ERROR INDOOR SWITCH WATCHGUARD − AFTER HEAT FAN LIMIT SWITCH CODE CLOSED WITHIN 3 BLOWER ERROR CODE OFF DELAY (LOW...
  • Page 44 CALL FOR SECOND-STAGE HEAT CALL FOR 2ND STAGE HEAT (HIGH FIRE) SINGLE STAGE 2 STAGE THERMOSTAT THERMOSTAT 2ND STAGE RECOGNITION DELAY ON DELAY (30 SECONDS) EXPIRED? EXPIRED? ONLY FOR 1ST REQUEST FOR 2ND STAGE HEAT INDUCER SWITCHED TO HIGH SPEED HIGH PRESSURE SWITCH INDUCER SWITCHED...
  • Page 45 CALL FOR HEAT SATISFIED FIRST-STAGE HEAT SECOND-STAGE HEAT RUN MODE: 1ST OR 2ND STAGE CALL FOR HEAT. ALL INPUTS MONITORED (LIMIT, PRESSURE, CALL FOR HEAT/COOL, FLAME LEVEL) 2ND STAGE HEAT 2ND STAGE CALL FOR HEAT SATISFIED? DE−ENERGIZE 2ND STAGE GAS VALVE INDUCER SPEED SWITCHED TO LOW SPEED INDOOR BLOWER SWITCHED...
  • Page 46 CALL FOR COOLING 1ST STAGE COOLING REQUEST RECEIVED WAIT FOR COMPRESSOR TIMED OFF DELAY TO EXPIRE ENERGIZE 1ST STAGE COOLING CONTACTOR (COMPRESSOR & FAN) INDOOR BLOWER 2 SECOND ON DELAY ENERGIZE INDOOR BLOWER (LOW COOLING MODE) MAINTAIN INDOOR BLOWER (LOW COOLING MODE) 1ST STAGE 2ND STAGE COOLING REQUEST...
  • Page 47 CALL FOR FAN CALL FOR FAN INDOOR BLOWER ON CONTINUOUS FAN SPEED CALL FOR FAN MAINTAIN INDOOR BLOWER AT REMOVED? CONTINUOUS FAN REQUEST MAINTAIN INDOOR FOR COOLING GO TO CALL FOR COOLING BLOWER AT RECEIVED? CONTINUOUS FAN REQUEST FOR HEAT INDOOR BLOWER OFF GO TO CALL FOR 1ST STAGE HEAT RECEIVED?
  • Page 48 All specifications and illustrations subject to change without notice and without incurring obligations. Printed in the U.S.A.

This manual is also suitable for:

Ge nf80x060v3aGe nf80x080v4bGe nf80x100v5c

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