MrCool MGD 96SE XA Series Owners & Installation Manual
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MrCool MGD 96SE XA Series Owners & Installation Manual

MrCool MGD 96SE XA Series Owners & Installation Manual

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The Signature Series is NOT designed for amateur installation. Installation SHOULD be performed by an authorized technician.
Please read this manual carefully before installation and keep it for future reference.
Owner & Installation
Signature Series
MGD*96SE*XA Gas Furnace
Due to updates and constantly improving performance, the information and
instructions within this manual are subject to change without notice. Please visit
www.mrcool.com/documentation to ensure you have the latest version of this manual.
The Signature Series is NOT designed for amateur installation. Installation SHOULD be performed by an authorized technician.
Please read this manual carefully before installation and keep it for future reference.
Manual
Version Date: 07-29-22

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  • Page 1 Due to updates and constantly improving performance, the information and instructions within this manual are subject to change without notice. Please visit www.mrcool.com/documentation to ensure you have the latest version of this manual. Version Date: 07-29-22 The Signature Series is NOT designed for amateur installation. Installation SHOULD be performed by an authorized technician.

  • Page 2: Table Of Contents

    Blower Performance Data .........46 result from contact with sharp sheet metal edges. Be Service...............48 careful when you handle this equipment. Planned Service ............54 Repair Parts List ............54 *P507769C05* Manufactured By MRCOOL LLC Hickory, KY 42051 (P) 507769C05 507769C05 mrcool.com Page 1 of 55...

  • Page 3: Unit Dimensions

    TRAP CONNECTION (Either Side) (Either Side) 9−1/8 (232) Right 6−9/16 (167) Left 6−1/2 (165) (229) Either Side Supply (19) Supply (19) 19−1/4 (489) (19) FRONT VIEW Capacity 045-B3 17-1/2 16-3/8 070-B4 090-C4 19-7/8 19-1/2 110-C5 Page 2 of 55 mrcool.com 507769C05...

  • Page 4: Parts Arrangement

    COMPARTMENT ACCESS PANEL COMBUSTION AIR INDUCER BLOWER DECK HEATING PRIMARY LIMIT COMPARTMENT ACCESS PANEL COLD END HEADER BOX HEAT EXCHANGER GAS VALVE BURNER BOX ASSEMBLY (includes flame sensor, rollout switches and ignitor) Figure 1. 507769C05 mrcool.com Page 3 of 55...

  • Page 5: Gas Furnace

    Institute, Inc., 11 West 42nd Street, New York, NY 10036. In Canada, installation must conform with current National Standard of Canada CSA-B149 Natural Gas and Propane Installation Codes, local plumbing or waste water codes and other applicable local codes. Page 4 of 55 mrcool.com 507769C05...
  • Page 6 Supply and Return air ducts must be provided and the Canadian Electrical Code Part I (CSA Standard C22.1) sealed to the furnace. Return air must be terminated and/or local codes. outside of the space where furnace is installed. 507769C05 mrcool.com Page 5 of 55...

  • Page 7: General

    INSTRUCTIONS VOIDS MANUFACTURER’S EQUIPMENT LIMITED WARRANTY. MRCOOL Combustion, Dilution & Ventilation Air DISCLAIMS ALL LIABILITY IN CONNECTION WITH INSTALLER’S FAILURE TO FOLLOW THE ABOVE INSTALLATION INSTRUCTIONS. If this unit is installed as a Non-Direct Vent Furnace, follow the guidelines in this section.
  • Page 8 50 cubic feet (1.42 m³) per 1,000 Btu (.29 kW) per hour of the combined input rating of all appliances installed in that space. This space also includes adjacent rooms which are 507769C05 mrcool.com Page 7 of 55...
  • Page 9 Figure 5. Equipment in Confined Space - All Air from Outside Figure 7. Equipment in Confined Space - all Air from Outside Page 8 of 55 mrcool.com 507769C05...

  • Page 10: Installation

    Gas fumes, which combustion air required for all gas appliances serviced could contain carbon monoxide, can be drawn into by this space. living space resulting in personal injury or death. 507769C05 mrcool.com Page 9 of 55...
  • Page 11 See Table 1 for correct floor opening size. cooling coil cabinet. Do not drag the unit across the floor in the downflow position. Floor and furnace flange damage Flange warm air plenum and lower the plenum into the will result. opening. Page 10 of 55 mrcool.com 507769C05...
  • Page 12 11M61 22-3/4 NOTE: Downflow combustible flooring kit is not used. Table 2. Combustible Floor Base Opening Size 1. Refer to reverse-flow coil installation instructions for correctly sized opening in floor and installation of cabinet. 507769C05 mrcool.com Page 11 of 55...

  • Page 13: Filters

    Filter Size or separation that cannot be removed by stirring. Refer to B (17.5”) Table 4 below for approved piping and fitting materials. 16 x 25 x 1 (1) C (21”) Table 3. Filter Size Page 12 of 55 mrcool.com 507769C05...
  • Page 14 PVC & CPVC Pipe and Fittings PVC & CPVC Solvent Cement ULCS636 ABS to PVC or CPVC Transition Cement POLYPROPYLENE VENTING SYSTEM ULC-S636 PolyPro® by Duravent InnoFlue® by Centrotherm ULC-S636 ECCO Polypropylene Vent ULC-S636 Table 4. 507769C05 mrcool.com Page 13 of 55...
  • Page 15 If end is not chamfered, edge of pipe distribute cement evenly. Do not turn ABS or cellular may remove cement from fitting socket and result in a core pipe. leaking joint. Page 14 of 55 mrcool.com 507769C05...

  • Page 16: Venting Practices

    If this gas furnace replaces a furnace which was commonly vented with another gas appliance, be used. Contact MRCOOL for assistance in sizing vent the size of the existing vent pipe for that gas appliance pipe in these applications.
  • Page 17 Which needs most Intake or elbows? Exhaust? How many? 1-1/2”, 2”, Desired pipe size? 2-1/2”, or 3” What is the altitude? Use Table 7 to find max pipe length. Figure 21. Page 16 of 55 mrcool.com 507769C05...
  • Page 18 Exhaust must be same pipe size. NOTE - Additional vent pipe and elbows used to terminate the vent pipe outside the structure must be included in the total vent length calculation. Table 7B. 507769C05 mrcool.com Page 17 of 55...
  • Page 19 Exhaust must be same pipe size. NOTE - Additional vent pipe and elbows used to terminate the vent pipe outside the structure must be included in the total vent length calculation. Table 7D. Page 18 of 55 mrcool.com 507769C05...
  • Page 20 NOTE - Additional vent pipe and elbows used to terminate the vent pipe outside the structure must be included in the total vent length calculation. NOTE - Contact your local FTC if more than 85ft of venting is needed. Table 8B. 507769C05 mrcool.com Page 19 of 55...
  • Page 21 * When transitioning up in pipe size, use the shortest length of 2” PVC pipe possible. NOTE: Exhaust pipe and intake pipe must be the same diameter. Figure 23. Typical Intake Pipe Connections (Direct Vent Applications) Page 20 of 55 mrcool.com 507769C05...
  • Page 22 The inlet air opening must be sized to accommodate the maximum volume of exhaust air as well as the maximum volume of combustion air required for all gas appliances serviced by this space. 507769C05 mrcool.com Page 21 of 55...
  • Page 23 Canada for details. Position termination according to location given in Figure 27 or Figure 28. In addition, position termination so it is free from any obstructions and 12” above the average snow accumulation. Page 22 of 55 mrcool.com 507769C05...
  • Page 24 5 linear feet or the maximum allowable intake or exhaust vent length listed in Table 7A through Table 7D or Table 8A through Table NOTE - If insulation is required an unconditioned space, it must be located on the pipe closed to the furnace. Table 9. 507769C05 mrcool.com Page 23 of 55...
  • Page 25 Permitted only if veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor. Avoiding this location is recommended if possible. Figure 27. Vent Termination Clearances For Non-Direct Vent Installations in the USA and Canada Page 24 of 55 mrcool.com 507769C05...
  • Page 26 ‡ Permitted only if veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor. Avoiding this location is recommended if possible. Figure 28. Vent Termination Clearances For Direct Vent installations in the USA and Canada 507769C05 mrcool.com Page 25 of 55...
  • Page 27 NOTE: Care must be taken to avoid recirculation of four terminations assembled together horizontally, as exhaust back into intake pipe. shown in Figure 36. Page 26 of 55 mrcool.com 507769C05...
  • Page 28 Exhaust pipe 45° elbow can be rotated to the side away from the combustion air inlet to direct exhaust away from adjacent property. The exhaust must never be directed toward the combustion air inlet. Figure 31. 507769C05 mrcool.com Page 27 of 55...
  • Page 29 TO ADAPT LARGER VENT In any exterior portion of chimney, the exhaust vent must be PIPE SIZE TO TERMINATION insulated. Figure 37. Direct Vent Concentric Rooftop Figure 34. Direct Vent Application Using Existing Termination Chimney Page 28 of 55 mrcool.com 507769C05...
  • Page 30 Figure 39. Non-Direct Vent Application Using Existing SNOW ACCUMULATION Chimney 3” (76MM) OR UNCONDITIONED 2” (51MM) PVC ATTIC SPACE PROVIDE SUPPORT FOR EXHAUST LINES Figure 38. Non-Direct Vent Roof Termination Kit (15F75 or 44J41) 507769C05 mrcool.com Page 29 of 55...

  • Page 31: Condensate Piping

    1” min. 2” max . 5’ max. to drain *Piping from furnace must slope down a minimum 1/4” per ft. toward trap Figure 42. Condensate Trap Location (shown with right side exit of condensation) Page 30 of 55 mrcool.com 507769C05...
  • Page 32 When combining the furnace and evaporator coil drains together, the A/C condensate drain outlet must be vented to relieve pressure in order for the furnace pressure switch to operate properly. Figure 45. Condensate Trap with Optional Overflow Switch 507769C05 mrcool.com Page 31 of 55...
  • Page 33 Of Condensate Drain Connection In Unit Vent DrainTrap Assembly Vent (Furnished) 3/4 inch 1/2 inch Condensate Drain Condensate Drain (178) Connection In Unit Connection In Unit Drain Drain Figure 46. Trap Drain Assembly Using 1/2” PVC or 3/4” PVC Page 32 of 55 mrcool.com 507769C05...

  • Page 34: Gas Piping

    In some localities, codes may require installation of a manual main shut off valve and union (furnished by installer) external to the unit. Union must be of the ground joint type. 507769C05 mrcool.com Page 33 of 55...
  • Page 35 (447.39) (362.44) (308.64) (274.67) (274.67) (229.36) (212.37) (203.88) (189.72) NOTE: Capacity given in cubic feet of gas per hour (kilo liters of gas per hour) and based on 0.60 specific gravity gas. Table 11. Page 34 of 55 mrcool.com 507769C05...
  • Page 36 Resize the common venting system to the minimum vent pipe size determined by using the appropriate tables in Appendix G. These are in the current standards of the National Fuel Gas Code ANSI Z223.1. 507769C05 mrcool.com Page 35 of 55...

  • Page 37: Electrical

    Refer to Figure 52 for field wiring and Figure 53 for One 24V “H” 1/4” spade terminal is provided on the furnace schematic wiring diagram and troubleshooting. integrated control board. See Figure 54 or Figure 55 for control board configuration. The terminal is energized Page 36 of 55 mrcool.com 507769C05...
  • Page 38 ‘R’ IS REQUIRED ON SOME OUTDOOR UNITS L13 POWER CHOKE USED ON 3/4 AND 1 HP ONLY S145 IS USED WITH GAS VALVE WHEN APPLIED IN LP GAS UNTIS Figure 52. Typical Field Wiring Diagram 507769C05 mrcool.com Page 37 of 55...
  • Page 39 045*B3 070*B4 090*C4 110*C5 Figure 53. Typical Wiring Diagram Page 38 of 55 mrcool.com 507769C05...
  • Page 40 Most recent will be displayed first, LED off for 3 sec, then next error code is displayed, etc. To clear error codes, depress and hold button longer than 5 sec. Table 13. Diagnostic Codes for 107163-01 Control 507769C05 mrcool.com Page 39 of 55...

  • Page 41: Unit Start-Up

    Push Button Heating Blower Off Diagnostic LED Error Recall Delay Selector Switch Figure 55. 107163-01 Integrated Control Page 40 of 55 mrcool.com 507769C05...
  • Page 42 Are access panels securely in place? Gas Valve Operation See Figure 56 Is the main disconnect switch closed? Is there a blown fuse or tripped breaker? 1. STOP! Read the safety information at the beginning of this section. 507769C05 mrcool.com Page 41 of 55...
  • Page 43 Divide by two and compare to time in Table 15. If manifold pressure matches Table 17 and rate is incorrect, check gas orifices for proper size and restriction. Remove temporary gas meter if installed. Page 42 of 55 mrcool.com 507769C05...
  • Page 44 11U68 No Change 11U70 11U68 Pressure switch is factory set. No adjustment necessary. All models use the factory-installed pressure switch from 0-4500 feet (0- 1370 m). Table 19. Pressure Switch Requirements at Varying Altitudes 507769C05 mrcool.com Page 43 of 55...

  • Page 45: Testing For Proper Venting And Sufficient Combustion Air For Non-Direct Vent Applications

    3, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous condition of use. Page 44 of 55 mrcool.com 507769C05...

  • Page 46: Other Unit Adjustments

    Check for the correct voltage at the furnace (with furnace operating). Correct voltage is 120 VAC ± 10%. Check amp–draw on the blower motor with the blower compartment access panel in place. Motor Nameplate____________ Actual____________ 507769C05 mrcool.com Page 45 of 55...

  • Page 47: Blower Performance Data

    1180 1060 0.50 1560 1340 1140 1015 0.60 1500 1300 1095 0.70 1405 1255 1040 0.80 1325 1215 NOTE: All air data is measured external to unit without filter (not furnished - field provided) Page 46 of 55 mrcool.com 507769C05...
  • Page 48 Allowed Not Allowed Allowed Allowed Allowed Factory Setting Not Allowed Table 21. Allowable Circulation Speeds Model Yellow Blue Brown Black All Models Factory Setting Not Allowed Not Allowed Not Allowed Not Allowed Table 22. 507769C05 mrcool.com Page 47 of 55...

  • Page 49: Service

    Check for the correct voltage at the furnace (furnace 15. Remove two screws from the front cabinet flange at operating). Correct voltage is 120 VAC ± 10%. the blower deck. Spread cabinet sides slightly to allow clearance for removal of heat exchanger. Page 48 of 55 mrcool.com 507769C05...
  • Page 50 38. Follow lighting instructions to light and operate furnace for 5 minutes to ensure that heat exchanger is clean and dry and that furnace is operating properly. 39. Replace heating compartment access panel. 507769C05 mrcool.com Page 49 of 55...
  • Page 51 HAS COMBUSTION AIR PRESSURE PRESSURE SWITCH IS IN WATCHGUARD MODE. GAS SWITCH CLOSED IN 2.5 MINUTES? VALVE OFF. COMBUSTION AIR INDUCER OFF. INDOOR BLOWER OFF WITH DELAY. IS 5 MINUTE RESET PERIOD COMPLETE? CONTINUED NEXT PAGE Page 50 of 55 mrcool.com 507769C05...
  • Page 52 HAS CAI SWITCH CLOSED IN 2.5 MINUTES? COMB. AIR INDUCER CONTINUES 5 SECOND POST PURGE AFTER T'STAT DEMAND IS SATISFIED. INDOOR AIR BLOWER COMPLETES SELECTED “OFF” DELAY BEFORE SHUTTING OFF. 5 MINUTE PRESSURE SWITCH WATCHGUARD MODE. 507769C05 mrcool.com Page 51 of 55...
  • Page 53 LED: SLOW FLASH RATE REMAINS UNCHANGED THROUGHOUT COOLING CYCLE. THERMOSTAT CALLS FOR COOLING. COMPRESSOR CONTACTOR AND SYSTEM FAN ENERGIZED WITH 2 SECOND DELAY (COOLING SPEED) THERMOSTAT OPENS. COMPRESSOR OFF. SYSTEM FAN AND EAC TERM. OFF WITH 45 SECOND DELAY. Page 52 of 55 mrcool.com 507769C05...
  • Page 54 CONTROL (G) ENERGIZES SYSTEM FAN AT FAN SPEED. EAC TERM. ENERGIZED. HUM. TERMINALS OFF AFTER POST PURGE BY COMBUSTION AIR INDUCER. SYTEM FAN SWITCHES TO FAN SPEED AFTER BLOWER OFF DELAY. EAC CONTINUES WITHOUT INTERUPTION. 507769C05 mrcool.com Page 53 of 55...

  • Page 55: Planned Service

    Repair Parts List The following repair parts are available through MRCOOL dealers. When ordering parts, include the complete furnace model number listed on the CSA nameplate. All service must be performed by a licensed professional installer (or equivalent), service agency, or gas supplier.
  • Page 56 The sign shall read, in print size no less equipment at the completion of the installation. than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS.” 507769C05 mrcool.com Page 55 of 55...
  • Page 57 Signature Series MGD*96SE*XA Gas Furnace ELECTRICIAN and/or HVAC TECHNICIAN: LICENSE #: INSTALLATION DATE: INSTALLATION LOCATION: SERIAL NUMBER: The design and specifications of this product and/or manual are subject to change without prior notice. Consult with the sales agency or manufacturer for details.

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