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VersaPro™
96% Gas Furnace
Installation Manual
MODELS:
• MGM96EE060B3NB
• MGM96EE080B3NB
• MGM96EE080C4NB
• MGM96EE100C5NB
• MGM96EE120D5NB
Read this manual carefully before installation and keep it where
the operator can easily find it for future reference.
Due to updates and constantly improving performance, the
information and instructions within this manual are subject to
change without notice.
Version Date: 05/06/2024
Please visit www.mrcool.com/documentation
to ensure you have the latest version of this manual.
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Table of Contents
Related Manuals for MrCool VersaPro MGM96EE060B3NB
Summary of Contents for MrCool VersaPro MGM96EE060B3NB
- Page 1 Due to updates and constantly improving performance, the information and instructions within this manual are subject to change without notice. Version Date: 05/06/2024 Please visit www.mrcool.com/documentation to ensure you have the latest version of this manual.
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Page 2: Table Of Contents
7.6 Gas Input Rate Measurement (Natural Gas Only) ............... 53 7.7 Temperature Rise Adjustment ....................... 53 OPERATIONAL CHECKS ........................... 54 8.1 Burner Flame ............................ 54 SAFETY CIRCUITS ............................. 54 9.1 General .............................. 54 9.2 Integrated Control Module ......................54 mrcool.com... - Page 3 Do not use any phone in the building. • Immediately call your gas supplier from a phone outside of the building and follow the gas supplier's instructions. • If you cannot reach your gas supplier, call the fire department. mrcool.com...
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Page 4: Safety
A special base is not required when installed on the manufacturer's coil assembly. 5. Furnace operation needs air for combustion and ventilation. Do not block or obstruct air openings on the furnace. Spacing around the furnace is required for supplying sufficient combustion air and ventilation. mrcool.com... - Page 5 There are no obvious signs of deterioration of the furnace. • The burner flames are adjusted appropriately. WARNING: PROPOSITION 65 • This appliance contains fiberglass insulation. Respirable particles of fiberglass are known to the state of California to cause cancer. For more information, go to www.P65Warnings.ca.gov. mrcool.com...
- Page 6 1. Set the thermostat to its lowest setting. 2. Turn off all electric power to the appliance if service is to be performed. 3. Remove control access panel. 4. Push gas control to "OFF". Do not force. 5. Replace control access panel. mrcool.com...
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Page 7: Unit Overview
17.5 (445) 16 (406) 15-27/32 (402) 139.5 / 152 080C4 21 (533) 19.5 (495) 19-13/32 (493) 151 / 165 100C5 21 (533) 19.5 (495) 19-13/32 (493) 153 / 170.5 120D5 24.5 (622) 23 (584) 22-27/32 (580) 166 / 187 mrcool.com... -
Page 8: Unit Description
US: National Fuel Gas Code (NFGC) NFPA 54/ANSIZ223.1 and the Installation Standards, Warm Air Heating and • Air Conditioning Systems ANSI/NFPA 90B CANADA: National Standard of Canada Natural Gas and Propane Installation Codes (CAN/CSA -B149.1-05) • Fig. 2.3- Return Air Temperature mrcool.com... - Page 9 US: National Electrical Code (NEC) ANSI/NFPA 70. • CANADA: Canadian Electrical Code CSA C22.I. • Electrical Power Supply Voltage: ANSI C84.1-2006 (104-127 volt) • Venting US: NFGC NFPA 54/ANSI Z223.1-2006 ; chapters 12 and 13. • CANADA: CAN/CSA-B149.1-05 Part 8 and Appendix C. • mrcool.com...
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Page 10: Electrostatic Discharge Precaution Procedure
In Canada, refer to installation instructions for vent materials. Construction through which vent/air intake pipes may be installed is a maximum of 24 inches (610mm), and a minimum of 3/4 inches (19mm) thickness (including roofing materials). mrcool.com... - Page 11 All fuel-burning equipment must be supplied with air for fuel combustion. Sufficient air must be provided to avoid negative pressure in the equipment room or space. A positive seal must be made between the furnace cabinet and the return-air duct to prevent pulling air from the burner area and from draft safeguard opening. mrcool.com...
- Page 12 The furnace, ductwork and filters are cleaned as necessary to remove drywall dust and construction debris from all HVAC system components after construction is completed. • Verify proper furnace operating conditions including ignition, gas input rate, air temperature rise, and venting according to these installation instructions. mrcool.com...
- Page 13 Safety control operation will be adversely affected. Never connect return-air ducts to the back of the furnace. This furnace may be installed in an upflow position or horizontal position on either the left or right side panel. Do not install this furnace on its back side. mrcool.com...
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Page 14: Upflow Installation
Side return-air openings can be used in UPFLOW and most HORIZONTAL configurations. Upflow Installation Tilt the unit slightly (minimum 1/2" (12.7mm) to maximum of 3/4" (19mm)) from back to front to aid in the draining of the heat exchanger. BACK FRONT Figs. 3.2b- Upflow Application-Setting Equipment mrcool.com... -
Page 15: Horizontal Installation
Horizontal applications, in particular, may dictate many of the installation’s specifics such as airflow direction, ductwork connections, flue and combustion air pipe connections, etc. The basic application of this furnace as a horizontal furnace differs only slightly from an upright installation. When installing a furnace horizontally,additional consideration must be given to the following: mrcool.com... - Page 16 If the furnace is installed in a crawl space it must be suspended from the floor joist or supported by a concrete pad. Never install the furnace on the ground or allow it to be exposed to water. Figs. 3.3- Horizontal Installation mrcool.com...
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Page 17: Drain Line & Overflow Pressure Switch
All installation positions require the use of the drain trap, hoses, tubes, and clamps. The following quantity of hoses, tubes, and hose clamps are provided with the unit. * The inner diameter of the 14mm hose is 12mm. The inner diameter of the 16mm hose is 15.5mm. Figs. 3.4a- Hose & Tube Identification mrcool.com... - Page 18 Cut the excess hoses if necessary. • Relocate junction box to the other side of the cabinet • if necessary. Secure and tighten all hoses. • Fig. 3.4b- Upflow Installation, Top Venting Fig. 3.4c- Upflow Installation, Right Side Vent mrcool.com...
- Page 19 Connect 16mm hose between collector box and trap and connect 14mm hose between inducer draining tap • and trap. Plug both holes on rubber elbow use provided plugs. Cut the excess hoses if necessary. • Secure and tighten all hoses. • Relocate junction box to the other side of cabinet if necessary. • mrcool.com...
- Page 20 Cut the excess hoses if necessary. • Relocate junction box to the other side of cabinet if necessary. • Fig. 3.4e- Horizontal Left Side Installation, Vent Fig. 3.4f- Horizontal Left Side Installation, Through Top Panel Vent Through Side Panel mrcool.com...
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Page 21: Filter Arrangement
IMPORTANT: Some accessories such as electronic air cleaners and pleated media may require a larger side opening. Follow the instructions supplied with that Fig. 3.5- Side Return Cutout Markings accessory for side opening instructions. mrcool.com... -
Page 22: Air Ducts
The air circulating fan of the furnace, if installed in an enclosure communicating with another fuel- burning appliance not of the direct-vent type, shall be operable only when any door or panel covering an opening in the furnace fan compartment or in a return air plenum on ducts is in the closed position. mrcool.com... - Page 23 * A filter is required for each return-air inlet. Airflow performance includes 3/4" (19mm) washable filter media such as contained in factory-authorized accessory filter rack. To determine airflow performance with this filter, assume an additinal 0.1" wc available external static pressure. mrcool.com...
- Page 24 * A filter is required for each return-air inlet. Airflow performance includes 3/4" (19mm) washable filter media such as contained in factory-authorized accessory filter rack. To determine airflow performance with this filter, assume an additinal 0.1" wc available external static pressure. mrcool.com...
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Page 25: Circulator Blower Speed Adjustment
Refer to Table 6-3 for blower speed factory setting specifications. These blower speeds should be adjusted by the installer to match the installation requirements so as to provide the correct heating temperature rise and the correct cooling CFM. mrcool.com... -
Page 26: Combustion Air & Vent System
1/2" Armaflex or other heat resistant type insulation if two feet or more of pipe is exposed. Vent piping must be insulated if it will be subjected to freezing temperatures such as routing through unheated areas or through an unused chimney. mrcool.com... - Page 27 40 (12.1) 60 (17.6) 3 (7.6) 90 (27.4) 80 (23.4) 2 (5.1) 80 (23.4) 3 (7.6) 90 (27.4) 100 (29.3) 2 (5.1) 30 (9.1) 100 (29.3) 3 (7.6) 70 (21.3) 120 (35.1) 2 (5.1) 120 (35.1) 3 (7.6) 50 (15.2) mrcool.com...
- Page 28 45º (degree) elbows will be required for 3" 45° Sweep Elbow 5 ft of 3" pipe plenum clearance when the vent is increased to 3" (7.6 cm). 2" Corrugated Connector 10 ft of 2" pipe 3" Corrugated Connector 10 ft of 3" pipe mrcool.com...
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Page 29: Combustion Air & Vent Piping Assembly
9. Seal around the openings where the combustion air and/or vent piping pass through the roof or sidewalls. 4.4 Combustion Air/Venting Important: The vent must be installed with the minimum required clearances, and must comply with local codes and requirements. Fig. 4.4- Home Layout mrcool.com... - Page 30 Responsibility for the provision of proper adequate venting and air supply for application shall rest with the installer. Vent shall extend high enough above building, or a neighboring obstruction, so that wind from any direction will not create apositive pressure in the vicinity of the vent. mrcool.com...
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Page 31: Vent System
6. Horizontal portions of the vent system must slope upwards and be supported to prevent sagging. 7. Direct vent systems must be installed so the vent and the combustion air pipes terminate in the same atmospheric zone. Fig. 4.5b- Termination Configuration - 2 pipe Fig. 4.5a- Termination Configuration - 1 pipe mrcool.com... - Page 32 Under NO circumstances can the two combustion air or vent pipes be tied together. The combustion air and vent pipes must terminate in the same atmospheric zone. Fig. 4.5d- Double Horizontal Combustion Air Intake Fig. 4.5e- Double Vertical Combustion Air Intake & and Vent Termination Vent Termination mrcool.com...
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Page 33: Combustion & Ventilation Air Requirements
Also, the terminal assembly should be located as far as possible from a swimming pool or a location where swimming pool chemicals might be stored. Be sure the terminal assembly follows the outdoor clearances listed in these instructions. Fig. 4.6a- Direct Vent Air Intake Connection & Vent Connection mrcool.com... - Page 34 1 square inch per 1,000BTU per hour of the total input rating of all gas utilization equipment in the confined space. One opening shall be within 12 inches of the top and one within 12 inches of the bottom of the enclosure. mrcool.com...
- Page 35 Fig. 4.6c- Outside & Ambient Combustion Air 7. An air supply inlet opening from the outdoors shall be located not less than 12" (30.5 cm) above the outsidegrade level. mrcool.com...
- Page 36 It is recommended that you follow the venting safety procedure. This procedure is designed to detect an inadequate ventilation system that can cause the appliances in the area to operate improperly causing unsafe levels of carbon monoxide or create unsafe conditions. mrcool.com...
- Page 37 The above requirements shall be permitted to be waived where special engineering, approved by the authority having jurisdiction, provides an adequate supply of air for combustion and ventilation. WARNING Be sure to instruct the owner not to block the intake pipe. mrcool.com...
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Page 38: Gas Supply & Piping
The furnace derate is 4% for each 1,000 feet above sea level. This table is based upon a heating value of approximately 1,000 Btu/ft3. In Canada, the input rating must be derated by 10% for altitudes of 2,000 ft. (610m) to 4,500 feet (1370m) above sea level by an authorized Gas Conversion Station or Dealer. mrcool.com... -
Page 39: Propane Gas Conversion
Contact your distributor for a tabular listing of appropriate manufacturer's kits for propane gas and/or high altitude installations. The indicated kits must be used to insure safe and proper furnace operation. All conversions must be performed by a qualified installer, or service agency. mrcool.com... -
Page 40: Gas Piping Connections
The gas piping supplying the furnace must be properly sized based on the gas flow required, specific gravity of the gas, and length of the run. The gas line installation must comply with local codes, or in their absence, refer to the latest version of NFPA54/ANSI Z223.1 for US and the latest version of CSA B149.1 for Canada. mrcool.com... - Page 41 When the gas piping enters through the right side of the furnace, the installer must supply the following fittings (starting from the gas valve): 90° elbows (2) • Close nipple • Straight pipe to reach the exterior of the furnace • mrcool.com...
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Page 42: Gas Piping Checks
1/2 psig (3.48 kPa). This unit must be isolated from the gas supply system by closing its manual shutoff valve before testing. Pressure testing must be conducted with test pressures equal to or less than 1/2 psig (3.48 kPa). mrcool.com... -
Page 43: Electrical Connections
If factory location of J-Box is acceptable, go to next section. On 14" wide casing models, the J-Box shall not be relocated to the other side of the furnace casing when the vent pipe is routed within the casing. 1. Remove and save two screws holding J-Box. mrcool.com... -
Page 44: Electrical Connection To J-Box
4. Route and secure field ground wire to green ground screw on J-Box bracket, or the furnace will fail to operate. 5. Connect line voltage leads as shown in Fig. 9-3. 6. Reinstall cover to J-Box. Do not pinch wires between cover and bracket. mrcool.com... -
Page 45: Power Cord Installation To J-Box
4. Secure field ground wire to green ground screw on J-Box bracket. 5. Connect line voltage leads as shown in Wiring Diagram with 2-Stage Heating Thermostat. 6. Reinstall cover to J-Box. Do not pinch wires between cover and bracket. mrcool.com... -
Page 46: Bx Cable Installation In Furnace J-Box
The furnace must be electrically grounded in accordance with local codes or, in the absence of local codes, with the National Electrical Code, ANSI/NFPA 70, and /or the Canadian Electrical Code, CSA C22.1, Part 1, if an external electrical source is utilized. mrcool.com... -
Page 47: Furnace Control Diagram
ELECTRICAL CONNECTIONS 6.8 Furnace Control Diagram W2 Delay Heat Off Delay Cool Off Delay DIP SW DIP SW DIP SW Nominal Nominal Nominal (Seconds) (Seconds) (Minutes) S2-1 S2-2 S2-3 S2-4 S1-1 S1-2 *OFF *OFF *OFF AUTO mrcool.com... -
Page 48: Wiring Diagram With 2-Stage Thermostat
"Gas Furnace Control Module in Picture 32", and move the drive plate SW1-2 to the "ON" position. Refer to the coil manual for installation locations of refrigerant gas sensors. Operation indication of refrigerant gas sensor When the sensor detects a refrigerant leak, the unit will respond according to the following rules. mrcool.com... -
Page 49: Start-Up Adjustment & Safety Check
3. Gas supply pressure to the furnace must be greater than 4.5-in. W.C. (0.16 psig ) but not exceed 14-in. W.C. (0.5 psig). 4. Check all manual-reset switches for continuity. 5. Install blower compartment door. Door must be in place to operate furnace. 6. Replace outer door. mrcool.com... -
Page 50: Start-Up Procedures
Failure to follow this warning could cause personal injury, death and/or property damage. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. mrcool.com... -
Page 51: Sequence Of Operation
Once the specified delay time has expired the second stage valve will be energized. See the table below for the different duty cycles. mrcool.com... - Page 52 When using a single stage thermostat, second-stage delay is based on the setting of switch S1-1, S1-2 shown here. OPTION SWITCHES S1-1 and S1-2 POSITIONS: 2nd Stage Delay for Single-Stage Thermostats On "S1" Set Switch # Delay Time: Off" 10 min. Auto min. 20 min. mrcool.com...
- Page 53 The circulator will be energized at cool speed after the COOL delay-to-fan-on period. After the thermostat is satisfied, the compressor is de-energized and the COOL delay-to-fan-off period begins. After the COOL delay-to- fan-off period ends, the circulator and the electronic air cleaner are de-energized. mrcool.com...
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Page 54: Gas Manifold Pressure Measurement & Adjustment
11. Turn ON system power and set thermostat to call for heat. 12. Using a leak detection solution or non-chlorine soap suds, check for leaks at hose connection. Bubbles forming indicate a leak. SHUT OFF GAS AND FIX ALL LEAKS IMMEDIATELY! Figs. 7.50 Gas Valve & Regulation Adjustment mrcool.com... -
Page 55: Gas Input Rate Measurement (Natural Gas Only)
An incorrect temperature rise can cause condensing in or overheating of the heat exchanger. Determine and adjust the temperature rise as follows. The temperature rise must be within the range specified on the rating plate. mrcool.com... - Page 56 The integrated control module is an electronic device which controls all furnace operations. Responding to the thermostat, the module initiates and controls normal furnace operation, and monitors and addresses all safety circuits. If a potential safety concern is detected, the module will take the necessary precautions and provide diagnostic information through an LED display. mrcool.com...
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Page 57: Operational Checks
WARNING-FIRE, EXPLOSION, OR CARBON MONOXIDE POISONING HAZARD Failure to replace with proper control could result in fire, explosion or carbon monoxide poisoning. This appliance uses a NEGATIVE PRESSURE REGULATED gas control. Replace ONLY with the same model number or as specified by the manufacturer. mrcool.com... -
Page 58: Diagnostic Chart
Improper adjustment, alteration, service, maintenance or installation can cause serious injury or death. Read and follow instructions and precaution in User’s Information Manual provided with this furnace. Installation and service must be performed by a qualified service agency or the gas supplier. mrcool.com... - Page 59 Refer to the • Verify proper operation after servicing. diagnostic chart for • This appliance uses a NEGATIVE PRESSURE REGULATED gas control. help in determining • Replace ONLY with the same model number or as specified by the the cause. manufacturer. mrcool.com...
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Page 60: Service & Maintenance Procedures
• If badly torn or uncleanable, these filters must be replaced by equal size permanent, high velocity filters. Throwaway filters must not be used as replacement for permanent filters. Under normal use, permanent filters should last for several years. mrcool.com... -
Page 61: Induced Draft & Circulating Blower Motors
If the igniter and the surrounding air are at about 70°F and the igniter wires are not connected to any other electrical components, the resistance of the igniter should not exceed 200 ohms. If it does, the igniter should be replaced. mrcool.com... -
Page 62: Component Identification Chart
Outlet Flue Vent Transformer Air Inlet Flame Sensor Condensate Trap Burner Primary Limit Switch Junction Box Rollout Limit Switch Condensate Overflow Switch Condensate Collector Inducer Pressure Switch Door Switch Two-Stage Gas Valve Integrated Control Module Hot Surface Igniter Blower Gas Manifold mrcool.com... -
Page 63: Wiring Diagram
SERVICE & MAINTENANCE PROCEDURES 11.10 Wiring Diagram mrcool.com... - Page 64 VersaPro™ 96% Gas Furnace Installation Manual 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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