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Revolv VMA4-50D36N Installation And Service Manual

Gas fired high efficiency furnace
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GAS FIRED HIGH EFFICIENCY FURNACE
DOWNFLOW & DIRECT VENT (SEALED COMBUSTION)
For installation in:
1. Manufactured Homes
2. Modular Homes/Buildings
3. Site Constructed—Residential
(Single Story Dwellings)
PLEASE READ THESE INSTRUCTIONS PRIOR TO INSTALLATION, INITIAL FIRING, AND BEFORE PERFORMING
ANY SERVICE OR MAINTENANCE. THESE INSTRUCTIONS MUST BE LEFT WITH THE USER AND SHOULD BE
RETAINED FOR FUTURE REFERENCE BY QUALIFIED SERVICE PERSONNEL.
VEUILLEZ LIRE CES INSTRUCTIONS AVANT L'INSTALLATION, LA MISE À FEU INITIALE ET AVANT TOUT
ENTRETIEN OU MAINTENANCE. CES INSTRUCTIONS DOIVENT ÊTRE LAISSÉES À L'UTILISATEUR ET DOIVENT
ÊTRE CONSERVÉES POUR RÉFÉRENCE ULTÉRIEURE PAR UN PERSONNEL DE MAINTENANCE QUALIFIÉ.
MG-523
ECN 5580-MA 190515
MODELS:
VMA4-50D36N, VMA4-75D36N
VMC2-50D36N, VMC2-75D36N
VMC2-50DV3N, VMC2-75DV3N
INSTALLATION AND SERVICE MANUAL
STYLE CREST, INC.
2450 ENTERPRISE STREET
FREMONT, OH 43420
PHONE: (419) 332-7369
Pour l'installation dans :
1. Maisons fabriquées
2. Maisons modulaires / Bâtiments
3. Site a construit - Résidentiel
(Habitations à étage unique)
MADE IN USA

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Summary of Contents for Revolv VMA4-50D36N

  • Page 1 GAS FIRED HIGH EFFICIENCY FURNACE DOWNFLOW & DIRECT VENT (SEALED COMBUSTION) MODELS: VMA4-50D36N, VMA4-75D36N VMC2-50D36N, VMC2-75D36N VMC2-50DV3N, VMC2-75DV3N INSTALLATION AND SERVICE MANUAL For installation in: Pour l'installation dans : 1. Manufactured Homes 1. Maisons fabriquées 2. Modular Homes/Buildings 2. Maisons modulaires / Bâtiments 3.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS LIST OF SECTIONS BEGINNING PAGE SAFETY INFORMATION………………………………………………………...………… 1 FURNACE SPECIFICATIONS………………………………………………………..7 VMA4 series……………………………………………………………………………… 7 VMC2 series……………………………………………………………………………... 8 Installation Parts Packages…………………………………………………………..10 III. GENERAL INSTRUCTIONS AND CLEARANCES…………………………..………… 11 IV. GENERAL INSTALLATION…………………………………………………..…………… 13 Furnace Location………………………………………………………………………… 13 Base Installation………………………………………………………………………….. 15 Combustible Floor Base……………………………………………………………..
  • Page 4 House Air Blower………………………………………………………………………… 50 Return Air Filter…………………………………………………………………………... 50 Filter Maintenance Procedure……………………………………………………… 51 Filter Replacement…………………………………………………………………... 51 VIII. TROUBLE SHOOTING…………………………………………………………………... 51 Diagnostic Features……………………………………………………………………… 52 Troubleshooting Guide…………………………………………………………………... 53 APPENDIX-A REPLACEMENT PARTS……………………………………………… 57 APPENDIX-B WIRING DIAGRAM…………………………………………………….. 61 LIST OF FIGURES Combustible Floor Base……………………………………………………………..…………... 13 Coil Cabinets……………………………………………………………………………………….
  • Page 5 c WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury, or loss of life. c AVERTISSEMENT: Si les informations contenues dans ces instructions ne sont pas suivies à...

  • Page 6: Safety Information

    All installations and services must be performed by qualified service personnel. I. SAFETY INFORMATION This and the following page contain reproductions of the various warning and instruction labels placed on the Condensing Gas Furnaces. Please read and comply with the contents of these labels.
  • Page 7 All installations and services must be performed by qualified service personnel. This and the previous page contain reproductions of the various safety and instruction labels placed on Condensing Gas Furnaces. Please read and comply with the contents of these labels.
  • Page 8 All installations and services must be performed by qualified service personnel. This and the previous page contain reproductions of the various safety and instruction labels placed on the Condensing Gas Furnaces. Please read and comply with the contents of these labels.
  • Page 9 All installations and services must be performed by qualified service personnel. The following safety information should be read, understood, and followed by the installer. 1. Use only with type of gas approved for this furnace. Refer to furnace rating plate. 2.
  • Page 10 All installations and services must be performed by qualified service personnel. : Do not obstruct any return air openings, including the return grille on the furnace. To do so may cause the furnace to activate the high limit and shut down.
  • Page 11 All installations and services must be performed by qualified service personnel. the gas supply by closing its manual shut off valve at test pressures equal to or greater than 1/2 PSIG or 14.0" w.c. : Copper and brass tubing and fittings (except tin lined) shall not be used if the gas contains more than a trace (0.3 grains per 100 cubic ft.) of hydrogen sulfide gas.

  • Page 12: Furnace Specifications

    All installations and services must be performed by qualified service personnel. II. FURNACE SPECIFICATIONS MODEL VMA4-50D36 VMA4-75D36 INPUT IN BTUH 50,000 75,000 OUTPUT IN BTUH 48,000 72,000 MAIN ORIFICE-NAT. MAIN ORIFICE-LP GAS SUPPLY PRESSURE L.P. MINIMUM 11” IN.W.C. NAT. MINIMUM 4.5”IN.W.C.

  • Page 13: Vmc2 Series

    All installations and services must be performed by qualified service personnel. FOR BURNER COMBUSTION INFORMATION REFER TO INITIAL STARTUP. MODEL VMC2-50D36 VMC2-75D36 INPUT IN BTUH 50,000 75,000 OUTPUT IN BTUH 48,000 72,000 MAIN ORIFICE-NAT. MAIN ORIFICE-LP GAS SUPPLY PRESSURE L.P. MINIMUM 11”...
  • Page 14 All installations and services must be performed by qualified service personnel. FOR BURNER COMBUSTION INFORMATION REFER TO INITIAL STARTUP. MODEL VMC2-50DV3 VMC2-75DV3 INPUT IN BTUH 50,000 75,000 OUTPUT IN BTUH 48,000 72,000 MAIN ORIFICE-NAT. MAIN ORIFICE-LP GAS SUPPLY PRESSURE L.P. MINIMUM 11”...

  • Page 15: Installation Parts Packages

    All installations and services must be performed by qualified service personnel. FOR BURNER COMBUSTION INFORMATION REFER TO INITIAL STARTUP. INSTALLATION PARTS PACKAGES VMA4-50D36N VMA4-75D36N PARTS PKG# VS00S4248 VS00S4249 DESCRIPTION PART # QTY PART # J-box cover V350020 V350020 Wire nut...

  • Page 16: General Instructions And Clearances

    All installations and services must be performed by qualified service personnel. III. GENERAL INSTRUCTIONS AND CLEARANCES – READ BEFORE START OF INSTALLATION 1. The BTU output capacity of the furnace proposed for installation should be based on a heat loss calculation made according to the manuals provided by the Air Conditioning Contractors of America (ACCA) or the American Society of Heating, Refrigeration and Air Conditioning Engineers, Inc.

  • Page 17: Non-Combustible Material

    All installations and services must be performed by qualified service personnel. c. American National Standard (ANSI-Z223.1/NFPA-54) for all gas-fired furnaces. d. American National Standard (ANSI-C1/NFPA-70 Electric Code for all electrical field wiring. e. These gas-fired units are in compliance with ANSI Z 21.47 CAN/CGA Z223- 2001 Central Furnace test standard.

  • Page 18: General Installation

    All installations and services must be performed by qualified service personnel. IV. GENERAL INSTALLATION A. FURNACE LOCATION 1. For best performance, locate the furnace so that it is centralized with respect to the duct system. 2. The furnace installation is only intended for free air return through the furnace door louvers.

  • Page 19: Coil Cabinets

    All installations and services must be performed by qualified service personnel. Coil Cabinet Model: VE113S Note: Coil cabinet cannot be utilized as a cottage base. VE113S Figure 1B. Cottage Base Model: VCOT-BASE For VMA4 models only. NOTE: Serves as a plenum for single story applications with exposed supply air systems.

  • Page 20: Base Installation

    All installations and services must be performed by qualified service personnel. B. BASE INSTALLATION – VMA4 models only 1. Combustible Floor Base Model: V70-BASE (for VMA4 models only) Use the base bottom panel as a template to mark floor opening locations (see Figure 2).

  • Page 21: Cottage Base

    All installations and services must be performed by qualified service personnel. connector duct. Remove the bottom panel. Cut an opening in the distribution duct slightly larger than the connector duct. (refer to Figure 2 for location of this cut.) Cut the connector duct to length. Install the connector duct. Bend over each tab. Insure an airtight seal by using high temperature sealant or tape on the joint.

  • Page 22: Alcove Installation

    All installations and services must be performed by qualified service personnel. C. ALCOVE INSTALLATION In this application, a minimum of 18 inches of clearance must be provided to the front of the unit. See Figure 4. Note – access to diagnostic view port. VMA4 SERIES VMC2 SERIES Figure 4.

  • Page 23: Closet Installation Clearances

    All installations and services must be performed by qualified service personnel. VMA4 SERIES VMC2 SERIES Figure 5. Do not obstruct any return air openings, including the return grille on the furnace. To do so may cause the furnace to activate the high limit and shut down.

  • Page 24: Fuel Piping

    All installations and services must be performed by qualified service personnel. E. FUEL PIPING Sizing and installation of fuel lines must be in accordance with Federal, State & Local regulations. Including the National Fuel Gas Code NFPA 54/ANSI-Z233.1 (Latest Edition). NOTE: These furnaces are designed to be gas piped through the left side or the bottom.

  • Page 25: General Venting Requirements

    All installations and services must be performed by qualified service personnel. occurs. Wait at least 24 hours for the circuit to fully dry before energizing the system. The furnace and its gas valve must be disconnected from the gas supply during pressure testing of the gas supply system at pressures in excess of 1/2 PSIG or 14 inches w.c F.

  • Page 26: Maximum Vent Length

    All installations and services must be performed by qualified service personnel. MAXIMUM VENT LENGTH VENT SIZE 2 IN. PVC FURNACE VENT EXHAUST COMBUSTION AIR INTAKE MODEL LENGTH VENT ELBOWS (NO.) (FT.) ELBOWS (NO.) VMA*/VMC* *Note the drain elbow supplied with furnace count as 1 elbow. **Note the two 45...

  • Page 27: Connecting Exhaust Vent And Combustion Air Intake

    All installations and services must be performed by qualified service personnel. G. CONNECTING THE EXHAUST VENT AND COMBUSTION AIR INTAKE Figure 6. shows the typical exhaust vent and combustion air intake connection for VMA/VMC furnace. Figure 6. Models VMA and VMC have a removable top front panel that will allow for improved access to assist installation of the exhaust vent and combustion air intake connection to the top of the furnace.

  • Page 28: Top Front Access Panel

    All installations and services must be performed by qualified service personnel. the conclusion of the vent pipe installation. This will insure a leak free return air compartment. Refer to Figure 6A. Figure 6A. NOTICE: The exhaust vent pipe must be supported every 4 feet. After making sure the length of the piping is correct glue all connections in place.

  • Page 29: Direct Venting Through A Sidewall

    All installations and services must be performed by qualified service personnel. gas flame. Should acid compounds form in your furnace, it may reduce the life of the furnace. H. Direct Venting Through a Sidewall 1. Vent And Combustion Air Pipes Vent and combustion air pipes may pass through a maximum wall thickness of 18 inches.

  • Page 30: Exhaust Vent Terminal Location Clearance Requirements

    All installations and services must be performed by qualified service personnel. b. The bottom edge of the vent termination elbow must be installed at least 12-inches above the outlet of intake termination elbow. c. The horizontal distance between the inlet and exhaust terminations should be minimized, when possible, and should never exceed 24- inches.

  • Page 31: Minimum Clearances Between Vent Terminal And Various Building Features

    All installations and services must be performed by qualified service personnel.  where wetting of components by condensate, or water vapor, could be detrimental to the operation of pressure regulators, relief valves, or any other equipment. d. The vent terminal shall be installed a minimum of 14-inches from any obstruction and 3-feet from an inside corner of an L-shaped structure.

  • Page 32: Vent Terminal Location Guidelines

    All installations and services must be performed by qualified service personnel. 4. Vent Terminal Location Guidelines : Bushes, shrubs, or any vegetation that may restrict the flow of flue products must be kept away from vent and air intake terminations. Terminations must also be kept clear of any leaves, weeds, combustible materials, snow, and ice build-up.

  • Page 33: Connecting The Furnace To Roof Vent/ Intake Terminations

    All installations and services must be performed by qualified service personnel. Figure 10: Typical Construction Details of Sidewall Vent and Air Intake Terminations 3. Finish the vent installation by caulking the annulus to seal around the two (2) holes where the thermoplastic pipes pass through the wall. 4.

  • Page 34: Construction Details Of Vertical Vent And Air Intake Terminations

    All installations and services must be performed by qualified service personnel. The furnace may be vented vertically through the roof. The outlet/inlet of the vent and air intake terminations shall be a minimum of 12 inches above highest anticipated snow level. The vent outlet must be installed a minimum of 12 in. above the air intake inlet.

  • Page 35: Condensate Drain Line And Trap Assembly

    All installations and services must be performed by qualified service personnel. CEILING: Frame out area around where PVC pipe is to penetrate ceiling. Cut a 2-3/8” diameter hole for 2” PVC in the ceiling and a corresponding hole in a firestop to be made of a minimum of 18 gauge galvanized metal large enough to cover the entire framed area.

  • Page 36: Electrical Wiring

    All installations and services must be performed by qualified service personnel. L. ELECTRICAL WIRING All wiring shall be performed by a qualified electrician or service person. The wiring must comply with local codes, the instructions in this manual, and in the absence of codes with the National Electrical Code ANSI/NFPA-70 (LATEST EDITION).

  • Page 37: Maximum Recommended Thermostat Wire Length

    All installations and services must be performed by qualified service personnel. IMPORTANT: The room thermostat should be installed 4 to 5 feet above the floor on an interior wall which is relatively free from direct sources of heat (sunlight or supply airflow) or exposure to cold (drafts from open windows and doors).

  • Page 38: Blower Motor Speed Wiring

    All installations and services must be performed by qualified service personnel. 4. BLOWER MOTOR SPEED WIRING Figure 15.
  • Page 39 All installations and services must be performed by qualified service personnel. VMA4-50D36 ALTERATIONS REQ’D FOR A/C @ DESIGN EXTERNAL STATIC PRESSURE COOLING UNIT HTG Speed Recommended CLG Speed 24,000 MED-LOW 30,000 MED-HIGH 36,000 HIGH Furnace Airflow (CFM) vs. External Static pressure (in. WC.) Speed Tap \ Static Pressure...
  • Page 40 All installations and services must be performed by qualified service personnel. VMA4-75D36 ALTERATIONS REQ’D FOR A/C @ DESIGN EXTERNAL STATIC PRESSURE HTG Speed Recommended CLG Speed COOLING UNIT 24,000 MED-LOW MED-LOW 30,000 MED-LOW MED-HIGH 36,000 MED-LOW HIGH Speed Tap \ Furnace Airflow (CFM) vs.
  • Page 41 All installations and services must be performed by qualified service personnel. VMC2-50D36 ALTERATIONS REQ’D FOR A/C @ DESIGN EXTERNAL STATIC PRESSURE COOLING UNIT HTG Speed Recommended CLG Speed 24,000 MED-LOW 30,000 MED-HIGH 36,000 HIGH Furnace Airflow (CFM) vs. External Static pressure (in. WC.) Speed Tap \ Static Pressure...
  • Page 42 All installations and services must be performed by qualified service personnel. VMC2-75D36 ALTERATIONS REQ’D FOR A/C @ DESIGN EXTERNAL STATIC PRESSURE HTG Speed Recommended CLG Speed COOLING UNIT 24,000 MED-LOW MED-LOW 30,000 MED-LOW MED-HIGH 36,000 MED-LOW HIGH Speed Tap \ Furnace Airflow (CFM) vs.
  • Page 43 All installations and services must be performed by qualified service personnel. VMC2-50DV3 ALTERATIONS REQ’D FOR A/C @ DESIGN EXTERNAL STATIC PRESSURE COOLING UNIT HTG Speed Recommended CLG Speed 24,000 MED-LOW 30,000 MED-HIGH 36,000 HIGH Furnace Airflow (CFM) vs. External Static pressure (in. WC.) Speed Tap \ Static Pressure...
  • Page 44 All installations and services must be performed by qualified service personnel. VMC2-75DV3 ALTERATIONS REQ’D FOR A/C @ DESIGN EXTERNAL STATIC PRESSURE HTG Speed Recommended CLG Speed COOLING UNIT 24,000 MED-LOW MED-LOW 30,000 MED-LOW MED-HIGH 36,000 MED-LOW HIGH Speed Tap \ Furnace Airflow (CFM) vs.

  • Page 45: Field Wiring And Replacing Wiring

    All installations and services must be performed by qualified service personnel. : TURN OFF THE ELECTRICAL POWER to the furnace before attempting to change blower speed wiring. The furnace is factory wired to the ignition control with standard heating and cooling speeds. When changing motor speeds, simply switch the needed speed to either the heating or cooling terminal as applicable on the module to obtain the desired CFM.

  • Page 46: Starting The Unit

    All installations and services must be performed by qualified service personnel. V. STARTING THE UNIT A. SEQUENCE OF OPERATIONS AT ANY TIME THE CONTINUOUS SAFE OPERATION CHECK GAS VALVE IS IF FLAME SIMULATION CONDITION NOT ENERGIZED PRESENT OR ROLL-OUT SWITCH OPENS, SYSTEM ENERGIZES INDUCER FAN FOR 15 SECONDS AND CIRCULATOR BLOWER AT HEATING SPEED UNTIL SITUATION CORRECTION START...
  • Page 47 All installations and services must be performed by qualified service personnel. AFTER DELAY-TO-FAN-ON THE RETRY SEQUENCE MAIN PERIOD ENDS, CIRCULATING PROVIDES A 60 SECOND BURNER AIR FAN IS ENERGIZED AT WAIT BEFORE IGNITION OPERATION HEATING SPEED. THE (OPTIONAL) RETRY. RETRY IS ELECTRONIC AIR CLEANER ATTEMPTED WITH AN AND HUMIDIFIER ARE...

  • Page 48: Initial Start Up

    All installations and services must be performed by qualified service personnel. B. INITIAL START UP: This furnace does not have a pilot. It is equipped with a hot surface igniter which automatically lights the burner. Do not attempt to light the burner by hand. Check the following items before the initial start-up.

  • Page 49: Adjustment Of Btu Input Rate

    All installations and services must be performed by qualified service personnel. C. ADJUSTMENT OF BTU INPUT RATE: The orifice for this furnace was sized: 1) for natural gas having a heating value of 1025 BTU per cubic foot and a specific gravity of .65, or 2) for liquefied propane gas with a heating value of 2500 BTU per cubic foot and a specific gravity of 1.55.

  • Page 50: Burner Adjustment

    All installations and services must be performed by qualified service personnel. GAS PRESSURE CHART FOR VMA*/VMC* MODEL FURNACES SUPPLY PRESSURE MANIFOLD PRESSURE MAX 14” WC 3.5 + .3” WC MIN 4.5” WC MAX 14” WC PROPANE 10.0” + .3” WC MIN 11”...

  • Page 51: Setting Temperature Rise

    All installations and services must be performed by qualified service personnel. Figure 16. The VMA/VMC furnace models are direct vent design and do not require an air shutter adjustment (air shutters are not used) for proper flame characteristics. Burner box access cover must always be secured with all screws in place and tightened before operating furnace.

  • Page 52: Furnace Checkout Procedure

    All installations and services must be performed by qualified service personnel. F. FURNACE CHECKOUT PROCEDURE Before any system of gas piping is finally put into service, it shall be carefully tested to assure that it is gas tight as indicated in the Fuel Piping Section of this Furnace Manual.

  • Page 53: Installer's Instructions To User

    All installations and services must be performed by qualified service personnel. VI. INSTALLER'S INSTRUCTIONS TO USER: After completing the installation, the installer shall inform and/or demonstrate to the homeowner: 1. The location of all the instructions in the furnace and that the instructions must be kept along with instructions for any accessories in the plastic pouch.

  • Page 54: Electrical

    All installations and services must be performed by qualified service personnel. Label wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. A. ELECTRICAL: 1. Check diagnostic code through view port prior to removing access door. 2.

  • Page 55: Gasket/Sealing Materials

    All installations and services must be performed by qualified service personnel. necessary, clean the accessible portions of the housing and blower with a damp cloth. Vacuum to remove any lint or dust from the motor assembly. 5. GASKETS/SEALING MATERIALS Inspect all visible gaskets for signs of degradation or liquid seepage, especially any seals which were removed as part of the inspection.

  • Page 56: Filter Maintenance Procedure

    All installations and services must be performed by qualified service personnel. assure proper furnace operation. Follow the cleaning, removal and replacement procedure below. FILTER MAINTENANCE PROCEDURE The filter is located inside front door of the VMA/VMC. Remove filter retaining rod and remove dirty filter.

  • Page 57: Diagnostic Features

    All installations and services must be performed by qualified service personnel. DIAGNOSTIC FEATURES The integrated control continuously monitors its own operation and the operation of the system. If a failure occurs, the LED will indicate a failure code as shown below.

  • Page 58: Troubleshooting Guide

    All installations and services must be performed by qualified service personnel. TROUBLESHOOTING GUIDE THE SYSTEM IS STARTED BY SETTING THE THERMOSTAT TO CALL FOR HEAT. THE FOLLOWING SHOULD HELP ESTABLISH THE TYPE OF MALFUNCTION OR DEVIATION FROM THE NORMAL OPERATION. TO USE THIS DIAGRAM, YOU JUST NEED TO FOLLOW THE INSTRUCTIONS IN THE BOXES.
  • Page 59 All installations and services must be performed by qualified service personnel. IS THERE LINE VOLTAGE CHECK THE INTEGRATED ACROSS INDUCER POWER CONTROL DIAGNOSTIC LED TERMINALS "IND" & "IND N" LAMP. RESET BY INTERRUPTING AT THE INTEGRATED CONTROL? POWER TO CONTROL FOR MORE THAN ONE SECOND.
  • Page 60 All installations and services must be performed by qualified service personnel. AFTER GAS VALVE CHECK FOR PROPER ADJUST TO 3.5" FOR NATURAL GAS OPENS, DO THE MANIFOLD PRESSURE. OR 10.0" WC FOR LP GAS BURNERS IGNITE? IS IGNITOR REPOSITION TO POSITIONED CORRECTLY? CORRECT LOCATION.
  • Page 61 All installations and services must be performed by qualified service personnel. DOES SYSTEM RUN UNTIL IS LED LIGHT CHECK ALL THERMOSTAT IS SATISFIED? ON INTEGRATED WIRING FOR CONTROL FLASHING? LOOSE CONNECTIONS. DOES BURNER SHUT OFF CHECK FOR SHORT IN WIRE TO WHEN THERMOSTAT IS THERMOSTAT AND CORRECT SATISFIED?
  • Page 63 All installations and services must be performed by qualified service personnel.
  • Page 65 All installations and services must be performed by qualified service personnel.

This manual is also suitable for:

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