background image

7

P

OSSIBLE

 

PROPERTY

 

DAMAGE

PERSONAL

 

INJURY

 

OR

 

DEATH

 

DUE

 

TO

 

FIRE

EXPLOSION

SMOKE

SOOT

CONDENSATION

ELECTRICAL

 

SHOCK

 

OR

 

CARBON

 

MONOXIDE

 

MAY

 

RESULT

 

FROM

 

IMPROPER

 

INSTALLATION

REPAIR

 

OPERATION

OR

 

MAINTENANCE

 

OF

 

THIS

 

PRODUCT

.

WARNING

• 

•  Centrally locate the furnace with respect to the 

proposed or existing air distribution system.

•  Ensure the temperature of the return air entering the 

furnace is between 55°F and 100°F when the furnace is 

heating.

• 

Provide provisions for venting combustion products 

outdoors through a proper venting system.  Special 

consideration should be given to vent/flue pipe routing 

and combustion air intake pipe when applicable.  

Refer to 

Vent/Flue Pipe and Combustion Air Pipe 

-Termination Locations 

for appropriate termination 

locations and to determine if the piping system from 

furnace to termination can be accomplished within 

the guidelines given.  

NOTE:

  The length of flue and/

or combustion air piping can be a limiting factor in the 

location of the furnace. 

• 

Locate the furnace so condensate flows downwards 

to the drain.  Do not locate the furnace or its 

condensate drainage system in any area subject to 

below freezing temperatures without proper freeze 

protection.

• 

Ensure adequate combustion air is available for the 

furnace.  Improper or insufficient combustion air 

can expose building occupants to gas combustion 

products that could include carbon monoxide.  Refer 

to 

 Combustion and Ventilation Air Requirements.

• 

Set the furnace on a level floor to enable proper 

condensate drainage.  If the floor becomes wet or 

damp at times, place the furnace above the floor on 

a concrete base sized approximately 1-1/2” larger 

than the base of the furnace.  Refer to the 

Horizontal 

Applications and Considerations

 for leveling of 

horizontal furnaces.

• 

Ensure upflow or horizontal furnaces are not installed 

directly on carpeting, or any other combustible 

material.  The only combustible material allowed is 

wood.

•  A special accessory sub-base must be used for 

upright counterflow unit installations over any 

combustible material (including wood).  Refer to sub-

base instructions for installation details.  (

NOTE:

 A 

sub-base will not be required if an air conditioning coil 

is located beneath the furnace between the supply air 

opening and the combustible floor.

•  Exposure to contaminated combustion air will result in 

safety and performance-related problems.  Do not install 

the furnace where the combustion air is exposed to the 

following substances:  

 

 

permanent wave solutions 

 

chlorinated waxes or cleaners 

 

chlorine-based  

 

carbon tetrachloride 

 

water softening chemicals 

 

 

swimming pool  chemicals

 

deicing salts or chemicals 

 

 

halogen type refrigerants 

 

printing inks

 

cleaning solutions (such as perchloroethylene) 

 

paint removers 

 varnishes

 

hydrochloric acid                                         

 

cements and glues 

 

antistatic fabric softeners for clothes dryers

 

masonry acid washing materials 

•  Enclose a 

non-direct vent

 furnace if it is installed near 

an area frequently contaminated by any of the above 

substances.  This protects the 

non-direct vent

 furnace 

from airborne contaminants. To ensure that the 

enclosed 

non-direct

 

vent

 furnace has an adequate 

supply of combustion air, provide air from a nearby 

uncontaminated room or from outdoors.  Refer to 

the 

Combustion and Ventilation Air Requirements

 for 

details.

•  If the furnace is used in connection with a cooling coil 

unit, install the furnace upstream or in parallel with the 

cooling coil unit.  Premature heat exchanger failure will 

result if the cooling unit is placed ahead of the furnace.

• 

For vertical (upflow or downflow) applications, the 

minimum cooling coil width shall not be less than 

furnace width minus 1”. Additionally, a coil installed 

above an upflow furnace or under a counterflow 

furnace may be the same width as the furnace or may 

be one size larger than the furnace.  

Example: a “C” 

width coil may be installed with a “B” width furnace.

• 

For upflow applications, the front of the coil and 

furnace must face the same direction.

•  If the furnace is installed in a residential garage, 

position the furnace so that the burners and ignition 

source are located not less than 18 inches (457 mm) 

above the floor.  Protect the furnace from physical 

damage by vehicles.

•  If the furnace is installed horizontally, ensure the 

access doors are not on the “up/top” or “down/

bottom” side of the furnace.

• 

Do not connect this furnace to a chimney flue that 

serves a separate appliance designed to burn solid 

fuel. 

• 

On Counterflow Installations, the air conditioning coil 

must be downstream on the supply (positive) side of 

the furnace heat exchanger.

• 

Counterflow Installation over a noncombustible floor. 

Before setting the furnace over the plenum opening, 

ensure the surface around the opening is smooth 

and level. A tight seal should be made between the 

furnace base and floor by using a silicone rubber 

caulking compound or cement grout.

Summary of Contents for DC96SN

Page 1: ...in this manual ONLY PERSONNEL THAT HAVE BEEN TRAINED TO INSTALL ADJUST SERVICE OR REPAIR HEREINAFTER SERVICE THE EQUIPMENT SPECIFIED IN THIS MANUAL SHOULD SERVICE THE EQUIPMENT THE MANUFACTURER WILL...

Page 2: ...rical Connections 25 Wiring Harness 25 115 Volt Line Connections 25 115 Volt Line Voltage Connection of Accessories Humidifier and Electronic Air Cleaner 25 Connection of 24 Volt Humidifier 26 Junctio...

Page 3: ...E UTILIZED WARNING TO PREVENT POSSIBLE PROPERTY DAMAGE PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK THE FURNACE MUST BE LOCATED TO PROTECT THE ELECTRICAL COMPONENTS FROM WATER WARNING SAFETY CONSI...

Page 4: ...la pr sence de fuites de gaz au moyen d une flamme nue V rifier tous les raccords en utilisant une solution savonneuse commerciale con ue sp cialement pour la d tection de fuites Un incendie ou une e...

Page 5: ...module to electrostatic discharge This procedure is applicable to both installed and non installed ungrounded furnaces 1 Disconnect all power to the furnace Do not touch the integrated control module...

Page 6: ...including ignition input rate temperature rise and venting are verified according to these installation instructions Furnace doors must be in place on the furnace while the furnace is operating in an...

Page 7: ...esult in safety and performance related problems Do not install the furnace where the combustion air is exposed to the following substances permanent wave solutions chlorinated waxes or cleaners chlor...

Page 8: ...aux aux exigences du fournisseur de gaz et aux instructions d installation du fabricant In all cases accessibility clearance must take precedence over clearances from the enclosure where accessibility...

Page 9: ...moment de sa mise en marche cela peut entra ner une intoxication au monoxyde de carbone ou la mort Les tapes suivantes doivent tre suivies pour chacun des appareils raccord s au syst me de ventilation...

Page 10: ...able provisions of the local building codes for determining the combustion air requirements for the appliances Most homes will require outside air be supplied to the furnace area by means of ventilati...

Page 11: ...coil to flow forward to the recuperator coil front cover Figure 3A Figure 3B Figure 3C Recommended Installation Positions Alternate Electrical and Gas Line Connections This furnace has provisions all...

Page 12: ...ith materials or components of another manufacturer Refer to the following chart for plastic pipe fittings specifications MATERIALS INSTALLATIONS IN CANADA All installations in Canada must conform to...

Page 13: ...he combustion air intake pipe is to be installed above a finished ceiling or other area where dripping of condensate will be objectionable insulating the combustion air pipe may be necessary Use 1 2 t...

Page 14: ...13 106 99 92 85 78 2 30 25 20 15 10 5 N A N A 3 72 65 58 51 44 37 30 23 2 30 25 20 15 10 5 N A N A 3 72 65 58 51 44 37 30 23 2 40 35 30 25 20 15 10 5 3 72 65 58 51 44 37 30 23 2 60 55 50 45 40 35 30 2...

Page 15: ...directly to the furnace intake coupling if condensation rain water is a concern If the RF000142 is used on the combustion air inlet it must be installed with the arrow pointing up It should be noted...

Page 16: ...al left side down installation or a vertical installation using down venting the alternate combustion air opening can be used A locating dimple is located on the right side of the furnace cabinet The...

Page 17: ...rmination shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators relief valves or o...

Page 18: ...ure 19 Vent Combustion Air Intake Measurements for Standard Horizontal Terminations Dual Pipe Center to center 10 min 24 max Vertical separation 0 24 Vent termination from wall 8 min 12 max Combustion...

Page 19: ...RAIN TRAP A condensing gas furnace achieves its high level of efficiency by extracting heat from the products of combustion to the point where condensation takes place The condensate must be collected...

Page 20: ...ow the drain trap to be removed for cleaning The drain trap must be primed before initial furnace start up When an air conditioning coil drain is connected to the field supplied furnace drain it must...

Page 21: ...drain hoses 2 Remove the two screws holding the drain trap to the blower deck 3 Remove the trap and two hoses from the blower deck 4 Remove the two plugs from the right side of the cabinet and install...

Page 22: ...box and secure with a silver clamp 13 Use two silver clamps and secure the hoses to drain trap The trap outlet faces the front of the furnace Secure the trap to the cabinet using two screws removed in...

Page 23: ...move the four screws that fasten the gas manifold assembly to the bracket 2 Remove hose clamps and hoses from trap 3 Remove trap 4 Draining the Vent Elbow Insert the non grommet end hose 10 into the c...

Page 24: ...metal screws provided in the cabinet secure the trap to the furnace 8 Refer to Field Supplied Drain section for instructions on field supplied installed drain on outlet of furnace trap Counterflow Mo...

Page 25: ...ker The fuse or circuit breaker must be sized in accordance with the maximum overcurrent protection specified on the unit rating plate An electrical disconnect must be provided at the furnace location...

Page 26: ...st not to interfere with circulator blower operation filter removal or routine maintenance 115 VAC EAC 115 VAC HUM W R G C Y Figure 32 Connection of 24 Volt Humidifier The integrated control module si...

Page 27: ...naces NOTE Each furnace must be connected to it s own 115 VAC power supply The L1 connection to each furnace must be in phase connected to circuit breakers on the same 115 VAC service panel phase leg...

Page 28: ...es and a pressure switch s must be installed These changes are necessary to compensate for the natural reduction in the density of both the gas fuel and the combustion air at higher altitude Installat...

Page 29: ...lve The drip leg must be a minimum of three inches long Install a 1 8 NPT pipe plug fitting accessible for test gauge connection immediately upstream of the gas supply connection to the furnace Always...

Page 30: ...as Line Hole Ground Joint Pipe Union Ground Joint Pipe Union NOTE Union may be inside furnace cabinet where allowed by local codes Manifold UPFLOW Figure 37 Alternate Gas Line Location Plug in Alterna...

Page 31: ...instructions listed in the Safety Considerations section of this manual All propane gas equipment must conform to the safety standards of the National Board of Fire Underwriters NBFU Manual 58 CANADA...

Page 32: ...test hole in it and reinstalling the block off plate Take a duct static reading at the test hole Tape up the test hole after your test is complete The negative pressure must be read between the filter...

Page 33: ...n the furnace is installed and shall be of such a size that the heat exchanger can be viewed for visual light inspection or such that a sampling probe can be inserted into the air stream The access pa...

Page 34: ...often provide better filtration to protect equipment and the air distribution system than a standard 1 filter and often has lower static pressure loss than a 1 filter Also a deep pleated filter will...

Page 35: ...od Verify that all required kits propane gas high altitude etc have been appropriately installed Furnace Startup 1 Close the manual gas shutoff valve external to the furnace 2 Turn off the electrical...

Page 36: ...ssed the current displayed speed will be selected and control will immediately apply that speed setting THERMOSTAT CALL AVAILABLE SPEEDS G F01 F02 F03 DEFAULT F04 F05 F06 F07 F08 F09 Circulation Speed...

Page 37: ...urnace at the manual shutoff valve and disconnect manometer Reinstall plug before turning on gas to furnace 6 Turn OFF any unnecessary gas appliances stated in step 3 When the center switch is pressed...

Page 38: ...valve Bubbles forming indicate a leak SHUT OFF GAS AND REPAIR ALL LEAKS IMMEDIATELY NOTE For gas to gas conversion consult your dealer for appropriate conversion CAUTION TO PREVENT UNRELIABLE OPERATI...

Page 39: ...rflow combustion air and flue products through the heat exchanger via pressure taps located on the induced draft blower and the coil front cover These switches guard against insufficient airflow combu...

Page 40: ...cleaner can be used as an alternate filter Follow the filter sizes given in the Recommended Minimum Filter size table to ensure proper unit performance To remove filters from an external filter rack...

Page 41: ...three times Verify cooling and fan only operation Review the Owner s Manual with the homeowner and discuss proper furnace operation and maintenance Leave literature packet near furnace REPAIR AND REP...

Page 42: ...tments can be made in 7 Secs increments from0 to 35 Secs Cool Off Delay I G Delay Seconds Default set at 65 Secs Adjustments can be made in 5 Secs increments from 0 to 120 Secs Blower Speed for Gas He...

Page 43: ...43 1 Stage Status Codes Status Menu 30 6 6 6 0 Idle G Continous Fan Q Compressor Cooling Low Stage Compressor Cooling High Stage Gas heat Single Stage Control J OEM test Mode 2 Mode Main Menu...

Page 44: ...anger Check circulator blower speed and performance Blocked filters restrictive ductwork improper circulator blower speed or failed circulator blower motor Correct speed or replace blower motor if nec...

Page 45: ...ontrol module Blown fuse or tripped circuit breaker Correct condition which caused fuse to open replace fuse Integrated control module is non functional Replace non functional integrated control modul...

Page 46: ...1269 1206 1133 1063 999 934 861 F06 1796 1744 1691 1638 1584 1532 1473 1422 F07 1874 1823 1775 1729 1675 1621 1567 1512 F08 1798 1754 1719 1672 1627 1585 1546 1497 F09 1991 1947 1900 1854 1808 1759 1...

Page 47: ...1338 1269 1206 1133 1063 999 934 861 F06 1796 1744 1691 1638 1584 1532 1473 1422 F07 1874 1823 1775 1729 1675 1621 1567 1512 F08 1798 1754 1719 1672 1627 1585 1546 1497 F09 1991 1947 1900 1854 1808 1...

Page 48: ...4 1309 1260 F05 1338 1269 1206 1133 1063 999 934 861 F06 1796 1744 1691 1638 1584 1532 1473 1422 F07 1874 1823 1775 1729 1675 1621 1567 1512 F08 1798 1754 1719 1672 1627 1585 1546 1497 F09 1991 1947 1...

Page 49: ...45 1534 46 1478 48 1415 50 1357 1299 1246 F04 1600 44 1555 46 1505 47 1460 49 1412 50 1364 1309 1260 F01 1176 N A 1107 N A 1037 N A 969 N A 891 N A 825 753 692 F02 1773 42 1721 43 1671 44 1621 46 157...

Page 50: ...039 1008 F05 874 828 791 750 703 655 602 547 F06 950 908 865 826 786 739 689 638 F07 1097 1056 1019 988 952 921 880 842 F08 1166 1127 1092 1060 1027 994 960 926 F09 1407 1373 1338 1308 1282 1253 1229...

Page 51: ...3 1596 1538 1480 1422 1362 1306 1247 F05 1496 1437 1376 1315 1250 1189 1126 1056 F06 1640 1587 1527 1471 1414 1357 1294 1235 F07 1955 1937 1909 1860 1813 1765 1712 1662 F08 2086 2039 1991 1944 1896 18...

Page 52: ...070 1039 1008 F05 874 828 791 750 703 655 602 547 F06 950 908 865 826 786 739 689 638 F07 1097 1056 1019 988 952 921 880 842 F08 1166 1127 1092 1060 1027 994 960 926 F09 1407 1373 1338 1308 1282 1253...

Page 53: ...1653 1596 1538 1480 1422 1362 1306 1247 F05 1496 1437 1376 1315 1250 1189 1126 1056 F06 1640 1587 1527 1471 1414 1357 1294 1235 F07 1955 1937 1909 1860 1813 1765 1712 1662 F08 2086 2039 1991 1944 1896...

Page 54: ...097 1070 1039 1008 F05 874 828 791 750 703 655 602 547 F06 950 908 865 826 786 739 689 638 F07 1097 1056 1019 988 952 921 880 842 F08 1166 1127 1092 1060 1027 994 960 926 F09 1407 1373 1338 1308 1282...

Page 55: ...1520 1465 F04 1653 1596 1538 1480 1422 1362 1306 1247 F05 1496 1437 1376 1315 1250 1189 1126 1056 F06 1640 1587 1527 1471 1414 1357 1294 1235 F07 1955 1937 1909 1860 1813 1765 1712 1662 F08 2086 2039...

Page 56: ...31 122 F02 1823 37 1776 38 1720 40 1679 41 1642 41 1597 1553 1504 F03 1778 38 1729 39 1690 40 1648 41 1605 42 1558 1497 1449 F04 1722 40 1660 41 1609 42 1553 44 1507 45 1455 1402 1350 F01 809 N A 740...

Page 57: ...8 1078 F09 1427 1390 1362 1327 1297 1260 1224 1193 F01 715 658 589 524 465 412 360 279 F02 1415 1385 1355 1322 1291 1255 1219 1186 F03 1388 1360 1325 1291 1259 1223 1191 1157 F04 1290 1252 1215 1182 1...

Page 58: ...1755 1710 1664 1619 1574 1526 1479 F05 1475 1421 1369 1314 1260 1207 1152 1097 F06 1626 1578 1522 1475 1427 1353 1328 1283 F07 1693 1639 1588 1542 1491 1437 1390 1340 F08 1775 1723 1674 1629 1580 152...

Page 59: ...1118 1078 F09 1427 1390 1362 1327 1297 1260 1224 1193 F01 715 658 589 524 465 412 360 279 F02 1415 1385 1355 1322 1291 1255 1219 1186 F03 1388 1360 1325 1291 1259 1223 1191 1157 F04 1290 1252 1215 118...

Page 60: ...804 1755 1710 1664 1619 1574 1526 1479 F05 1475 1421 1369 1314 1260 1207 1152 1097 F06 1626 1578 1522 1475 1427 1353 1328 1283 F07 1693 1639 1588 1542 1491 1437 1390 1340 F08 1775 1723 1674 1629 1580...

Page 61: ...1154 1118 1078 F09 1427 1390 1362 1327 1297 1260 1224 1193 F01 715 658 589 524 465 412 360 279 F02 1415 1385 1355 1322 1291 1255 1219 1186 F03 1388 1360 1325 1291 1259 1223 1191 1157 F04 1290 1252 121...

Page 62: ...656 1610 F04 1804 1755 1710 1664 1619 1574 1526 1479 F05 1475 1421 1369 1314 1260 1207 1152 1097 F06 1626 1578 1522 1475 1427 1353 1328 1283 F07 1693 1639 1588 1542 1491 1437 1390 1340 F08 1775 1723 1...

Page 63: ...425 42 1370 1325 1271 F04 1537 39 1490 40 1447 41 1403 42 1354 44 1301 1247 1190 F01 1029 N A 959 N A 890 N A 811 N A 727 N A 647 579 511 F02 1814 33 1766 34 1722 34 1679 35 1637 36 1595 1555 1511 F03...

Page 64: ...ST 105v C USE COPPER CONDUCTORS ONLY 4 UNIT MUST BE PERMANENTLY GROUNDED AND CONFORM TO N E C AND LOCAL CODES 5 TO RECALL THE LAST 6 FAULTS MOST RECENT TO LEAST RECENT DEPRESS SWITCH FOR MORE THAN 2 S...

Page 65: ...gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 INSPECTION The state or loca...

Page 66: ...se DB F Delta T Difference between Supply and Return Temperatures DB F GAS PRESSURES Gas Inlet Pressure IN W C Gas Manifold Pressure Low Fire IN W C Gas Manifold Pressure High Fire IN W C Gas Type NG...

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