background image

27

Inlet gas supply pressures must be maintained within the
ranges specified in the following table.  The supply pressure
must be constant and available with all other household gas
fired appliances operating.  The minimum gas supply
pressure must be maintained to prevent unreliable ignition.
The maximum must not be exceeded to prevent unit
overfiring.

CAUTION

T

O

 

PREVENT

 

UNRELIABLE

 

OPERATION

 

OR

 

EQUIPMENT

 

DAMAGE

THE

 

INLET

 

GAS

 

SUPPLY

 

PRESSURE

 

MUST

 

BE

 

AS

 

SPECIFIED

 

ON

 

THE

 

UNIT

 

RATING

 

PLATE

 

WITH

 

ALL

 

OTHER

 

HOUSEHOLD

 

GAS

 

FIRED

 

APPLIANCES

 

OPERATING

.

Natural Gas

Minimum:  4.5" w.c. Maximum: 10.0" w.c.

Propane Gas Minimum: 11.0" w.c. Maximum: 13.0" w.c.

INLET GAS SUPPLY PRESSURE

H

IGH

 A

LTITUDE

 D

ERATE

When this furnace is installed at high altitude, the appropriate
High Altitude orifice kit must be applied.  This is required
due to the natural reduction in the density of both the gas
fuel and combustion air as altitude increases.  The kit will
provide the proper design certified input rate within the
specified altitude range.

High altitude kits are purchased according to the installation
altitude and usage of either natural or propane gas.  Consult
the furnace Specification Sheet for appropriate kits.

Do 

not

 derate the furnace by adjusting the manifold pressure

to a lower pressure than specified on the furnace rating plate.
The combination of the lower air density and a lower manifold
pressure will prohibit the burner orifice from drawing the
proper amount of air into the burner.  This may cause
incomplete combustion, flashback, and possible yellow
tipping.

In some areas the gas supplier may artificially derate the
gas in an effort to compensate for the effects of altitude.  If
the gas is artificially derated, the appropriate orifice size
must be determined based upon the BTU/ft

3

 content of the

derated gas and the altitude.  Refer to the National Fuel Gas
Code, NFPA 54/ANSI Z223.1 or CAN/CSA B149.1-15 in Canada,
and information provided by the gas supplier to determine
the proper orifice size.

A different pressure switch may be required at high altitude
regardless of the BTU/ft

3

 content of the fuel used.  Consult

the furnace Specification Sheet for pressure switch.

P

ROPANE

 G

AS

 C

ONVERSION

WARNING

P

OSSIBLE

 

PROPERTY

 

DAMAGE

PERSONAL

 

INJURY

 

OR

 

DEATH

 

MAY

 

OCCUR

 

IF

 

THE

 

CORRECT

 

CONVERSION

 

KITS

 

ARE

 

NOT

 

INSTALLED

. T

HE

 

APPROPRIATE

 

KITS

 

MUST

 

BE

 

APPLIED

 

TO

 

ENSURE

 

SAFE

 

AND

 

PROPER

 

FURNACE

 

OPERATION

. A

LL

 

CONVERSIONS

 

MUST

 

BE

 

PERFORMED

 

BY

 

A

 

QUALIFIED

 

INSTALLER

 

OR

 

SERVICE

 

AGENCY

.

This unit is configured for natural gas.  The appropriate
manufacturer’s propane gas conversion kit, must be applied
for propane gas installations.  Refer to the 

Propane Gas and/

or High Altitude Installations

 for details.

Consult the furnace Specification Sheet for a  listing of
appropriate kits.  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.

G

AS

 V

ALVE

This unit is equipped with a 24 volt gas valve controlled during
furnace operation by the integrated control module.  As
shipped, the valve is configured for natural gas.  The valve
is field convertible for use with propane gas by replacing the
regulator spring with a propane gas spring from an
appropriate manufacturer’s propane gas conversion kit.  Taps
for measuring the gas supply pressure and manifold pressure
are provided on the valve.

The gas valve has a manual ON/OFF control located on the
valve itself.  This control may be set only to the “ON” or
“OFF” position.  Refer to the lighting instructions label or

Startup Procedure & Adjustment 

for use of this control during

start up and shut down periods.

G

AS

 P

IPING

 C

ONNECTIONS

T

O

 

AVOID

 

POSSIBLE

 

UNSATISFACTORY

 

OPERATION

 

OF

 

EQUIPMENT

 

DAMAGE

 

DUE

 

TO

 

UNDERFIRING

 

OR

 

EQUIPMENT

USE

 

THE

 

PROPER

 

SIZE

 

OF

 

NATURAL

/

PROPANE

 

GAS

 

PIPING

 

NEEDED

 

WHEN

 

RUNNING

 

PIPE

 

FROM

 

THE

 

METER

/

TANK

 

TO

 

THE

 

FURNACE

.

WARNING

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, with the latest edition
of the National Fuel Gas Code, NFPA 54/ANSI Z223.1 or CAN/
CSA B149.1-15.

To connect the furnace to the building’s gas piping, the
installer must supply a ground joint union, drip leg, manual
shutoff valve, and line and fittings to connect to gas valve.
In some cases, the installer may also need to supply a
transition piece from 1/2" pipe to a larger pipe size.

The following stipulations apply when connecting gas piping.
Refer to 

Gas Piping Connections 

figure for typical gas line

connections to the furnace.

• Gas piping must be supported external to the furnace

cabinet so that the weight of the gas line does not
distort the burner rack, manifold or gas valve.

Use black iron or steel pipe and fittings for building piping.
Where possible, use new pipe that is properly chamfered,
reamed, and free of burrs and chips.  If old pipe is used,
be sure it is clean and free of rust, scale, burrs, chips,
and old pipe joint compound.

Summary of Contents for DM96VC

Page 1: ...ibutor or our website for the applicable Specification Sheet referred to in this manual TABLE OF CONTENTS SAFETY CONSIDERATIONS 3 SHIPPING INSPECTION 4 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS 4 TO THE...

Page 2: ...BLESHOOTING 43 NORMAL SEQUENCE OF OPERATION 43 POWER UP 43 HEATING MODE 43 COOLING MODE 45 FAN ONLY MODE 45 OPERATIONAL CHECKS 45 SAFETY CIRCUIT DESCRIPTION 45 INTEGRATED CONTROL MODULE 45 PRIMARY LIM...

Page 3: ...IPMENT IF THE FURNACE ENVIRONMENT HAS THE POTENTIAL OF FREEZING THE DRAIN TRAP AND DRAIN LINE MUST BE PROTECTED THE USE OF ACCESSORY DRAIN TRAP HEATERS ELECTRIC HEAT TAPE AND OR RV ANTIFREEZE IS RECOM...

Page 4: ...ommages permanents au cerveau et meme la mort Cette ventilation est n cessaire pour viter le danger d intoxication au CO pouvant survenir si un appareil produisant du monoxyde de carbone continue de f...

Page 5: ...tions It must be installed per the installation instructions provided and per local and national codes It must be installed indoors in a building constructed on site It must be part of a ducted system...

Page 6: ...ow and the guidelines provided in the Combustion and Ventilation Air Requirements section when selecting a furnace location Centrallylocatethefurnacewithrespecttotheproposed or existing air distributi...

Page 7: ...ions 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 ple...

Page 8: ...akage corrosion and other deficiencies which could cause an unsafe condition 3 As far as practical close all building doors and windows and all doors between the space in which the appliance s connect...

Page 9: ...rnace horizontally additional consideration must be given to the following FURNACE SUSPENSION If suspending the furnace from rafters or joists use 3 8 threaded rod and 2 x2 x1 8 angle iron as shown in...

Page 10: ...w c 6 0 w c None Gas Altitude Kit Orifice M anifold Pressure Pressure Switch Change 0 7000 1 LPM 08 supports both Honeywell and White Rodgers 2 stage valves N OT E In Canada gas furnaces are only cert...

Page 11: ...fied and may be installed as a non direct vent single pipe or direct vent dual pipe appliance A non direct vent installation requires only a vent flue pipe while a direct vent installation requires bo...

Page 12: ...own in this manual or in unheated areas must be insulated with 1 2 thick closed cell foam Inspect piping for leaks prior to installing insulation TERMINATION LOCATIONS NOTE Refer to Location Requireme...

Page 13: ...d to obtain a permit IPEX System 636 is a trademark of IPEX Inc Carefully follow the pipe manufacturers instructions for cut ting cleaning and solvent cementing PVC and or ABS The vent can be run thro...

Page 14: ...lockage ALTERNATE VENT FLUE LOCATION The alternate vent flue location is the large hole directly in line with the induced draft blower outlet To use the alternate vent flue location refer to the follo...

Page 15: ...llowing table for applicable length elbows and pipe diameter for construction of the vent flue pipe system of a non direct vent installation In addition to the vent flue pipe a single 90 elbow should...

Page 16: ...ings must be joined per material manufacturer s specifications to prevent separation and flue gas leaks Both Pipes Terminated Outside Structure 1 4 per foot min slope 6 MAX Field Supplied Drain Tee on...

Page 17: ...e insulation of the combustion air pipe may be required Use 1 2 thick closed cell foam insulation such as Armaflex or Insultube where required VENT FLUE AND COMBUSTION AIR PIPE TERMINATIONS The vent f...

Page 18: ...ain location must meet local and nation codes The drain line between furnace and drain location must maintain a 1 4 inch per foot downward slope toward the drain Do not trap the drain line in any othe...

Page 19: ...ow and secure with 1 clamp 5 Refer to Field Supplied Drain section for instructions on field supplied installed drain on outlet of furnace trap DRAIN EXITING LEFT SIDE 1 Install the 45 degree pipe hos...

Page 20: ...8 Locate hose 5 and cut 3 from the non grommet end Discard the section without the grommet 9 Insert the cut end of tube 5 through the lower cabinet drain hole 10 Connect hose 6 hose 5 using 100 elbow...

Page 21: ...m the right side requires re location of the trap to outside the cabinet Hose 4 x 3 Hose 5 Figure 27 DRAIN EXITING LEFT SIDE 1 Install a field supplied rubber coupling secured with a 1 1 4 clamp to en...

Page 22: ...100 elbow inserted and clamped in the vent drain elbow 2 Remove two 1 plugs from left side of cabinet 3 Draining the Collector Box Remove the cap from the left side of the collector box drain port bot...

Page 23: ...ect vent applications the cabinet opening to the junction box must be sealed air tight using either an UL approved bushing such as Heyco Liquid Tight or by applying non reactive UL approved sealant to...

Page 24: ...cool system This furnace is equipped with a 40 VA transformer to facilitate use with most cooling equipment Consult the wiring diagram located on the blower compartment door for further details of 11...

Page 25: ...nction is enabled during a combination call for cooling T Stat and dehumidification DEHUM Stat FOSSIL FUEL APPLICATIONS This furnace can be used in conjunction with a heat pump in a fossil fuel applic...

Page 26: ...enu 1 ON Humidifier is turned on with a heat demand 2 OFF Humidifier remains off relay never closes 3 IND Humidifier will cycle with humidification demand independent of heat demand This mode allows t...

Page 27: ...NS MUST BE PERFORMED BY A QUALIFIED INSTALLER OR SERVICE AGENCY This unit is configured for natural gas The appropriate manufacturer s propane gas conversion kit must be applied for propane gas instal...

Page 28: ...ere Use listed gas appliance connectors in accordance with their instructions Connectors must be fully in the same room as the furnace Protect connectors and semirigid tubing against physical and ther...

Page 29: ...48 kPa Isolate this unit from the gas supply piping system by closing its external manual gas shutoff valve before pressure testing supply piping system with test pressures equal to or less than 1 2 p...

Page 30: ...urn air chamber CHECKING DUCT STATIC NEVER ALLOW THE PRODUCTS OF COMBUSTION INCLUDING CARBON MONOXIDE TO ENTER THE RETURN DUCT WORK OR CIRCULATION AIR SUPPLY WARNING Refer to your furnace rating plate...

Page 31: ...that a sampling probe can be inserted into the airstream The access panel must be made to prevent air leaks when the furnace is in operation When the furnace is heating the temperature of the return...

Page 32: ...omfort products Air Cleaner Installation Location Maximum Heating Airflow Filter Media Dimensions Part Number Air Cleaner Family Side or bottom return 1200 CFM 16 in X 20 in x 5 AM11 1620 5 Side or bo...

Page 33: ...RE MEASUREMENT GAS PRESSURE TEST This test is to be used for field test mode only and it will allow gas valve pressure to be checked at 100 firing rate 1 If both FAULT RECALL and LEARN push buttons ar...

Page 34: ...leg or Honeywell VR9205 gas valve a field supplied hose barb fitting must be installed prior to making the hose connection If using the inlet pressure tap on the White Rodgers 36J54 gas valve then us...

Page 35: ...wise to decrease pressure Replace regulator cover screw 11 Turn off all electrical power and gas supply to the system 12 Remove the manometer hose from the hose barb fitting or outlet pressure tap 13...

Page 36: ...These blower speeds should be adjusted by the installer to match the installation requirements so as to provide the correct heating temperature rise and correct cooling CFM Use the dual 7 segment LED...

Page 37: ...demand for 30 seconds The motor then ramps to 100 of the required airflow Aone 1 minute OFF delay at 100 of the cooling airflow is provided 50 CFM 1 2 min 100 CFM 100 CFM 1 min OFF OFF Figure 51 Profi...

Page 38: ...must be connected as a traditional or non communicating system see Electrical Connections for wiring connections Model Tap Low Stage Cool High Stage Cool Low Stage Heat High Stage Heat A 403 596 422...

Page 39: ...t then sends the demand to the ECM motor The table below lists the various ComfortNet systems the operating mode and airflow demand source For example assume the system is an air conditioner matched w...

Page 40: ...n Furnace and Thermostat Figure 55 COMFORTNET COMPATIBLE FURNACE WITH NON COMFORTNET COMPATIBLE SINGLE STAGE AIR CONDITIONER Four wires are required between the furnace and thermostat Two wires are re...

Page 41: ...y s th e a p p lic a t io n s o ft w a re re vis io n ID E N T IF IC A T IO N Submenu Item User Modifiable Options Comments Heat Airflow Trim HT TRM 10 to 10 in 2 increments default is 0 Trims the he...

Page 42: ...FL A B C or D default is A Selects the airflow profile for the non communicating compatible single stage AC unit Cool ON Delay CL ON 5 10 20 or 30 seconds default is 5 seconds Selects the indoor blowe...

Page 43: ...codes possible causes and corrective actions FAULT RECALL SEQUENCE Only allowed in standby mode while display is showing ON Hold fault recall push button for 2 5 seconds until display is blank and th...

Page 44: ...r to repair Broken disconnected data wire s Furnace is installed as a legacy traditional system Check communications wiring data 1 data 2 wires Check wire connections at terminal block Verify furnace...

Page 45: ...Circulator blower is de energized Electronic air cleaner terminal is de energized Furnace awaits next call from thermostat OPERATIONAL CHECKS The burner flames should be inspected with the burner comp...

Page 46: ...MAINTENANCE WARNING DIAGNOSTIC CHART Refer to the Troubleshooting Chart in the back of this manual for assistance in determining the source of unit operational problems The dual 7 segment LED display...

Page 47: ...INDUCED DRAFT AND CIRCULATOR BLOWERS The bearings in the induced draft blower and circulator blower motors are permanently lubricated by the manufacturer No further lubrication is required Check moto...

Page 48: ...dd 5 Off Off Minus 5 On Off Add 10 Off On Minus 10 On On A Off Off B On Off C Off On D On On A Off Off B On Off C Off On D On On Disabled Off Enabled On Disabled Off Enabled On 25 Off Off 50 On Off 75...

Page 49: ...ALTERNATES WITH F L 0 b 1 b 6 1 2 b 9 L O b 7 F C 2 b 5 b 3 b 4 d 0 0140F01169 REV A C 1 HIGH STAGE HEAT PUMP HEAT P 1 P 2 E F AUXILIARY SWITCH OPEN P 1 O n E 4 H I INTERNAL CONTROL FAULT NO POWER NO...

Page 50: ...Call for Service icon illuminated ComfortNet thermostat scrolls Check Furnace message E0 Furnace lockout due to an excessive number of ignition retries 3 total LOCKOUT E0 Failure to establish fame Ca...

Page 51: ...rs and ductwork for blockage Clean flters or remove obstruction Check circulator blower speed and performance Correct speed or replace blower motor if necessary Check burners for proper alignment Chec...

Page 52: ...d improperly Blocked fue and or inlet air pipe blocked drain system or weak induced draft blower Incorrect pressure switch set point or malfunctioning switch contacts Loose or improperly connected wir...

Page 53: ...ontrol module has lost communications with circulator blower motor MOTOR COMM b1 Loose wiring connection at circulator motor control leads Failed circulator blower motor Failed integrated control modu...

Page 54: ...t scrolls Check Furnace message b7 MOTOR PARAMS b7 Furnace operates at reduced performance or Integrated control module LED display provides b9 error code b9 LOW ID AIRFLOW B9 Blocked filters Restrict...

Page 55: ...AMPS LIMIT CONTROL AUXILIARY AUTO RESET PK WARNING DISCONNECT TRANSFORMER 40 VA PU GY N NO 3 BR 4 UNIT MUST BE PERMANENTLY GROUNDED AND CONFORM TO N E C AND LOCAL CODES COLOR CODES 1 E SWITCH PRESSUR...

Page 56: ...e no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment...

Reviews: