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Page  50

31-5000726   Rev. 0

3. 

Inspect screens and rinse with tap water if needed.

4. 

Reinstall screens, reconnect hoses and turn on power 

to unit.

Hose

Figure 52. Condensate Hose Screens

Winterizing and Condensate Trap Care

1. 

Turn off power to the unit.

2. 

Have a shallow pan ready to empty condensate water.

3. 

Remove the clean out cap from the condensate trap 

and  empty  water.  Inspect  the  trap  then  reinstall  the 

clean out cap.

Cleaning the Heat Exchanger

If  cleaning  the  heat  exchanger  becomes  necessary, 

follow  the  below  procedures  and  refer  to  Figure  1  when 

disassembling unit. Use papers or protective covering in 

front of furnace while removing heat exchanger assembly.

1. 

Turn off electrical and gas supplies to the furnace.

2. 

Remove the furnace access panels.

3. 

Disconnect the 2 wires from the gas valve.

4. 

Remove  gas  supply  line  connected  to  gas  valve. 

Remove  the  burner  box  cover  (if  equipped)  and 

remove gas valve/manifold assembly.

5. 

Remove  sensor  wire  from  sensor.  Disconnect  2-pin 

plug from the ignitor.

6. 

Disconnect wires from flame roll-out switches.

7. 

Disconnect  combustion  air  intake  pipe.  It  may  be 

necessary to cut the existing pipe to remove burner 

box assembly.

8. 

Remove four burner box screws at the vestibule panel 

and  remove  burner  box.  Set  burner  box  assembly 

aside.

NOTE: 

If necessary, clean burners at this time. Follow 

procedures outlined in Burner Cleaning section.

9. 

Loosen the clamps to the flexible exhaust coupling.

10. 

Disconnect  condensate  drain  line  from  the  cold  end 

header box.

11. 

Disconnect condensate drain tubing from flue collar. 

Remove screws that secures the flue collar into place. 

Remove  flue  collar.  It  may  be  necessary  to  cut  the 

exiting exhaust pipe for removal of the fitting.

12. 

Mark  and  disconnect  all  combustion  air  pressure 

tubing from cold end header collector box.

13. 

Mark and remove wires from pressure switch assembly. 

Remove  the  assembly.  Keep  tubing  attached  to 

pressure switches.

14. 

Disconnect the plug from the combustion air inducer. 

Remove  two  screws  which  secure  combustion  air 

inducer  to  collector  box.  Remove  combustion  air 

inducer  assembly.  Remove  ground  wire  from  vest 

panel.

15. 

Disconnect the condensate drain line.

16. 

Remove cold end header box.

17. 

Remove  electrical  junction  box  from  the  side  of  the 

furnace.

18. 

Mark and disconnect any remaining wiring to heating 

compartment  components.  Disengage  strain  relief 

bushing and pull wiring and bushing through the hole 

in the blower deck.

19. 

Remove the primary limit from the vestibule panel.

20. 

Remove two screws from the front cabinet flange at 

the blower deck. Spread cabinet sides slightly to allow 

clearance for removal of heat exchanger.

21. 

Remove  screws  along  vestibule  sides  and  bottom 

which  secure  vestibule  panel  and  heat  exchanger 

assembly to cabinet. Remove two screws from blower 

rail  which  secure  bottom  heat  exchanger  flange. 

Remove heat exchanger from furnace cabinet.

22. 

Back wash heat exchanger with soapy water solution 

or  steam.  If  steam  is  used  it  must  be  below  275°F 

(135°C) .

23. 

Thoroughly rinse and drain the heat exchanger. Soap 

solutions can be corrosive. Take care to rinse entire 

assembly.

24. 

Reinstall  heat  exchanger  into  cabinet  making  sure 

that  the  clamshells  of  the  heat  exchanger  assembly 

is  engaged  properly  into  the  support  bracket  on  the 

blower deck. Remove the indoor blower to view this 

area through the blower opening.

25. 

Re-secure the supporting screws along the vestibule 

sides and bottom to the cabinet.

26. 

Reinstall  cabinet  screws  on  front  flange  at  blower 

deck.

27. 

Reinstall the primary limit on the vestibule panel.

28. 

Route  heating  component  wiring  through  hole  in 

blower deck and reinsert strain relief bushing.

29. 

Reinstall electrical junction box.

30. 

Reinstall the cold end header box.

31. 

Reinstall  the  combustion  air  inducer.  Reconnect  the 

plug to the wire harness.

32. 

Reinstall  pressure  switches  and  reconnect  pressure 

switch wiring.

Summary of Contents for GE NF96UV

Page 1: ...31 5000726 Rev 0 10 22 GEA NF96UV 96 Upflow Horizontal Two Stage Variable Speed Gas Furnace Service Manual READ CAREFULLY KEEP THESE INSTRUCTIONS...

Page 2: ...l on labels or in manuals be alert to the potential for personal injury or death Electric shock hazard Can cause injury or death Before attempting to perform any service or maintenance turn the electr...

Page 3: ...5 7 7 40 154 NF96U090V5C 57 000 55 000 88 000 85 000 96 0 5 1 2 120 60 1 20 12 8 40 166 NF96U110V5C 72 000 70 000 110 000 105 000 96 0 5 1 2 120 60 1 15 12 8 40 173 NF96U135V5C 88 000 84 000 132 000 1...

Page 4: ...945 1100 1245 Norm 830 935 980 1084 720 840 970 1115 30 60 Low Fire 960 1040 1120 1206 1st Stage 625 710 830 950 875 945 995 1100 565 670 760 860 Norm 790 840 920 950 520 610 685 785 NF96U090V5C 1 11...

Page 5: ...idth 68W63 21 0 C Width 68W64 24 5 D Width Flush Mount Termination 90 Furnaces only 51W11 2 3 0 Vent US Concentric Vent Kit 90 Furnaces only 71M80 1 1 2 Vent Version US 69M29 2 Vent Version US 60L46 3...

Page 6: ...726 Rev 0 Parts Arrangement Figure 1 CONTROL BOX BLOWER ASSEMBLY ACCESS PANEL COMBUSTION AIR INDUCER FLUE COLLAR BURNER BOX ASSEMBLY BLOWER DECK PRIMARY LIMIT CABINET HEAT EXCHANGER ASSEMBLY GAS VALVE...

Page 7: ...ensure furnace ignition and ignitor durability The control provides gas ignition safety checks and indoor blower control with two stage gas heating The furnace combustion air inducer gas valve and ind...

Page 8: ...100 CFM count the flashes and multiply by 100 to determine the actual CFM delivered for example 5 flashes x 100 500 CFM Pin Function 1 Gas Valve Second Stage 2 Second Stage Prove Switch 3 Rollout Swit...

Page 9: ...Humidifier 120VAC Line Input 120VAC XFMR Transformer 120VAC EAC Indoor Air Accessory 120VAC Cool Cool Speed 120VAC Park 1 Dead terminal for alternate speed tap Park 2 Dead terminal for alternate speed...

Page 10: ...earings MOTOR CONTROLLER J49 J48 Figure 5 GenTeq Blower Motor B3 STATOR WINDINGS OUTPUT SHAFT BEARING ROTOR Figure 6 Blower Motor Components Internal Operation Each time the controller switches a stat...

Page 11: ...is the power plug Line voltage must be applied to J48 pins 4 and 5 in order for the motor to operate When using 120VAC pins 1 and 2 must be jumpered Jack J49 connects the unit controls to the motor Th...

Page 12: ...AT output from controller to motor windings O volts 325VDC One revolution O volts 325VDC O volts 325VDC WINDING 1 WINDING 2 WINDING 3 O volts 325VDC O volts 325VDC O volts 325VDC WINDING 1 WINDING 2 W...

Page 13: ...e burner box front panel in place Each burner uses an orifice that is precisely matched to the burner input Burners can be removed as a one piece assembly for service If burner assembly has been remov...

Page 14: ...Page 14 31 5000726 Rev 0 Intake Air Top Cap Sensor Rollout Switch Rollout Switch Burner Assembly Ignitor Manifold And Gas Orifices Two Stage Gas Valve Burner Box Cover Figure 9 Heating Components...

Page 15: ...ug Reading should be between 39 and 70 ohms If the reading is correct then the problem is with the wiring between the jack plug and the control If reading is not correct the issue is the ignitor Test...

Page 16: ...e Tap positive Unit Set Point Low Heat Set Point High Heat 045 0 40 0 70 070 0 50 0 85 090 0 50 0 85 110 0 50 0 90 135 0 45 0 90 Table 6 Pressure Switch Setting 0 4500 Pressure Switch Check To check p...

Page 17: ...Page 17 31 5000726 Rev 0 Black Tubing positive Red and Black or Red Tubing negative Tee 2 long Square Tubing Measuring Device 10 Long Square Tubing Figure 12 Pressure Switch Check...

Page 18: ...commended during cooler weather Metal or plastic strapping may be used for vent pipe hangers Uniformly apply a liberal coat of PVC primer for PVC or use a clean dry cloth for ABS to clean inside socke...

Page 19: ...to end of pipe 7 Immediately after applying last coat of cement to pipe and while both inside socket surface and end of pipe NF96UV VENT PIPE DIA in STANDARD CONCENTRIC Outdoor Exhaust Accelerator Dia...

Page 20: ...er only FURNACE WATER HEATER OPENINGS To Adjacent Room If the NF96UV furnace replaces a furnace that was commonly vented with another gas appliance the size of the existing vent pipe for that gas appl...

Page 21: ...t the problem 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 A...

Page 22: ...utdoors 1 Use transition solvent cement or a sheet metal screw to secure the intake pipe to the inlet air connector 2 Route piping to outside of structure Continue with installation following instruct...

Page 23: ...shortest length of 2 PVC pipe possible NOTE Exhaust pipe and intake pipe must be the same diameter TYPICAL INTAKE PIPE CONNECTIONS IN HORIZONTAL DIRECT OR NON DIRECT VENT APPLICATION RIGHT HAND DISCHA...

Page 24: ...n sizing vent pipe in these applications NOTE The exhaust collar on all models is sized to accommodate 2 Schedule 40 vent pipe In horizontal applications any transition to exhaust pipe larger than 2 m...

Page 25: ...n exhaust or intake terminations Doing so will cause freeze ups and may block the terminations IMPORTANT Model Min Vent Length All 15 ft or 5 ft plus 2 elbows or 10 ft plus 1 elbow Any approved termin...

Page 26: ...0 70 48 13 93 92 73 73 69 10 31 16 65 65 43 8 88 87 68 68 64 Standard Termination Elevation 4500 10 000 ft Number of 90 Elbows Used 1 1 2 Pipe 2 Pipe 2 1 2 Pipe 3 Pipe Model Model Model Model 45 70 90...

Page 27: ...0 60 44 9 76 76 69 69 60 10 23 8 55 55 39 n a 71 71 64 64 55 Concentric Termination Elevation 4 501 10 000 ft Number of 90 Elbows Used 1 1 2 Pipe 2 Pipe 2 1 2 Pipe 3 Pipe Model Model Model Model 45 70...

Page 28: ...10 21 6 50 50 28 68 67 48 48 44 Standard Termination at Elevation 4500 10 000 ft Number of 90 Elbows Used 1 1 2 Pipe 2 Pipe 2 1 2 Pipe 3 Pipe Model Model Model Model 45 70 90 110 135 45 70 90 110 135...

Page 29: ...protective coatings over building materials prolonged exposure to exhaust condensate can destroy protective coatings It is recommended that the exhaust outlet not be located within 6 feet 1 8m of an o...

Page 30: ...6 14 14 23 23 0 to 20 18 to 29 1 1 2 in 8 N A 13 N A N A N A N A N A N A N A 2 in 6 4 12 10 19 16 18 15 N A N A 2 1 2 in N A N A 7 N A 13 N A 12 N A N A N A 3 in N A N A N A N A 8 8 7 7 13 13 1 Refer...

Page 31: ...s 152mm for appliances 10 000 pliances 10 000 Btuh 3kw and 50 000 pliances 50 000 Btuh 15kw 6 inches 152mm for appliances 10 000 Btuh 3kw 12 inches 305mm for appliances 10 000 Btuh 3kw and 100 000 Btu...

Page 32: ...t Air Minimum 12 in 305MM above grade or snow accumulation Figure 26 Exiting Exhaust and Intake Vent no common pressure zone 2 Intake and exhaust pipes should be placed as close together as possible a...

Page 33: ...PROVIDED REDUCER MAY BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION 12 305mm INTAKE AIR EXHAUST VENT Figure 29 Direct Vent Concentric Rooftop Termination 71M80 69M29 or 60L46 US 44W92 or 44...

Page 34: ...above paved sidewalk or paved driveway located on public property Clearance under veranda porch deck or balcony 12 Equal to or greater than soffit depth 3 feet 9m 12 3 feet 9m within a height 15 feet...

Page 35: ...exhaust pipe size must be done after the final elbow 4 Distance between exhaust pipe terminations on multiple furnaces must meet local codes UNCONDITIONED ATTIC SPACE 3 76MM OR 2 51MM PVC PROVIDE SUP...

Page 36: ...bove grade or average snow accumulation B Horizontal separation between intake and exhaust C Minimum from end of exhaust to inlet of intake D Exhaust pipe length E Wall support distance from top of ea...

Page 37: ...for all provinces of Canada GEA approves the following termination for use in all provinces of Canada C 12 D B A 2 51MM Vent Pipe 3 76MM Vent Pipe 12 305 mm Min 12 305 mm Min 6 152 mm Min 24 610 mm Ma...

Page 38: ...elbow fitting into cold end header box Use Teflon tape or appropriate pipe dope NOTE Cold end header box drain plugs are factory installed Check the unused plug for tightness to prevent leakage 3 Ins...

Page 39: ...not possible a heat cable kit may be used on the condensate trap and line Heating cable kit is available in various lengths 6 ft 1 8m kit no 26K68 24 ft 7 3m kit no 26K69 and 50 ft 15 2m kit no 26K70...

Page 40: ...required Trap at coil is optional Field Provided Vent Figure 43 Furnace with Evaporator Coil Using a Common Drain Unit shown in horizontal left hand discharge position Condensate Drain Connection 4 m...

Page 41: ...h PVC Pipe Not Furnished Drain Assembly for 3 4 inch Drain Pipe Condensate Drain Connection In Unit Condensate Drain Connection In Unit Vent To Drain Condensate Drain Connection In Unit Optional Conde...

Page 42: ...inch PVC To Drain 90 Elbow 1 2 inch PVC Not Furnished 1 2 inch PVC Pipe Not Furnished Drain Assembly for 3 4 inch Drain Pipe 90 Street Elbow 1 2 inch PVC Not Furnished Condensate Drain Connection In...

Page 43: ...ove the switch Never use tools If the the switch will not move by hand replace the valve Do not try to repair it Force or attempted repair may result in a fire or explosion Placing the Furnace into Op...

Page 44: ...ontrol to shut the unit off 6 Is gas turned on at the meter 7 Is the manual main shut off valve open 8 Is the internal manual shut off valve open 9 Is the unit ignition system in lockout If the unit l...

Page 45: ...ted 1 Connect the test gauge positive side to manifold pressure tap on gas valve as noted above 2 Tee into the gas valve regulator vent hose and connect to test gauge negative 3 Ignite unit on low fir...

Page 46: ...00ft 6501 7500ft 7501 10000ft Low Fire High Fire Low Fire High Fire Low Fire High Fire Low Fire High Fire Low Fire High Fire Min Max All Models Natural 1 7 3 5 1 6 3 3 1 5 3 2 1 5 3 1 1 7 3 5 4 5 13 0...

Page 47: ...n of load indicates a poor or partial ground Compare the readings to Table 17 If the readings exceed the maximum shown in Table 17 make repairs before operating the furnace 2 In addition measure the A...

Page 48: ...Temperature Rise ________ SUPPLY AIR Temperatures RETURN AIR Figure 50 Temperature Rise External Static Pressure 1 Tap locations shown in Figure 51 2 Punch a 1 4 diameter hole in supply and return air...

Page 49: ...pressure drop may also cause the limit to trip more frequently during the winter and the indoor coil to freeze in the summer resulting in an increase in the number of service calls Before using any f...

Page 50: ...ssure switch assembly Remove the assembly Keep tubing attached to pressure switches 14 Disconnect the plug from the combustion air inducer Remove two screws which secure combustion air inducer to coll...

Page 51: ...res from the gas valve 3 Remove the burner box cover if equipped 4 Disconnect the gas supply line from the gas valve Remove gas valve manifold assembly 5 Mark and disconnect sensor wire from the senso...

Page 52: ...ING OF AT LEAST 90 c 2 PROPER POLARITY MUST BE OBSERVED FOR FIELD LINE VOLTAGE SUPPLY IGNITION CONTROL WILL LOCK OUT IF POLARITY IS REVERSED 3 FOR TEMPORARY SERVICE REPLACEMENT OF CIRCULATING BLOWER M...

Page 53: ...ains energized until the limits are closed Fan On When the thermostat is set for continuous fan operation and there is no demand for heating or cooling a call for fan closes the R to G circuit and the...

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