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*SD FAULT CODES AND TROUBLESHOOTING GUIDE

ALARM

ALARM

EXPLANATION

LED

BOARD

DISPLAY

TROUBLESHOOTING

DESCRIPTION

Pressure Switch 

#2 and Collector 

Switch Error 

Pressure Switch #2

or collector switch

closed at intitial

call for heat

E3.3

Both inducer and collector switches are shorted 

closed.

All pressure switches are checked at the 

beginning of the heat cycle to be open. If the 

control detects the inducer pressure switch #2 or 

collector switch(PS2 on the board) closed,  the 

control will display 3.3

Pressure Switch #2

or Collector Switch

opens during hea

 cycle

E3.4

1. Check for a blocked vent. 

2. Check for faulty Inducer Pressure switch #2 

or Collector Switch faulty.

3. Pressure switch hoses could be switched.

4. Check the wires, refer to the wiring diagram. 

All pressure switches are checked at the 

beginning of the heat cycle to be open. The 

inducer pressure switch #2 and the collector 

switch control signal is ignored throughout the 

ignition cycle. The inducer pressure switch #2 

and the collector switch is monitored 35 seconds 

after ignition, both should be closed.  If one or 

both opens after 35 seconds after ignition , Error 

3.4 will show on the LED Display and the heat 

cycle stops.

Pressure Sensor 

Errors

Pressure Sensor

Voltage too low

E4.1

1. Check pressure sensor wire assembly for 

connection and wire damage.

2. Verify hose is from pressure sensor to the 

bottom of the air inlet venturi is free of debris 

and fully connected.

3. Check for faulty pressure transducer.

Control monitors the voltage from the pressure 

transducer but ignores low voltage before the 

inducer is activated. Once the inducer is activated, 

a voltage from the pressure transducer .2 volts or 

less is considered low and will show a 4.1 Error 

code.  If the voltage is between .2 and .7 volts 

and pressure switch #1 fails to close at a call for 

heat, Error 3.2 is reported

Pressure Sensor

Voltage too high

E4.2

Pressure sensor voltage is reading too high with 

the inducer not running.

1. Check for faulty pressure sensor.

2. Measure the pressure. If the pressure is as 

expected, replace the pressure transducer.   There 

should not be measurable amount of pressure 

when furnace is idle. 

At a call for heat the control monitors the pressure 

sensor voltage. A voltage measured .7 volts or 

higher will report a 4.2 Error

Pressure Sensor

out of span

E4.3

1. Check for incorrect Pressure Switch #1.

2. Pressure Switch #1 hole partially clogged.

3. Verify hose is from pressure sensor to the 

bottom of the air inlet venturi is free of debris.

4. Faulty Pressure transducer- replace.

5. Check inducer for blockage.

6. Check for a faulty pressure switch.

The pressure transducer and Pressure switch #1 

work together to ensure the control can continue 

the ignition sequence. The inducer is initiated, and 

pressure switch #1 closes.  The control board 

should read pressure transducer voltage output 

between -.2 and -.7 Volts .  If not, the control will 

report a 4.3 Error code.

Blocked Vent Detected

Error-Inducer RPM

Limit exceeded

E4.4

1.Check the vent for proper installation and 

blockage.

2. Check the inducer wiring/connection.

3. Check for a faulty inducer.

4. Check the condensate drain for a restriction. 

The control will limit the inducer to 4700 RPM.  

The control will stop the heat cycle if the inducer 

RPM stays greater than 4700 RPM for 5 seconds.

Flame Sensed

when No Flame

should Be

Present

(Internal Lockout)

Flame Sensed when

No Flame should

Be Present

(Internal Lockout)

E05

Check to see if there is a flame present. If so, 

the check for a faulty gas valve.   If no flame is 

present, control board should be replaced.

The control monitors output voltage to the flame 

sensor and has detected the presence of voltage 

when no call for heat is present.

Reversed

Polarity

Grounding

Voltage reversed

polarity 

E6.1

Neutral and Hot Wire Switched

The control monitors voltage and can detect a 

reversed polarity.

Bad Grounding

E6.2

1. Check all ground wires.

2. Make sure a field Ground is attached to the 

factory provided stripped end wire

There 5 green grounds 1. Incoming field ground 

2. Board ground to chassis 3 on the top right of 

the control board. Ground to chassis on the 12 

pin plug. 4. Inducer ground to chassis 5. Blower 

motor ground to the blower housing.

Table 6. Continued

Summary of Contents for SD Ultra Low Nox Series

Page 1: ...asoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use...

Page 2: ...Pressure Switch Location 14 Accessories 15 Finish Flange 15 Rubber Grommets 15 PVC Components 15 Typical Orientation 15 Alternate Orientation 16 Optional PVC Pipe Installation 16 Condensate Drain Line...

Page 3: ...tallation service and operation of this furnace Failure to follow safety recommendations could result in possible damage to the equipment serious personal injury or death This furnace must be installe...

Page 4: ...ping Gas Pipe Pressure Testing US NFGC and National Plumbing Codes General Installation US Current edition of the NFGC and the NFPA 90B For copies contact the National Fire Protection Association Inc...

Page 5: ...36 in Figure 1 Minimum Clearances to Combustible Materials COMBUSTION AIR VENTING REQUIREMENTS WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance c...

Page 6: ...hat force air from the house to the outdoors can create a negative pressure inside the house resulting in improper furnace operationorunsafeconditionssuchasflameroll out It is imperative that sufficie...

Page 7: ...ces crawl or attic that freely exchange with the outdoors See Figure 3 Figure 3 Combustion Air Drawn from a Crawl Space or Vented Attic TOTAL INPUT RATING BTUH MINIMUM FREE AREA EACH OPENING ROUND DUC...

Page 8: ...which draw combustion air from that space In general a furnace installed in an unconfined space will not requireoutsideairforcombustion However inhomesbuiltfor energy efficiency low air change rates...

Page 9: ...ft for each additional 2 inch short radius elbow 3 5 ft for each additional 3 inch long radius elbow and 7 ft for each additional 3 inch short radius elbow Subtract 5 ft for each 2 tee and 8 ft for e...

Page 10: ...g horizontally a side wall vent kit is available according to the pipe diameter size of the installation For 2 inch pipe use side wall vent kit 904617 and for 3 inch pipe use kit 904347 Please follow...

Page 11: ...ustion air piping may be installed in an existing chimney which is not in use provided that Both the exhaust vent and air intake run the length of the chimney The top of the chimney is sealed and weat...

Page 12: ...and condensing on the heat exchanger If a manually operated damper is installed it must be designed so that operation of the furnace is prevented when the damper is in the cooling position and operat...

Page 13: ...any combustible material other than wood flooring SD series gas furnaces are shipped with the bottom panel installed as shown in Figure 23 page 31 If the furnace is installed with only side return air...

Page 14: ...he left or right side of the furnace use the extra screw provided in the parts package 6 Remove the cabinet plug from side of furnace and reinstall in hole on opposite side of cabinet 7 Install in lin...

Page 15: ...m the top to the bottom section of the cabinet or open grommet holes in the cabinet PVC Components IMPORTANT NOTES Before permanently installing these components it is recommended you dry fit them fir...

Page 16: ...retighten the clamp It is permissible to locate the trap away from the furnace The condensate drain system J trap and drain tube should be no more than 30 equivalent feet while maintaining 1 4 per foo...

Page 17: ...building immediately Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department All gas piping mus...

Page 18: ...y omitted for clarity of pipe installation Gas Valve See Note B See Note A Plug Flexible Gas Line Flexible Gas Line FURNACE INPUT MAIN BURNER ORIFICE SIZE MAIN AIR ORIFICE DIAMETER MANIFOLD PRESSURE 5...

Page 19: ...page 36 Figure 25 page 37 or the unit wiring label IMPORTANT NOTES An electrical disconnect must be installed readily accessible from and located within sight of the furnace See Figure 24 page 36 or...

Page 20: ...k White Black White START UP ADJUSTMENTS Pre Start Check List Verify the polarity of the connections are correct the line voltage power leads are securely connected and the furnace is properly grounde...

Page 21: ...possible The thermometer on the supply air side must be shielded from direct radiation from the heat exchanger to avoid false readings 2 Adjustallregistersandductdamperstothedesiredposition and run t...

Page 22: ...ower motor is running tP is displayed following with the Tap number For instance If the blower motor has been set for Tap 4 tP4 will be displayed Ifanalarmisdetected theerrorcodedisdisplayedstarting w...

Page 23: ...3 digit display will show 1dL which means idle Press the MENU button the control will show the options on the display Keep pressing the MENU button the options are Err L6F Cr Cod OdU HOd COF COP HtP...

Page 24: ...36 and Figure 25 page 37 Heating Cycle 1 ThethermostatcallsforheatbyenergizingtheWterminal with 24VAC 2 The control checks the HLI input for a closed limit 3 The control performs a circuitry check an...

Page 25: ...eady for the next call Cooling Cycle When Y1 and G or Y1 Y2 and G signals are detected the control will operate in compressor cooling mode The Electronic Air Cleaner EAC relay will energize 5 seconds...

Page 26: ...be inspected and cleaned if required by a qualified service technician annually to ensure continued safe operation Pay attentiontoanydeteriorationfromcorrosionorothersources WARNING Holes in the vent...

Page 27: ...ce the recycle count will start over Internal Control Fault E2 3 Internal relay in the control board has failed Replace the board Control senses 24V output to the gas valve If voltage is not sensed to...

Page 28: ...2 Measure the pressure If the pressure is as expected replacethepressuretransducer There should not be measurable amount of pressure when furnace is idle Atacallforheatthecontrolmonitorsthepressure se...

Page 29: ...s stuck on the board Replace the board The control senses 24V output from internal relays at all times If power is detected at the HLO output on the 12 pin plug at any time even without a call for hea...

Page 30: ...nsate Drain Switch The Condensate Drain Switch will shut down the furnace if the condensate drain from the Collector Pan becomes clogged BlowerLimitSwitch Preventsoperationoftheblowermotor when the bl...

Page 31: ...TTOM VIEW TOP VIEW 4 Knockouts both sides 1 LEFT SIDE RIGHT SIDE 3 1 4 Gas 1 5 8 T stat 7 8 Electric 7 8 Vent pipe 3 Cond 1 1 16 T stat 7 8 Electric 7 8 Gas 1 5 8 Condensate 1 1 16 Vent pipe 3 Combust...

Page 32: ...0 5 CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE 050U T23A 50 000 BTU Hr Input 50 000 Btuh Input Btuh Output Bottom Tap 9 Tap 8 Tap 7 Tap 6 Tap 5 970 45 935 47 915 48 880 50 845 52 Tap 4 875 50 835 53...

Page 33: ...50 1 315 1 285 1 255 1 225 1 200 Tap 8 1 290 1 260 1 230 1 195 1 160 1 135 1 100 1 070 Tap 7 1 145 1 115 1 090 1 055 1 030 995 960 920 Tap 6 1 045 1 015 980 950 920 885 855 825 Tap 5 935 915 880 845 8...

Page 34: ...0 Btuh Input 95 000 Btuh Output Bottom Only 9 8 7 6 1 850 48 1 790 49 1 745 50 1 700 52 1 650 53 5 1 745 50 1 690 52 1 645 53 1 590 55 1 535 57 4 1 480 59 1 420 62 1 360 65 3 2 1 Side Only 9 8 7 6 1 7...

Page 35: ...95 1 015 945 870 790 715 665 615 1 980 905 835 740 665 590 525 440 Bottom Side 9 2 245 2 195 2 155 2 095 2 065 2 070 2 015 1 950 8 2 080 2 030 1 980 1 930 1 880 1 820 1 765 1 705 7 1 915 1 875 1 820 1...

Page 36: ...GROUND TO CHASSIS TO CHASSIS Refer to the Installation Instructions provided with the furnace for the proper heating and cooling speeds for your application Refer to the Installation Instructions for...

Page 37: ...R TWIN W2 W1 B C Y2 GND Y1 O R G PRESSURE TRANSDUCER GND P1 5V INDUCER PRESSURE SWITCH 1 INDUCER PRESSURE SWITCH 2 COLLECTOR SWITCH PS2 PS1 PS0 MVC HLI ILI HLO MVL GND 5A FUSE K4 TR TH K2 GAS VALVE FL...

Page 38: ...88 375 98 37 184 367 100 36 180 360 102 35 176 353 104 35 173 346 106 34 170 340 108 33 167 333 110 33 164 327 112 32 161 321 114 32 158 316 116 31 155 310 118 31 153 305 120 30 150 300 CAPACITY OF BL...

Page 39: ...tended above meter regulator assembly I Clearance to service regulator vent outlet J Clearance to non mechanical air supply inlet to building or the combustion air inlet to any other appliance 6 inche...

Page 40: ...st slope upward 1 4 per foot 5 7 90 Elbows 90 Elbow COMBUSTION AIR Straps or other suitable supports at minimum 5 ft intervals both pipes 90 Elbows Flue Pipe must slope upward 1 4 per foot First suppo...

Page 41: ...E 2 Inline Drain Field Supplied See NOTES 2 3 Collector Box Drain Factory Equipped See NOTE 2 X See NOTE 5 X See NOTE 5 FLUE PIPE X See NOTE 5 X See NOTE 5 FLUE PIPE Inline Drain Tube Factory Supplied...

Page 42: ...IGHT 1 PIPE OPTIONS Plug VIEW D VIEW E VIEW F VIEW G COMBUSTION AIR FLUE PIPE OPTION 7 OPTION 8 COMBUSTION AIR Rubber Grommet See VIEW D for drain line positions See VIEW E for drain line positions Pl...

Page 43: ...d See NOTES 2 3 Collector Box Drain Factory Equipped See NOTE 2 Inline Drain Field Supplied See NOTES 2 3 Field Supplied Drain Line Attached to PVC Trap Do Not Trap COMBUSTION AIR FLUE PIPE Flange COM...

Page 44: ...ft Installation Inducer Vertical Horizontal Left Installation Inducer Rotated Left Horizontal Right Installation Inducer Vertical Horizontal Right Installation Inducer Rotated Right Alternate Location...

Page 45: ...lation Inducer Vertical Horizontal Left Installation Inducer Rotated Left Horizontal Right Installation Inducer Vertical Horizontal Right Installation Inducer Rotated Right Alternate Locations Alterna...

Page 46: ...46...

Page 47: ...47...

Page 48: ...instructing the customer on how to operate and maintain the equipment for the life of the product Safety should always be the deciding factor when installing this product and using common sense plays...

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