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54

Integrated Furnace Control

INTEGRATED FURNACE CONTROL

1

2

R

C

H

U

M 

S

TAT

W

1

W

2

G

Y

1

Y

2

B

TWO-STAGE

THERMOSTAT

(NON-COMMUNICATING)

TWO-STAGE / MODULATING

GAS FURNACE CONTROL

CONDENSER

UNIT

FIGURE 39

WIRING DIAGRAM FOR A LEGACY TWO-STAGE THERMOSTAT.

ST-A1194-62-04

THERMOSTAT WIRING DIAGRAMS-CONDENSING UNIT
(NON-COMMUNICATING)

Summary of Contents for 802V SERIES

Page 1: ...ERIES 80MDV UPFLOW HORIZONTAL SERIES U L and or C S A recognized fuel gas and CO carbon monoxide detectors are rec ommended in all applications and their installation should be in accordance with the...

Page 2: ...perature Sensors 30 11 HIGH ALTITUDE 32 Natural Gas at High Altitudes 32 Orifice Ordering Information 32 LP Gas at High Altitudes 34 12 STARTUP PROCEDURES 35 To Start Furnace 35 To Shut Down Furnace 3...

Page 3: ...n If the model number is correct open the carton and verify that the furnace rating label specifies the same furnace model number that is speci fied on the carton label If the model numbers do not mat...

Page 4: ...ition National Electrical Code NFPA90A Installation of Air Conditioning and Ventilating Sys tems NFPA90B Installation of warm air heating and air conditioning systems The equipment has been evaluated...

Page 5: ...erature rise in heat record air temperature rise ______ Air temperature rise in cool record air temperature rise VENTING ______ Correct vent pipe diameter and length according to NFGC tables _________...

Page 6: ...NPUT RATE IF THE FURNACE IS A MULTI STAGE FURNACE WARNING USE ONLY WITH THE TYPE OF GAS APPROVED FOR THIS FURNACE REFER TO THE FURNACE RATING PLATE WARNING NEVER TEST FOR GAS LEAKS WITH AN OPEN FLAME...

Page 7: ...ATED IN GARAGES OR OFF GARAGE STORAGE AREAS ALL JOINTS SEAMS AND OPENINGS IN THE EQUIPMENT AND DUCT MUST BE SEALED TO LIMIT THE MIGRATION OF TOXIC FUMES AND ODORS IN CLUDING CARBON MONOXIDE FROM MIGRA...

Page 8: ...SITE SELECTION 1 Select a site in the building near the center of the pro posed or existing duct system 2 Give consideration to the vent system piping when se lecting the furnace location Be sure the...

Page 9: ...PLACEMENT OF COMBUSTIBLE MATERIALS ON AGAINST OR AROUND THE FURNACE JACKET CAN CAUSE AN EXPLOSION OR FIRE RESULTING IN PROP ERTY DAMAGE PERSONAL INJURY OR DEATH THE HOMEOWNER SHOULD BE CAUTIONED THAT...

Page 10: ...0 WITH TYPE B VENT MAY BE 1 WITH TYPE B VENT LEFT SIDE REDUCED CLEARANCE IN SHIP WGTS FIGURE 4 UPFLOW HORIZONTAL DIMENSIONS Location ST A1220 04 REDUCED CLEARANCE IN Input A B C D E F Left Right Back...

Page 11: ...Where the maximum airflow is 1800 CFM or more BOTH sides or the bottom must be used for the return air Do not take return air from the back of the unit NOTE DO NOT take return air from furnace rooms g...

Page 12: ...M FLANGES OF CABINET BEFORE THE UNIT IS INSTALLED LIFT UP PULL OUT 1 REMOVE 2 SCREWS LIFT BASE UP SLIDE FORWARD TO REMOVE 2 INSTALLATION IS REVERSE OF REMOVAL VERIFY REAR FLANGE IS SEALED PROPERLY AS...

Page 13: ...ustion gases from an adjacent fuel burning appliance NOTE Do not block furnace access with support rods Main tain clearances recommended in Figure 8 Allow enough space for proper service maintenance o...

Page 14: ...r each 1 000 BTUH of the total input of all appliances in the space If the open space contain ing the appliances is in a building with tight construction contem porary construction outside air may sti...

Page 15: ...e inch of free area for each 1 000 BTUH of total input in the space Table 2 shows some typical examples of openings required for com bustion air openings required for a confined space B USING OUTDOOR...

Page 16: ...EACH OPENING WHEN TWO OPENINGS ARE USED WITH A FURNACE 1 LOCATED IN A CONFINED SPACE 2 USING OUTDOOR AIR FOR COMBUSTION 3 COMMUNICATING DIRECTLY TO THE 3 OUTSIDE THROUGH AN OPENING OR 3 THROUGH A VERT...

Page 17: ...S IS NOT A REQUIREMENT SEE PREVIOUS PAGE SINGLE ELBOW IS ALLOWED BUT MAY NOT PREVENT DEBRIS FROM BEING DROPPED INTO THE FURNACE GROUND OR SHELF SURFACE 6 MIN 6 MININUM CLEARANCE PVC DOUBLE ELBOW 8 SCR...

Page 18: ...attic must be ventilated by gable or soffit vents COMBUSTION AIR FROM ATTIC If attic combustion air is used the inlet air opening at the furnace must be protected from accidental blockage Install a 9...

Page 19: ...d lined masonry chimneys Follow the National Fuel Gas Code ANSI Z223 1 NOTE Follow combustion air instructions as outlined in this man ual Single wall vent connectors to B 1 vent or masonry chimneys m...

Page 20: ...equipped appli ances shall not be greater than 75 percent of the vertical height of the vent Single appliance venting of a fan assisted furnace into a tile lined masonry chimney is prohibited The chi...

Page 21: ...R cont FIGURE 18 DEDICATED VENTING THROUGH CHIMNEY WITH B 1 VENT Combustion Air FIGURE 17 FRESH AIR INLET ST A1220 09 01 1 STANDARD 3 FLUE CONNECTION 2 4 ADAPTER OPTIONAL SEE NATIONAL FUEL GAS CODE FO...

Page 22: ...sed openings in the com mon venting system NOTE Ensure existing venting system complies with latest addi tion of National Fuel Gas Code ANSI Z223 1 and all local codes regulations 1 Visually inspect t...

Page 23: ...OR PROPANE GAS IS HEAVIER THAN AIR AND TENDS TO COLLECT AT LOWER LEVELS MAKING IT MORE DIFFICULT TO SMELL AT NOSE LEVEL NATURAL GAS IS LIGHTER THAN AIR AND WILL RISE POSSIBLY ACCUMULATING IN HIGHER PO...

Page 24: ...3 feet to easily remove the control valve assembly Install a manual shut off valve in the gas line outside the furnace cas ing The valve should be readily accessible to turn the gas supply on or off I...

Page 25: ...LED HIGH ALTITUDE INSTALLATIONS OF THIS BOOK FOR INSTRUCTIONS WARNING NEVER PURGE A GAS LINE INTO THE COMBUS TION CHAMBER NEVER USE MATCHES FLAME OR ANY IGNITION SOURCE FOR CHECKING LEAK AGE FAILURE T...

Page 26: ...7 With LP gas have the LP supplier adjust the line pressure at the regulator MANIFOLD GAS PRESSURE MEASUREMENT Natural gas manifold pressure should be 3 5 3 w c for high fire and 1 8 1 w c for low fir...

Page 27: ...r and the gas supply to the furnace 2 Remove the burner door from the furnace 3 Remove the burner assembly handle with care 4 Remove the two screws attaching the NOx insert retainer bracket to the cen...

Page 28: ...ng steps should be taken 1 The furnace must NOT be electrically connected to line volt age prior to reversing the electrical connection 2 Disconnect the wires from the door switch 3 Remove the junctio...

Page 29: ...ble with the integrated furnace control The low voltage wiring should be sized as shown NOTE Do not use 24 volt control wiring smaller than No 18 AWG Install the room thermostat in accordance with the...

Page 30: ...ovided with the furnace but one must be field supplied and installed It is recommended to replace the furnace filter periodically to maintain optimum furnace performance RXGW B01 CHIMNEY ADAPTER IMPOR...

Page 31: ...HE FURNCE AT THE LOCATIONS PROVIDED CUT OUT USING EMBOSSED ANGLES AS A GUIDE FOR PROPER SIZE 23 X 14 ST A1220 07 00 RXGF CB 6625 7 5 5 FIELD SUPPLIED FILTER ST A1220 06 X0 FIGURE 26 FILTER LOCATIONS A...

Page 32: ...81ft3 I Sea Level input per burner 25000 H Sea Level Heating Value 1050 Q 23 81 ft3 Natural Gas per hour From Table F 1 of Natural Fuel Gas Code Handbook 2002 3 5 w c column Orifice required at Sea Le...

Page 33: ...nly with 25 000BTU Burner DO NOT USE THIS CHART FOR ANY 90 FURNACE MODEL NATURAL GAS ORIFICE SELECTION BASED ON HEATING VALUE ELEVATION Table is derived from Appendix of the National Fuel Gas Code To...

Page 34: ...e LP orifices are based on an 11 of water column pressure at the orifice which dif fers from products that use 10 of water column at the orifice This difference requires a deviation from the NFGC orif...

Page 35: ...rners by turning the gas con trol to the OFF position SEQUENCE OF OPERATION HONEYWELL CONTROLS Integrated Controls with Direct Spark Ignition 1 Each time the thermostat W Heating contacts close legacy...

Page 36: ...Y CARD CONNECTOR S1 S2 S3 DIP SWITCH BANKS P4 CIRCULATION BLOWER COMMUNICATIONS CONNECTION HUMIDIFIER RELAY OUT DRY CONTACTS ELECTRONIC AIR CLEANER OUTPUT NEUTRAL FOR ELECTRONIC AIR CLEANER OUTPUT NEU...

Page 37: ...0 amp at 115 VAC This output is energized any time the blower motor is above the airflow CFM values specified below Airflow below this value is not considered to be enough for a typical electronic ai...

Page 38: ...r operation during heating refer to Figure 29 and make sure to install the jumper between the thermostat ter minals labeled R and HUM STAT A sepa rate humidistat is not required for this configuration...

Page 39: ...TROL Communicating Furnace FIELD INSTALLED JUMPER FROM R TO HUM STAT TERMINALS OPTION A DO NOT INSTALL JUMPER THERMOSTAT CONTROLS HUM DEHUMIDIFIER B INSTALL JUMPER ACTIVATES HUM ON HEAT CALL DOES NOT...

Page 40: ...hes that must be penetrated to change the dipswitch position Use a pen or similar tool to penetrate the cover and change the position This is normal and penetration of the protective cover will not da...

Page 41: ...ow is 75 of full airflow with switch 9 in the OFF position If Switch 9 is in the ON position low airflow is 50 of full airflow 1200 1000 800 600 2000 1600 1400 1200 Switch 9 1st Stage Compressor Airfl...

Page 42: ...irflow HP Blower S1 4 S1 5 50 75 BTU HP Blower 17 Cabinet R802VA075417 100 125 OFF OFF 900 CFM 1200 CFM 1500 CFM Factory Setting ON OFF 750 CFM 1050 CFM 1200 CFM OFF ON 600 CFM 900 CFM 1050 CFM ON ON...

Page 43: ...adjust ment in legacy mode Each selection will use a dif ferent airflow demand for first stage gas heat The selections are set to approximate a specified tem perature rise as follows Note Temperature...

Page 44: ...are con sidered normal some operational codes are displayed simultaneously with low level faults which do not inter rupt operation see paragraphs below for details Since usually only one fault can be...

Page 45: ...ribed above A D 4 When both the low pressure switch and high pres sure switch are closed and both should be open as in during the pressure switch proving period In this case fault codes 44 and 55 will...

Page 46: ...play when two or more faults are present simultaneously Circuit Open P41 P42 should be filtered 30 93 d1 68 61 26 58 14 33 23 22 10 44 45 46 55 57 11 13 66 60 12 H h C c cd Cd hP HP dF F 82 84 81 d4 d...

Page 47: ...instead of adding the new fault to the buffer the previous fault and level are replaced with the new fault and level The time stamp will also be updated This way the existing fault will be updated bu...

Page 48: ...on that the fault buffer is clear the IFC will flash segments A and D of the right most seven segment displays one sec ond on and one second off three times after the fault clear command has been reco...

Page 49: ...esistance and a valid thermistor value was sensed on the same power cycle a fault 82 is to be displayed on the seven segment displays If the resistance between the outdoor air terminals OAT is determi...

Page 50: ...be labeled Aux 1 and Aux 2 The switch inputs are for communicating systems only One or both inputs can be configured at the communicating thermostat as either normally opened or normally closed conta...

Page 51: ...is application 3 If the thermostat wiring will be located near or in paral lel with high voltage wiring cable TV Ethernet wiring or radio frequency equipment then shielded thermo stat wire can be used...

Page 52: ...ING FURNACE AND THERMOSTAT ST A1194 54 03 Integrated Furnace Control INTEGRATED FURNACE CONTROL Figure 36 is the wiring diagram for connecting the furnace to an approved EcoNet communicating thermosta...

Page 53: ...ER BETWEEN Y1 AND Y2 IS REQUIRED SINGLE STAGE THERMOSTAT NON COMMUNICATING TWO STAGE MODULATING GAS FURNACE CONTROL CONDENSER UNIT FIGURE 38 WIRING DIAGRAM FOR A LEGACY SINGLE STAGE THERMOSTAT WITH AU...

Page 54: ...R C HUM STAT W1 W2 G Y1 Y2 B TWO STAGE THERMOSTAT NON COMMUNICATING TWO STAGE MODULATING GAS FURNACE CONTROL CONDENSER UNIT FIGURE 39 WIRING DIAGRAM FOR A LEGACY TWO STAGE THERMOSTAT ST A1194 62 04 T...

Page 55: ...R NON COMMUNICATING OUTDOOR UNIT E1 E2 R C D Y1 B R C Y2 SA1 SA2 OAT1 OAT2 S1 S2 S3 HUM HUM EAC L1 NEUTRAL 1 2 R C HUM STAT W1 W2 G Y1 Y2 B O SA1 SA2 OAT1 OAT2 S1 S2 S3 HUM HUM EAC L1 NEUTRAL 1 2 R C...

Page 56: ...JUMPER BETWEEN Y1 AND Y2 IS REQUIRED SINGLE STAGE THERMOSTAT NON COMMUNICATING TWO STAGE MODULATING GAS FURNACE CONTROL OUTDOOR UNIT FIGURE 41 WIRING DIAGRAM FOR A LEGACY SINGLE STAGE THERMOSTAT WITH...

Page 57: ...former Terminals are quick connect style 20 FUSE P100 P101 A fuse is provided to protect low voltage 24VAC circuits from shorts between 24VAC and Ground or Common A fault code 30 is displayed at the f...

Page 58: ...eplace the regulator cap securely Any necessary major changes in the gas flow rate should be made by changing the size of the burner orifices To change orifice spuds shut off the manual gas valve and...

Page 59: ...ce size may need to be changed to adjust the furnace to its nameplate input Consult the local gas utility to obtain the yearly average heating value and orifice size required to fire each individual b...

Page 60: ...PROPERLY APPLYING THE APPROPRIATE INDUSTRY AC CEPTED STANDARD IF LESS THAN MINIMUM STAN DARDS ARE APPLIED THE EQUIPMENT USER COULD EXPECT TO EXPERIENCE HIGHER UTILITY BILLS MAJOR COMPONENT FAILURE VAR...

Page 61: ...pplier should be called to diagnose and or correct the source of tripping If this unit is mounted in a closet the door must be closed when making this check PRESSURE SWITCH This furnace is equipped wi...

Page 62: ...g across and through it to keep from overheating CAUTION DO NOT OPERATE THE SYSTEM WITHOUT FILTERS A PORTION OF THE DUST ENTRAINED IN THE AIR MAY TEMPORARILY LODGE IN THE AIR DUCT RUNS AND AT THE SUPP...

Page 63: ...re legibility Attach a replacement marking which can be obtained through the distributor if any are found to be illegible or missing REPLACEMENT PARTS Please visit www myrheem com myruud com for repla...

Page 64: ...icates that there is a both cooling and dehumidication demand present at the same time When de humidification is active the cooling airflow will be reduced in order to allow water to accumulate on the...

Page 65: ...ace should operate in any mode d4 NO VALID MODEL DATA ON MEMORY CARD DESCRIPTION The memory card inserted into the slot at position P6 of the furnace control is corrupt and can not be used OR there is...

Page 66: ...ner after the first or even second failure However it will be displayed in the active fault screen of thermostat immediately after the first failure and all subsequent failures during a single heat ca...

Page 67: ...purge After both the post purge and blower off delay are complete the fault code 13 is removed and a new attempt at ignition is made Often the new ignition attempt will fail and operation will proceed...

Page 68: ...68 Diagnostics TABLE 13 continued 802V FAULT CODES WITH DESCRIPTIONS AND SOLUTIONS...

Page 69: ...eck that all gaskets between the inducer and center panel heat exchanger are properly installed and sealed 3 Unstable flame pattern CAUSE 2 Loose or faulty wiring SOLUTION 1 Replace low pressure contr...

Page 70: ...board inducer relay 5 Loose or faulty wiring 6 Disconnected blocked split or cut pressure switch hoses 45 EXPECTED OPERATION 1 DISPLAYED BEFORE HEAT IS ESTABLISHED The IBM Indoor Blower Motor will no...

Page 71: ...ce hoses as necessary 8 Insure proper termination and determine if high altitude kit may be necessary see item 4 2 Check the specification sheets and or installation instructions Remove excess venting...

Page 72: ...s normal with no perceivable difference in operation DESCRIPTION A blower fault which is non critical allows the blower to continue to run but at less than optimal conditions 6 Replace the motor 4 Wir...

Page 73: ...ulty or corrupted 99 REMOTE FAULTS RESET PERFORMED This is a notification that fault codes in the fault buffer have been reset NO BLOWER COMMUNICATIONS STATUS This is a critical fault The furnace will...

Page 74: ...xpectedly on the gas valve con tacts welded relay and will not clear by cycling the inducer Fault code 93 is set and displayed This lockout condition cannot be reset by cycling the heat call 3 The fur...

Page 75: ...pins of the connector are fully seated in the housing to en sure good contact with the connection at the motor When voltage is confirmed at these pins replace the connector on the motor B Remove the m...

Page 76: ...erheating the fault code 61 will be dis played Internal overloading may reset once the condition causing the problem has been removed However it is likely that the motor will need to be re placed A Is...

Page 77: ...in I O if present Check line voltage to motor 115VAC Does ECM blower start on Low heat speed 15 20 seconds after burners light Note IFC SSD s will display 22 or 33 Note If good flame is not sensed a...

Page 78: ...de not timing out 1 hour limit Fault code displayed See FAULT CODES under troubelshooting in the I O Manual Does IDM Shut off after post purge Does I B M shut off after 90 seconds plus slew Double che...

Page 79: ...S PUSH BUTTON SWITCH HPC HIGH PRESSURE CONTROL PFC POWER FACTOR CHOKE FLAME SENSOR FLMS 3 PIN CONNECTOR PL 9 MAIN LIMIT CONTROL OVERTEMP SWITCHES 5 PIN CONNECTOR PL 7 5 PIN CONNECTOR PL 6 100K 125K MO...

Page 80: ...80 CM 0616...

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