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W415-0919 / D / 03.27.13

IMPORTANT

Read these instructions thoroughly before attempting to operate this furnace.

DO NOT DESTROY THIS MANUAL

Please read carefully and keep in a safe place for future reference by a service technician.

TABLE OF CONTENTS

1.0

SAFETY SYMBOLS AND WARNINGS

2.0 SAFETY ISSUES

2.1

GENERAL SAFETY

RULES

3.0

FURNACE OPERATION INFORMA

TION

3.1 STAR

TING

THE

FURNACE

3.2

SHUTTING DOWN THE FURNACE

3.3 OPERATING

TIPS

4.0

ROUTINE MAINTENANCE BY HOMEOWNER

4.1 AIR

FILTER

4.2 LUBRICATION

4.3 ROUTINE

EXAMINATION

4.4 ANNUAL INSPECTION/SER

VICE

4.5 FURNACE

APPEARANCE

4.6 CLEANING

4.7

SEQUENCE OF OPERATION - ECM 2.3

AND X-13

4.8 VARIA

TIONS

5.0 HOMEOWNER’S

REFERENCE

Содержание 9600 Series

Страница 1: ...performed by a qualified installer service agency or the gas supplier Before servicing disconnect all electrical power to furnace When servicing controls label all wires prior to disconnecting Reconne...

Страница 2: ...9 2 IN CANADA 21 9 3 IN united states 21 9 4 furnace venting installations 22 9 4 1 non direct vent installation using indoor combustion air one pipe system 22 9 4 2 direct vent installation using ou...

Страница 3: ...e is unpacked NOTE Changes other than editorial are denoted by a vertical line in the margin 15 0 low voltage wiring 42 15 1 single stage thermostat 42 15 2 two stage thermostat 42 15 3 thermostat loc...

Страница 4: ...installing WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life THIS PRODUCT MUST BE INSTALL...

Страница 5: ...ns as specified in Section 12 of this manual Gas Supply and Piping 6 Always install furnace to operate within the furnace s intended temperature rise range with a duct system which has an external sta...

Страница 6: ...is associated with respiratory disease including cancer Natural gas and propane are normally odorized by the fuel supplier In some cases the odorant may not be perceivable Installation of UL and ULC r...

Страница 7: ...1 7 8 2 7 21 7 20 867 21 5 2 7 21 7 6 1 6 20 867 21 5 7 51 7 7 51 7 8 2 7 21 9 17 TABLE A FURNACE DIMENSIONS inches TOP LEFT SIDE RIGHT SIDE 5 1 16 UPFLOW DOWNFLOW HORIzONTAL Top 0 0 0 plENum Top 1 2...

Страница 8: ...were equipped with large belt drive blower systems operating at low RPM s If replacing an existing furnace be sure that the existing ductwork can handle the amount of airflow necessary for a reasonab...

Страница 9: ...he rear of the furnace be el evated 1 4 higher than the front to facilitate proper condensate drainage 6 If the furnace is being installed so that the return air will enter through the bottom the peri...

Страница 10: ...f the furnace be elevated 1 4 higher than the front to facilitate proper condensate drainage If the furnace and air conditioner is located above a finished space install a drain pan underneath the uni...

Страница 11: ...LT IN FIRE CAUSING PROPERTY DAMAGE PERSONAL INJURY OR DEATH THE AREA AROUND THE FURNACE MUST BE KEPT CLEAR AND FREE OF ALL COMBUSTIBLE MATERIALS INCLUDING GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUI...

Страница 12: ...The total static pressure drop of the air distribution system including filters should not exceed 1 0 w c DO NOT ALLOW GAS PIPING TO BE ROUTED THROUGH JOIST SPACES THAT ARE USED FOR RETURN AIR PURPOS...

Страница 13: ...13 c 55 f min return air temperature WARNING 3 Connect the return air duct or filter fitting to the furnace The connection should be sealed air tight to prevent entraining combustion gases from an ad...

Страница 14: ...ials and fittings for flue gas venting must be ULC S636 listed and identified as such on the material The first 3ft 900mm of venting must be readily available for visual inspection Specified primers a...

Страница 15: ...dry rooms Furnaces in hobby or craft rooms Furnaces installed near chemical storage areas Exposure to the following substances in the combustion air supply but not limited to the following will also r...

Страница 16: ...1 2 case 2 furnace located in a confined space A confined space any space smaller than the minimums discussed in Case 1 must have two air openings one within 12 of the ceiling and the other within 12...

Страница 17: ...se of the furnace IMPORTANT If an exhaust fan fireplace clothes dryer or any similar device is present in the indoorareafrom which the combustionand ventilationair will be drawn negative pressure coul...

Страница 18: ...obtain sufficient combustion and ventilation air the duct could be an equivalent rectangular duct 8 x 7 for example Based on 50 free area for the inlet grills the actual grill size would have to be 14...

Страница 19: ...sed as long as there is no heat tape applied to the vent pipe For horizontal runs where water may collect wrap the vent pipe with self regulating 3 or 5 watt heat tape The heat tape must be CSA UL or...

Страница 20: ...ws Avoid locating the terminal in locations where dripping condensate may cause problems such as sidewalks patios above planters near windows where exhaust gases may cause fogging etc Avoid locating t...

Страница 21: ...building Above a meter regulator assembly within 3 feet horizontally of the center line of the regulator Within 6 feet of any service regulator vent outlet Less than 12 above grade level or anticipate...

Страница 22: ...ecial kit or modifications are required for direct vent installations Dedicated combustion air and vent piping eliminates the need to use already heated air for combustion purposes The probability of...

Страница 23: ...rculation of the exhaust Figure 9 VERTICAL No termination fitting is required if venting vertically through a roof The end of the exhaust pipe must be 12 higher than the entrance of the combustion air...

Страница 24: ...requires dedicated combustion air and exhaust venting FIGURE 13 multiple venting standard vertical 12 MIN ABOVE SNOW LEVEL 3 MAX 30 MAX 12 MIN 3 MAX TO BE REDUCED FROM 3 PVC TO 2 PVC BELOW THE ROOF LI...

Страница 25: ...W415 0919 D 03 27 13 25 FIGURE 14A direct vent terminal clearances...

Страница 26: ...W415 0919 D 03 27 13 26 FIGURE 14b non direct vent terminal clearances...

Страница 27: ...tight rooms with other combustion devices be completely isolated from the room unless indirect vent Ensure that the combustion door gasket is in good condition Orientation ROTATE EXHAUSTER SEE FIGURE...

Страница 28: ...e side panel in the burner compartment for downflow positions using the two screws provided in parts bag For horizontal positions affix the condensate trap assembly to the exterior side panels 7 Make...

Страница 29: ...on then the combustion compartment and can pull combustion air from the burners and cause incomplete combustion and erratic furnace operation WARNING FIGURE 22 upflow vent and draining option left ven...

Страница 30: ...TER AND CUT DRAIN HOSES TO PROPER LENGTH CUT PRESSURE SWITCH TUBING TO PROPER LENGTH FIGURE 23 horizontal left vent and draining option left vent INSTALLATION top vent INSTALLATION IMPORTANT PRIME CON...

Страница 31: ...CUT PRESSURE SWITCH TUBING TO PROPER LENGTH top vent installation FIGURE 25 downflow vent and draining option left vent installation right vent installation IMPORTANT PRIME CONDENSATE TRAP WITH WATER...

Страница 32: ...N note All condensate drain tubing must slope towards the condensate trap ensuring that the drain hoses do not create traps prior to the condensate trap assembly IMPORTANT The condensate drain trap as...

Страница 33: ...trap Install the con densate trap according to instructions included in the Installation and Operating Manual 11 5 alternate condensate drain piping installation using 1 2 pvc or 3 4 cpvc If installi...

Страница 34: ...e to install it with an overflow bypass tube IMPORTANT If an air conditioning evaporator coil drain is to share the furnace drain line it should be connected with a tee fitting downstream from the tra...

Страница 35: ...12 2 gas piping In Canada the gas piping should be installed in accordance with CAN CSA B149 1 and 2 and in accordance with any local codes In the United States the gas piping should be installed in...

Страница 36: ...ting at maximum conditions IMPORTANT Do not exceed 13 w c inlet pressure with either fuel The gas valve has two adjustable internal regulators for controlling burner manifold pressure Burner manifold...

Страница 37: ...8 for complete instruction TABLE 6a HIGH ALTITUDE SPECIFICATIONS U S A Input K Btu hr ALTITUDE FT ORIFICE size DMS NATURAL LP GAS 45 0 2000 50 57 2000 3000 53 58 3000 4000 54 59 4000 5000 55 60 5000 6...

Страница 38: ...ould overlap boss 3 8 The manometer must have a scale range of at least 0 to 15 of water column 3 Turn on the gas supply and electrical power to the furnace and energize main solenoid by connecting R...

Страница 39: ...furnace is based on 1000 Btu ft gas with a specific gravity of 0 6 Since heating values for the gas vary geographically the actual furnace input and output will vary accord ingly For example natural...

Страница 40: ...G IN PERSONAL INJURY OR LOSS OF LIFE THE FURNACE CABINET MUST HAVE AN UNINTERRUPTED GROUND A GROUND WIRE IS PROVIDED IN THE ELECTRICAL JUNCTION BOX DO NOT USE GAS PIPING AS A GROUND FAILING TO GROUND...

Страница 41: ...t side panel and place it on the panel not being serviced 2 Secure power line connection into junction box following above reference 3 Fasten the junction box to the selected panel NOTE Use good quali...

Страница 42: ...high heat after 5 minutes of continuous low heat op eration If the jumper is in the 10 minute position the control will automatically start high heat after 10 minutes of continuous low heat operation...

Страница 43: ...ing diagram NOTE All HUM and EAC terminals are 120V Do not directly connect 24V equipment to these terminals The integrated furnace control has provisions to supply power and control a line voltage hu...

Страница 44: ...trap on the previous pages in this manual A dry trap will allow flue gases to flow through the recovery coil drain which will prevent the condensate from draining from the recovery coil If enough con...

Страница 45: ...er from low to high speed When high pressure switch closes the control changes indoor blow er speed from Low heat to High heat and energizes high gas output If the high pressure switch is open the Gre...

Страница 46: ...supply air temperature The difference is the temperature rise also called T 5 Compare the measured T to the temperature rise range shown on the rating plate Unless stated differently on the rating pl...

Страница 47: ...eat speed 3 Remove the jumper from position A and place it on the corre sponding letter B C or D as required Refer to TABLE 2 HEAT ING SPEEDS 4 To adjust the cooling airflow ECM 2 3 remove the COOL ju...

Страница 48: ...speed This feature in the heating cycle allows the heat exchanger to reach operating temperature before the set heat speed which minimizes noise and increases comfort Soft Stop At the end of the heati...

Страница 49: ...of the duct system to deliver sufficient air flow if this type of filter is considered Recommended Electronic air cleaners using electrostatic precipitation to remove dust are an excellent filtration...

Страница 50: ...Programmed Delay Flame Sense Lost Thermostat Call For Heat Ends Low Main Valve Closes Combustion Air Blower Off After Post Purge 5 Seconds Circulating Air Fan Off After Programmed Delay Wait For Next...

Страница 51: ...ault detected LED ON Normal Operation 1 Flash High limit switch open 2 Flashes Pressure switch open with exhauster on 3 Flashes Pressure switch closed with exhauster off 4 Flashes Lockout due to too m...

Страница 52: ...D POSITION COLOUR LEAD NUMBER BLACK WHITE RED BLACK WHITE EMPTY 1 2 3 4 5 6 1 2 3 4 5 C1 3 7 1 6 5 C2 HOUSING VIEW FROM OPPOSITE OF WIRE INSERTION END PLASTIC 9 PIN HOUSING AMP 1 480707 0 METAL CONTAC...

Страница 53: ...E SOCKET AMP 350536 1 5 REQUIRED POSITION COLOUR LEAD NUMBER BLACK BLACK RED 1 2 3 4 1 3 3 2 1 C6 WHITE WHITE 4 5 2 5 5 4 1 9 3 4 5 C7 HOUSING VIEW FROM OPPOSITE OF WIRE INSERTION END PLASTIC 9 PIN HO...

Страница 54: ...lacement part without charge for the part only to replace any part that is found to be defective due to workmanship or materials under normal use and maintenance To make a warranty claim the defective...

Страница 55: ...120 W010 2538 ASSY MOTOR KIT 1 3 HP ECM 2 3 45 W010 2539 ASSY MOTOR KIT 1 2 HP ECM 2 3 60 W010 2540 ASSY MOTOR KIT 1 2 HP ECM 2 3 80 W010 2541 ASSY MOTOR KIT 3 4 HP ECM 2 3 100 W010 2542 ASSY MOTOR KI...

Страница 56: ...me Sensor located underneath 13 Two Speed Exhauster 4 Two Stage Gas Valve 14 Pressure Switch Assembly 5 Air High Temperature Limit 15 Front Manifold Cover Pressure Tap 3 6 Vent and Drain Assembly 16 P...

Страница 57: ...0919 D 03 27 13 57 23 0 service history Appliance Service History This heater must be serviced annually depending on usage Date Service Technician Name Service Performed Special Concerns Dealer Name...

Страница 58: ...ial No serial number located on bottom of inside door Date Installed Contractor Contact Address Postal Code Zip Code Telephone No After Hours No If different from Installation Contractor Service Tech...

Страница 59: ...ower level 4 When there is a demand for 2 nd stage heat from Thermostat W2 or automatic staging the control changes the inducer from low to high speed When high pressure switch closes the control chan...

Страница 60: ...here it contributes to home comfort Each pound of condensation formed releases approximately 970 Btu s Your furnace may condense up to gallon 5 pounds of water per hour if running continuously This co...

Страница 61: ...attachment Figure 5 FIGURE 5 4 5 FURNACE APPEARANCE The furnace exterior fi nish is a durable automotive like coating It may be washed with mild soap if necessary Galvanized metal surfaces require no...

Страница 62: ...is probably dust particles burning If you observe lazy yellow fl ames call your heating or service contractor immediately The yellow fl ames inevitably lead to soot ups The combustion air and exhaust...

Страница 63: ...s instructions for removing and cleaning the fi lter Allow the fi lter to dry thoroughly before reinstallation and never operate the blower fan with a wet fi lter Consult your installation contractor...

Страница 64: ...season keep windows and doors closed to reduce the heating load on the system 3 Avoid excessive use of kitchen exhaust hoods and other exhaust fans to reduce the heating load on the system 4 Arrange...

Страница 65: ...the OFF position If burning LP gas smell for gas near the fl oor since propane and butane are both heavier than air If after this time you do not smell gas continue to the next step 9 Turn the manual...

Страница 66: ...e aware that some insulating materials are combustible Do not allow building insulating materials to come into contact with the furnace 5 Any additions alterations or conversions required in order for...

Страница 67: ...moisture which could freeze to build up in the vent If you see moisture building up in the regulator vent contact your gas supplier FIGURE 2 GAS REGULATOR VENT Regulator vent Keep free of ice snow and...

Страница 68: ...D BY A QUALIFIED INSTALLER SER VICE AGENCY OR THE GAS SUPPLIER DEVICES ATTACHED TO EITHER THE VENT OR COMBUSTION AIR INTAKE FOR THE PUR POSES OF EXCEEDING THE LIMITATIONS DESCRIBED IN THE INSTALLATION...

Страница 69: ...e the furnace can result in fi re or explosion A qualifi ed service agency should be contacted to inspect the furnace and to replace all gas controls control system parts electrical parts that have be...

Страница 70: ...AINST UNSAFE PRACTICES CAUTION Understand and pay particular attention to the words DANGER WARNING and CAUTION and the following defi ned symbols are used throughout this manual to notify the reader o...

Страница 71: ...SYMBOLS AND WARNINGS 3 2 0 SAFETY ISSUES 4 2 1 GENERAL SAFETY RULES 7 3 0 FURNACE OPERATION INFORMATION 8 3 1 STARTING THE FURNACE 8 3 2 SHUTTING DOWN THE FURNACE 9 3 3 OPERATING TIPS 9 4 0 ROUTINE MA...

Страница 72: ...er servicing Do not store or use gasoline or other fl ammable 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 tou...

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