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33

D

RAIN

 T

RAP

 P

RIMING

The drain trap MUST be primed prior to furnace startup.  To
prime, fill both sides of the drain trap with water.  This
ensures proper furnace drainage upon startup and prohibits
the possibility of flue gases escaping through the drain
system.

F

URNACE

 O

PERATION

Purge gas lines of air prior to startup.  Be sure not purge
lines into an enclosed burner compartment.  Follow NFPA 54,
National Fuel Gas Code for proper purging methods.  In
Canada, follow approved purping methods in CAN/CSA
B149.1-15.

Check for leaks using an approved chloride-free soap and
water solution, an electronic combustible gas detector, or
other approved method.  Verify that all required kits (propane
gas, high altitude, etc.) have been appropriately installed.

F

URNACE

 S

TARTUP

1. Close the manual gas shutoff valve external to the furnace.
2. Turn off the electrical power to the furnace.
3. Set the room thermostat to the lowest possible setting.
4. Remove the burner compartment door.

NOTE:  

This furnace is equipped with an ignition device

which automatically lights the burner.  Do not try to
light the burner by hand.

5. Move the furnace gas valve manual control to the OFF

position.

6. Wait five minutes then smell for gas. Be sure check near

the floor as some types of gas are heavier than air.

7. If you smell gas after five minutes, immediately follow

the safety instructions in the 

Safety Considerations

on page 3 of this manual.  If you do not smell gas after
five minutes,  move the furnace gas valve manual control
to the ON position.

8. Replace the burner compartment door.
9. Open the manual gas shutoff valve external to the furnace.
10. Turn on the electrical power to the furnace.
11. Adjust the thermostat to a setting above room

temperature.

12. After the burners are lit, set the thermostat to desired

temperature.

F

URNACE

 S

HUTDOWN

1. Set the thermostat to the lowest setting.

The integrated control will close the gas valve and
extinguish flame.  Following a 15 second delay, the induced
draft blower will be de-energized.  After a 120, 150, 180
or 210-second delay period (field selectable delay OFF
[90, 120, 150, 180] plus 30-second ramp down), the
circulator blower de-energizes.

2. Remove the burner compartment door and move the

furnace gas valve manual control to the OFF position.

3. Close the manual gas shutoff valve external to the furnace.
4. Replace the burner compartment door.

G

AS

 S

UPPLY

 P

RESSURE

 M

EASUREMENT

G

AS

 P

RESSURE

 T

EST

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 are

pressed for greater than 1 second, the display will blank
to indicate the push buttons are pressed. Within 5
seconds, both push buttons should be released. If any
push button is not released, the test mode will not
activate. The display will return to normal.

2. Once the push buttons are released, the display will

flash “Ft” to indicate the push buttons are released
and successful entry into test mode has been achieved.

3. The control will force a high capacity demand. If a low

capacity demand is already being serviced, it will be
forced to high capacity.

4. The display will continue to flash “Ft” until high capacity

(100%) is achieved. Once achieved, the display will show
“Ft” without flashing. A 5-minute timer will be started
to allow sufficient opportunity for the gas pressure to
be tested.

5. If a call for heat is given or removed during the test,

the system will still operate until the 5 minute test
time is complete.

6. During test mode, if both push buttons are pressed for

greater than 1 second, the display will blank to indicate
push buttons are pressed. If both push buttons are
released within 5 seconds, the test mode will terminate
and the system will return to normal operation.
Otherwise, the test mode will continue uninterrupted.

7. After completion of the 5-minute timer or test mode

termination, whichever is earlier, the system will return
to normal operation, either continuing an existing heat
demand or going to the idle state.

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

.

The line pressure supplied to the gas valve must be within
the range specified below.  The supply pressure can be
measured at the gas valve inlet pressure tap or at a hose
fitting installed in the gas piping drip leg.  The supply pressure
must be measured with the burners operating.  To measure
the gas supply pressure, use the following procedure.

1. Turn OFF gas to furnace at the manual gas shutoff valve

external to the furnace.

2. Connect a calibrated water manometer (or appropriate

gas pressure gauge) at either the gas valve inlet pressure
tap or the gas piping drip leg. See Honeywell VR9205 gas
valve figure or White-Rodgers 36J54 gas valve figure for
location of inlet pressure tap.

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...

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