Haier GE NF96DS, Installation Instructions Manual

Page 1: ...ice agency or the gas supplier WARNING As with any mechanical equipment personal injury can result from contact with sharp sheet metal edges Be careful when you handle this equipment CAUTION Table of Contents Unit Dimensions 2 Parts Arrangement 3 Gas Furnace 4 Shipping and Packing List 4 Safety Information 4 General 6 Combustion Dilution Ventilation Air 6 Installation 9 Filters 12 Duct System 12 V...

Page 2: ...19 1 4 489 9 1 8 232 Right 6 9 16 167 Left 2 51 Either Side 3 4 19 B Supply Air 9 16 14 9 16 14 9 16 14 19 7 16 494 CONDENSATE TRAP CONNECTION 5 127 6 1 2 165 Either Side 2 1 4 57 Either Side 1 25 Front Panel 705 AIR FLOW 33 838 C 3 4 19 3 4 19 FRONT VIEW Supply Air 9 16 14 9 229 Unit Dimensions Capacity A B C in mm in mm in mm 045 3B 070 4B 17 1 2 446 16 3 8 416 16 406 090 4C 21 533 19 7 8 504 19...

Page 3: ...ormer and door switch BAG ASSEMBLY BLOWER MOTOR hidden COMBUSTION AIR INDUCER BURNER BOX ASSEMBLY includes flame sensor rollout switches and ignitor GAS VALVE BLOWER DECK HEAT EXCHANGER COLD END HEADER BOX PRIMARY LIMIT BLOWER ACCESS PANEL HEATING ACCESS PANEL COMPARTMENT COMPARTMENT Parts Arrangement ...

Page 4: ...ter debris screen 1 3 4 Threaded street elbow NOTE The required bellows grommet is field provided See the Gas Piping section for relevant diagrams Check equipment for shipping damage If you find any damage immediately contact the last carrier Please refer to specification sheets for available accessories Safety Information DANGER OF EXPLOSION There are circumstances in which odorant used with LP P...

Page 5: ...rnace must be electrically grounded according to local codes In addition in the United States installation must conform with the current National Electric Code ANSI NFPA No 70 The National Electric Code ANSI NFPA No 70 is available from the following address National Fire Protection Association 1 Battery March Park Quincy MA 02269 In Canada all electrical wiring and grounding for the unit must be ...

Page 6: ...ng with clothing boxes doors etc Air is needed for proper combustion and safe unit operation When the furnace is installed in an attic or other insulated space keep insulation away from the furnace When the furnace is installed in an unconditioned space consider provisions required to prevent freezing of the condensate drain system NOTE The Commonwealth of Massachusetts stipulates these additional...

Page 7: ...our of the combined input rating of all appliances installed in that space This space also includes adjacent rooms which are not separated by a door Though an area may appear to be unconfined it might be necessary to bring in outdoor air for combustion if the structure does not provide enough air by infiltration Do not install the furnace in a corrosive or contaminated atmosphere Meet all combusti...

Page 8: ...opening shall have a minimum free area of 1 square inch 645 mm per 2 000 Btu 56 kW per hour of the total input rating of all equipment in the enclosure See Figure 7 When ducts are used they shall be of the same cross sectional area as the free area of the openings to which they connect The minimum dimension of rectangular air ducts shall be no less than 3 inches 75 mm In calculating free area the ...

Page 9: ...ace on its front back or in the horizontal position See Figure 11 Do no connect the return air ducts to the back of the furnace Doing so will adversely affect the operation of the safety control devices which could result in personal injury or death CAUTION Select a location that allows for the required clearances that are listed on the unit nameplate Also consider gas supply connections electrica...

Page 10: ...and sufficient installation and servicing clearances See Table 1 for correct floor opening size 2 Flange warm air plenum and lower the plenum into the opening Figure 12 Setting Equipment FRONT VIEW SIDE VIEW AIR FLOW AIR FLOW 1 2 max AIR FLOW SIDE VIEW Unit must be level side to side Unit may be positioned from level to 1 2 toward the front to aid in draining Improper installation of the furnace c...

Page 11: ...ble material other than wood flooring CAUTION Table 2 Combustible Floor Base Opening Size Cabinet Width Catalog Number Front to Rear Side to Side in mm in mm B 17 5 11M60 22 559 18 3 4 476 C 21 11M61 22 559 22 3 4 578 Figure 15 FURNACE SUPPLY AIR PLENUM COMBUSTIBLE FLOORING BASE PROPERLY SIZED FLOOR OPENING FLOORING COMBUSTIBLE 2 After opening is cut set the combustible flooring base into opening ...

Page 12: ... w c Operation at these conditions may result in improper limit operation Supply Air Plenum If the furnace is installed without a cooling coil a removable access panel should be installed in the supply air duct The access panel should be large enough to permit inspection by reflected light of the heat exchanger for leaks after the furnace is installed The furnace access panel must always be in pla...

Page 13: ... PVC CPVC ABS All Purpose Cement For Fittings Pipe of the same material D2564 D2235 F493 ABS to PVC or CPVC Transition Solvent Cement D3138 CANADA PIPE FITTING SOLVENT CEMENT MARKING PVC CPVC Pipe and Fittings ULCS636 PVC CPVC Solvent Cement ABS to PVC or CPVC Transition Cement POLYPROPYLENE VENTING SYSTEM ULC S636 PolyPro by Duravent InnoFlue by Centrotherm ULC S636 ECCO Polypropylene VentTM ULC ...

Page 14: ...equired must be fied required Table 5 Outdoor Termination Kits Usage Joint Cementing Procedure All cementing of joints should be done according to the specifications outlined in ASTM D 2855 NOTE A sheet metal screw may be used to secure the intake pipe to the connector if desired Use a drill or self tapping screw to make a pilot hole DANGER OF EXPLOSION Fumes from PVC glue may ignite during system...

Page 15: ...n from indoors and flue gases are discharged outdoors In Direct Vent installations combustion air is taken from outdoors and flue gases are discharged outdoors Intake and exhaust pipe sizing Size pipe according to Table 6 and Table 7A through Table 7D Table 6 lists the minimum vent pipe lengths permitted Table 7A through Table 7D list the maximum pipe lengths permitted Regardless of the diameter o...

Page 16: ... screens or perforated metal in exhaust or intake terminations Doing so will cause freeze ups and may block the terminations IMPORTANT Use the following steps to correctly size vent pipe diameter 045 070 090 Standard or Concentric See Table 5 Intake or Exhaust 1 1 2 2 2 1 2 or 3 Furnace capacity 1 Which termination 2 Which needs most elbows 3 How many 4 Desired pipe size 5 What is the altitude 6 U...

Page 17: ...pe size NOTE Additional vent pipe and elbows used to terminate the vent pipe outside the structure must be included in the total vent length calculation Table 7A Maximum Allowable Intake or Exhaust Vent Length in Feet Standard Termination at Elevation 2 001 10 000 ft Number of 90 Elbows Used 2 Pipe 2 1 2 Pipe 3 Pipe Capacity Capacity Capacity 045 070 090 045 070 090 045 070 090 1 35 25 15 100 73 4...

Page 18: ... Additional vent pipe and elbows used to terminate the vent pipe outside the structure must be included in the total vent length calculation Table 7C Maximum Allowable Intake or Exhaust Vent Length in Feet Concentric Termination at Elevation 2 001 10 000 ft Number of 90 Elbows Used 2 Pipe 2 1 2 Pipe 3 Pipe Capacity Capacity Capacity 045 070 090 030 045 070 090 030 045 070 090 1 35 25 15 90 63 39 1...

Page 19: ...ucture must be included in the total vent length calculation NOTE Contact your local FTC if more than 85ft of venting is needed Table 8A Maximum Allowable Exhaust Vent Lengths With Furnace Installed in a Closet or Basement Using Ventilated Attic or Crawl Space For Intake Air in Feet Standard Termination at Elevation 2 001 10 000 ft Number of 90 Elbows Used 1 1 2 Pipe 2 Pipe 2 1 2 Pipe 3 Pipe Capac...

Page 20: ...er pipe in horizontal runs of exhaust pipe When transitioning up in pipe size use the shortest length of 2 PVC pipe possible NOTE Exhaust pipe and intake pipe must be the same diameter Figure 23 Typical Intake Pipe Connections Direct Vent Applications 2 Pipe size determined in table 7 2 2 2 2 or TOP VIEW EXHAUST INTAKE TRANSITION 3 2 2 TRANSITION 3 2 2 1 1 2 or TRANSITION NOTE 1 1 2 Vent Pipe Diam...

Page 21: ...ng with the protective screen should always be directed forward or sideways 2 If intake air is drawn from a ventilated attic Figure 25 or ventilated crawlspace Figure 26 the exhaust vent length must not exceed those listed in Table 8A through Table 8B If 3 diameter pipe is used reduce to 2 diameter pipe at the termination point to accommodate the debris screen 3 Use cement to secure the intake pip...

Page 22: ... 6 C units with long runs of vent pipe through unconditioned space even when insulated may form ice in the exhaust termination that prevents the unit from operating properly Longer run times of at least 5 minutes will alleviate most icing problems Also a heating cable may be installed on exhaust piping and termination to prevent freeze ups Heating cable installation kits are available see unit spe...

Page 23: ...A 7 N A 15 N A 3 in N A N A 2 2 10 10 1 Refer to 99 Minimum Design Temperature table provided in the current edition of the ASHRAE Fundamentals Handbook 2 Poly Propylene vent pipe PP by Duravent and Centrotherm 3 Vent length in table is equivalent length Each elbow is equivalent to 5ft of straight pipe and should be included when measuring total length NOTE Concentric terminations are the equivale...

Page 24: ...arance 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 4 5m above the meter regulator assembly 3 feet 9m 6 inches 152mm for appliances 10 000 Btuh 3kw 12 inches 305mm for appliances 10 000 Btuh 3kw and 100 000 Btuh 30kw 36 inches 9m for appliances 100 000 Btuh 30kw 3 feet 9m above if within 10 feet 3m horizontally 6 feet 1...

Page 25: ... 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 Btuh 30kw 36 inches 9m for appliances 100 000 Btuh 30kw 3 feet 9m above if within 10 feet 3m horizontally 6 feet 1 8m 7 feet 2 1m 12 inches 305mm 1 In accordance with the current ANSI Z223 1 NFPA 54 Natur...

Page 26: ...ust away from the intake piping See Table 10 Capacity Exhaust Pipe Size Termination Pipe Size 045 070 2 51 mm 2 1 2 64 mm 3 76 mm 1 1 2 38 mm 090 2 51 mm 045 070 and 090 units with the flush mount termination must use the 1 1 2 accelerator supplied with the kit Table 10 Exhaust Pipe Termination Size Reduction 5 On field supplied terminations for side wall exit exhaust piping may extend a maximum o...

Page 27: ... above 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 each pipe intake exhaust 12 305 mm Min 12 305 mm Min 6 152 mm Min 24 610 mm Max 9 227 mm Min 12 305 mm Min 16 405 mm Max 6 152 mm Max 6 152 mm Min 24 610 mm Max 9 227 mm Min 12 305 mm Min 20 508 mm Ma...

Page 28: ...and terminate as illustrated In any exterior portion of chimney the exhaust vent must be insulated Figure 34 Direct Vent Application Using Existing Chimney Figure 35 Direct Vent Concentric Wall Termination 12 305mm Min above grade or average snow accumulation 71M80 69M29 or 60L46 US 44W92 or 44W93 Canada INTAKE AIR INTAKE AIR INTAKE AIR OUTSIDE WALL GRADE CLAMP Not Furnished FIELD PROVIDED REDUCER...

Page 29: ...aust piping must be run up an outside wall any reduction in exhaust pipe size must be done after the final elbow Figure 38 Non Direct Vent Roof Termination Kit UNCONDITIONED ATTIC SPACE 3 76MM OR 2 51MM PVC PROVIDE SUPPORT FOR EXHAUST LINES 12 305MM ABOVE AVE SNOW ACCUMULATION SIZE PER EXHAUST PIPE TERMINATION SIZE REDUCTION TABLE Figure 39 Non Direct Vent Application Using Existing Chimney STRAIG...

Page 30: ...p See Figure 45 4 Install drain trap using appropriate PVC fittings glue all joints Glue the provided drain trap as shown in Figure 45 Route the condensate line to an open drain Condensate line must maintain a 1 4 downward slope from the furnace to the drain 5 If unit will be started immediately upon completion of installation prime trap per procedure outlined in Unit Start Up section Do Not use c...

Page 31: ... into the drain line from the evaporator coil CAUTION When combining the furnace and evaporator coil drains together the A C condensate drain outlet must be vented to relieve pressure in order for the furnace pressure switch to operate properly IMPORTANT Figure 43 Evaporator Coil Using a Common Drain Field Provided Vent 1 min 2 max above condensate drain Evaporator Drain Line vent required Condens...

Page 32: ...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 Condensate Drain Connection OptionalDrainPipingFromTrap DrainTrapAssembly Furnished DrainTrap Assembly with 1 2 inch Piping DrainTrap Assembly with 3 4 inch Piping 1 2 inch 3 4 inch 1 25 mm Min 2 50 mm Max Above Top ...

Page 33: ...sediment or condensate 5 A 1 8 N P T plugged tap or pressure post is located on the gas valve to facilitate test gauge connection See Figure 46 6 In some localities codes may require installation of a manual main shut off valve and union furnished by installer external to the unit Union must be of the ground joint type Compounds used on threaded joints of gas piping must be resistant to the action...

Page 34: ...81 151 4 28 138 3 91 125 3 54 118 3 34 110 3 11 103 2 92 1 25 4 1 049 26 645 680 19 25 465 13 17 375 10 62 320 9 06 285 8 07 260 7 36 240 6 80 220 6 23 205 5 80 195 5 52 1 1 4 31 75 1 380 35 052 1400 39 64 950 26 90 770 21 80 660 18 69 580 16 42 530 15 01 490 13 87 460 13 03 430 12 18 400 11 33 1 1 2 38 1 1 610 40 894 2100 59 46 460 41 34 1180 33 41 990 28 03 900 25 48 810 22 94 750 21 24 690 19 5...

Page 35: ...akage corrosion or other deficiencies which could cause an unsafe condition 3 Close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn ON clothes dryers and any appliances not connected to the common venting system Turn ON any exhaust fans such as range hoods and b...

Page 36: ...nections to the equipment Use the provided unit wiring diagram and the field wiring diagram shown in Figure 51 Use 18 gauge wire or larger that is suitable for Class II rating for thermostat connections Electrically ground the unit according to local codes or in the absence of local codes according to the current National Electric Code ANSI HFPA No 70 for the USA and current Canadian Electric Code...

Page 37: ...ording to the instructions provided with the thermostat See Figure 50 for thermostat designations If the furnace is being matched with a heat pump refer to the FM21 installation instruction or appropriate dual fuel thermostat instructions Indoor Blower Speeds 1 When the thermostat is set to FAN ON the indoor blower will run continuously on the fan speed when there is no cooling or heating demand S...

Page 38: ...507769 05G 31 5000656 Page 38 of 55 Issue 2223 045 3B 070 4B 090 4C Figure 52 Typical Wiring Diagram ...

Page 39: ...or 103217 03 Control Red LED Flash Code2 Diagnostic Codes Status of Furnace Off No power to control or control hardware fault detected On Board Fault Detected Fast Heartbeat3 Call for Heat Burner Operation Slow Heartbeat1 Normal Operation Idle Continuous Fan or Cool 1 Flash2 Reverse Line Voltage Polarity or Phasing of 120V power 2 Flashes2 Improper earth ground 3 Flashes2 Burner failed to light or...

Page 40: ... Continuous Fan Speed From Indoor Blower Motor 24VAC PARK 3 Terminals For Unused Motor Speed Taps FS Flame Sensor Electrode 120VAC 24V COM Common 24VAC Table 14 Terminal Designations Applicable to 103217 03 and 107163 01 Controls Unit Start Up FOR YOUR SAFETY READ BEFORE OPERATING Do not use this furnace if any part has been underwater A flood damaged furnace is extremely dangerous Attempts to use...

Page 41: ... sufficient water to ensure proper condensate drain operation If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or death WARNING Gas Valve Operation See Figure 55 1 STOP Read the safety information at the beginning of this section 2 Set the thermostat to the lowest setting 3 Turn OFF all electrical power to the unit 4 This furnac...

Page 42: ...ifices for proper size and restriction Remove temporary gas meter if installed Supply Pressure Measurement A threaded plug on the inlet side of the gas valve provides access to the supply pressure tap Remove the threaded plug install a field provided barbed fitting and connect a manometer to measure supply pressure Replace the threaded plug after measurements have been taken Manifold Pressure Meas...

Page 43: ...0 000 ft 2 286 3048m Natural to LP Propane High Altitude Natural Burner Orifice Kit High Altitude LP Propane Burner Orifice Kit All 11K50 51W01 11K45 Conversion requires installation of a gas valve regulator spring which is provided with the gas conversion kit LP kits include low line pressure switch Table 18 Burner Orifice Conversion Kits at Varying Altitudes Capacity 0 4500 ft 0 1 373m 4501 7500...

Page 44: ...system 2 Visually inspect the venting system for proper size and horizontal pitch Determine there is no blockage or restriction leakage corrosion or other deficiencies which could cause an unsafe condition 3 To the extent that it is practical close all building doors and windows and all doors between the space in which the appliances connected to the venting system are located and other spaces of ...

Page 45: ...turn air temperatures See Figure 56 Ignition Control 107163 01 The heat fan on time of 30 seconds is not adjustable The heat fan off delay amount of time that the blower operates after the heat demand has been satisfied may be adjusted by changing the two position dip switch on the integerated control to one of four slections Blower off delay is factory set at 90 seconds For other blower off delay...

Page 46: ...n the ignition sequence Blower Performance Data NF96D045S3B Performance Less Filter External Static Pressure in w c Air Volume Watts at Different Blower Speeds High Medium High Medium Medium Low Low cfm watts cfm watts cfm watts cfm watts cfm watts 0 00 1455 370 1275 255 1175 190 920 90 865 85 0 10 1425 375 1250 260 1145 200 885 100 830 90 0 20 1395 380 1225 265 1115 210 850 110 795 95 0 30 1365 3...

Page 47: ...0 1025 175 0 50 1590 485 1380 345 1225 285 1125 235 985 185 0 60 1530 465 1340 360 1195 295 1085 245 945 195 0 70 1445 450 1315 370 1150 305 1065 255 895 200 0 80 1350 420 1280 375 1115 315 1015 265 860 210 NOTE All air data is measured external to unit without filter not furnished field provided Allowable Heating Speeds Model Red Yellow Blue Brown Black 045 Allowed Factory Setting Allowed Not All...

Page 48: ...meplate____________Actual____________ Winterizing and Condensate Trap Care 1 Turn off power to the furnace 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 Heat Exchanger If cleaning the heat exchanger becomes necessary follow the below procedures and refer to Figure 1...

Page 49: ...line up in center of burner ports 34 Reinstall gas valve manifold assembly Reconnect gas supply line to gas valve 35 Reconnect 2 wires to gas valve 36 Replace the blower compartment access panel 37 Refer to instruction on verifying gas and electrical connections when re establishing supplies 38 Follow lighting instructions to light and operate furnace for 5 minutes to ensure that heat exchanger is...

Page 50: ...E ENERGIZED GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR BLOWER ON HEATING SPEED LED FLASHES CODE 11 PRESSURE SWITCH CLOSED GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF WITH DELAY Sequence holds until pressure switch opens or thermostat resets control NO NO YES YES IS VOLTAGE ABOVE 70 VOLTS LED FLASHES CODE 13 LOW LINE VOLTAGE CONTROL WILL NOT RESPOND TO A CALL FOR HEATING UNTIL VO...

Page 51: ...OWER OFF WITH DELAY IS 60 MINUTE RESET PERIOD COMPLETE YES 4 SECONDS YES HAS CONTROL RESET IGNITION SEQUENCE FOUR TIMES FLAME SIGNAL 1 5 MICROAMPS OR GREATER YES YES YES ROLLOUT SWITCH CLOSED LED FLASHES CODE 8 ROLLOUT SWITCH OPEN GAS VALVE POWER OFF COMBUSTION AIR INDUCER POWER ON INDOOR BLOWER ON SEQUENCE HOLDS UNTIL ROLLOUT SWITCH IS RESET AND MAIN POWER IS INTERRUPTED OR THERMOSTAT IS CYCLED O...

Page 52: ...ITCH MONITORED CONTINUOUSLY IS ROLLOUT SWITCH CLOSED LED SLOW FLASH RATE REMAINS UNCHANGED THROUGHOUT COOLING CYCLE THERMOSTAT CALLS FOR COOLING COMPRESSOR CONTACTOR AND SYSTEM FAN ENERGIZED WITH 2 SECOND DELAY COOLING SPEED COMPRESSOR OFF THERMOSTAT OPENS SYSTEM FAN AND EAC TERM OFF WITH 45 SECOND DELAY NO NO LED FLASHES CODE 8 ROLLOUT SWITCH OPEN GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR BL...

Page 53: ...G THERMOSTAT OPENS SYSTEM FAN SWITCHED TO COOL SPEED EAC TERM REMAINS ON THERMOSTAT OPENS MANUAL FAN SELECTION MADE AT THERMOSTAT CONTROL G ENERGIZES SYSTEM FAN AT FAN SPEED EAC TERM ENERGIZED NO YES YES NO SYSTEM FAN SWITCHES TO HEAT SPEAD AFTER 30 SECOND DELAY EAC AND HUM TERMINALS REMAIN ON SYSTEM FAN CONTINUES FAN SPEED WITHOUT INTERRUPTION EAC TERMINAL REMAIN ON HUM TERMINALS ARE ENERGIZED WI...

Page 54: ... Must be open and unobstructed to provide combustion air Burners Must be inspected for rust dirt or signs of water Vent pipe Must be inspected for signs of water cracked damaged or sagging pipe or disconnected joints Unit appearance Must be inspected for rust dirt signs of water burnt or damaged wires or components Blower access door Must be properly in place and provide a seal between the return ...

Page 55: ...minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size 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 shall n...