Haier GE NF97UM, Service Manual

Page 1: ...31 5000723 Rev 0 11 22 GEA NF97UM 97 Upflow Horizontal Modulating Variable Speed Gas Furnace Service Manual READ CAREFULLY KEEP THESE INSTRUCTIONS...

Page 2: ...handling this equipment and wear gloves and protective clothing CAUTION Improper installation adjustment alteration service or maintenance can cause property damage personal injury or loss of life In...

Page 3: ...7 0 5 Tons 1 2 120 60 1 20 12 8 40 165 NF97U110M5C 110 000 106 000 97 0 5 Tons 1 2 120 60 1 20 12 8 40 175 NF97U135M5D 132 000 127 000 97 0 5 Tons 1 2 120 60 1 20 12 8 40 190 Note For vent length and...

Page 4: ...1267 1444 1645 Default 716 1075 1434 10 938 1148 1324 1469 35 65 Min Input 1st Stage 10 843 1007 1159 1315 7 5 652 997 1342 Default 780 915 1047 1190 15 589 919 1249 10 693 838 959 1070 NF97U090M5C 1...

Page 5: ...1235 1398 1566 Default 706 1051 1395 10 913 1124 1279 1402 35 65 Min Input 1st Stage 10 823 1009 1135 1292 7 5 608 814 1020 Default 758 882 1026 1151 15 571 747 923 10 684 816 928 1068 NF97U090M5C 1...

Page 6: ...fault 1064 1240 1400 1594 Default 703 1052 1401 10 928 1133 1298 1441 35 65 Min Input 1st Stage 10 844 955 1124 1280 7 5 650 986 1323 Default 775 910 1011 1173 15 596 921 1245 10 695 816 932 1045 NF97...

Page 7: ...24 5 D Width Flush Mount Termination 90 Furnaces only US Only 51W11 2 3 0 Vent Concentric Vent Kit 90 Furnaces only US Only 71M80 1 1 2 Vent Version United States 69M29 2 Vent Version United States 6...

Page 8: ...NEL CONTROL BOX includes variable capacity integrated control transformer circuit breaker and door switch VARIABLE SPEED BLOWER MOTOR BAG ASSEMBLIES shipping location COLD END HEADER BOX PRESSURE SWIT...

Page 9: ...32V If the current exceeds this limit the breaker will trip and all unit operation will shutdown The breaker can be manually reset by pressing the button on the face See Figure 3 PRESS TO RESET Figur...

Page 10: ...nly operational with a two stage thermostat The thermostat selection is made using dip switches one and or two Figure 4 and must be positioned for the particular application Variable Capacity Using a...

Page 11: ...XC COMMON RS BUS INDOOR E44 not used R 24VAC I DATA HIGH CONNECTION I DATA LOW CONNECTION C 24VAXC COMMON 1 4 QUICK CONNECT TERMINALS HUM 120 VAC OUTPUT TO HUMIDIFIER XMFR 120 VAC OUTPUT TO TRANSFORME...

Page 12: ...Page 12 31 5000723 Rev 0 Figure 5 Integrated Control Configuration Guide...

Page 13: ...dual applications Adjust the blower off delay to achieve a supply air temperature between 90 and 110 F at the exact moment that the blower is de energized Longer off delay settings provide lower suppl...

Page 14: ...motor ramps down to stop OFF OFF 82 CFM 100 CFM COMPRESSOR DEMAND 7 1 2 MIN Ramping Option C Motor runs at 100 until demand is satisfied Once demand is met motor runs at 100 for 45 seconds then ramps...

Page 15: ...4 On board link W915 is a clippable connection between terminals Y1 and Y2 on the integrated control W915 must be cut if two stage cooling will be used If the link is not cut the outdoor unit will op...

Page 16: ...e after 45 minutes of operation These options are displayed on the menu when the button is pressed during normal operation Display Action when button is released No change idle Remain in idle mode Sol...

Page 17: ...ode is correct and stored in non volatile memory by cycling the 24 volt power to the furnace control At 24 volt power up of the furnace control the 7 segment LED will display a unit size code If three...

Page 18: ...ltage and frequency problems System resumes normal operation 5 seconds after fault recovered E115 Low 24V Control will restart if the error recovers 24 Volt Power high Range is 18 to 30 Volts Check an...

Page 19: ...c Inspect vent and combustion air inducer for correct operation and restriction Resumes normal operation after fault is cleared E224 Low pressure switch failed closed Refer to troubleshooting Check p...

Page 20: ...m number of recycles Last recycle due to the pressure switch opening Check operation of low pressure to see if it is stuck closed on heat call Check pressure inches w c of high pressure switch closing...

Page 21: ...airflow Reduce firing rate every 60 seconds to match available CFM Check filter and duct system To clear replace filter if needed or repair add duct 2 stage controls will reduce firing rate to 1 stag...

Page 22: ...erates independent of a Y1 thermostat demand Normal Operation 1 On On On Acceptable 24 VAC High 100 Dehumidification mode begins when humidity is greater than set point Maximum overcool from cooling s...

Page 23: ...mperature setpoint has been reached in order to maintain room humidity setpoint Maximum overcool from cooling setpoint is 2 F ROOM THERMOSTAT CALLS FOR FIRST AND SECOND STAGE COOLING BASIC MODE only a...

Page 24: ...Blower Motor Components The controller uses sensing devices to sense what position the rotor is in at any given time By sensing the position of the rotor and then switching the motor windings on and...

Page 25: ...t power from unit and wait at least five minutes to allow capacitors to discharge before attempting to service motor Failure to wait may cause personal injury or death DANGER Power Choke L13 A choke c...

Page 26: ...5 Pin J48 5 Pin Line Voltage Connector J49 4 Pin Control Connector J48 5 Pin J49 4 Pin MOTOR with INTEGRATED CONTROLLER SHAFT P49 4 Pin P48 5 Pin P48 5 Pin P49 4 Pin J48 Connector installed on motor...

Page 27: ...sistance should be the same If the measured resistance is greater than 20 ohms replace the motor and control module Figure 13 Test B Heating Components Ignitor The ignitor is made of durable silicon n...

Page 28: ...ys operate the unit with the burner box front panel in place Each burner uses an orifice that is precisely matched to the burner input Burners can be removed as a one piece assembly for service If bur...

Page 29: ...f explosion There are circumstances in which odorant used with LP propane gas can lose its scent In case of a leak LP propane gas will settle close to the floor and may be difficult to smell An LP pro...

Page 30: ...open RPM margin value 3 If low pressure switch is open set flag for calibration on next call for heat Turn inducer off until next call for heat 4 If low pressure switch is closed move inducer speed to...

Page 31: ...measures the pressure differential across the CAI orifice difference in the channel and cold end header box If replacement is necessary the gaskets used to seal the box to the vestibule panel and the...

Page 32: ...nd Header Box Vent Pipe Assembly CAI Embossment Intake Air Coupling Clamp Tubing Exhaust Elbow Exhaust Coupling Blower Deck Seal Pipe Clamp Exhaust Pipe Intake Air Pipe Cold End Header Box Combustion...

Page 33: ...ecommended during cooler weather Metal or plastic strapping may be used for vent pipe hangers Uniformly apply a liberal coat of PVC primer for PVC or use a clean dry cloth for ABS to clean inside sock...

Page 34: ...d of pipe into socket until it bottoms out Turn PVC pipe 1 4 turn during assembly but not after pipe is fully inserted to distribute cement evenly DO NOT turn ABS or cellular core pipe NOTE Assembly s...

Page 35: ...make provisions for draining condensate collection trap and lines Exhaust Piping Figure 21 and Figure 22 Route piping to outside of structure Continue with installation following instructions given i...

Page 36: ...22 Typical Exhaust and Intake Pipe Connections and Condensate Trap Installation in Horizontal Air Applications Right Hand Discharge Shown SIDE VIEW 45 MAX 45 MAX 2 2 2 or 2 2 12 max EXHAUST 2 2 2 2 2...

Page 37: ...22 In some applications which permit the use of several different sizes of vent pipe a combination vent pipe may be used Contact GE Appliances Application Department for assistance in sizing vent pipe...

Page 38: ...e diameter Figure 24 070 090 110 or 135 btuh Standard or Concentric See Table 20 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 Desire...

Page 39: ...0 53 n a 122 103 78 74 9 46 24 95 48 117 98 73 69 10 41 19 90 43 112 93 68 64 Standard Termination at Elevation 4 501 10 000 ft Number of 90 Elbows Used 1 1 2 Pipe 2 Pipe 2 1 2 Pipe 3 Pipe Model Model...

Page 40: ...3 27 90 49 106 99 74 65 9 38 22 85 44 101 94 69 60 10 33 17 80 39 96 89 64 55 Concentric Termination Elevation 4 501 10 000 ft Number of 90 Elbows Used 1 1 2 Pipe 2 Pipe 2 1 2 Pipe 3 Pipe Model Model...

Page 41: ...d that the exhaust outlet not be located within 6 feet 1 8m of an outdoor AC unit because the condensate can damage the painted coating NOTE See Table 21 for maximum allowed exhaust pipe length withou...

Page 42: ...18 to 29 1 1 2 in N A N A N A N A N A N A N A N A 2 in N A N A N A N A N A N A N A N A 2 1 2 in N A N A N A N A N A N A N A N A 3 in N A N A N A N A N A N A N A N A 1 Refer to 99 Minimum Design Tempe...

Page 43: ...s 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 Btu...

Page 44: ...n 305MM above grade or snow accumulation Figure 28 Exiting Exhaust and Intake Vent no common pressure zone 2 Intake and exhaust pipes should be placed as close together as possible at termination end...

Page 45: ...TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION 12 305mm INTAKE AIR EXHAUST VENT Figure 31 Direct Vent Concentric Rooftop Termination 71M80 69M29 or 60L46 US 44W92 or 44W93 Canada Figure 32 Direct Vent...

Page 46: ...bove 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 ea...

Page 47: ...for all provinces of Canada GEA approves the following termination for use in all provinces of Canada C 12 D B A 2 51MM Vent Pipe 3 76MM Vent Pipe 12 305 mm Min 12 305 mm Min 6 152 mm Min 24 610 mm Ma...

Page 48: ...3 4 drain connection use a large flat head screw driver or a 1 2 drive socket extension and remove plug Install provided 3 4 NPT street elbow fitting into cold end header box Use Teflon tape or approp...

Page 49: ...id freezing of condensate and blockage of drain line If this is not possible a heat cable kit may be used on the condensate trap and line Condensate DrainConnection Field Provided Vent 1 min 2 max abo...

Page 50: ...rain line required Trap at coil is optional Field Provided Vent Figure 42 Furnace with Evaporator Coil Using a Common Drain Unit shown in horizontal left hand discharge position Condensate Drain Conne...

Page 51: ...h PVC Pipe 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 Conde...

Page 52: ...inch PVC To Drain 90 Elbow 1 2 inch PVC Not Furnished 1 2 inch PVC Pipe Not Furnished Drain Assembly for 3 4 inch Drain Pipe 90 Street Elbow 1 2 inch PVC Not Furnished Condensate Drain Connection In...

Page 53: ...eplace the valve Do not try to repair it Force or attempted repair may result in a fire or explosion Placing the Furnace into Operation NF97UM units are equipped with an ignition system Do NOT attempt...

Page 54: ...nit ignition system in lockout If the unit locks out again inspect the unit for blockages 10 Is blower harness connected to integrated control Furnace will not operate unless harness is connected Safe...

Page 55: ...atural gas should burn blue 5 After allowing unit to run for 5 minutes record manifold pressure and compare to value given in Table 28 6 Repeat steps 3 4 and 5 on high fire 7 Shut unit off and remove...

Page 56: ...ld Installed Gas Valve Figure 48 Manifold Pressure Measurement Negative Port Positive Port Gas Valve Measuring Device Field Installed Black Tubing Red and Black Tubing or Red Tubing Figure 49 Operatin...

Page 57: ...s The combustion air pressure switch is factory set and requires no adjustment Firing Rate Manifold Pressure Nat Gas Manifold Pressure LP Propane Operating Pressure Signal Delta P Min Normal Max Min N...

Page 58: ...e on second stage heat If using a single stage thermostat furnace must fire at least 10 minutes before switching to second stage heat 3 After plenum thermometers have reached their highest and steadie...

Page 59: ...filters If the pressure drop is too great system capacity and performance may be reduced The pressure drop may also cause the limit to trip more frequently during the winter and the indoor coil to fre...

Page 60: ...nnect all combustion air pressure tubing from cold end header collector box 12 Mark and remove wires from pressure switches Remove pressure switches Keep tubing attached to pressure switches 13 Discon...

Page 61: ...eating compartment access panel Cleaning the Burner Assembly 1 Turn off electrical and gas power supplies to furnace Remove upper and lower furnace access panels 2 Disconnect the 2 pin plug from the g...

Page 62: ...O DS 3 RO IN CUT W951 JUMPER FROM O TO R LABELED HEAT PUMP AT A92 CONTROL BOARD WHEN USED FOR DUAL FUEL APPLICATIONS TYPICAL SYSTEM SHOWN FOR 2 HEAT 2 COOL WITH A CONVENTIONAL THERMOSTAT SEE INSTALLAT...

Page 63: ...C 24VAXC COMMON RS BUS INDOOR E44 not used R 24VAC I DATA HIGH CONNECTION I DATA LOW CONNECTION C 24VAXC COMMON 1 4 QUICK CONNECT TERMINALS HUM 120 VAC OUTPUT TO HUMIDIFIER XMFR 120 VAC OUTPUT TO TRAN...

Page 64: ...ill present the furnace will continue to operate at the present firing rate until the heat cycle ends 7 When the demand for first and second stage heat is satisfied the gas valve is de energized and t...

Page 65: ...N delay When the delay ends the indoor blower motor is energized at a speed that matches the firing rate After the 10 second ignition stabilization delay expires the inducer speed is adjusted to the a...

Page 66: ...ON 12 minutes ON Intact Intact Intact T STAT CONTROL TERM STRIP OUTDOOR UNIT 1 Heat 2 Cool NOTE Use DIP switch 3 to set sceond stage heat ON delay OFF 7 minutes ON 12 minutes ON Cut Intact Intact T S...

Page 67: ...R Heat Pumps 2 Heat 2 Cool OFF Cut Intact Intact T STAT CONTROL TERM STRIP OUTDOOR UNIT 2 Heat 2 Cool with t stat with dehumidification mode OFF Cut Cut Intact T STAT CONTROL TERM STRIP OUTDOOR UNIT...

Page 68: ...bilities Capable of 2 stage gas heat control OFF Intact Intact Cut T STAT CONTROL TERM STRIP HEAT PUMP 67M41 Y H L Y2 D B L Y2 T T outdoor sensor Dual Fuel Two Stage Heat Pump thermostat w dual fuel c...

Page 69: ...20Seconds Soft Lockout Error Code Flashes YES NO NO YES Call For Heat Ends NO YES YES NO C A L L F O R 1 S T S T A G E H E A T 3A 2 1 1 OR Call For Heat NO 4 Calibrations Attempted Calibration Success...

Page 70: ...10 Seconds NO Error Code Flashes NO YES Wait 5 Minutes 3A 2 1 2 1 System will always light at 70 even if 2nd stage call for heat is in place If the high pressure switch does not close within 5 attempt...

Page 71: ...R Combustion Air Inducer switched to 70 rate speed Adjust Indoor Blower to appropiate speed Combustion Air Inducer OFF after 20 Second Post Purge Indoor Blower OFF after OFF Delay RUN MODE 2 STAGE THE...

Page 72: ...ckout Error Code Flashes YES NO NO YES Call For Heat Ends NO YES YES NO C A L L F O R H E A T 3B 1 4 Move to Mid Firing Rate and High Firing Rate after 2nd and 3rd Stage Delays based on DI P Switch se...

Page 73: ...ling mode High Cooling mode Per Ramping Profile NO NO YES NO 5 1 2 1 2 2 2 1 Indoor Blower On After 2 second delay Energize Indoor Blower Per Ramping Profile Energize Indoor Blower Maintain Indoor Blo...

Page 74: ...1 1 Call for Continuous Blower Indoor Blower On Maintain Indoor Blower at set speed Maintain Indoor Blower at set speed OR Maintain Indoor Blower at set speed Indoor Blower Per Go to Call for Heat Sin...

Page 75: ...Page 75 31 5000723 Rev 0 Notes...

Page 76: ...Printed in the U S A All specifications and illustrations subject to change without notice and without incurring obligations...