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F96VTN and G96VTN: Installation, Start-up, Operating and Service and Maintenance Instructions

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

58

SERVICE AND MAINTENANCE PROCEDURES 

Untrained personnel  can perform basic maintenance  functions such as

cleaning and replacing air filters. All other operations must be performed

by trained service personnel. A qualified service person should inspect

the furnace once a year.

General

These instructions are written as if the furnace is installed in an upflow

application.  An  upflow  furnace  application  is  where  the  blower  is

located below the combustion and controls section of the furnace, and

conditioned air is discharged upward. Since this furnace can be installed

in  any  of  the  4  positions  shown  in 

Fig. 2

,  you  must  revise  your

orientation to component location accordingly. 

Electrical Controls and Wiring

Each  pressure  switch  is  labeled  with  the  reference  location  (noted  as

“COLLECTOR  BOX-LPS”  or  “HOUSING-HPS”  on  the  switch). The

nominal  break  point  of  each  switch  is  shown  on  the  label  below  the

reference location in inches of water column, “W.C.” The maximum and

minimum break point of the switch is +/- 0.05 inches of water column

from the nominal break point of the switch. The maximum make point of

the switch is 0.10 inches of water above the maximum break point of the

switch.

Example

: Nominal break point on pressure switch is 0.68-in. W.C. The

minimum break point of the switch is 0.63-in. W.C. The maximum break

point  of  the switch  is 0.73-in. W.C. The maximum  make  point of  the

switch is 0.83-in. W.C. 

Table 21 – Gas Rate (CU ft./hr)

SEC.

FOR 1 

REV. 

SIZE OF TEST DIAL 

SEC. 

FOR 1 

REV. 

SIZE OF TEST DIAL 

1 Cu 

Ft. 

2 Cu 

Ft. 

Cu Ft. 

1 Cu 

Ft. 

2 Cu 

Ft. 

5 Cu 

Ft. 

10 

360 

720  1800 

50 

72 

144 

360 

11 

327 

655  1636 

51 

71 

141 

355 

12 

300 

600  1500 

52 

69 

138 

346 

13 

277 

555  1385 

53 

68 

136 

340 

14 

257 

514  1286 

54 

67 

133 

333 

15 

240 

480  1200 

55 

65 

131 

327 

16 

225 

450 

1125 

56 

64 

129 

321 

17 

212 

424  1059 

57 

63 

126 

316 

18 

200 

400  1000 

58 

62 

124 

310 

19 

189 

379 

947 

59 

61 

122 

305 

20 

180 

360 

900 

60 

60 

120 

300 

21 

171 

343 

857 

62 

58 

116 

290 

22 

164 

327 

818 

64 

56 

112 

281 

23 

157 

313 

783 

66 

54 

109 

273 

24 

150 

300 

750 

68 

53 

106 

265 

25 

144 

288 

720 

70 

51 

103 

257 

26 

138 

277 

692 

72 

50 

100 

250 

27 

133 

267 

667 

74 

48 

97 

243 

28 

129 

257 

643 

76 

47 

95 

237 

29 

124 

248 

621 

78 

46 

92 

231 

30 

120 

240 

600 

80 

45 

90 

225 

31 

116 

232 

581 

82 

44 

88 

220 

32 

113 

225 

563 

84 

43 

86 

214 

33 

109 

218 

545 

86 

42 

84 

209 

34 

106 

212 

529 

88 

41 

82 

205 

35 

103 

206 

514 

90 

40 

80 

200 

36 

100 

200 

500 

92 

39 

78 

196 

37 

97 

195 

486 

94 

38 

76 

192 

38 

95 

189 

474 

96 

38 

75 

188 

39 

92 

185 

462 

98 

37 

74 

184 

40 

90 

180 

450 

100 

36 

72 

180 

41 

88 

176 

439 

102 

35 

71 

178 

42 

86 

172 

429 

104 

35 

69 

173 

43 

84 

167 

419 

106 

34 

68 

170 

44 

82 

164 

409 

108 

33 

67 

167 

45 

80 

160 

400 

110 

33 

65 

164 

46 

78 

157 

391 

112 

32 

64 

161 

47 

76 

153 

383 

116 

31 

62 

155 

48 

75 

150 

375 

120 

30 

60 

150 

49 

73 

147 

367 

WARNING

!

FIRE, INJURY OR DEATH HAZARD

Failure  to  follow  this  warning  could  result  in  personal  injury,  death

and/or property damage. 

The ability to properly perform maintenance on this equipment requires

certain knowledge, mechanical skills, tools, and equipment. If you do

not  possess  these,  do  not  attempt  to  perform  any  service  and

maintenance  on  this  equipment  other  than  those  procedures

recommended in the Owner’s Manual.

CAUTION

!

ENVIRONMENTAL HAZARD

Failure to follow this caution may result in environmental pollution.
Remove and recycle all components or materials (i.e. oil, refrigerant,

control board, etc.) before unit final disposal.

CAUTION

!

ELECTRICAL OPERATION HAZARD

Failure to follow this caution may result in improper furnace operation

or failure of furnace. 
Label all wires prior to disconnection when servicing controls. Wiring

errors can cause improper and dangerous operation. 

WARNING

!

ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury or death,

or property damage. 

Before  installing,  modifying,  or  servicing  system,  main  electrical

disconnect switch must be in the OFF position and install a lockout tag.

There  may  be  more  than  one  disconnect  switch.  Lock  out  and  tag

switch  with  a  suitable  warning  label.  Verify  proper  operation  after

servicing. Always  reinstall  access  doors  after  completing  service and

maintenance.

WARNING

!

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death. 

There may be more  than one electrical  supply to  the  furnace.  Check

accessories and cooling unit for additional electrical supplies that must

be shut off during furnace servicing. Lock out and tag switch with a

suitable warning label. 

Summary of Contents for F96VTN

Page 1: ...ANCE PROCEDURES 58 WINTERIZATION 65 SEQUENCE OF OPERATION 68 PARTS REPLACEMENT INFORMATION GUIDE 71 MODEL NOMENCLATURE 71 Most states in the USA and jurisdictions in Canada have laws that require the...

Page 2: ...o the exterior of the building at a 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...

Page 3: ...ARNING FIRE INJURY OR DEATH HAZARD Failure to follow this warning could result in property damage personal injury or death This furnace was manufactured to operate with natural gas When fuel supply is...

Page 4: ...ion of leaks to check all connections as specified in the Gas Piping section 6 Always install furnace to operate within the furnace s intended temperature rise range with a duct system which has an ex...

Page 5: ...scomfort and or vent freezing Failure to follow these guidelines is considered faulty installation and or misapplication of the furnace and resulting failure damage or repairs may impact warranty cove...

Page 6: ...lumbing codes CANADA Current edition of CAN CSA B149 1 Parts 4 5 6 and 9 In the state of Massachusetts This product must be installed by a licensed plumber or gas fitter When flexible connectors are u...

Page 7: ...ficient air must be provided to avoid negative pressure in the equipment room or space A positive seal must be made between the furnace cabinet and the return air duct to prevent pulling air from the...

Page 8: ...ustion Air Method 1 Provide the space with sufficient air for proper combustion ventilation and dilution of flue gases using permanent horizontal or vertical duct s or opening s directly communicating...

Page 9: ...4 Unusually tight construction is defined as Construction with a Walls and ceilings exposed to the outdoors have a continuous sealed vapor barrier Openings are gasketed or sealed and b Doors and open...

Page 10: ...09 9 229 40 26087 7 178 30 19355 6 152 140 000 70 45161 10 254 47 30435 8 203 35 22581 7 178 FURNACE WATER HEATER TOTAL INPUT 100 000 30 000 130 000 divided by 4 000 32 5 Sq In for each two Vertical D...

Page 11: ...horizontal drain trap grommet is ONLY REQUIRED FOR DIRECT VENT APPLICATIONS It it NOT required for applications using single pipe or ventilated combustion air venting The condensate trap extends belo...

Page 12: ...ured per local codes Supports and clamps should be spaced to prevent the drain line from sagging or being dislocated from the furnace or termination point In the absence of local codes consult the cur...

Page 13: ...amp and insert the long end of the adapter or the 1 2 in CPVC pipe into the outlet stub on the drain tube 9 Connect additional condensate piping to a code approved drain or to a condensate pump approv...

Page 14: ...an be constructed from field supplied 1 2 in CPVC or 3 4 in PVC pipe in compliance with local building codes A factory supplied 1 2 in CPVC to 3 4 in PVC adapter is supplied in the loose parts bag for...

Page 15: ...viewed for possible openings using light assistance or a probe can be inserted for sampling the air stream The cover attachment shall prevent leaks Connect supply air duct to flanges on furnace supply...

Page 16: ...s cased evaporator coil or coil casing is used install as shown in Fig 25 NOTE It is recommended that the perforated supply air duct flanges be completely removed from furnace when installing the furn...

Page 17: ...ustible flooring subbase required 15 1 8 384 19 483 16 3 4 425 20 5 8 524 Downflow Applications on Combustible Flooring with coil assembly or coil box subbase not required 15 1 2 394 19 483 16 1 2 419...

Page 18: ...onnect supply air duct to flanges on furnace supply air outlet Bend flange upward to 90 with wide duct pliers See Fig 20 The supply air duct must be connected to ONLY the furnace supply outlet air duc...

Page 19: ...on sheet for performance data for a particular filter media or IAQ device Design the filter and associated ductwork for the best match of pressure drop versus filter size Best practice usually chooses...

Page 20: ...5 13 0 08 21 0 13 32 0 29 72 0 20 49 1000 472 0 06 16 0 11 28 0 17 43 0 27 67 1200 566 0 07 18 0 14 36 0 22 56 1400 661 0 08 21 0 18 45 0 28 70 1600 755 0 09 23 0 21 54 1800 850 0 10 25 0 26 64 20 x 2...

Page 21: ...5 See Note 4 ON ON ON 385 335 See Note 4 Heating SW1 High Heat Airflow3 800 770 730 700 665 635 605 570 540 510 Low Heat Airflow3 560 520 470 425 390 See Note 4 SW1 5 and SW2 2 set to OFF except as in...

Page 22: ...e 4 Heating SW1 High Heat Airflow3 1470 1435 1400 1365 1330 1295 1260 1225 1190 1155 Low Heat Airflow3 1150 1110 1070 1030 990 950 910 870 830 790 SW1 5 and SW2 2 set to OFF except as indicated See No...

Page 23: ...ote 4 Heating SW1 High Heat Airflow3 1810 1765 1720 1675 1625 1575 1525 1475 1425 1375 Low Heat Airflow3 1405 1350 1290 1225 1160 1100 See Note 4 SW1 5 and SW2 2 set to OFF except as indicated See Not...

Page 24: ...e dampers or other flow control must prevent chilled air from entering the furnace If the dampers are manually operated they must be equipped with means to prevent operation of either unit unless the...

Page 25: ...is used black pipe shall be installed at the furnace gas control valve and extend a minimum of 2 in 51 mm outside the furnace WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could resu...

Page 26: ...pe must be disconnected from furnace and capped before and during supply pipe pressure test If test pressure is equal to or less than 0 5 psig 14 in w c turn off electric shutoff switch located on fur...

Page 27: ...M WIRE LENGTH FT M Length shown is as measured one way along wire path between furnace and service panel for maximum 2 percent voltage drop MAXIMUM FUSE OR CKT BKR AMPS Time delay type is recommended...

Page 28: ...piping or the indoor coil drain See Fig 30 for alternate electric entry through top panel 1 Select and remove 7 8 in 22 mm knock out on the desired side of the casing Remove the knock out from the cas...

Page 29: ...Install J Box mounting bracket to inside of furnace casing See Fig 34 2 Route BX connector through 7 8 in 22 mm diameter hole in casing and J Box bracket 3 Secure BX cable to J Box bracket with connec...

Page 30: ...HUM terminal is a 24 VAC output energized when the blower is operating during a call for heat 3 Twinning Connector The furnace can only be controlled by a single or two stage thermostat A Communicati...

Page 31: ...he venting system should be done in conjunction with planning for the ductwork drainage and furnace accessories such as air cleaners and humidifiers Begin assembling the venting system AFTER the furna...

Page 32: ...Canadien recommande l inspection par un personel qualifi et ce une fois par ann e Les autorit es ayant juridiction inspecteurs de gas inspecteurs en b timents d partement des incendies etc devraient t...

Page 33: ...moisture from entering the furnace from the combustion air inlet pipe See Fig 51 When sizing venting systems the equivalent length of the optional inlet pipe moisture trap must be taken into account W...

Page 34: ...damage plants shrubs air conditioning equipment or utility meters 3 Do not locate termination directly into prevailing winds Termination should be positioned so that it will not be affected by sustain...

Page 35: ...lvents Primers Cements PVC Pressure Pipe Schedule 40 D1785 UL 1738 D2466 or D2665 F656 D2564 DWV Schedule 40 D1785 D2665 SDR 26 N A D2241 SDR 21 N A D2241 IPEX Schedule 40 ULC S636 ULC S636 ULC S636 U...

Page 36: ...Maintain 12 in 305mm minimum clearance above highest anticipated snow level or grade whichever is greater Side wall termination with 2 elbows preferred 12 in min 305 mm from overhang or roof Maintain...

Page 37: ...air supply inlet 6 ft 1 8 M 3ft 9 M above if within 10 ft 3 M horizontally L Clearance under a veranda porch deck or balcony 12 in 305 mm Permitted only if veranda porch deck or balcony is fully open...

Page 38: ...n See Note 8 K Clearance to a mechanical air supply inlet 6 ft 1 8 M 3ft 9 M above if within 10 ft 3 M horizontally L Clearance under a veranda porch deck or balcony 12 in 305 mm Permitted only if ver...

Page 39: ...arance distances when vent termination is located more than 6 ft 2 M away from an inside corner refer to the appropriate Direct Vent or Non Direct Vent Clearance Table Clearance description when termi...

Page 40: ...to Fig 50 for terminations approved for use in Alberta and Saskatchewan Size the Vent and Combustion Air Pipes General Furnace combustion air and vent pipe connections are sized for 2 in 50 mm ND PVC...

Page 41: ...nt Termination NOTE Maximum Equivalent Vent Length MEVL includes standard and concentric vent termination and does NOT include elbows Use Table 15 Deductions from Maximum Equivalent Vent Length to det...

Page 42: ...gth Unit Size 40 000 1 60 000 2 80 000 100 000 3 120 000 Altitude feet Pipe Dia in 1 2 2 1 2 2 3 1 2 2 3 4 2 2 3 4 2 3 4 0 2000 40 155 185 20 100 175 200 15 55 130 175 200 20 80 175 200 10 75 185 2001...

Page 43: ...each pipe 2 Count the number of elbows for each pipe 3 For each pipe multiply the number of elbows by the equivalent length for the type of elbow used Record the equivalent length of all the elbows fo...

Page 44: ...be necessary to remove one knockout for the vent pipe and the other knockout for the combustion air connection See Fig 15 Use a flat blade screwdriver and tap on the knockout on opposite sides where t...

Page 45: ...1 64 76 7 6 1 6 1 6 1 6 1 15 2 13 7 6 1 18 3 15 2 6 1 9 1 9 1 7 6 6 1 22 9 19 8 18 3 6 1 25 9 22 9 19 8 18 3 0 1 5 1 5 6 1 7 6 6 1 6 1 9 1 7 6 4 6 4 6 3 0 3 0 6 1 12 2 9 1 7 6 6 1 13 7 12 2 9 1 29 1 5...

Page 46: ...w Configurations Appearance May Vary See Notes for Venting Options A11327A HORIZONTAL LEFT VERTICAL VENT CONFIGURATION 1 2 3 4 6 7 5 5 Rotate vent elbow to required position Any other unused knockout...

Page 47: ...adapter Slide clamps over the coupling 3 Slide vent pipe through adapter and coupling into vent elbow 4 Insert vent pipe into vent elbow 5 Torque all clamps 15 lb in 6 Attach combustion air pipe adapt...

Page 48: ...r with sheet metal screws DO NOT DRILL INTO POLYPROPYLENE VENT PIPES Use an optional accessory vent coupling if needed 12 Seal around the combustion air pipe with silicone or foil tape SILICONE SEALER...

Page 49: ...than 18 in 457 mm apart to help avoid vent gas recirculation into combustion air intake Termination elbows will be installed after the vent and if used combustion air pipe is installed Sidewall Termi...

Page 50: ...t restrictor 1 Remove the vent elbow from the inducer outlet 2 Align the lock tabs on the outlet restrictor with the slots on inside outlet of the inducer assembly 3 Snap the outlet restrictor in plac...

Page 51: ...te setup switches on furnace control 3 Configure the setup switches as necessary for the application 4 Replace blower door NOTE If a bypass humidifier is used setup switch SW1 4 Comfort Efficiency sho...

Page 52: ...ontinuous Fan CF Setup Switches SW2 3 4 5 The CF setup switches are used to select desired airflow when thermostat is in continuous fan mode or to select low cooling airflow for two speed cooling unit...

Page 53: ...low these warnings could result in personal injury or death Failure to use a properly configured trap or NOT water priming trap before operating furnace may allow positive pressure vent gases to enter...

Page 54: ...le to adjust the manifold pressure to obtain the proper input rate To check the inlet gas pressure 1 Make sure the gas supply is turned off to the furnace and at the electric switch on the gas valve 2...

Page 55: ...erved by the meter b Move setup switch SW1 2 to ON position This keeps furnace locked in low heat operation when only W W1 is energized c Jumper R to W W1 d Run furnace for 3 minutes in low heat opera...

Page 56: ...low in high heat 1 Remove jumpers from R and W W1 and W2 2 Wait until the blower off delay is completed 3 Turn 115 VAC power off 4 Check the position of setup switch SW1 4 When set to OFF airflow is r...

Page 57: ...42 3 4 1 4 42 3 5 1 5 42 3 6 1 5 42 3 7 1 6 2001 611 825 43 3 8 1 6 42 3 3 1 4 42 3 4 1 4 42 3 5 1 5 to 850 43 3 6 1 5 43 3 7 1 6 42 3 2 1 3 42 3 3 1 4 3000 914 875 43 3 4 1 4 43 3 5 1 5 43 3 7 1 5 43...

Page 58: ...25 144 288 720 70 51 103 257 26 138 277 692 72 50 100 250 27 133 267 667 74 48 97 243 28 129 257 643 76 47 95 237 29 124 248 621 78 46 92 231 30 120 240 600 80 45 90 225 31 116 232 581 82 44 88 220 32...

Page 59: ...r switch install blower door and refer to the SERVICE label on the blower door for more information Component Self Test Component Test can ONLY be initiated by performing the following 1 Remove blower...

Page 60: ...posable media filter replace only with a factory specified media filter of the same size 6 Slide filter into cabinet 7 Replace filter cabinet door 8 Turn on electrical supply to furnace A190094B Fig 6...

Page 61: ...mbly c Mark blower wheel orientation and cutoff plate location to ensure proper reassembly d Remove screws securing cutoff plate and remove cutoff plate from housing e Remove bolts holding motor mount...

Page 62: ...oth rollout switches 15 Slide one piece burner out of slots on sides of burner assembly 16 Remove the flame sensor from the burner assembly 17 Optional Remove the Hot Surface Igniter HSI and bracket f...

Page 63: ...the collector box opening or water will flow out of tube 4 Remove the collector box plug from the top port on the upper corner of the collector box See Fig 61 5 Attach a funnel with a flexible tube to...

Page 64: ...ich needs to be corrected such as improper adjustment of manifold pressure insufficient or poor quality combustion air improper vent termination incorrect size or damaged manifold orifice s improper g...

Page 65: ...Antifreeze should run through the inducer housing overfill condensate trap and flow to an open drain 8 Replace the rubber plug in the port on the collector box 9 Remove the middle unused rubber plug f...

Page 66: ...Y Y2 simultaneously until the heartbeat flashes When done put setup switch SW1 1 in the OFF position Was there a previous status code other than the heartbeat Go to section below for the status code...

Page 67: ...urners operate in high heat then switch to low heat check manifold pressure If OK check burner carryover and flame sensor location Clean flame sensor with fine steel wool and recheck current Nominal c...

Page 68: ...ch HPS closes and the high heat gas valve solenoid GV HI is energized The furnace control CPU begins a 15 second prepurge period after the low heat pressure switch LPS closes If the high heat pressure...

Page 69: ...ow High cooling airflow is based on the A C air conditioning selection shown in Fig 59 The electronic air cleaner terminal EAC 1 is energized with 115 vac whenever the blower motor BLWM is operating W...

Page 70: ...ack on at heating airflow When the W W1 input signal disappears the furnace control begins a normal inducer post purge period while changing the blower airflow If Y Y2 input is still energized the fur...

Page 71: ...cer Inducer assembly Inducer motor capacitor when used Inducer motor module when used TO OBTAIN INFORMATION ON PARTS Consult your installing dealer or a licensed Heating and Air Conditioning company o...

Page 72: ...02 23 Catalog No 440 01 4801 00 REV C Replaces 440 01 4801 00 REV B F96VTN and G96VTN Installation Start up Operating and Service and Maintenance Instructions Manufacturer reserves the right to chang...

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