Installation Instructions for *CVC96*BB & *MVC96*BB Two-Stage Gas Furnace (Type FSP CATEGORY IV Direct or Non Direct Vent Air Furnace) (Type FSP CATÉGORIE IV Direct ou four á air soufflé non direct) These furnaces comply with requirements embodied in the American National Standard/National Standard of Canada ANSI Z21.47•CSA-2.3 Gas Fired Central Furnaces. Installer: Affix all manuals adjacent to the unit.
Safety Circuit Description...............................................41 Troubleshooting..............................................................42 Maintenance....................................................................42 Filters...............................................................................43 Before Leaving an Installation.......................................43 Repair and Replacement Parts......................................43 Menu Options................................
RISQUE D'EMPOISONNEMENT AU MONOXYDE DE CARBONE Advertencia especial para la instalación de calentadores ó manejadoras de aire en áreas cerradas como estacionamientos ó cuartos de servicio. Las emisiones de monóxido de carbono pueden circular a través del aparato cuando se opera en cualquier modo. CO can cause serious illness including permanent brain damage or death.
Shipping Inspection All units are securely packed in shipping containers tested according to International Safe Transit Association specifications. The carton must be checked upon arrival for external damage. If damage is found, a request for inspection by carrier’s agent must be made in writing immediately. 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.
NOTE: This furnace may be used as a construction site heater ONLY if all of the following conditions are met: • The vent system is permanently installed per these installation instructions. • A room thermostat is used to control the furnace. Fixed jumpers that provide continuous heating CANNOT be used and can cause long term equipment damage. Bi-metal thermostats, or any thermostat affected by vibration must not be used during construction. • Return air ducts are provided and sealed to the furnace.
A copy of the National Fuel Gas Code (NFPA 54/ANSI Z223.1) can be obtained from any of the following: American National Standards Institute 25 West 43rd Street, 4th Floor New York, NY 10036 National Fire Protection Association 1 Batterymarch Park Quincy, MA 02169-7471 • CSA International 8501 East Pleasant Valley Independence, OH 44131 The rated heating capacity of the furnace should be greater than or equal to the total heat loss of the area to be heated.
• Isolate a non-direct vent furnace if it is installed near an area frequently contaminated by any of the above substances. This protects the non-direct vent furnace from airborne contaminants. To ensure that the enclosed non-direct vent furnace has an adequate supply of combustion air, vent from a nearby uncontaminated room or from outdoors. Refer to the Combustion and Ventilation Air Requirements for details.
6. Follow the lighting instructions. Place the appliance being inspected in operation. Adjust thermostat so appliance shall operate continuously. 7. Test for spillage from draft hood appliances at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle. 8. If improper venting is observed during any of the above tests, the venting system must be corrected in accordance with the National Fuel Gas Code ANSI Z223.
Most homes will require outside air be supplied to the furnace area by means of ventilation grilles or ducts connecting directly to the outdoors or spaces open to the outdoors such as attics or crawl spaces. WARNING CARBON MONOXIDE POISONING HAZARD INSTALLATION POSITIONS Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death.
Front Cover Pressure Switch Tube Location When a furnace is installed horizontally with left side down the front cover pressure switch tube must be re-located to the lower port of the collector box cover. 1. Remove tube from front cover pressure switch and collector box cover. 2. Remove rubber plug from bottom collector box port and install on top collector box port. 3. Locate 24” x 1/4” tube in bag assembly. 4. Install one end on front cover pressure switch. 5.
MATERIALS - INSTALLATIONS IN THE U.S.A PVC, CPVC, or ABS pipe & fittings are typically used as venting and intake pipe materials. All 90° elbows must be medium or long radius types. A medium radius elbow should measure ~3-1/16” minimum from the plane of one opening to the center line of the other opening for 2” diameter pipe, and ~4-9/16” minimum for 3” pipe.
VENTING MATERIAL REQUIREMENTS PVC WARNING ASTM STANDARD SCHEDULE 40 PIPE D1785 SCHEDULE 40 CELLULAR CORE PIPE F891 SDR 21 OR 26 PIPE D2241 FITTINGS D2466 To avoid bodily injury, fire or explosion, solvent cements must be kept away from all ignition sources (i.e., sparks, open flames, and excessive heat) as they are combustible liquids. Avoid breathing cement vapors or contact with skin and/or eyes.
Termination Locations Non-Direct Vent & Direct Vent Vent/Flue Terminations Non-Direct Vent Vent/Flue Termination No Terminations Above Walkway Grade or Highest Anticipated Snow Level Non-Direct Vent Vent/Flue Termination Forced Air Inlet Direct Vent Vent/Flue Termination Figure 9 Vent Clearances Figure 7 Insert flange. Cut 2 ½” long. VENT-DRAIN Figure 8 WARNING Edges of sheet metal holes may be sharp. Use gloves as a precaution when removing hole plugs.
*MVC96/*CVC96 Direct Vent (2 - Pipe) and Non-Direct Vent (1- Pipe) Maximum Allowable Length of Vent/Flue Pipe (6) & Combustion Air Pipe (ft) (1) (2) MODEL *M V96C0403BN *M VC960603BN *M VC960803BN *M VC960804CN *M VC961005CN *M VC961005DN *M VC961205DN *CVC960403BN *CVC960603BN *CVC960804CN *CVC961005CN *CVC961205DN Pipe Size (4) (in.
6” MAX 4” MIN 12" MIN. TO GRADE OR HIGHEST ANTICIPATED SNOW LEVEL Standard Horizontal Terminations (Dual Pipe) Figure 13 DOWN VENTING UPFLOW MODEL FURNACES ONLY Use alternate vent & combination air locations Vent Pipe CAUTION Be sure not to damage internal wiring or other components when reinstalling coupling and screws. 6’ Max. Floor Combustion Air Pipe Field Supplied Drain Tee on Vent Pipe p rawls t/C men e s a B NOTE: For installations at or above 7,000 feet altitude, use 3” venting.
90° ELBOWS 3”-24” BETWEEN PIPES ELBOWS STRAIGHT Combustion Air Intake may also be snorkeled to obtain 12” min ground clearance.
Side Wall Vent Kit This kit is to be used with 2” or 3” direct vent systems. The vent kit must terminate outside the structure and may be installed with the intake and exhaust pipes located side-by-side or with one pipe above the other. These kits are NOT intended for use with single pipe (indirect vent) installations.
• 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 other location than at the drain trap supplied with the furnace. • If the drain line is routed through an area which may see temperatures near or below freezing, precautions must be taken to prevent condensate from freezing within the drain line. • If an air conditioning coil is installed with the furnace, a common drain may be used.
17.5” cabinet; cut at line “C” for a 21” cabinet; do not cut for a “D” width cabinet. 3. Install large end of hose #3 to trap outlet and secure with 1.25” clamp. 4. Install smaller end of hose #3 on 45º elbow 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 Right Side 1.
8. Refer to Field Supplied Drain section for instructions on field supplied/nstalled drain on outlet of furnace trap. position) and install it on the right side (top) collector box drain port. 12. Install the non-grommet end of hose #11 from outside the cabinet in the upper drain hole. Install on collector box and secure with a silver clamp. 13. Use two silver clamps and secure the hoses to drain trap. The trap outlet faces the front of the furnace.
Drain Exiting Right Side 9. Install the non-grommet end of hose #11 from outside the cabinet in the upper drain hole. Install on collector box and secure with a silver clamp. 10. Use two silver clamps and secure the hoses to drain trap. The trap outlet faces the front of the furnace. Secure the trap to the cabinet using two screws removed in step 2 by inserting the two screws through the large set of holes in the top mounting tabs of the trap into the two predrilled holes in the side of the cabinet.
Hose #4 Figure 30 Hose #4 1. Remove the drain trap and factory installed drain tube assemblies. 2. Remove two 1” plugs from right side of cabinet 3. (Draining the Collector Box) From outside the cabinet, insert the non-grommet end hose #7 into the back drain hole and secure to collector box drain port using a silver clamp. 4. (Draining the Vent Elbow) Insert the straight barbed coupling into the vent – drain elbow drip leg and secure with a red clamp. 5.
original bottom of the furnace. 16. Using the two sheet metal screws provided in the cabinet, secure the trap to the furnace. 17. Refer to Field Supplied Drain section for instructions on field supplied / installed drain on outlet of furnace trap. High altitude installations may require both a pressure switch and an orifice/spring change. These changes are necessary to compensate for the natural reduction in the density of both the gas fuel and the combustion air at higher altitude.
Gas Valve This unit is equipped with a 24 volt gas valve controlled during furnace operation by the integrated control module. As shipped, the valve is configured for natural gas. The valve is field convertible for use with propane gas by replacing the regulator spring with a propane gas spring from an appropriate manufacturer’s propane gas conversion kit. Taps for measuring the gas supply pressure and manifold pressure are provided on the valve. The following stipulations apply when connecting gas piping.
aluminum-alloy tubing and connectors are coated to protect against external corrosion when in contact with masonry, plaster, or insulation, or subjected to repeated wetting by liquids such as water (except rain water), detergents, or sewage. Alternate Union Location Grommet in Standard Gas Line Hole The gas piping may enter the left or right side of the furnace cabinet. The installer must supply rigid pipe long enough to reach the outside of the cabinet to seal the grommet cabinet penetration.
NOTE: Never exceed specified pressures for testing. Higher pressure may damage the gas valve and cause subsequent overfiring, resulting in heat exchanger failure. For satisfactory operation, propane gas pressure must be 10” WC at the furnace manifold with all gas appliances in operation. Maintaining proper gas pressure depends on three main factors: 1. Vaporization rate, depending on temperature of the liquid, and “wetted surface” area of the container or containers. 2. Proper pressure regulation.
Checking Duct Static 4. Consult the proper tables for the quantity of air. WARNING If the total external static pressure exceeds the maximum listed on the furnace rating plate, check for closed dampers, registers, undersized and/or oversized poorly laid out duct work. Never allow the products of combustion, including carbon monoxide, to enter the return duct work or circulation air supply.
differing filter arrangements can be applied. Filters can be installed in the central return register or a side panel external filter rack kit (upflows). As an alternative a media air filter or electronic air cleaner can be used as the requested filter. Consider installing an air cleaner with deep-pleated media filter at the time of furnace installation.
AIR FLOW SIDE RETURN EXTERNAL FILTER RACK KIT (EITHER SIDE) FILTER FILTER CENTRAL RETURN GRILLE Figure 39 Possible Upright Upflow Figure 44 Figure 40 CENTRAL RETURN GRILLE FILTER SUPPORT BRACKET (Field Supplied) Figure 41 Figure 42 AIR FLOW Possible Upright Counterflow Filter Locations Figure 45 Electrical Connections Figure 43 WARNING The following figures show possible filter locations.
Line polarity must be observed when making field connections. Line voltage connections can be made through either the right or left side panel. The furnace is shipped configured for a right side electrical connection with the junction box located inside the burner compartment (blower compartment for downflows).
1. Measure resistance between the neutral (white) connection and one of the burners. 2. Resistance should measure 10 ohms or less. This furnace is equipped with a blower door interlock switch which interrupts unit voltage when the blower door is opened for servicing. Do not defeat this switch. CoolCloud™ HVAC Phone Application Actual screens may look different based on the mobile device being used.
software updates have been installed. Review notes for optional software updates and install if necessary. instructed by the applicable wiring diagrams shown in this section. 2. Connect the 1 & 2 wires between the indoor and outdoor unit for communicating operation. Note: verify two stage outdoor units include a 24 VAC transformer (for outdoor control board power) Two stage outdoor units may not behave properly without this 24 VAC transformer.
INDOOR BOARD TERMINAL CONNECTIONS EXTREMELY IMPORTANT: For two-stage gas heating, the system only needs a single W input. Internal algorithms will control staging of the gas furnace automatically based on the single W input. For non-communicating outdoor unit wiring see instructions below. 1. Use the wiring diagrams below to connect low voltage thermostat wires.
3. Select the Non-Comm Outdoor Setting menu (OdS) using the on board push buttons or the CoolCloud HVAC phone application. Select 1 AC for single stage Air Conditioners, 1HP for single stage heat pumps, 2 AC for two stage air conditioners and 2 HP for two stage Heat Pumps. NOTE: For two stage non-communicating outdoor units, system will stage airflow automatically for low stage operation. Tonnage Selection Airflow Tonnage Selection Airflow Tonnage Selection Airflow 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.
6. b. Select any value less than 50% for low stage operation and any value greater than 50% for high stage operation. Confirm thermostat heating and cooling calls function properly with equipment. Quick Start Guide for Gas Heat Only Setup (No Outdoor Unit) EXTREMELY IMPORTANT: The furnace only requires a single W input for 2 stage gas heat control. Internal algorithms will control staging of the gas furnace automatically 1.
The furnace includes three on-board push buttons allowing users to navigate indoor and outdoor system menus. The Right and Left buttons allow the user to scroll through the main menus and to then scroll through available options within specific menus. The Center button is used to enter into a main menu and to then permanently select options within those menus. accessory in addition to independently testing continuous fan mode.
OFF 100% CFM wiring must conform to all local codes, and have a minimum temperature rating of 105°C. • All line voltage wire splices must be made inside the furnace junction box. OFF Figure 60 STARTUP PROCEDURE & ADJUSTMENT • Profile D (4) ramps up to 50% of the demand for 1/2 minute, then ramps to 85% of the full cooling demand airflow and operates there for approximately 7 1/2 minutes. The motor then steps up to the full demand airflow. Profile D has a 1/2 minute at 50% airflow OFF delay.
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.
If supply pressure differs from table, make the necessary adjustments to pressure regulator, gas piping size, etc., and/or consult with local gas utility. 5. Turn OFF gas to furnace at the manual shutoff valve and disconnect manometer. Reinstall plug before turning on gas to furnace. 6. Turn OFF any unnecessary gas appliances stated in step three.
that indicates 1/2 cu. ft. per revolution. You will use this number to calculate the quantity of gas in cubic ft. if the furnace would consume if it ran steadily for one hour (3600 seconds). 3. If the 1/2 cu. ft. dial was used, multiply your number by two. EXAMPLE: If it takes23 seconds to complete one revolution of the 1/2 ft. dial (23 x 2 = 46). SUPPLY AIR This tells us that at this rate, it would take 46 seconds to consume one cu. ft. of gas. 3600 / 46 = 78.
• • • • • • • • • • • • • • • • • • • Operational Checks The burner flames should be inspected with the burner compartment door installed. Flames should be stable, quiet, soft, and blue (dust may cause orange tips but they must not be yellow). Flames should extend directly outward from the burners without curling, floating, or lifting off. Flames must not impinge on the sides of the heat exchanger firing tubes. pressure switch contacts.
Flame Sensor The flame sensor is a probe mounted to the burner/ manifold assembly which uses the principle of flame rectification to determine the presence or absence of flame. Diagnostic Chart WARNING High voltage! To avoid personal injury or death due to electrical shock, disconnect electrical power BEFORE performing any service or maintenance. Refer to the Troubleshooting Chart in the back of this manual for assistance in determining the source of unit operational problems.
Flame Sensor (Qualified Servicer Only) Under some conditions, the fuel or air supply can create a nearly invisible coating on the flame sensor. This coating acts as an insulator causing a drop in the flame sense signal. If the flame sense signal drops too low the furnace will not sense flame and will lock out. The flame sensor should be carefully cleaned by a qualified servicer using steel wool. The furnace should be inspected by a qualified installer, or service agency at least once per year.
Menu Options LED Display St tt CAP CP CdL Menu Description LED Display Enable or disable inverter boost operation. (compressor speed may increase when this feature is on) (inverter only) Boost mode will operate above this selected temperature. On = boost mode always on (default = 105°F) (inverter only) Cooling Airflow Profile setting (default = profile D shown as 4) Heat Pump compressor lockout temperature. Furnace will act as primary heat source below this temperature.
Status Codes LED Display Description of System Status 1AC Compressor Cooling, Low Stage (non-communicating units) 2AC Compressor Cooling, High Stage (non-communicating units) 1AC Compressor Heat, Low Stage (non-communicating units) 2AC Compressor Heat, High Stage (non-communicating units) AC Compressor Cooling, Single-Stage (single stage non-comm.
Troubleshooting Chart Symptom LED Status d0 IdL None Corrective Actions Equipment lacks shared data Populate shared data set using memory card Normal operation None No 115 power to furnace or no 24 volt power to integrated control module Furnace fails to operate Integrated control module LED display provides no signal Fault Description Blown fuse or tripped circuit breaker Restore high voltage power to furnace and integrated control module. Replace non-functional integrated control module.
Troubleshooting Chart Symptom Furnace operates at reduced performance or operates on low stage when high stage is expected Furnace fails to operate LED Status Fault Description Corrective Actions Check filters for blockage, clean filters or remove obstruction E9 Airflow is lower than demanded Check ductwork for blockage, remove obstruction and verify all registers are fully open Verify ductwork is appropriately sized for system, resize and/or replace ductwork if necessary E10 Grounding fault Poo
Troubleshooting Chart Symptom Induced draft blower and circulator blower runs continuously LED Status Fault Description Flame sensed with no call for heat EE Short to ground in flame sense circuit Lingering burner flame No furnace operation Corrective Actions Correct short at flame sensor or in flame sensor wiring Check for lingering or lazy flame Verify proper operation of gas valve Slow closing gas valve No furnace operation Normal furnace operation Furnace fails to operate Furnace fails to o
Troubleshooting Chart Symptom LED Status Fault Description Corrective Actions Check filters and ductwork for blockage, clean filters or remove obstruction Furnace fails to operate EED Aux limit switch open (blower compartment) Check circulator blower speed and performance, correct speed or replace blower motor if necessary Tighten or correct wiring connection Furnace fails to operate EEF Aux switch (condensate switch) open 49 Check evaporator drain pan, trap, piping
Wiring Diagrams HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
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