Goodman MES96 U Series Guide
Service and Troubleshooting
*MES96*U
Copyright © 2019-2020 Goodman Manufacturing Company, L.P.
RS6612017r2
June 2020
TABLE OF CONTENTS
IMPORTANT INFORMATION............................................ 2
PRODUCT IDENTIFICATION ........................................... 4
SYSTEM OPERATION...................................................... 6
SCHEDULED MAINTENANCE ....................................... 13
SERVICING..................................................................... 16
CHECKING VOLTAGE .............................................. 17
CHECKING WIRING .................................................. 17
CHECKNG THERMOSTAT, WIRING ........................ 17
CHECKING TRANSFORMER AND CONTROL
CIRCUIT...................................................................... 17
CHECKING AIR CIRCULATOR BLOWER MOTOR 18
CHECKING DUCT STATIC........................................ 18
CHECKING TEMPERATURE RISE .......................... 19
CHECKING PRIMARY LIMIT CONTROL................. 19
CHECKING AUXILIARY LIMIT CONTROL............... 20
INDUCED DRAFT BLOWER MOTOR ...................... 20
CHECKING GAS VALVE (REDUNDANT) ................ 20
CHECKING GAS PRESSURE .................................. 21
CHECKING HOT SURFACE IGNITER ..................... 22
CHECKING PRESSURE TRANSDUCER ................ 22
CHECKING FOR DELAYED IGNITION.................... 23
CHECKING INTERGRATED IGNITION CONTROL
BOARDS ..................................................................... 23
CHECKING FLAME SENSOR................................... 24
TROUBLESHOOTING CHART ....................................... 25
WIRING DIAGRAMS....................................................... 28
Pride and workmanship go into every product to provide
our customers with quality products. It is possible, however,
that during its lifetime a product may require service.
Products should be serviced only by a qualied service
technician who is familiar with the safety procedures
required in the repair and who is equipped with the proper
tools, parts, testing instruments and the appropriate service
manual.
Cancer and Reproductive Harm -
www.P65Warnings.ca.gov
0140M00517-A
IMPORTANT INFORMATION
2
Pride and workmanship go into every product to provide our
customers with quality products. It is possible, however, that
during its lifetime a product may require service. Products
should be serviced only by a qualied service technician who
is familiar with the safety procedures required in the repair
and who is equipped with the proper tools, parts, testing in-
struments and the appropriate service manual.
OUTSIDE THE U.S., .
(Not a technical assistance line for dealers.) Your telephone company will bill you for the call.
REVE ERISK RER ME ERS IJUR R E
SRE MUSIEMERIS RUSE SIER ER
MMEIQUIS RVRSIEVIII IS IE
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WER ERESERVII R
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IMPORTANT INFORMATION
3
B10259-216
CO can cause serious illness including permanent brain
damage or death.
Advertencia especial para la instalación de calentadores ó manejadoras
de aire en áreas cerradas como estacionamientos ó cuartos de servicio.
B10259-216
El monóxido de carbono puede causar enfermedades severas
como daño cerebral permanente ó muerte.
Las emisiones de monóxido de carbono pueden circular a través
del aparato cuando se opera en cualquier modo.
B10259-216
RISQUE D'EMPOISONNEMENT AU MONOXYDE DE CARBONE
Cette ventilation est nécessaire pour éviter le danger d'intoxication
au CO pouvant survenir si un appareil produisant du monoxyde
de carbone continue de fonctionner au sein de la zone confinée.
PRODUCT IDENTIFICATION
4
The model and manufacturing number are used for positive identication of component parts used in manufacturing.
Please use these numbers when requesting service or parts information.
* M E S 9 6 0 6 0 3 B N A A
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Brand Minor Revision
A- Amana® Brand G- Goodman® A - Initial Release
V- GMC® B - 1st Revision
Configuration
M - Upflow/Horizontal Major Revision
C - Downflow/Horizontal A - Initial Release
B - 1st Revision
Airflow
C - Variable Speed/ComfortNet Nox
E - High Efficiency Multi Speed N - Natural Gas
S - Single Speed X - Low Nox
U - Ultra - Low Nox
Gas Valve Stages
M - Modulating Cabinet Width
V - 2 Stage A - 14"
S - Single Stage B - 17.5"
C - 21"
AFUE D - 24.5"
97 - 97% AFUE
80 - 80% AFUE Maximum CFM
92 - 92% AFUE 3 - 1200 CFM
80 - 80% AFUE 4 - 1600 CFM
5 - 2000 CFM
MBTU/h
040 - 40,000
060 - 60,000
080 - 80,000
Furnace Nomenclature
PRODUCT IDENTIFICATION
5
AMES960403BU AA
AMES960603BU AA
AMES960805CU AA
, This furnace complies with the
SCAQMD Rule 1111 14 ng/J NOx emission limit.. Up flow/Horizontal Left and Right,
Induced Draft, Nidec multi-speed ECM motor. Stainless Steel tubular heat exchanger.
115 volt silicon nitride igniter. Left or right gas entry. Line voltage EAC & HUM terminals
GMES960403BU AA
GMES960603BU AA
GMES960805CU AA
, This furnace complies with the
SCAQMD Rule 1111 14 ng/J NOx emission limit.. Up flow/Horizontal Left and Right,
Induced Draft, Nidec multi-speed ECM motor. Stainless Steel tubular heat exchanger.
115 volt silicon nitride igniter. Left or right gas entry. Line voltage EAC & HUM terminals
SYSTEM OPERATION
6
Please adhere to the following warnings and cautions when
installing, adjusting, altering, servicing, or operating the
furnace.
REVE ERS IJURR E UE IMRERISI
JUSME ERI SERVIE RMIEE REER IS
MUR II SSISERIRMISU
QUIIE ISERSERVIE ER E SSUIER
REVE SSIE RER ME ERS IJURR E
UE EERI SK EUREMUS EE RE
EEERI MES RMWER
Discharge your body’s static electricity before touching
unit. An electrostatic discharge can adversely aect electrical
components.
Use the following precautions during furnace installation
and servicing to protect the integrated control module from
damage. By putting the furnace, the control, and the person
at the same electrostatic potential, these steps will help
avoid exposing the integrated control module to electrostatic
discharge. This procedure is applicable to both installed and
uninstalled (ungrounded) furnaces.
1. Disconnect all power to the furnace. Do not touch the
integrated control module or any wire connected to the
control prior to discharging your body’s electrostatic
charge to ground.
2. Firmly touch a clean, unpainted, metal surface of the
furnace near the control. Any tools held in a person’s
hand during grounding will be discharged.
3. Service integrated control module or connecting wiring
following the discharge process in Step 2. Use caution
not to recharge your body with static electricity; (i.e., do
not move or shue your feet, do not touch ungrounded
objects, etc.). If you come in contact with an ungrounded
object, repeat Step 2 before touching control or wires.
4. Discharge any static electricity from your body to ground
before removing a new control from its container. Follow
Steps 1 through 3 if installing the control on a furnace.
Return any old or new controls to their containers before
touching any ungrounded object.
This product is designed for use as a residential home gas
furnace. It is designed or certied for use in mobile home,
trailer, or recreational vehicle applications.
In the U.S.A., this furnace can be used in the following non-industrial
commercial applications: Schools, Oce buildings, Churches, Retail
stores, Nursing homes, Hotels/motels, Common or oce areas. In
all applications, the furnace must be installed per the installation
instructions.
Goodman®brand GMES96*U and Amana®brand AMES96*U
furnaces are ETL certied. All *MES96*U furnaces are built
for use with Natural gas only & may not be converted for use
with LP gas.
Goodman®brand GMES96*U and Amana®brand AMES96*U
high eciency furnaces are dual certied. Dual certication
means that the combustion air inlet pipe is optional and the
furnace can be vented as a:
• Non-direct vent (single pipe) central forced air furnace
in which combustion air is taken from the installation
area or from air ducted from the outside or,
• Direct vent (dual pipe) central forced air furnace in
which all combustion air supplied directly to the furnace
burners through a special air intake system outlined in
this manual and the installation instructions.
To ensure proper installation, operation and servicing,
thoroughly read the installation and service manuals
for specics pertaining to the installation, servicing and
application of this product.
SSIE RER MEERSIJUR R E UE IRE
EXSI SMKE SESI EERI SK RR
MXIEM RESU RMIMRERISIREIR ERI
RMIEE IS RU
REVE RER ME ERS IJUR R E UE IRE
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To ensure proper furnace operation, install, operate, maintain
and service the furnace in accordance with the installation,
operation and service instructions, all local building codes
and ordinances. In their absence, follow the latest edition of
the National Fuel Gas Code (NFPA 54/ANSI Z223.1), and/or
CAN/CGA B149 Installation Codes, local plumbing or waste
water codes, and other applicable codes.
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
SYSTEM OPERATION
7
National Fire Protection Association
1 Batterymarch Park
Quincy, MA 02169-7471
CSA International
8501 East Pleasant Valley
Cleveland, OH 44131
A copy of the CAN/CGA B149 Installation Codes can be
obtained from:
CSA International
178 Rexdale Boulevard
Etobicoke, Ontario, Canada M9W, 1R3
The rated heating capacity of the furnace should be greater
than or equal to the total heat loss of the area to be heated.
The total heat loss should be calculated by an approved
method or in accordance with “ASHRAE Guide” or “Manual
J-Load Calculations” published by the Air Conditioning
Contractors of America.
0 - 4,999 FT ALTITUDE
1 2 3 4 5 6 7 8
295 90 85 80 75 70 65 60
3103 96 89 82 75 68 61 54
290 85 80 75 70 65 60 55
3158 151 144 137 130 123 116 109
255 50 45 40 35 30 25 20
3151 144 137 130 123 116 109 102
*MES960805CU
MODEL
Pipe Size (in)
Number of Elbows
*MES960603BU
*MES960403BU
5,000 - 7,500 FT ALTITUDE
1 2 3 4 5 6 7 8
43
37
73
67
61
55
49
*MES960805CU
3
3
100
MODEL
Pipe Size (in)
Number of Elbows
*MES960603BU
69
93
87
81
75
63
57
80
*MES960403BU
3
100
93
57
87
81
75
69
63
1) Maximum allowable limits listed on individual lengths for inlet and ue and NOT
a combination.
2) Minimum requirement for each vent pipe is ve (5) feet in length and one elbow/
tee.
3) Tee used in the vent/ue termination must be included when determining the
number of elbows in the piping system.
4) 2 1/2” or 3” diameter pipe can be used in place of 2” diameter pipe.
5) Increased Clearance Congurations using (2) 45 deg. Long Sweep elbows should
be considered equivalent to one 90 deg. elbow.
6) One 90° elbow should be secured to the combustion air intake connection.
EREE UREWI ERI REMVES
REIRUI E UE SESMUR
W
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URERESURE
IURE W ISWRI RESUI
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A condensing gas furnace achieves its high level of eciency
by extracting almost all of the heat from the products of
combustion and cooling them to the point where condensation
takes place. The condensate which is generated must be
piped to an appropriate drain location.
I URIUWISIS E RIR MUS EMUE
E SIESIE EUI RMEJUI X ISWI
REUEERISK WERREI EJUI XI EEVE
KERI IIIURE W ESEISRUIS
RESU I SSIE RERMEERSIJUR R E
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• 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. An open tee must
be installed in the drain line, near the cooling coil, to
relieve positive air pressure from the coil’s plenum.
This is necessary to prohibit any interference with the
function of the furnace’s drain trap.
Horizontal installations require 5.5” under the furnace
to accommodate the drain trap. The horizontal furnace
must be installed with ¾” slope from back to front to permit
condensate ow towards the front of the furnace.
When installing a *MES9* horizontally with the left side
down, there are two options for connecting the vent pipe to
the furnace.
Option 1
Venting may be connected to the furnace vent pipe tting on
the original top (now the end) of the furnace.
Option 2
The internal vent pipe and elbow may be removed from the
furnace to permit the vent to exit the top (original side) of
the furnace. If this option is used, an RF000142 Vent-Drain
coupling must be used to keep condensate from collecting
in the inducer assembly.
To install the drain, refer to the following instructions and
illustration.
SYSTEM OPERATION
8
COMBUSTION AIR INTAKE PIPE OPTIONS:
The RF000142 coupling can be secured directly to the
furnace intake coupling if condensation is occurring in the
combustion air inlet pipe. If the RF000142 is used on the
combustion air inlet, it must be installed with the arrow
pointing up. It should be noted, the combustion air will
actually be moving in a direction opposite of the arrow on the
RF000142 coupling.
Alternatively a tee may be used in the combustion air
intake pipe for the same purpose. If either option is used,
a eld supplied trapped drain tube, free-draining to proper
condensate disposal location must be present. A loop in the
drain tube can serve as a trap. The unused RF000142 drain
tting should be capped.
1. Remove screws from vent ange.
2. Remove internal elbow and vent pipe.
3. Cut pipe 2 1/2” from ange.
4. Remove cabinet plug adjacent to inducer outlet and
install an original cabinet vent hole.
5. Install RF000142 coupling on inducer outlet.
6. Install anged vent section removed in step 2 and se-
cure with clamps.
7. Secure ange to cabinet using screws removed in step
1.
Insert flange. Cut 2 ½” long.
R 000142F
The furnace rating plate includes the approved furnace gas
input rating.
REVEUREIEERIREQUIMEMEEIE
SSU RESSUREMUS E SSEIIE EUIRI E
WI ER USE SIRE IES ERI
Inlet gas supply pressures must be maintained within the
ranges specied below. The supply pressure must be constant
and available with all other household gas red appliances
operating. The minimum gas supply pressure must be
maintained to prevent unreliable ignition. The maximum must
not be exceeded to prevent unit overring.
Minimum: 4.5" w.c. Maximum: 10.0" w.c.
This unit is equipped with a 24 volt gas valve controlled during
furnace operation by the integrated control module. Taps for
measuring the gas supply pressure and manifold pressure
are provided on the valve.
The gas valve has a manual ON/OFF control located on
the valve itself. This control may be set only to the “ON” or
“OFF” position. Refer to the Lighting Instructions Label or the
“Putting the Furnace Into Operation” section of this manual or
the installation instructions for use of this control during start
up and shut down periods.
Length of Nominal Black Pipe Size
Pipe in Feet 1/2" 3/4" 1" 1 1/4" 1 1/2"
132 278 520 1050 1600
92 190 350 730 1100
73 152 285 590 980
63 130 245 500 760
56 115 215 440 670
50 105 195 400 610
46 96 180 370 560
43 90 170 350 530
40 84 160 320 490
38 79 150 305 460
CFH =
(Pressure 0.5 psig or less and pressure drop of 0.3" W.C.; Based on 0.60
Specific Gravity Gas)
BTUH Furnace Input
Heating Value of Gas (BTU/Cubic Foot)
SYSTEM OPERATION
9
Before placing unit in operation or after servicing, leak test
gas connections.
VIE SSII EXSIR IRE EVERUSE M
RE ME ES R EKS
Check for leaks using an approved chloride-free soap and
water solution, an electronic combustible gas detector, or
other approved testing methods.
Never exceed specied pressures for testing. Higher
pressure may damage the gas valve and cause subsequent
overring, resulting in heat exchanger failure. Disconnect
this unit and shuto valve from the gas supply piping system
before pressure testing the supply piping system with
pressures in excess of 1/2 psig (3.48 kPa). Isolate this unit
from the gas supply piping system by closing its external
manual gas shuto valve before pressure testing supply
piping system with test pressures equal to or less than 1/2
psig (3.48 kPa).
I
EIRMI IESEISRUISIS WE EX
IRE REXSI M RESUUSI RER ME ERS
IJUR R SS IE
–
D
O NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND
LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.
–
W
I
U
SME
S
•
D
O NOT TRY TO LIGHT ANY APPLIANCE.
•
D
O NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY
PHONE IN YOUR BUILDING.
•
I
MMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR’S
PHONE.
F
OLLOW THE GAS SUPPLIER’S INSTRUCTIONS.
•
I
F YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE
DEPARTMENT.
–
I
NSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER,
SERVICE AGENCY OR THE GAS SUPPLIER.
The furnace, as shipped, requires no change to run between
0-4500 feet. At all altitudes the air temperature rise must be
within the range listed on the Specication Sheet ap¬plicable
to your model for the fuel used. Manifold pressure adjustments
and combustion analysis are required for all installations
above 4500 ft. Refer to “Gas Supply Pressure Measurement”
section for instruction on how to properly measure and adjust
manifold “outlet” pressure. The furnace should operate
for a minimum of 15 minutes before taking a combustion
sample. Combustion samples should be taken from beyond
the furnace exhaust and must be within provided CO2%
range. See table 3 for recommended manifold pres¬sure
adjustments and proper CO2% range. Gas heating val¬ues
can vary; further pressure adjustment may be necessary to
ensure furnace operates within acceptable CO2 range.
2.5" w .c.
2.4" w .c.
6.5 - 8.5
100 ft
100 ft
80 ft
40
60
80
MODEL
TSRK02
Two Stage Releay Kit. For use with single stage Ultra-Low
NOx furnaces with multi-speed (constant torque) ECM motors.
The TSRK02 allows connection of *MES96 ULN constant
torque furnace to be paired with a two-stage air conditioner
or two-stage heat pump to provide dierent indoor fan speeds
during Y1 and Y2 cooling or heat pump operation.
VIERISK EERI SK WIRI EUI MUSE
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WERERESERVII R
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MEERS IJUR RE
E WIRES RIR ISEI WE SERVII RS
WIRI ERRRS USEIMRER ERUS ERI
VERI RER ERI ERSERVII
The wiring harness is an integral part of this furnace. Field
alteration to comply with electrical codes should not be
required. Wires are color coded for identication purposes.
Refer to the wiring diagram for wire routings. If any of the
original wire as supplied with the furnace must be replaced,
it must be replaced with wiring material having a temperature
rating of at least 105° C. Any replacement wiring must be
copper conductor.
SYSTEM OPERATION
10
115 VOLT LINE VOLTAGE CONNECTION OF
ACCESSORIES (HUMIDIFIER AND ELECTRONIC AIR
CLEANER
The furnace integrated control module is equipped with line
voltage accessory terminals for controlling power to an optional
eld-supplied humidier and/or electronic air cleaner.
The accessory load specications are as follows:
Turn OFF power to the furnace before installing any accessories.
Follow the humidier or air cleaner manufacturers’ instructions for
locating, mounting, grounding, and controlling these accessories.
Accessory wiring connections are to be made through the 1/4”
quick connect terminals provided on the furnace integrated control
module. The humidier and electronic air cleaner hot terminals
are identied as HUM and EAC. The humidier and electronic
air cleaner neutral terminals are identied as NEUTRAL. All eld
wiring must conform to applicable codes. Connections should
be made as shown.
If it is necessary for the installer to supply additional line
voltage wiring to the inside of the furnace, the 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.
The integrated control module single humidier terminal
(HUM) is energized with 115 volts whenever the induced
draft blower is energized. This terminal can also be used
to provide 115 volt power to a humidier transformer. The
remaining primary transformer wire would be connected to the
Line N on the control board. The integrated control module
electronic air cleaner terminals (EAC) are energized with 115
volts whenever the circulator blower is energized.
Wire routing must not to interfere with circulator blower
operation, lter removal, or routine maintenance.
VI ERISK EERI SK IJUR RE E
UREMUS EEERI RUE IREWI
ESRI EIR SEE WIE ES EII E
I
E
ERI
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I
VE
ISE
WERERESERVII R
IEERIWIRI
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UIE WER
SURESM ERESE
IURE S M USE
RER MEERS IJUR RE
If it is necessary for the installer to supply additional line
voltage wiring to the inside of the furnace, the 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.
Low voltage connections can be made through either
the right or left side panel. Wire routing must not interfere
with circulator blower operation, lter removal, or routine
maintenance.
A 40 V.A. transformer and an integrated electronic control are
built into the furnace to allow use with most cooling equipment.
Consult the wiring diagram, located in the Technical Manual
or on the blower door for further details of 115 Volt and 24
Volt wiring.
The single stage furnace will have a “W” terminal and will use
a single stage thermostat. The following drawing illustrates
the typical eld wiring for a heat only single stage system and
a single stage heating/single stage cooling system. Refer to
the following gures for proper connections to the integrated
control module.
SYSTEM OPERATION
11
The external lter rack kit is intended to provide a location
external to the furnace casing, for installation of a permanent
lter on upow model furnaces. The rack is designed to mount
over the indoor blower compartment area of either side panel,
and provide lter retention as well as a location for attaching
return air ductwork.
The electronic air cleaner and media air cleaner are multi-
positional high eciency air ltration devices that can be
installed in any position, except with the access door facing
down. The best location for the air cleaner is in the return
air duct next to the blower compartment. Before installing
the air cleaner, consider the application. The electronic air
cleaner must be readily accessible for periodic inspection and
cleaning of the pre-lters and electronic cells while the media
air cleaner must be readily accessible for periodic inspection
and replacement of the Media.
• 120 VAC power applied to furnace.
• Integrated ignition control performs internal checks.
• LED light will ash once at power up and then remain on.
• Integrated ignition control monitors safety circuit
continuously.
• Furnace awaits call from thermostat.
The normal operational sequence in heating mode is as
follows:
• R and W thermostat contacts close, initiating a call for
heat.
• Integrated control module performs safety circuit checks.
The control operates
the inducer in a manner to verify the pressure sensor
null value and span operation are within specication.
If the system is operating correctly, this test takes only
a few seconds. If the system is not functioning properly,
the control times out after a maximum 90 seconds and
display the proper fault code.
• Induced draft blower is energized for 30 second
prepurge.
• Igniter warm up begins after 30 second prepurge expires.
• Gas valves open at end of igniter warm up period,
delivering gas to burners and establishing ame.
• Integrated control module monitors ame presence. Gas
valve will remain open only if ame is detected.
• Circulator blower is energized on high heat speed
following a xed 30 second blower on delay. Electronic
air cleaner terminals are energized with circulator blower.
• Furnace operates; integrated control module monitors
safety circuits continuously.
• R and W thermostat contacts open, completing the call
for heat.
• Gas valve closes, extinguishing ame.
• Induced draft blower is de-energized following a thirty
second post purge.
• HUM terminal is de-energized.
• Circulator blower continues running for selected heat o
delay period factory set at 120 seconds. If required this
can be changed in the eld.
• Electronic air cleaner is de-energized.
• Furnace awaits the next call from thermostat.
The normal operational sequence in cooling mode is as
follows:
• R, Y and G thermostat contacts close, initiating a call
for cool.
• Integrated control module performs safety circuit checks.
• Outdoor fan and compressor are energized.
• Circulator blower is energized on cool speed following a
xed six second on delay. If required this can be changed
in the eld to 45 seconds. Electronic air cleaner terminals
are energized with circulator blower.
• Furnace circulator blower and outdoor cooling unit
run, integrated control module monitors safety circuits
continuously.
• R, Y and G thermostat contacts open, completing the
call for cool.
• Outdoor fan and compressor are de-energized.
• Circulator blower is de-energized following a xed forty
rve second cool o delay period. Electronic air cleaner
terminals are de-energized.
• Furnace awaits the next call from thermostat.
The normal operational sequence in Fan Only Mode is as
follows:
• R and G thermostat contacts close, initiating a call for
SYSTEM OPERATION
12
fan.
• Integrated control module performs safety circuit checks.
• Circulator blower is energized on low heat speed.
Electronic air cleaner terminals are energized.
• Circulator blower runs, integrated control module
monitors safety circuits continuously.
Combustion Quality
Combustion quality can be aected by several factors. Major
factors are venting and draining.
Venting
The venting system should be planned and installed with the
following in mind;
• Should not be longer than necessary
• Use 45°elbows rather than 90° elbows when possible
• Must not sag or otherwise trap condensate
• Use longest radius ttings possible
• If using 3” venting, make the transition from 2” to 3” as
close as practically possible
• Make sure there is no ue gas recirculation into the
combustion air pipe
•
Condensate Drainage
Furnace combustion can be aected if a furnace is holding
condensate. Check for proper connections of drain hoses,
make sure furnace condensate trap is clean. Make sure
furnace is not improperly sloped. Make sure air conditioning
coil drain is not interfering with furnace drain.
Other Causes
1. Manifold Gas Pressure must be set within the range stated
on the furnace rating plate.
2. Remove Draft Inducer, Check the integrity of the gasket
between the inducer and the collector box cover, any
air leak here will have a negative eect on combustion.
Check the orice hole in the collector box, it must be free
of burrs on both sides.
3. Make sure the eld installed gas line is not binding and
causing distortion of burner assembly
4. If the furnace is installed as a one pipe system; make
sure the surrounding area and structure are adequate
to provide combustion air
5. Make sure there are no cabinet air leaks allowing sup-
ply air to aect combustion
6. If heat exchanger integrity is uncertain, follow proce-
dures in Service Bulletin SF-041
The DCVK-20 and DCVK-30 kit is designed to allow the
terminations of a direct vent furnace to be “concentrically”
vented through a wall or roof. This kit allows a single
penetration to support terminations for both the vent/ue pipe
and the combustion air intake pipe.
1. Determine termination locations based on clearances
specied in furnace installation instructions, and following
steps as shown in Figures 1,3,6,7,8 and 9.
2. The vent termination must be located at least 12” above
ground or normally expected snow accumulation levels.
3. Do NOT terminate over public walkways. Avoid areas
where condensate may cause problems such as above
planters, patios, or adjacent to windows where steam
may cause fogging.
4. The vent termination shall be located at least 4’
horizontally from any electric meter, gas meter, regulator
and any relief equipment. These distances apply ONLY
to U.S. Installations.
5. The vent termination shall be located at least 3’ above
any forced air inlet located within 10’; and at least 10’
from a combustion air intake of another appliance, except
another direct vent furnace intake.
6. In Canada, the Canadian Fuel Gas Code takes
precedence over the preceding termination instructions.
3" or 4" Diameter
SDR-26 Pipe
2 or 2 1/2" Diameter
SDR-26 Pipe
2" or 3" Diameter
Y Concentric Fitting
2" or 3" Diameter
Rain Cap
These kits are for vertical or horizontal termination of the
combustion air inlet and the exhaust vent pipes on Category
IV gas-red condensing furnaces. The DCVK-30 kit can be
used for 3” diameter pipe systems. The DCVK-20 kit can be
used for the 2” diameter pipe system. For the correct pipe size
for the furnace. Both the combustion air inlet and the exhaust
vent pipes must attach to the termination kit. The termination
kit must terminate outside the structure and must be installed
per the instructions outlined below for vertical or horizontal
termination. Vertical termination is preferred. Field supplied
pipe and ttings are required to complete the installation.
SCHEDULED MAINTENANCE
13
IVE
ISE WERERESERVII R
ISIISUIMUIE WERSURESM
ERESE IURE S M USE RER
MEERS IJUR RE
I
UMUS E EIIR EWI RE
UI
EIIR WI RE IERS RU I R
VIRI U RESU I ER IIR IURE
QUIIE SERVIERSU EVER E EIIR
The furnace should be inspected by a qualied installer, or
service agency at least once per year. This check should be
performed at the beginning of the heating season. This will
ensure that all furnace components are in proper working
order and that the heating system functions appropriately. Pay
particular attention to the following items. Repair or service
as necessary.
• Flue pipe system. Check for blockage and/or leakage.
Check the outside termination and the connections at
and internal to the furnace.
• Heat exchanger. Check for corrosion and/or buildup
within the heat exchanger passageways.
• Burners. Check for proper ignition and ame sense.
• Wiring. Verify that electrical connections are tight and
free from corrossion.
• Filters.
EVER EREUREWIU IERISES US
I WI UIU IER RSRESUI I SS
EIIE EQUIME MME SSIE IRE
Filters must be used with this furnace. Filters do not ship
with these furnaces but must be provided by the installer for
proper furnace operation.
Dirty lters are the most common cause of inadequate heating
or cooling performance.
Improper lter maintenance is the most common cause of
inadequate heating or cooling performance. Filters should
be cleaned (permanent) or replaced (disposable) every two
months or as required.
Filters in horizontal installations are located in the central
return register.
The bearings in the induced draft blower and circulator blower
motors are permanently lubricated by the manufacturer. No
further lubrication is required. Check motor windings for
accumulation of dust which may cause overheating. Clean
as necessary.
Under some conditions, the fuel or air supply can create a
nearly invisible coating on the ame sensor. This coating acts
as an insulator, causing a drop in the ame sensing signal. If
this occurs, a qualied servicer must carefully clean the ame
sensor with steel wool. After cleaning, the ame sensor output
should be as listed on the specication sheet.
The following is a must for every service technician and
service shop.
1. Dial type thermometers or thermocouple meter (option-
al) - to measure dry bulb temperature.
2. Amprobe - to measure amperage and voltage.
3. Volt-Ohm Meter - testing continuity, capacitors, and
motor windings.
4. Inclined Manometer - to measure static pressure, pres-
sure drop across coils, lters, and draft.
5. Water Manometer (12”) - to test gas inlet and manifold
pressure.
Other recording type instruments can be essential in solving
abnormal problems, however, in many instances they may
be rented from local sources.
Proper equipment promotes faster, more ecient service and
accurate repairs resulting in fewer call backs.
Before attempting to diagnose an operating fault code, run
a Heating Performance Test to determine if the heating
system is performing within 5% of the BTU input found on
the rating plate of the unit being tested. To conduct a heating
performance test, the BTU input to the unit must be calculated
(see Clocking a Gas Meter). Before clocking a gas meter,
contact your local utility to provide the caloric value (BTU
content) of the natural gas in the area.
It is also important to conrm the airow (CFM) is within the
temperature rise range (see Airow Data in spec sheet) and
external static pressure range (approximately 0.5” water
column). How-to instructions can be found in the service
manual under Checking External Static Pressure and
Checking Temperature Rise.
SCHEDULED MAINTENANCE
14
1. Turn o all gas appliances in the home.
2. Turn on the furnace. Ensure the furnace is operating at a 100% ring rate on 2 stage and modulating furnace product.
3. Once heating cycle is at a steady state (typically 15 minutes of operation), use a stopwatch to time how long it takes
the smallest unit of measure dial on the gas meter to make a full revolution. In Table 1, one cubic foot is selected. The
smallest unit of measure will vary depending on the gas meter.
CUBIC
FEET
11
One
In this example
we are using the
one cubic foot
dial on the gas
meter
TABLE 1
4. Using Table 2 below, nd the number of seconds it took for the dial to make a full revolution. To the right of that num-
ber of seconds and below the Size of Test Dial (selected in step 3 and shown in Table 1) will be the Cubic Feet per
Hour (CFH).
1/4
cu/ft
1/2
cu/ft
1
cu/ft
2
cu/ft
5
cu/ft
1/4
cu/ft
1/2
cu/ft
1
cu/ft
2
cu/ft
5
cu/ft
10 90 1803607201800 36 25 50 100200500
11 82 1643276551636 37 -- -- 97 195486
12 75 1503006001500 38 23 47 95 189474
13 69 1382775551385 39 -- -- 92 185462
14 64 1292575141286 40 22 45 90 180450
15 60 1202404801200 41 -- -- -- 176439
16 56 1132254501125 42 21 43 86 172429
17 53 1062124241059 43 -- -- -- 167419
18 50 1002004001000 44 -- 41 82 164409
19 47 95 189379947 45 20 40 80 160400
20 45 90 180360900 46 -- -- 78 157391
21 43 86 171343857 47 19 38 76 153383
22 41 82 164327818 48 -- -- 75 150375
23 39 78 157313783 49 -- -- -- 147367
24 37 75 150300750 50 18 36 72 144360
25 36 72 144288720 51 -- -- -- 141355
26 34 69 138277692 52 -- -- 69 138346
27 33 67 133265667 53 17 34 -- 136340
28 32 64 129257643 54 -- -- 67 133333
29 31 62 124248621 55 -- -- -- 131327
30 30 60 120240600 56 16 32 64 129321
31 -- -- 116232581 57 -- -- -- 126316
32 28 56 113225563 58 -- 31 62 124310
33 -- -- 109218545 59 -- -- -- 122305
34 26 53 106212529 60 15 30 60 120300
35 -- -- 103206514
GAS RATE -- CUBIC FEET PER HOUR
Secondsfo
r
One
Revolution
Size of Test Dial
Secondsfo
r
One
Revolution
Size of Test Dial
Locate 40 seconds for one
revoluon in the chart below
Then locate the 1 cu dial column and select the
corresponding CFH from the 40 seconds for one revoluon row
TABLE 2
SCHEDULED MAINTENANCE
15
5. Use this formula to verify the Cubic Feet per Hour (CFH) input determined in step 4 is correct:
(3600 x Gas Meter Dial Size) / Time (seconds) = Cubic Feet per Hour (CFH)
3600 is used as there are 60 seconds in
a minute and 60 minutes in an hour.
60x60=3600
6. Check with your local utility for actual BTU content (caloric value) of natural gas in the area (the average is 1025
BTU’s).
7. Use this formula to calculate the BTU/HR input (See BTU/HR Calculation Example):
8. Should the gure you calculated not fall within ve (5) percent of the nameplate rating of the unit, adjust the gas valve
pressure regulator or resize orices. To adjust the pressure regulator on the gas valve, turn downward (clockwise) to
increase pressure and input, and upward (counterclockwise) to decrease pressure and input. A properly operating unit
must have the BTU per hour input and CFM of air, within the limits shown to prevent short cycling of the equipment.
As the external static pressure goes up, the temperature rise will also increase. Consult the proper tables for tempera-
ture rise limitation.
The unit being tested takes 40 seconds for the 1 cubic foot dial to make one complete revolution. Using the chart, this
translates to 90 cubic feet per hour. Based upon the assumption that one cubic foot of natural gas has 1,025 BTU’s (Check
with your local utility for actual BTU content), the
90,000 BTU/HR
92,250 BTU/HR
This example is within the 5% tolerance input and does not need adjustment.
Always connect a manometer to the outlet tap at the
gas valve before adjusting the pressure regulator. In
no case should the final manifold pressure vary more
than plus or minus .2 inches water column from 3
inches water column for natural gas.
A properly operating unit must have the BTU per hour input and CFM of air, within the limits shown to prevent short cycling
of the equipment. As the external static pressure goes up, the temperature rise will also increase. Consult the proper tables
for temperature rise limitation.
SERVICING
16
GAS VALVE
BURNER ASSEMBLY
PRESSURE TRANSDUCER
INTEGRATED
CONTROL BOARD
CONTROL TRANSFORMER
PRESSURE SWITCHES
VENT PIPE CONNECTION
COMBUSTION AIR CONNECTION
DRAFT INDUCER
SERVICING
17
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1. Remove the burner door to gain entry to the Junction Box.
2. Remove cover from the Junction Box and gain access to
incoming power lines.
With Power ON:
IEVE W RESE
3. Using a voltmeter, measure the voltage across the hot
and neutral connections.
To energize the furnace, the Door Interlock Switch
must be engaged at this point.
4. No reading - indicates open wiring, open fuse, no pow-
er, or faulty Door Interlock Switch from unit to fused
disconnect service. Repair as needed.
5. With ample voltage at line voltage connectors, energize
the furnace blower motor by jumpering terminals R to
G on the integrated ignition control.
6. With the blower motor in operation, the voltage should
be 115 volts ± 10 percent.
7. If the reading falls below the minimum voltage, check
the line wire size. Long runs of undersized wire can
cause low voltage. If wire size is adequate, notify the
local power company of the condition.
8. After completing check and/or repair, replace Junction
Box cover and reinstall the service panel doors.
9. Turn on electrical power and verify proper unit opera-
tion.
ISE WER ERESERVII
1. Check wiring visually for signs of overheating, damaged
insulation and loose connections.
2. Use an ohmmeter to check continuity of any suspected
open wires.
3. If any wires must be replaced, replace with AWM, 105°C.
2/64 thick insulation of the same gauge or its equivalent.
ISE
WER ERESERVII
1. Remove the blower compartment door to gain access to
the thermostat low voltage wires located at the furnace
integrated control module terminals.
2. Remove the thermostat low voltage wires at the furnace
control panel terminal board.
3. Jumper terminals R to W on the integrated ignition control.
With Power On (and Door Interlock Switch closed):
IEVE W RESE
4. Induced Draft Motor must run and pull in pressure
switch.
5. If the hot surface ignitor heats and at the end of the
ignitor warm-up period the gas valve opens and the
burners ignite, the trouble is in the thermostat or wiring.
6. With power o, check the continuity of the thermostat
and wiring. Repair or replace as necessary.
If checking the furnace in the air conditioning mode, pro-
ceed as follows.
7. With power o, Jumper terminals R to Y to G.
8. Turn on the power.
9. If the furnace blower motor starts and the condensing
unit runs, then the trouble is in the thermostat or wiring.
Repair or replace as necessary.
10. After completing check and/or repair of wiring and
check and/or replacement of thermostat, reinstall blow-
er compartment door.
11. Turn on electrical power and verify proper unit opera-
tion.
A step-down transformer 120 volt primary to 24 volt secondary,
40 VA (Heating and Cooling Models) supplies ample capacity
of power for either operation.
I
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SERVICING
18
1. Remove blower compartment door to gain access to
the thermostat low voltage wires located at the furnace
integrated control module.
2. Remove the thermostat low voltage wires at the furnace
integrated control module terminals.
With Power On (and Door Interlock Switch closed):
IEVE W RESE
3. Use a voltmeter, check voltage across terminals R and
C. Must read 24 VAC.
4. No voltage indicates faulty transformer, open fuse, bad
wiring, bad splice, or open door interlock switch.
5. Check transformer primary voltage at incoming line
voltage connections, fuse, splices, and blower door in-
terlock switch.
6. If line voltage is available to the primary side of trans-
former and not at secondary side, the transformer is
inoperative. Replace.
7. After completing check and/or replacement of trans-
former and check and/or repair of control circuit, rein-
stall blower compartment door.
8. Turn on electrical power and verify proper unit opera-
tion.
ISE WER ERESERVII
1. Remove blower compartment door to gain access to the
circulator blower motor and integrated ignition control.
2. Check for any obstruction that would keep the fan wheel
/ fan motor from turning.
3. Check wiring, the motor has two wiring harnesses, a main
harness and a control harness. The main power harness
has: White neutral wire connected to the NEUTRAL
terminal on the control board. Black wire connected to
the MOTOR terminal on the control board. Red wire
connected to the COM terminal, which is a female spade
connection next to the HEAT and COOL wires on the
control board. Green ground wire connected to cabinet
ground. The control power harness has: Blue wire
connected to HEAT on the control board. (Medium High
Speed)Red wire connected to RED on the control board.
(High Speed) Orange wire connected to FAN on the
control board. (Medium Speed) Black (Low Speed) and
Brown (Medium Low Speed) wires connected to PARK on
the control board. The multi-speed ECM motor requires
a line voltage power supply (black connected to MOTOR
and white connected to neutral on the control board) as
well as a signal on one of the speed taps. The signal to
the motor is a 24vAC signal to the speed tap. .
ISE WER ERESERVII
The maximum and minimum allowable external static
pressures are found in the specication section. These tables
also show the amount of air being delivered at a given static
by a given motor speed or pulley adjustment.
The furnace motor cannot deliver proper air quantities (CFM)
against statics other than those listed.
Too great of an external static pressure will result in insucient
air that can cause excessive temperature rise, resulting in
limit tripping, etc. Whereas not enough static may result in
motor overloading.
To determine proper air movement, proceed as follows:
1. With clean lters in the furnace, use a draft gauge (inclined
manometer) to measure the static pressure of the return
duct at the inlet of the furnace. (Negative Pressure)
2. Measure the static pressure of the supply duct. (Positive
Pressure)
3. Add the two (2) readings together for total external static
pressure.
Both readings may be taken simultaneously and read
directly on the manometer if so desired. If an air conditioner
coil or Electronic Air Cleaner is used in conjunction with the
furnace, the readings must also include theses components,
as shown in the following drawing.
4. Consult proper tables for the quantity of air.
If the total external static pressure exceeds the minimum
or maximum allowable statics, check for closed dampers,
registers, undersized and/or oversized poorly laid out duct
work.
.
SERVICING
19
The more air (CFM) being delivered through a given furnace,
the less the rise will be; so the less air (CFM) being delivered,
the greater the rise. The temperature rise should be adjusted
in accordance to a given furnace specifications and its
external static pressure. An incorrect temperature rise may
result in condensing in or overheating of the heat exchanger.
An airow and temperature rise table is provided in the blower
performance specication section. Determine and adjust
temperature rise as follows:
1. Operate furnace with burners ring for approximately ten
minutes. Check BTU input to furnace - do not exceed
input rating stamped on rating plate. Ensure all registers
are open and all duct dampers are in their nal (fully or
partially open) position.
2. Place thermometers in the return and supply ducts as
close to the furnace as possible. Thermometers must not
be inuenced by radiant heat by being able to “see” the
heat exchanger.
SUPPLY
AIR
RETURN
AIR
3. Subtract the return air temperature from the supply air
temperature to determine the air temperature rise. Allow
adequate time for thermometer readings to stabilize.
4. Adjust temperature rise by adjusting the circulator blower
speed. Increase blower speed to reduce temperature rise.
Decrease blower speed to increase temperature rise.
Refer to Circulator Blower Speed section in the Product
Design section of this manual for speed changing details.
Temperature rise is related to the BTUH output of the
furnace and the amount of air (CFM) circulated over the
heat exchanger. Measure motor current draw to determine
that the motor is not overloaded during adjustments.
All use a nonadjustable, automatic reset, bi-metal type limit
control.
I
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WERERESERVII R
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M
UIE WER
SURESM ERESE
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RER MEERS IJUR RE
1. Remove burner compartment door to gain access to
the primary limit.
2. Remove low voltage wires at limit control terminals.
3. With an ohmmeter, test between these two terminals
as shown in the following drawing. The ohmmeter
should read continuous unless heat exchanger tem-
perature is above limit control setting. If not as above,
replace the control.
COLOR
IDENTIFYING
TAB
SERVICING
20
AUXILIARY LIMIT
CONTROL
AUXILIARY LIMIT
CONTROL
BLOWER HOUSING
IVE
ISE WERERESERVII R
ISIISUIMUIE WERSURESM
ERESE IURE S M USE RER
MEERS IJUR RE
RED
RESET
BUTTON
COLOR
IDENTIFYING
VISSIEIRE RESE EUXIIR IMI R
EIISUE SE IME QUIIE SERVIER
MUS EERMIEWE UXIIRIMIEEERE
RESEI I
I
VE
ISE
WERERESERVII R
ISIISUI
M
UIE WERSURESM
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MEERS IJUR RE
1. Remove burner compartment door to gain access to
the induced draft blower motor.
2. Disconnect the motor wire leads from its connection
point at the induced draft motor.
3. Using a ohmmeter, test for continuity between each of
the motor leads.
4. Touch one probe of the ohmmeter to the motor frame
(ground) and the other probe in turn to each lead.
If the windings do not test continuous or a reading is
obtained to ground, replace the motor.
5. If the windings have a continuity reading, reconnect
wires. Turn power on to the furnace and turn the
thermostat on in the heating mode. Check voltage for
115V at the induced draft motor terminals during the tri-
al for ignition. If you have 115V and the motor does not
run, replace the induced draft motor.
6. After completing check and/or replacement of induced
draft motor, reinstall burner compartment door.
7. Turn on electrical power and verify proper unit opera-
tion.
A combination redundant operator type gas valve which
provides all manual and automatic control functions required
for gas red heating equipment is used.
The valve provides control of main burner gas ow, pressure
regulation, and 100 percent safety shut-o.
ISE WERERESERVII
Single stage gas valves should be tested on the furnance with
24 VAC connected to the gas valve and manometers reading
supply line and manifold pressures.
This manual suits for next models
6
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