X40235D ChinookCompact EN
X40235D ChinookCompact EN
and
High efficiency
Owner’s Manual
modulating and multiposition
CONDENSING GAS FURNACE
IMPORTANT: The furnace must be installed with the Modulating Touch-Screen Thermostat R02P030 (#1F95M). If the furnace is to be installed with
the modulating cooling option, use the Communicating Thermostat R02P029 (#1F991292)
ATTENTION: Do not tamper with the unit or its controls. Call a qualified service technician.
INSTALLER / SERVICE TECHNICIAN: Use the information in this manual for the installation / servicing of the furnace and keep the document near the unit
for future reference.
Gas furnaces manufactured on or after May 1, 2017 are not permitted to be used in Canada for heating of buildings or structures
under construction.
These instructions must be read and understood completely before attempting installation.
HOMEOWNER: PLEASE Keep this manual near the furnace for future reference.
Manufactured by:
Dettson Industries Inc.
Sherbrooke (Québec) Canada
www.dettson.com
4.2- Down flow orientation ................................. 14 9- Start up, adjustment and safety check ......... 25
4.2.1- Down flow condensate drain connection ...... 14 9.1- To start the furnace .................................... 25
4.2.2- Down flow venting drainage ......................... 14 9.1.1- Lighting instructions ..................................... 25
4.2.3- Condensate box pressure switch ................. 14 9.2- Unit operation hazard ................................. 25
4.3- Horizontal orientation ................................. 14 9.3- Setup switches ........................................... 25
4.3.1- Horizontal condensate drain connection ...... 14 9.4- Fault code reset ......................................... 29
4.3.2- Horizontal venting drainage ......................... 14 9.5- Diagnostic features .................................... 29
4.3.3- Condensate box pressure switch ................. 14 9.6- Normal operation codes ............................. 29
5- Duct installation .............................................. 14 9.7- Sequence of operation ............................... 29
5.1- General requirements ................................ 14 9.7.1- Heating cycle initiation ................................. 29
5.2- Return air connections ............................... 15 9.7.2- Heating cycle response ............................... 29
5.2.1- Side return air inlet ...................................... 15 9.7.3- Setting input rate ......................................... 29
5.3- Filter arrangement...................................... 15 10- Thermostat ............................................... 29
5.4- Supply air ducts ......................................... 15 10.1- Non-communicating modulating
thermostats .............................................................. 29
5.4.1- Duct work acoustical treatment .................... 15
10.2- 24 VAC thermostat (TSTAT) INPUT (J4 &
5.5- Smart duct.................................................. 15
J6) ................................................................... 29
6- Gas piping ....................................................... 15
2
10.3- Fuse (F1) ................................................... 30 11.2- Lighting instructions ................................... 34
10.4- 120 VAC terminals ..................................... 30 11.3- Shutting down the furnace ......................... 34
10.5- Induced draft motor (inducer) control output 11.4- To turn off gas to the furnace ..................... 34
(E8) ................................................................... 30
11.5- Maintenance of your furnace...................... 34
10.6- Electronic air cleaner (E.A.C.) output (E-
103) ................................................................... 30 11.6- Combustion and ventilation air ................... 35
3
TABLE OF FIGURES
Figure 1: Freeze protection and return air temp. ............. 8 Figure 10 : Other than direct vent clearance .................. 23
Figure 2: Installation in a garage .................................... 10 Figure 11: Wiring diagram for modulating heat (no dual
fuel) (non-communicating).............................................. 29
Figure 3 : Dimension ...................................................... 11
Figure 12: 15-Pin connector; J1 with pin designations ... 31
Figure 4 : Top view......................................................... 11
Figure 26: Control switch modulating valve .................... 34
Figure 5 : Rear view ....................................................... 12
Figure 27 : Typical flame appearance ............................ 36
Figure 6 : Interface board wires connection ................... 12
Figure 20: Exploded View 1 Chinook Compact .............. 57
Figure 7: Upflow condensate drain connection .............. 13
Figure 21: Exploded View 2 Chinook Compact .............. 58
Figure 8: Wiring diagram ................................................ 18
Figure 9 : Direct venting ................................................. 22
LIST OF TABLES
Table 1 : Minimum clearance to combustible material for Table 24 : h – NO V........................................................ 42
all units*............................................................................ 9
Table 25 : 10 - Ignition 1 hour retry ................................ 42
Table 2 : Furnished parts list .......................................... 10
Table 26 : 11 - Failed ignition ......................................... 43
Table 3 : Maximum capacity of pipe in Ft³ of gas/hr ....... 15
Table 27 : 12 - Low flame sense .................................... 44
Table 4 : Gas pressure ................................................... 15
Table 28 : 13 - Flame lost............................................... 45
Table 5 : Electrical data .................................................. 16
Table 29 : 16 - Igniter fail................................................ 46
Table 6 : Thermostat choice vs system .......................... 17
Table 30 : 14 - Unexpected flame .................................. 46
Table 7 : Maximum venting length ................................. 20
Table 31 : 22 - Main limit open ....................................... 47
Table 8 : Deduction for fitting ......................................... 20
Table 32 : 26 - Line neutral reverse ............................... 47
Table 9: Approved combustion air and vent pipe, fitting
and cement materials (U.S.A. Installation) - (In Canada all Table 33 : 33 - MRLC (Manually Reset Limit Control)
vent material s shall comply to ULC S636)..................... 21 OPEN ............................................................................. 48
Table 10 : DIP switch S1 - Air flow adjustment - Dip switch Table 34 : 44 - LPC (low pressure control (switch)) Closed
setting............................................................................. 26 ....................................................................................... 49
Table 11 : DIP switch S3 - Cooling airflow select for non- Table 35 : 46 - LPC (low pressure control (switch)) Open
communicating condenser ............................................. 27 ....................................................................................... 50
Table 12 : DIP switch S3 - Cooling/heat pump airflow Table 36 : 55 - HPC (High Pressure Control (switch))
adjustment for non-communicating system .................... 27 CLOSED ........................................................................ 51
Table 13 : DIP switch S4 - Heat rise – test mode – Table 37 : 57 - HPC (High Pressure Control (switch))
continuous fan selection ................................................. 27 OPEN ............................................................................. 52
Table 14 : DIP switch S5 – Dehumidification and 1st Table 38 : 60 - Blower fault - running ............................. 53
stage cooling .................................................................. 28 Table 39 : 61 - Blower fault – not running....................... 53
Table 15 : DIP switch S3 and S5 – Setting cooling airflow Table 40 : 66 - Blower overspeed................................... 54
demand .......................................................................... 28
Table 41 : 68 - No blower communication ...................... 54
Table 16: Normal operation codes/messages ................ 37
Table 42 : 71 - No inducer communications ................... 55
Table 17 : Fault code ..................................................... 37
Table 43 : 77 - No gas valve feedback ........................... 55
Table 18 : D1 - No shared data ...................................... 38
Table 44 : 93 - Control fault ............................................ 56
Table 19 : D4 - Memory card.......................................... 39
Table 13: Parts List - Chinook Compact ......................... 59
Table 20 : D5 - Card hardware conflict ........................... 39
Table 21 : D6 - Blower horsepower conflict .................... 40
Table 22 : D7 - Blower manufacturer conflict ................. 40
Table 23 : D8 - old shared data ...................................... 41
4
Required notice for Massachusetts installations
Important
The Commonwealth of Massachusetts requires compliance with regulation 248 CMR as follows:
5.08: Modifications to NFPA-54, Chapter 10. Revise 10.8.3 by adding the following additional requirements:
For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential
purposes, including those owned or operated by the commonwealth and where the side wall exhaust vent termination is less than seven (7)
feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:
Installation of Carbon Monoxide Detectors
At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gas fitter shall observe that a hard
wired carbon monoxide detector with an alarm and battery backup is installed on the floor level where the gas equipment is to be installed. In
addition, the installing plumber or gas fitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is
installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall
be the responsibility of the property owner to secure the services of qualified license professionals for the installation of hard wired carbon
monoxide detectors.
In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide
detector with alarm and battery backup may be installed on the next adjacent floor level.
In the event that the requirements of this subdivision cannot be met at the time of completion of installation, the owner shall have a period of
thirty (30) days to comply with the above requirement; provided, however, that during said thirty (30) day period, a battery operated carbon
monoxide detector with an alarm shall be installed.
APPROVED CARBON MONOXIDE DETECTORS: Each carbon monoxide detector as required in accordance with the above provision shall
comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.
SIGNAGE: A metal or plastic identification plate shall be permanently mounted to 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 sign
shall read, in print size no less than in-half (1/2) inch in size, “gas vent directly below. Keep clear of all obstruction”.
INSPECTION: the state of local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation
unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248
CMR 5.08 (2) (a) 1 through 4:
EXEMPTION: the following equipment is exempt from 248 CMR 5.08(2) (a) 1 through 4:
The equipment listed in Chapter 10 entitled “equipment not required to be vented “in the most current edition of NFPA 54 as adopted by the
board; and
Product approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or
structure in whole or in part for residential purposes.
MANUFACTURER REQUIREMENTS – GAS EQUIPMENT VENTING SYSTEM PROVIDED
When the manufacturer of product approved side wall horizontally vented gas equipment provides a venting system design or venting system
component with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall
include:
Detailed instructions for the installation of the venting system design or the venting system components; and a complete parts list for the
venting system design or venting system.
MANUFACTURER REQUIREMENTS – GAS EQUIPMENT VENTING SYSTEM PROVIDED
When the manufacturer of product approved side wall horizontally vented gas fueled equipment does not provide the parts or venting the flue
gases, but identifies “special venting system”, the following requirements shall be satisfied by the manufacturer:
The referenced “special venting system” shall be product approved by the board, and the instruction for that system shall include a parts list
and detailed installation instructions.
A copy of all installation instructions for all product, approved side wall horizontally vented gas fueled equipment, all venting instructions, all
part s lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the
installation.
For questions regarding these requirements, please contact the Commonwealth of Massachusetts board of State Examiners of Plumbers
and Gas Fitters, 239 Causeway Street, Boston, MA, 02114, tel.: 617 727-9952.
5
1- SAFETY REGULATION WARNING
1.1- Safety labeling and warning signs CARBON MONOXIDE POISONING/COMPONENT DAMAGE
HAZARD
The words DANGER and WARNING are used to identify the
levels of seriousness of certain hazards. It is important that you Failure to follow this warning could result in personal injury or death
understand their meaning. You will notice these words in the and unit component damage.
manual as follows: Corrosive or contaminated air may cause failure of parts containing
flue gas, which could leak into the living space. Air for combustion
DANGER must not be contaminated by halogen compounds, which include
fluoride, chloride, bromide, and iodide. These elements can corrode
heat exchangers and shorten furnace life. Air contaminants are found
Immediate hazards that WILL result in death, serious bodily injury
in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air
and/or property damage
fresheners, and other household products. Do not install furnace in a
corrosive or contaminated atmosphere. Make sure all combustion
and circulating air requirements are met, in addition to all local codes
WARNING and ordinances.
NOTE: is used to highlight suggestions which will result in FIRE, EXPLOSION, ELECTRICAL SHOCK, AND CARBON
enhanced installation, reliability or operation. MONOXIDE POISONING HAZARD
Failure to follow this warning could result in dangerous operation,
1.2- Important information personal injury, death, or property damage. Improper installation,
adjustment, alteration, service, maintenance, or use can cause carbon
DANGER monoxide poisoning, explosion, fire, electrical shock, or other
conditions which may cause personal injury or property damage.
Consult a qualified service agency, local gas supplier, or your
Non-observance of the safety regulations outlined in this manual will distributor or branch for information or assistance. The qualified service
potentially lead to consequences resulting in death, serious bodily agency must use only factory authorized and listed kits or accessories
injury and/or property damage. when modifying this product.
It is the homeowner’s responsibility to engage a qualified
technician for the installation and subsequent servicing of this
furnace;
WARNING
Before calling for service, be sure to have the information page
of your manual (last page of your manual) close by in order to be
FIRE, EXPLOSION, AND CARBON MONOXIDE POISONING
able to provide the contractor with the required information, such HAZARD
as the model and serial numbers of the furnace.
Failure to follow this warning could result in personal injury, death, or
WARNING property damage.
Never operate a furnace without a filter or filtration device installed.
Installations and repairs performed by unqualified persons can result Never operate a furnace with filter or filtration device access doors
in hazards to them and to others. Installations must conform to local removed.
codes or, in the absence of same, to codes of the country having
jurisdiction.
Untrained personnel can perform basic maintenance functions such as
The information contained in this manual is intended for use by a cleaning and replacing air filters. All other operations must be performed
qualified technician, familiar with safety procedures and who is by trained service personnel. When working on heating equipment,
equipped with the proper tools and test instruments observe precautions in literature, on tags, and on labels attached to or
shipped with furnace and other safety precautions that may apply.
These instructions cover minimum requirements and conform to existing
1.3- Detection systems national standards and safety codes. In some instances, these
It is recommended that carbon monoxide detectors be installed wherever instructions exceed certain local codes and ordinances, especially those
oil or gas fired heaters are used. Carbon monoxide can cause bodily harm that may not have kept up with changing residential construction practices.
or death. For this reason, approved carbon monoxide detectors shall be We require these instructions as a minimum for a safe installation.
installed in your residence and properly maintained to warn of dangerously Follow all safety codes. Wear safety glasses, protective clothing, and work
high carbon monoxide levels. gloves. Have a fire extinguisher available. Read these instructions
Fire can cause bodily harm or death. For this reason, approved smoke thoroughly and follow all warnings or cautions included in literature and
detectors should be installed in your residence and be properly attached to the unit.
maintained, to warn early on, of a potentially dangerous fire. Also, the
house should be equipped with approved and properly maintained fire
extinguishers.
Your unit is equipped with safety devices that can prevent it from
functioning when anomalies are detected such as a blocked venting
system.
6
13. Gas furnace manufactured on or after May 1, 2017 are not
CAUTION permitted to be used in Canada for heating of buildings or
structures under construction.
INJURY HAZARD
Ignoring this warning could result in personal injury.
CAUTION
Sheet metal parts may have sharp edges or burrs. Use care and wear
appropriate protective clothing, safety glasses and gloves when
handling parts, and servicing furnaces FROZEN AND BURST WATER PIPE HAZARD
Failure to protect against the risk of freezing may result in property
damage. Special precautions MUST be made if installing furnace in an
1. Use only with type of gas approved for this furnace. Refer to the area which may drop below freezing. This can cause improper
furnace rating plate. operation or damage to equipment. If furnace environment has the
potential of freezing, the drain trap and drain line must be protected
2. Install this furnace only in a location and position as specified in
section 2.3-Location.
3. Provide adequate combustion and ventilation air to the furnace CAUTION
as specified in section 8-Venting and combustion air piping.
4. Combustion products must be discharged outdoors. Connect PROPERTY DAMAGE HAZARD
this furnace to an approved vent system only as specified in
section 8.4.2-Exhaust vent piping. Failure to follow this caution may result in burst water pipes and/or
property damage. If a condensate pump is installed, a clogged
5. Never test for gas leaks with an open flame. Use a commercially condensate drain or a failed pump may cause the furnace to shut down.
available soap solution made specifically for the detection of Do not leave the home unattended during freezing weather without
leaks to check all connections. turning off water supply and draining water pipes or otherwise
protecting against the risk of frozen pipes.
6. Always install furnace to operate within the furnace’s intended
temperature rise range with a duct system which has an Ensure all condensate drain connections are secured and liquid tight.
external static pressure within the allowable range, as specified Use the furnished tube clamps and verify tightness
in section 5-Duct installation. See furnace rating label.
7. When a furnace is installed so that supply ducts carry air
circulated by the furnace to areas outside the space containing
the furnace, the return air shall also be handled by duct(s) CAUTION
sealed to the furnace casing and terminating outside the space
containing the furnace. See section 5.2-Return air connections.
FURNACE CORROSION HAZARD
8. A gas fired furnace for installation in a residential garage must
Failure to follow this caution may result in furnace damage. Air for
be installed as specified in the WARNING box below:
combustion must not be contaminated by halogen compounds, which
include fluoride, chloride, bromide, and iodine. These elements can
WARNING corrode heat exchangers and shorten furnace life. Air contaminants are
found in aerosol spray, detergents, bleaches, cleaning solvents, salts,
FIRE, INJURY OR DEATH HAZARD air fresheners, and other household products.
9. The furnace is factory shipped for use with natural gas. A CSA
(A.G.A. and C.G.A.) listed accessory gas conversion kit is
required to convert furnace for use with propane gas.
10. See Table 1 : Minimum clearance to combustible material for all
units for required clearances to combustible construction.
11. Maintain a 1” (25 mm) clearance from combustible materials to
supply air ductwork for a distance of 36” (914 mm) horizontally
from the furnace. See NFPA 90B or local code for further
requirements.
12. These furnaces SHALL NOT be installed directly on carpeting,
tile, or any other combustible material other than wood flooring.
7
accordance with the instruction provided in this manual. A manufactured
WARNING home installation must conform with the Manufactured Home Construction
and Safety Standard, Title 24 CFR, Part 3280, or when this Standard is
CARBON MONOXIDE POISONING HAZARD not applicable, The Standard for Manufactured Home Installations
(Manufactured Home Sites, Communities and Set-Ups), ANSI/NCS
Failure to follow the steps outlined below for each appliance connected A225.1, and/or MH Series Mobile Homes, CAN/CSA-Z240. Follow all
to the venting system being placed into operation could result in carbon national and local codes and standards in addition to these
monoxide poisoning or death. The following steps shall be followed for instructions. The installation must comply with regulations of the serving
each appliance connected to the venting system being placed into gas supplier, local building, heating, plumbing, and other codes.
operation, while all other appliances connected to the venting system
are not in operation: This furnace is designed for minimum continuous return air temperature
of 60 °F (16 °C) or intermittent operation down to 55 °F (13 °C) such as
1. Seal any unused openings in venting system; when used with a night setback thermostat. Return air temperature must
2. Inspect the venting system for proper size and horizontal not exceed 80 °F (27 °C). Failure to follow these return air temperature
pitch, as required in the National Fuel Gas Code, NFPA limits may affect reliability of heat exchangers, motors, and controls
54/ANSI Z223.1-2009 and these instructions. In Canada, (Figure 1: Freeze protection and return air temp.).
refer to CAN/CSA-B149.1-2010. Determine that there is no The furnace should be sized to provide 100 % of the design heating load
blockage or restriction, leakage, corrosion and other requirement plus any margin that occurs because of furnace model size
deficiencies, which could cause an unsafe condition capacity increments. Heating load estimates can be made using approved
3. As far as practical, close all building doors and windows and methods available from Air Conditioning Contractors of America (Manual
all doors between the space in which the appliance(s) J); American Society of Heating, Refrigerating, and Air Conditioning
connected to the venting system are located and other Engineers; or other approved engineering methods. Excessive over sizing
spaces of the building. of the furnace could cause the furnace and/or vent to fail prematurely.
8
2.1.3- Combustion and air ventilation move or shuffle your feet, do not touch ungrounded objects,
etc.).
USA: Section 9.3 of the NFPA54/ANSI Z223.1-2009 Air for
Combustion and Ventilation 4) If you touch ungrounded objects (and recharge your body with
static electricity), firmly touch a clean, unpainted metal surface
CANADA: Part 8 of the CAN/CSA B149.1-2010, Venting Systems and of the furnace again before touching control or wires.
Air Supply for Appliances
5) Use this procedure for installed and uninstalled (ungrounded)
furnaces.
2.1.4- Duct systems
6) Before removing a new control from its container, discharge
USA and CANADA: Air Conditioning Contractors Association (ACCA)
your body’s electrostatic charge to ground to protect the control
(Manual D), Sheet Metal and Air Conditioning
from damage. If the control is to be installed in a furnace, follow
Contractors National Association (SMACNA), or
items 1 through 4 before bringing the control or yourself in
American Society of Heating, Refrigeration, and Air
contact with the furnace. Put all used and new controls into
Conditioning Engineers (ASHRAE).
containers before touching ungrounded objects.
2.1.5- Acoustical lining and fibrous glass duct 7) An ESD service kit (available from commercial sources) may
also be used to prevent ESD damage.
USA and CANADA: current edition of SMACNA, NFPA 90B as tested by
UL Standard 181 for Class I Rigid Air Ducts.
2.3- Location
2.1.6- Gas piping and pipe pressure testing 2.3.1- General
These furnaces are shipped with materials to assist in proper furnace
USA: NFPA 54/ANSI Z223.1-2009 NFGC; Chapters 5, 6, 7, and 8 installation. These materials are shipped in the main blower
and national plumbing codes. compartment. See Table 2 : Furnished parts list. This furnace must:
CANADA: CAN/CSA-B149.1-2010, Part 6 Be installed so the electrical components are protected from
water;
IN THE STATE OF MASSACHUSETTS:
Not be installed directly on any combustible material other than
This product must be installed by a licensed plumber or gas fitter. wood flooring;
When flexible connectors are used, the maximum length shall not Be located close to the chimney or vent and attached to an air
exceed 36 in. (914 mm). distribution system. Refer to section 5-Duct installation;
When lever type gas shutoffs are used they shall be "T" handle Be provided ample space for servicing and cleaning. Always
type. comply with minimum fire protection clearances shown in Table 1
: Minimum clearance to combustible material for all units or on the
The use of copper tubing for gas piping is not approved by the furnace rating label.
state of Massachusetts.
Install de furnace with a correct slope if installed in other position
than upflow. If installed upflow, make sure the furnace is leveled
See Table 4 : Gas pressure.
to ensure proper drainage of condensate.
9
Table 2 : Furnished parts list Cements and glues
Antistatic fabric softeners for clothes dryers
Quantity Description
Masonry acid washing materials
2 Plastic cap 5/8"
All fuel burning equipment must be supplied with air for fuel combustion.
8 Plastic cap 1/2" Sufficient air must be provided to avoid negative pressure in the
1 Gas pipe grommet 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
10 Screw TEKS HEX WSH #8-18 x ½ burner area.
1 Two holes drain trap gasket
Place the unit so that proper venting can be achieved, with a minimum
Two holes drain trap (Only used in downflow or number of elbows, in accordance with the instructions in this manual. The
1
horizontal configuration) furnace should be located as close to the chimney (vertical venting) or to
1 Three holes drain trap gasket the outside vent wall (horizontal venting) as possible.
1 Three holes drain trap (upflow) When installing the furnace, provisions must be made to ensure the supply
of adequate combustion and ventilation air in accordance with the “air for
1 Length of 1.5’’ PVC pipe
combustion and ventilation” section of the National Fuel Gas Code, NFPA
2 Gasket wall pipe flange 5/ANSI Z223.1-2002, or latest edition, or applicable provisions of the local
2 Wall pipe flange building code.
10
Figure 3 : Dimension
11
Figure 5 : Rear view
12
4- INSTALLATION Figure 7: Upflow condensate drain connection
The furnace is factory built for upflow position. When installing the furnace
in other orientation than the upflow position, simply re-route the tubing
accordingly with the instructions provided in this section of the manual.
Before installing the furnace, remove three panel in the following
order to position the condensate tubing:
1. Blue door
2. Top panel
3. Side panel
CAUTION
CAUTION
13
4.2- Down flow orientation
When installing the furnace in horizontal orientation you must tilt the
To install the furnace in down flow orientation, the following steps are furnace one inch forward to ensure proper drainage of the condensate.
required for proper operation
When installing the furnace in Downflow orientation you must tilt the
4.3.1- Horizontal condensate drain connection
furnace one inch forward to ensure proper drainage of the condensate.
5- DUCT INSTALLATION
4.2.2- Down flow venting drainage
All furnace with horizontal exhaust vent piping must have a drain tee 5.1- General requirements
assembly and trap installed in the exhaust pipe as close to the furnace as
possible. The duct system should be designed and sized according to accepted
national standards such as those published by: Air Conditioning
Contractors Association (ACCA), Sheet Metal and Air Conditioning
4.2.3- Condensate box pressure switch
Contractors National Association (SMACNA) or American Society of
Heating, Refrigerating and Air Conditioning Engineers (ASHRAE) or
Mechanical connection consult The Air Systems Design Guidelines reference tables available
from your local distributor.
Cut the 3/16” stub beside the drain of the condensate box. Connect one The duct system should be sized to handle the required system design
end of the square black tubing furnished with the furnace to this stub. CFM at the design external static pressure. When a furnace is installed so
Connect the other end to the multiposition pressure switch (-0.2 in w.c.). that the supply ducts carry air circulated by the furnace to areas outside
The square black tubing of the multiposition pressure switch must be the space containing the furnace, the return air shall also be handled by
connected to this stub. duct(s) sealed to the furnace casing and terminating outside the space
containing the furnace.
Electrical connection Secure ductwork with proper fasteners for type of ductwork used. Seal
supply and return duct connections to furnace with code approved tape or
duct sealer.
Using the brown jumper furnished with the furnace, connect the
multiposition pressure switch in series with the low fire pressure switch. Ductwork passing through an unconditioned space should be insulated to
enhance system performance. When air conditioning is used, a vapour
barrier is recommended.
4.3- Horizontal orientation
Maintain a 1 in. (25 mm) clearance from combustible materials to supply
To install the furnace in horizontal orientation, the following steps are air ductwork for a distance of 36 in. (914 mm) horizontally from the
required for proper operation furnace. See NFPA 90B or local code for further requirements.
14
Proper airflow is necessary for the correct operation of this furnace. If In the state of Massachusetts:
ductwork is not sized properly, the furnace can operate erratically.
3. Gas supply connections MUST be performed by a licensed
Installer should size the ducts according to industry standards and plumber or gas fitter.
methods. The total static pressure drop of the supply and return ducts
should not exceed 0.3’’ w.c. if this furnace is installed with traditional 4. When flexible connectors are used, the maximum length shall
ductwork. not exceed 36 in. (915 mm).
5. When lever handle type manual equipment shutoff valves are
used, they shall be "T" handle valves.
5.2- Return air connections 6. The use of copper tubing for gas piping is NOT approved by the
state of Massachusetts.
The return air duct must be connected to the bottom, left side or right side.
Report to Table 3: Maximum capacity of pipe for recommended gas pipe
sizing. Support all gas piping with appropriate straps, hangers, etc. Use a
It is not recommended to connect the return duct to the left side minimum of 1 hanger every 6 ft (1.8 m). Joint compound (pipe dope)
since this side gives access to the blower compartment. should be applied sparingly and only to male threads of joints. Pipe dope
must be resistant to the action of propane gas.
Connection to the bottom of the furnace is strongly recommended.
An accessible manual equipment shut off valve MUST be installed
NOTE: In downflow configuration, side return air is not permitted, it must external to furnace casing.
be connected to bottom.
Install a sediment trap in riser leading to furnace. Connect a capped nipple
into lower end of tee. Capped nipple should extend below level of furnace
5.2.1- Side return air inlet gas controls. Place a ground joint union between furnace gas control valve
1. Remove 4 knock-outs on the side of the furnace. and exterior manual equipment gas shutoff valve (for ridged black pipe).
15
The gas supply pressure shall be within the maximum and minimum inlet Table 5 : Electrical data
supply pressures marked on the rating plate and in Table 4 : Gas
pressure.
Volts- Max Min. Maximum Unit Max
Hertz- operating operating unit ampacity Fuse
6.1- Gas pipe grommet Phase voltage voltage amps
For direct vent (2 pipe) applications, the hole for the gas pipe on the
cabinet must be sealed to prevent air leakage. Install the grommet in the 120- 127 104 7.5 8.625 15
hole, then insert the gas pipe and apply fillet paste. 60-1
7- ELECTRICAL CONNECTIONS
7.2- 24 V wiring
WARNING
Make field 24 V connections at the 24 V terminal strip. Use only AWG No.
FIRE HAZARD 18 minimum, color-coded, copper thermostat wire.
NOTE: Use AWG No. 18 color coded copper thermostat wire for lengths
Failure to follow this warning could result in personal injury, death, or
up to 100ft. (30.5m). For wire lengths over 100 ft., use AWG No
property damage.
16 wire.
Do not connect aluminium wire between disconnect switch and
The 24 V circuit contains an automotive type, 3-amp fuse located on the
furnace. Use only copper wire.
control board. Any 24v direct shorts during installation, service, or
maintenance could cause this fuse to blow. If fuse replacement is required,
Check all factory and field electrical connections for tightness. use ONLY a 3 amp fuse. Refer to Figure 8: Wiring diagram for the location
of the fuse.
Supplied field wiring shall conform to the limitations of 63°F (33°C) rise.
16
Table 6 : Thermostat choice vs system
Communicating
Alizé Yes Yes Yes
R02P029
17
Figure 8: Wiring diagram
18
8- VENTING AND COMBUSTION AIR PIPING U.S.A. Installations: Section 5.3 of the NFPA 54/ANSI Z223.1-2009, Air
for Combustion and Ventilation and applicable provisions of the local
building codes.
8.1- Introduction
Canada: Part 8 of the CAN/CSA-B149.1-2010, Venting Systems and Air
Supply for Appliances.
8.1.1- Direct vent (2 pipe applications)
When this furnace is installed as a direct vent (2 pipe) furnace; no special 8.2- Special venting requirements for installations in
provisions for air for combustion are required. However, other gas Canada
appliances installed in the space with the furnace may require outside air
for combustion. Follow the guidelines below to insure that other gas The special vent fittings and accessory concentric vent termination kits
appliances have sufficient air for combustion. and accessory external drain trap have been certified to ULC S636 for use
with Royal Pipe, IPEX PVC and CPVC vent components.
Direct vent installations require a dedicated combustion air and venting
system. All air for combustion is taken from outside and all combustion In Canada, S636 certified primers and cements must be used and be of
products are discharged to the outdoors. the same manufacturer of the S636 venting system- do not mix primers
and cements from one manufacturer with a vent system from a
Therefore, no ventilation or combustion air openings are required. different manufacturer. Follow the manufacturer’s instructions in the use
In Canada, refer to manufacturer's instructions for supporting ULC S636 of primer and cement and never use primer or cement beyond its
venting. expiration date.
In a direct vent (2 pipes) system, all air for combustion is taken directly Safe operation, as defined by ULC S636, of the vent system is based on
from outdoor atmosphere, and all flue products are discharged to outdoor following the vent system manufacturer installation instructions, and
atmosphere. Combustion air and vent pipes must terminate either through proper use of required primers and cements.
the roof or sidewall.
All fire stop and roof flashing used with this system must be UL listed
TERMINATION REQUIREMENTS FOR THE PROVINCE OF ALBERTA material.
AND SASKATCHEWAN:
Acceptability under Canadian standard CAN/CSA B149 requires full
The Provinces of Alberta and Saskatchewan require a minimum compliance with all installation instructions.
unobstructed distance of 4 ft. (1.2 M) from the foundation to the property
line of the adjacent lot for vent termination of any appliance with an input The authority having jurisdiction (gas inspection authority, municipal
over 35,000 BTU/h. If there is less than 4 ft. (1.2 M) of unobstructed building department, fire department, etc.) should be consulted before
distance to the property line of the adjacent lot, no type of vent termination installation to determine the need to obtain a permit.
is permitted for appliances with inputs greater than 35,000 BTU/h. There
are no additional restrictions on unobstructed distances greater than 8 ft.
(2.4 M).
8.3- General
If this furnace replaces a furnace that was connected to a vent system or
All single, two pipe and concentric vents may be used, providing all other
chimney, the vent or vent connectors of other remaining appliances may
Codes and manufacturer’s requirements in these instructions are adhered
need to be re-sized. Vent systems or vent connectors of other appliance
to.
must be sized to the minimum size allowable.
If the unobstructed distance from the foundation to the property line of the
An abandoned masonry chimney may be used as a raceway for properly
adjacent lot is no less than 4 ft. (1.2 M) and no greater than 8 ft. (2.4 M),
insulated and supported combustion-air (when applicable) and vent pipes.
it will be necessary to re-direct the flue gas. In this situation, a concentric
Each furnace must have its own set of combustion air and vent pipes and
vent kit cannot be used.
be terminated individually.
A 2 pipe system (or single pipe system when permitted) that redirects the
A furnace shall not be connected to a chimney flue serving a separate
flue gas away by use of an elbow or tee, certified to ULC S636 from the
appliance designed to burn solid fuel.
adjacent property line must be used.
Other gas appliances with their own venting system may also use the
8.1.2- Non direct vent (1 pipe) applications abandoned chimney as a raceway providing it is permitted by local code,
the current edition of the National Fuel Gas Code, and the vent or liner
When the furnace is installed as a non-direct vent (1 pipe) furnace, it will manufacturer’s installation instructions. Care must be taken to prevent the
be necessary to ensure there is adequate air for combustion. Other gas exhaust gases from one appliance from contaminating the combustion air
appliances installed with the furnace may also require air for combustion of other gas appliances.
and ventilation in addition to the amount of combustion air and ventilation
required for the furnace.
8.4- Connecting to furnace
When the furnace is installed using the ventilated combustion air option,
the attic or crawlspace must freely communicate with the outdoors to Do not common vent with any other appliance. Do not install in the same
provide sufficient air for combustion. The combustion air pipe cannot be chase or chimney with a metal or high temperature plastic pipe from
terminated in attics or crawlspaces that uses ventilation fans designed to another gas or fuel-burning appliance unless the required minimum
operate during the heating season. If ventilation fans are present in these clearances to combustibles are maintained between the approved PVC
areas, the combustion pipe must terminate outdoors as a direct vent (2 pipe and other pipes. Clean and deburr all pipe cuts. The shavings must
pipe) system. not allowed to block the exhaust, inlet or condensate drain pipes.
All air for combustion is piped directly to the furnace from a space that is A 2” diameter PVC pipe is supplied with your furnace. This pipe length is
well ventilated with outdoor air (such as an attic, crawlspace or equipment either 1.5”. Connect this piece of PVC to the rubber coupling over the
closet) and the space is well isolated from the living space or garage. In induce draft blower. If this piece is not installed properly, flue gases will
addition, other gas appliances installed in the space with the furnace may circulate in the cabinet and cause burner to shut off.
require outside air for combustion. The exhaust pipe connection is a 2” female PVC pipe fitting extending
Provisions for adequate combustion, ventilation, and dilution air must be through the back right side of the furnace top plate.
provided in accordance with: All exhaust piping must be installed in compliance with Part 7, “Venting of
Equipment,” of the latest edition of the National Fuel Gas Code NPFA 54,
19
90A and 90B ANSI Z223.1-, local codes or ordinances and these NOTE: Furnaces may have a drain tee assembly and trap installed in
instructions: the combustion air pipe as close to the furnace as possible. This is to
drain any water that may enter the combustion air pipe to prevent it from
1. Provide the space with sufficient air for proper combustion, entering the furnace vestibule area.
ventilation, and dilution of flue gases using permanent
horizontal or vertical duct(s) or opening(s) directly
communicating with the outdoors or spaces that freely 8.4.2- Exhaust vent piping
communicate with the outdoors. The rubber coupling that attaches to the vent pipe adapter must be used.
The adapter seals the vent pipe to the casing and reduces the strain the
2. Insulate all vent runs through unconditioned spaces where inducer and the elbow (when present).
below freezing temperatures are expected with 1" thick medium
density, foil faced fiberglass or equivalent Rubatex/Armaflex
insulation. (In Canada per the vent manufacturer’s instructions) It is necessary to properly seal on either side of the adapter with an
appropriate adhesive. This is to prevent any condensate leakage.
3. For runs where condensate could collect and freeze, wrap the
vent pipe with self-regulating, 3 or 5 Watt heat tape. The heat The exhaust vent must terminate at least 12” above the combustion air
tape must be U.L./CSA. listed and installed per the termination inlet. The maximum length of the exposed vent pipe above the
manufacturer’s instructions. roof is 30".
4. All piping between the furnace and the roof or outside wall NOTE: The combustion air and exhaust terminations must be at least 12”
penetration is either 2" or 3". above grade. Use alternate horizontal terminations when
termination locations are limited and higher snow levels are
anticipated.
Table 7 : Maximum venting length
NOTE: Ensure the location of the combustion air inlet with respect to
the exhaust vent terminal complies with regulations.
INPUT 2’’ pipe diameter 3’’ pipe diameter
15,000 BTU/hr 300 ft N/A
8.5- Materials
USA: Combustion air and vent pipe, fittings, primers, and solvents
must conform to American National Standards Institute (ANSI)
Table 8 : Deduction for fitting standards and American Society for Testing and Materials
(ASTM) standards. See Table 9 : Approved combustion air and
vent pipe, fitting and cement materials (U.S.A. Installation) - (In
Type of elbow Equivalent Length (ft.) Canada all vent material s shall comply to ULC S636) for
45° Standard 5 approved materials for use in the U.S.A.)
20
Table 9 : Approved combustion air and vent pipe, fitting and cement materials (U.S.A.
Installation) - (In Canada all vent material s shall comply to ULC S636)
21
Figure 9 : Direct venting
22
Figure 10 : Other than direct vent clearance
23
insertion mark. Quickly apply approved cement to end of pipe
8.7- Combustion air and vent piping insulation and fitting socket (over primer). Apply cement in a light, uniform
guidelines coat on inside of socket to prevent build-up of excess cement.
Apply second coat.
The vent pipe may pass through unconditioned areas.
24. While cement is still wet, twist pipe into socket with 1/4” turn. Be
1. Using winter design temperature (used in load calculations), find sure pipe is fully inserted into fitting socket.
appropriate temperature for your application and furnace model.
25. Wipe excess cement from joint. A continuous bead of cement
2. Determine the amount of total and exposed vent pipe. will be visible around perimeter of a properly made joint.
3. Determine required insulation thickness for exposed pipe 26. Handle pipe joints carefully until cement sets.
length(s).
27. Horizontal portions of the venting system shall be supported to
4. When combustion air inlet piping is installed above a suspended prevent sagging. Support combustion air piping and vent piping
ceiling, the pipe MUST be insulated with moisture resistant a minimum of every 5 ft. (1.5 M) [3 ft. (.91 M) for SDR-21 or -26
insulation such as Armaflex™ or other equivalent type of PVC] using perforated metal hanging strap or commercially
insulation. available hangars designed to support plastic pipe.
5. Insulate all vent runs through unconditioned spaces where 28. Prevent condensate from accumulating in the pipes by sloping
below freezing temperatures are expected with 1" thick medium the combustion air piping and vent piping downward towards
density, foil faced fiberglass or equivalent Rubatex/Armaflex furnace a minimum of 1/4” per linear ft. with no sags between
insulation. hangers.
6. For horizontal runs where water may collect, wrap the vent pipe 29. Complete the vent and combustion air pipe installation by
with self-regulating, 3 or 5 Watt heat tape. The heat tape must installing the required termination elbows.
be U.L./CSA. listed and installed per the manufacturer’s
instructions. 30. Use appropriate methods to seal openings where combustion
air pipe and vent pipe pass through roof or sidewall.
7. Insulate combustion air inlet piping when run in warm, humid
spaces.
8.8- Installing the vent termination
8. Install the insulation per the insulation manufacturer’s
installation instructions. A roof termination of any type will require a 4” (102 mm) flashing for a 2”
(51 mm) concentric vent or a 5” diameter (127 mm) flashing for a 3” (76
NOTE: Pipe length specified for maximum pipe lengths located in mm) concentric vent kit. For two-pipe or single pipe vent systems, a
unconditioned spaces cannot exceed total allowable pipe flashing for each pipe of the required diameter will be necessary. It is
length. recommended that the flashing be installed by a roofer or competent
professional prior to installing the concentric vent. The terminations can
9. Apply the wall pipe flange gaskets to the vent wall pipe and
be installed on a flat or pitched roof.
combustion air wall pipe flanges.
NOTE: The vent wall pipe flange and the combustion air wall pipe flange 8.8.1- Concentric vent
have the same ID.
Single or multiple concentric can be install. Maintain the required
10. For the exhaust vent, place the wall pipe flange over the 2” separation distance between vents or pairs of vents and all clearances.
diameter pipe provided. Take good care to glue the piece of
PVC to the wall pipe flange to avoid any condensate Cut one 4” (102 mm) diameter hole for 2” (51 mm) kit, or one 5” (127 mm)
leakage. diameter hole for 3” (76 mm) kit in the desired location. Loosely assemble
concentric vent/combustion air termination components together using
11. Align the pipe on the rubber coupling with drain and tighten instructions in kit. Slide assembled kit with rain shield REMOVED through
the clamp around the rubber coupling. hole in wall or roof flashing.
12. Align the screw holes in the plastic wall pipe flange with the NOTE: Do not allow insulation or other materials to accumulate inside
dimples in the casing. of pipe assembly when installing it through hole. Disassemble loose pipe
fittings. Clean and cement using same procedures as used for system
13. Pilot drill the screw holes for the flange in the casing and attach
piping.
the vent wall pipe flange to the furnace with sheet metal screws
14. Repeat for the air combustion wall pipe flange and secure to the 8.8.2- Two pipe termination
top casing.
Maintain the required separation distance between vents or pairs of vents
15. Install the remaining vent and combustion air pipes. It is and all clearance. Cut the required number of holes in the roof or sidewall
recommended that all pipes be cut, prepared, and for vent and combustion air pipes. Sidewall holes for two pipes vent
preassembled before permanently cementing any joint. terminations should be side-by-side, allowing space between the pipes for
16. Working from furnace to outside, cut pipe to required length(s). the elbows to fit on the pipes. Holes in the roof for two pipe terminations
should be spaced no more than 18” (457 mm) apart. Termination elbows
17. Deburr inside and outside of pipe. will be installed after the vent and combustion air pipe is installed.
18. Chamber outside edge of pipe for better distribution of primer
and cement. 8.8.3- Sidewall termination
19. Clean and dry all surfaces to be joined. Determine an appropriate location for termination kit.
20. Check dry fit of pipe and mark insertion depth on pipe. 1. Cut one 4” diameter hole for 2” kit, or one 5” diameter hole for
3” kit.
21. Insert the combustion air pipe into the adapter.
2. Loosely assemble concentric vent/combustion air termination
22. Seal around the combustion air pipe with silicone or foil tape. components together using instructions in kit.
23. After pipes have been cut and preassembled, apply generous
layer of cement primer to pipe fitting socket and end of pipe to
24
3. Slide assembled kit with rain shield REMOVED through hole 1. Remove the burner compartment control access door.
(NOTE: Do not allow insulation or other materials to accumulate
inside of pipe assembly when installing it through hole). 2. IMPORTANT: Be sure that the manual gas control has been in
the “OFF” position for at least five minutes. Do not attempt to
4. Locate assembly through sidewall with rain shield positioned no manually light the main burners.
more than 1” (25 mm) from wall.
3. Set the room thermostat to its lowest setting and turn off the
5. Disassemble loose pipe fittings. Clean and cement using same furnace electrical power.
procedures as used for system piping.
4. Turn the gas control knob to the “ON” position.
6. Cut 2 holes, 1 for each pipe, of appropriate size for pipe size
being used.
7. Loosely install elbow in bracket and place assembly on WARNING
combustion-air pipe.
8. Disassemble loose pipe fittings. Clean and cement using same Replace the burner compartment control access door.
procedures as used for system piping. Failure to replace the burner door can cause products of combustion
to be released into the conditioned area resulting in personal injury or
9- START UP, ADJUSTMENT AND SAFETY death.
1. Furnace must have a 120 V power supply properly connected 6. Turn on the furnace electrical power.
and grounded (NOTE: Proper polarity must be maintained for
7. Put thermostat to “Heat” mode and set the room thermostat at
120 V wiring. Control status indicator light flashes rapidly and
least 10°F above room temperature to light the main burners.
furnace does not operate if polarity is incorrect.)
8. After the burners are lit, set the room thermostat to a desired
2. If the modulating thermostat is used, thermostat wire
temperature.
connections at terminals R, W/W1, G, Y/Y2, etc. must be made
at 24 V terminal block on furnace control
9.2- Unit operation hazard
3. Natural gas service pressure must not exceed 0.38 psig (10.5
in. w.c.), but must be no less than 0.16 psig (4.5-in. w.c.). These furnaces are equipped with a manual reset limit switch in burner
Propane service pressure must not exceed 0.47 psig (13 in. assembly. This switch opens and shuts off power to the gas valve if an
w.c.) but must be no less than 0.40 psig (11 in. w.c.) overheat condition (flame rollout) occurs in burner assembly. Correct
inadequate combustion-air supply or improper venting condition before
4. Blower door must be in place to complete 120 V electrical circuit resetting switch. DO NOT jumper this switch.
to furnace.
Before operating furnace, check flame rollout manual reset switch for
EAC-1 terminal is energized whenever blower operates. continuity. If necessary, press the button to reset switch.
HUM terminal is only energized when blower is energized in heating.
9.3- Setup switches
9.1- To start the furnace The furnace control has setup switches that may be set to meet the
application requirements. To set these setup switches for the appropriate
9.1.1- Lighting instructions requirement:
This appliance is equipped with a hot surface ignition device. This device 9. Turn off electrical power.
lights the main burners each time the room thermostat calls for heat. See
the lighting instructions on the furnace. 10. Remove upper door.
During initial start-up, it is not unusual for odour or smoke to come out of 11. Locate setup switches on furnace control.
any room registers. To ensure proper ventilation, it is recommended to 12. Configure the set-up switches as necessary for the application.
open windows and doors before initial firing.
13. Replace upper door and turn on electrical power.
The furnace has negative pressure switches that are a safety during a call
for heat. The induced draft blower must pull a negative pressure on the These switches are ignored on communicating system (using the
heat exchanger to close the negative pressure switch. The induced draft Alizé and the communicating T-stat).
blower must maintain at least the negative pressure switch set point for
See Table 10 : DIP switch S1 - Air flow adjustment - DIP switch setting to
the furnace to operate. If the induced draft blower fails to close or maintain
Table 14 : DIP switch S5 – Dehumidification and 1st stage cooling for
the closing of the negative pressure switch, an error code would result.
more details.
25
Table 10 : DIP switch S1 - Air flow adjustment - DIP switch setting
FACTORY DEFAULT
26
Table 11 : DIP switch S3 - Cooling airflow select for non-communicating condenser
Table 12 : DIP switch S3 - Cooling/heat pump airflow adjustment for non-communicating system
Table 13 : DIP switch S4 - Heat rise – test mode – continuous fan selection
27
Table 14 : DIP switch S5 – Dehumidification and 1st stage cooling
CFM
Motor Hp S5-2 S5-1
S3-1 S3-2 Y1 Y1 + Y2
OFF OFF 1400 1800
OFF ON 1200 1600
OFF
ON OFF 1050 1400
1HP AND ON ON 900 1200
¾ HP OFF OFF 1080 1460
OFF ON 960 1280
ON
ON OFF 840 1120
ON ON 720 960
ON
OFF OFF 900 1200
OFF ON 750 1000
OFF
ON OFF 600 800
ON ON 450 600
½ HP
OFF OFF 720 960
OFF ON 600 800
ON
ON OFF 480 675
ON ON 360 480
OFF OFF
OFF ON
OFF
ON OFF
Please refer to the
ON ON CFM table in the
ALL OFF
OFF OFF annex at the end of
the manual
OFF ON
ON
ON OFF
ON ON
28
9.4- Fault code reset When flame is proven, the ignition control is de-energized - 8
second maximum trial times.
To clear the fault code memory, push and hold the Fault Recall Button for
The gas valve maintains 90% rate through the warm-up period -
more than 5 seconds and less than 10 seconds. The right-most Seven-
20 seconds (aka «Blower On Delay»).
Segment display will energize horizontal upper and lower segments for
four seconds. This will clear faults in the buffer displayed at power-up.
9.7.2- Heating cycle response
9.5- Diagnostic features MODULATING FUNCTION:
The control continuously monitors its own operation and the operation of (“W” and “V” signal inputs)
the system. If the failure is internal to the control, the light will stay on. In
this case, the entire control should be replaced, as the control is not field After the warm-up period, the furnace will respond to the thermostat
repairable. demand by adjusting the gas valve pressure and blower speed anywhere
between 40 % to 100 % heating capacity.
If the sensed failure is in the system (external to control), the dual 7
segment red LED will flash error codes. HEATING CYCLE TERMINATION:
9.7- Sequence of operation Checking furnace input is important to prevent over firing beyond its
design-rated input. NEVER SET INPUT ABOVE THAT SHOWN ON THE
RATING PLATE. Prior to checking the furnace input, make certain that all
9.7.1- Heating cycle initiation other gas appliances are shut off, with the exception of pilot burners. Time
The heating cycle is always initiated by a 24 volt signal on W of the the meter with only the furnace in operation. Start the furnace, in Furnace
thermostat. When the controller senses 24 volts on W or the Test Mode (see Table 13 : DIP switch S4 - Heat rise – test mode –
communicated message for heat call, the following sequence occurs: continuous fan selection), 100% rate, and measure the time required to
burn one cubic foot of gas.
High and low pressure switches are checked to insure contacts
The furnace is shipped from the factory with #48 orifices. They are sized
are open.
for natural gas having a heating value of 1075 BTU/cu. ft. and a specific
Inducer is powered on high speed for a thirty (30) second pre- gravity of .60.
purge.
Since heating values vary geographically, the manifold pressure may
Pre-Purge: need to be changed to adjust the furnace to its nameplate input. Consult
There are two different types of pre-purge; a normal pre-purge and a the local gas utility to obtain the yearly average heating value.
learning-sequence pre-purge. During a learning-sequence pre-purge, the
inducer motor will incrementally increase in RPM (stepping) until the low
and high pressure switches are both closed. After both switches are
10- THERMOSTAT
sensed to be closed, the inducer motor will continue to run for an additional
30 seconds before the ignition trial.
WARNING
A learning sequence pre-purge will be initiated under the following
conditions: Do not apply 24Vac to V/W2 at the furnace control (this is sometimes
First heat call after power reset. done during setup, troubleshooting and/or while diagnosing problems).
Doing so will damage the thermostat.
Every 25th heat call.
Next heat attempt after a failed pre-purge (pressure switch (es)
does not close). 10.1- Non-communicating modulating thermostats
Next heat attempt after a pressure switch has opened The furnace must be installed with the Modulating Touch-Screen
unexpectedly during normal heating operation. Thermostat R02P030 (#1F95M).
A normal pre-purge will not go through the incremental stepping process NOTE: Do not use 24 volt control wire smaller than No. 18 AWG.
of the inducer motor and should be much quicker. The inducer will start at
a pre-determined RPM (determined during learning-sequence pre-purge) Wire all non-communicating thermostats to the 24V connections on the
and this should close both pressure switches quickly. Once both pressure integrated furnace control. See Figure 11.
switches are sensed to be closed, the inducer will run for 25 seconds
before the ignition trial starts. NOTE: A larger wire gage may be required for longer lengths of
thermostat wire.
Hot-surface igniter is energized during the pre-purge period.
Operations with a non-communicating modulating thermostat are fully
The modulating gas valve is set to the highest possible rate (no modulating between 40% and 100% of furnace capacity. The firing rate is
flow yet). first determined by the thermostat and then sent to the furnace. This is the
The main solenoids on the gas valve are energized allowing gas optimum mode of operation and will give the best temperature control with
to flow to the burners. minimal temperature variation from the desired set point.
Figure 11: Wiring diagram for modulating heat (no dual fuel) (non-communicating)
Y2, G, C and R are the traditional thermostat inputs used in nearly all
10.2- 24 VAC thermostat (TSTAT) INPUT (J4 & J6) HVAC equipment. Installation of the thermostat to these connections is
straight- forward and simple.
These connections are used with any traditional 24 V AC modulating non-
communicating, thermostat specified for this modulating furnace. W1, Y1,
29
HUM STAT – This terminal is used to connect the output of a humidistat 10.4- 120 VAC terminals
to the furnace control to control humidification and/or dehumidification.
Optional equipment is required for these features. These terminals supply 120 VAC to the furnace control. Additionally, spare
terminals are provided for use with electronic air cleaners and other
V/W2 – This terminal is used to connect the modulating signal (V) from a accessories as needed (Check the voltage rating of your equipment.)
non-communicating, fully modulating thermostat specified for use with this
furnace. It is used to transmit the firing rate (determined by the thermostat)
to the furnace control. 10.5- Induced draft motor (inducer) control output (E8)
NOTE: Do not apply 24 VAC to the V/W2 terminal (as with a jumper to R This four-pin connector is white and provides control command to both the
for diagnostic purposes) with a non-communicating, modulating high and low speed inducer outputs.
thermostat.
Pin 1 to Inducer 12V
B - This terminal is used to pass a reversing valve signal to a condenser.
Pin 2 to Inducer Rx
It is only a holding place for connecting a wire from the thermostat and a
wire from the condenser. It does not change the airflow of the cool/heat Pin 3 to inducer GND
commands.
Pin 4 to inducer Tx
10.3- Fuse (F1)
10.6- Electronic air cleaner (E.A.C.) output (E-103)
A three-amp automotive-style (ATC blade type) fuse is supplied on the
furnace control board. This fuse should provide protection from short- This output is used to energize an electronic air cleaner. The output will
circuits on the control board and associated 24 VAC wiring. provide 1.0 amp at 120 VAC. This output is energized any time the blower
motor is above 40% of maximum airflow capacity. Airflow below this value
Any direct shorts during installation, service, or maintenance could cause is not considered to be enough for a typical electronic air cleaner to
this fuse to blow. If fuse replacement is required, use ONLY a 3 amp. It is perform properly.
located on the control board.
For ½ HP and ¾ HP motors – Electronic air cleaner is energized any time
the blower is above 320 CFM
For 1 HP motors - Electronic air cleaner is energized any time the blower
is above 800 CFM
30
Pin 7. PSO: PRESSURE SWITCH OUTPUT 10.10- Communications L.E.D.’s (Light emitting
Pin 8. MVC: MAIN VALVE COMMON diodes)
Pin 9. ILI: INDUCER LIMIT INPUT “RX” (Green) L.E.D. – This L.E.D. indicates that communications is
being sensed to or from (i.e.: something on the network is trying to
Pin 10. HLO: HIGH LIMIT OUTPUT communicate) other components (e.g. a condenser) on the network. This
L.E.D. will blink randomly any time a message is received by the furnace
Pin 11. TR: 24V RETURN
control. If no blinking is seen within five minutes, it can be assumed that
Pin 12. PS2: SECOND PRESSURE SWITCH OUTPUT there is not valid communications established. Check wiring to make sure
that all points are connected properly.
Pin 13. MVL: MAIN VALVE LOW
Further, if this L.E.D. is on continuously, it is an indication that mis-wiring
Pin 14. MVH: MAIN VALVE HIGH has occurred.
“STAT” (STATUS) (Red) L.E.D. – This L.E.D. blinks twice slowly (¼
Figure 12: 15-Pin connector; J1 with pin designations second ON, ¾ second OFF) upon power-up.
Pressing the learn button for two seconds will cause the green “RX” L.E.D.
to blink rapidly (for a short period) to indicate an attempt at
communications. If the L.E.D. does not blink, communications cannot be
established.
31
on the network should only be considered as a backup to the memory
WARNING card.
Do not replace the furnace control or memory card of the furnace with D. If valid furnace shared data is available from the network and
a furnace control or memory card of another furnace or another no memory card is present, a “d4” (MEM CARD INVALID) fault
component (e.g. a memory card from a condenser or air handler). The is displayed at the furnace seven-segment displays when in
wrong furnace control or memory card may specify parameters which standby mode only (see fault code table).
will make the furnace run at undesired conditions including (but not
limited to) reduced airflow during heating causing excessive undesired
operation of the main limit control. Further, the memory card is specific If furnace shared data from the memory card is not valid or is not present
to the model number and BTU input rating for a specific furnace and and shared data from network can be used, the appropriate fault (d4, d5,
this information should not be transported from one furnace (or d6, d7 or d8 – see fault codes in this manual) is displayed at the furnace
component) to another. seven-segment displays during standby mode only.
If memory card present:
The memory card is the default memory location to be used first when
there is any conflict. If the memory card has been replaced with a card Furnace shared data from the memory card (if valid) will be used to write
that has data for another furnace, the furnace will assume the identity of (or rewrite) the network furnace shared data and furnace shared data from
the “other” furnace. In all cases, the memory card has the final say about card will be used. If the data on that card is not valid:
the data to use. It is only when the memory card is not present, is corrupt
A. If furnace shared data on the memory card
or specifies a motor larger or smaller than what is found in the furnace that
the furnace control will use the data stored in the microprocessor (a mirror i. is corrupt or invalid (“d4”–MEM CARD INVALID”),
of the most recent memory card with blower size matching that found in
the furnace). The hierarchy of data to be used in the event of a lost card and/or
or conflict is listed in order of importance below.
ii. is for another component or different furnace series (“d5”–
If no memory card present: CARD-HARD CNFLCT),
A. Furnace shared data from the “network” is used. Furnace network and/or
shared data is defined as a redundant copy (or copies) of the
iii. does not match the horsepower of the attached motor (“d6”-
critical furnace shared data stored at various places and
BLWR HP CNFLCT),
components on the communicating network. The “network” can
be defined as follows: and/or
i. The “network” can be the furnace control itself if it was iv. does not support the motor manufacturer of the motor present
programmed at the factory and the memory card has been (“d7”-BLWR MFG CNFLCT),
removed for some reason.
and/or
ii. The “network” can be a furnace control which has had a
valid card previously (either attached or inserted) and v. is from an older furnace and is missing critical newer furnace
removed for some reason. shared data (“d8”-OLD SHARED DATA), furnace shared data
from the network (if valid) is used to control the furnace (see
iii. The “network” can be a furnace control attached to a description of “network” under “If no memory card present” (item
communicating condenser and/or thermostat which has i above). Furnace shared data on the network will not be written
copies of the furnace shared data that can be retrieved by or rewritten from the memory card. If the furnace shared data
the furnace control. on the network is valid, the appropriate fault for the memory card
will be displayed at the furnace seven-segment displays when
B. A furnace control sent as a replacement part will have no
in standby mode only
furnace shared data either in the microprocessor or on the
memory card. The replacement control does not include a valid B. If neither the furnace shared data on the memory card is valid
memory card. The furnace shared data can be added by: nor the furnace shared data on the network is valid, the fault
code status is elevated. The fault code d1 (NO VALID SHARED
i. Inserting a valid memory card (e.g. the original memory
DATA) is displayed at the furnace seven-segment displays
card sent with the original furnace control or a valid
provided a higher priority fault is not also present (in which case
replacement memory card)
the higher priority fault is displayed).
OR
C. If no furnace shared data is available on either the memory card
ii. By attaching the furnace control to a communicating or the network, the fault code “d1” (NO SHARED DATA) is
network (e.g. a condenser and thermostat) which was displayed at the furnace seven-segment displays.
previously connected to (and operating with) a valid
furnace control with valid furnace shared data. 10.12- Replacing the furnace control
Regardless, the memory card of a replacement control cannot be In the event that the furnace control must be replaced, the memory card
programmed or reprogrammed in the field with furnace shared data and must be detached from the original furnace control and retained with the
will always remain blank. In fact, this card does not even contain the furnace. Failure to save and connect the memory card properly to the
electronic components necessary to turn it into a valid memory card. replacement control may result in no operation or undesired operation of
C. In the event that the original memory card is lost, the original the furnace.
furnace control has been replaced and there is no furnace When replacing the furnace control, be sure to match the DIP switch
shared data on the network, the replacement memory card must settings of the original control on the replacement.
be ordered and installed into the connector at E117 to give the
furnace valid furnace shared data. The furnace will not operate NEVER USE A CONTROL BOARD TAKEN FROM ANOTHER
properly without the correct furnace shared data. When no FURNACE AS A REPLACEMENT CONTROL FOR THIS FURNACE.
furnace shared data is present (either at the memory card or on FURNACE CONTROLS TAKEN FROM OTHER FURNACES MAY
the network) a “d1” (NO SHARED DATA) fault code will be CONTAMINATE THE NETWORK WITH THE WRONG SHARED DATA
displayed at the furnace control (I.F.C.) seven-segment WHICH CAN ONLY BE FIXED BY REPLACING THE MEMORY CARD
displays. WITH THE ORIGINAL MEMORY CARD FROM YOUR FURNACE OR A
REPLACEMENT MEMORY CARD DESIGNED FOR YOUR FURNACE.
If the original memory card is lost, it should be replaced even if there is
valid furnace shared data on the network. The valid furnace shared data
32
10.13- DIP switch 16. Switch the 120 volt power to the furnace ON.
NOTE: The integrated furnace control does not recognize switch setting 17. Set the thermostat mode to HEAT; adjust the set point at least
changes while energized. 4°F above room temperature to demand a call for heating.
The Test Switches will place the IFC into a test mode, operating the Do not touch any electrical switch; do not use any phone in your
furnace at continuous input rates of either 100% of full rate (maximum fire) building
or 40% of full rate (minimum fire). This is accomplished by setting the Test
Leave the building immediately
Switches. See Table 13 : DIP switch S4 - Heat rise – test mode –
continuous fan selection. Immediately call your gas supplier. Follow the gas supplier’s
instructions.
To enter the Furnace Test Mode, proceed as follows:
14. Switch the 120 volt power to the furnace OFF. Do not change If you cannot reach the gas supplier, call the fire department.
settings with control energized.
For your safety, read the following before operating your furnace:
15. Position Test Switches for the desired test mode.
33
Move the gas control switch to “OFF” (see Figure 13).
1. The furnace area must be kept clear and free of combustible
materials, gasoline, and other flammable vapors and liquids. Figure 13: Control switch modulating valve
2. Insulating materials may be combustible. A furnace installed in
an attic or other insulated space must be kept free and clear of
insulating materials. Examine the furnace when it is installed and
also any time insulation is added.
3. For proper safe operation, the furnace needs air for combustion
and ventilation. Do not block or obstruct air openings to the area
in which the furnace is installed, and the spacing around the
furnace.
4. This furnace is equipped with an ignition device which
automatically lights the burners. See OPERATING YOUR
FURNACE for information on lighting and shutting down the
furnace.
5. Should the gas supply fail to shut off or if overheating occurs,
shut off the gas valve to the furnace before shutting off the
electrical supply. 6. Wait 5 minutes to clear out any gas, then smell for gas (including
at the bottom of the unit near the ground). If you smell gas, stop
6. Do not use the furnace if any part has been under water. A flood and follow the directions in WHAT TO DO IF YOU SMELL GAS.
damaged furnace is extremely dangerous. Attempts to use the If you don’t smell gas, continue to next step.
furnace can result in fire or explosion. A qualified service agency
should be contacted to inspect the furnace and to replace all gas 7. Move the gas control knob or switch to “ON”.
controls, control system parts, electrical parts that have been wet, 8. Replace the burner compartment access panel.
or the entire furnace if deemed necessary.
9. Turn on all electric power to the furnace.
7. Examine the furnace installation to determine that:
10. Set the thermostat to the desired setting.
a) All flue gas carrying areas external to the furnace, such as the
chimney and vent connector, are clear and free of obstructions. 11. If the furnace will not operate, follow the instructions found
below in to turn off Gas to Furnace and call your service
b) Vent connector is in place, slopes upward, and is physically technician or gas supplier.
sound without holes or excessive corrosion.
c) Return air duct connection(s) is physically sound, sealed to the 11.3- Shutting down the furnace
furnace casing, and terminates outside the space containing the
furnace. To shut down the furnace, set the thermostat to the “OFF” position.
8. It is important that you conduct a physical inspection of the 20. Remove the burner compartment access panel.
furnace at least twice a year. It is also recommended that the
21. Move the gas control knob or switch to “OFF” (see Figure 13).
furnace should be inspected by a qualified service agent at least
Do not force.
once per year.
34
can result if you are not qualified to do this work. Please call your It is important that the outside area where the vent terminates is kept clear
dealer when service is needed. of any obstructions which might block or impede the venting of the furnace.
Should venting become blocked at any time, your furnace is equipped with
Your gas furnace is designed to give many years of efficient, satisfactory a special safety control to prevent operation of the furnace until the
service. However, the varied air pollutants commonly found in most areas condition has been corrected. Contact your dealer if you desire more
can affect longevity and safety. Chemicals contained in everyday information about this important safety feature.
household items such as laundry detergents, cleaning sprays, hair sprays,
deodorizers, and other products which produce airborne residuals may NOTE: After any heavy snow, ice or frozen fog event the furnace vent
have an adverse effect upon the metals used to construct your appliance. pipes may become restricted. Always check the vent system and
The cabinet of the furnace can be cleaned with soap and water. Grease remove any snow or ice that may be obstructing the intake or
spots can be removed with a household cleaning agent. exhaust plastic pipes.
It is important that you conduct periodic physical inspections of your Should any unusual conditions be observed during your inspections, call
appliance, paying special attention to the gas burner and the flue outlet an authorized service dealer immediately.
from the furnace. These components are located at the front of the unit. A
flashlight will be useful for these inspections. Make one inspection prior to
the beginning of the heating season and another during the middle.
11.7- Return air
All return air duct connections must be tight and sealed to furnace cabinet
Should you observe unusual amounts of any of the following conditions, it
and all return air grilles or registers must be located outside the space
is important that you call your authorized dealer at once to obtain a
containing the furnace.
qualified service inspection:
Rust, flakes, or other deposits 11.8- Filter location
Coatings
The filter on your furnace will be located in one of two different locations:
Corrosion
On one side of the furnace
Even if no unusual rust or other conditions are observed, it is
recommended that the furnace be inspected and serviced at least once On the bottom of the furnace
per year by a qualified service technician. Regular inspections and
planned maintenance will assure many years of economic performance 11.8.1- Cleaning/replacing the filter
from your gas furnace.
It is very important to clean or replace the air filter regularly.
11.6- Combustion and ventilation air Dirty filters are the most common cause of inadequate heating or cooling
performance and can sharply increase the operational costs of your unit.
Adequate air supply in single pipe application must be provided to In some cases, they can double the cost. The air filter should be
furnaces located in a closet, alcove, or utility room by means of a grilles in inspected at least every 6 weeks and cleaned or replaced as required.
the lower part of the door, or by the introduction of outside air, or both, in
accordance with the National Fuel Gas Code, ANSI Z223.1/ NFPA 54 Your furnace may use either a disposable filter or a cleanable filter. The
(latest edition) or the CSA B149.1, Natural Gas and Propane Installation type of filter may be indicated on a label attached to the filter. If a
Codes, and local codes. disposable filter is used, replace with the same type and size. To remove
excess dirt from a cleanable filter, shake filter and/or use a vacuum
Adequate combustion and ventilation air must reach the furnace to provide cleaner. Wash filter in soap or detergent water and replace after filter is
for proper and safe operation. Air openings in front of furnace must be dry.
kept free of obstructions. Any obstruction may cause improper operation
that can result in a fire hazard or carbon monoxide injury. Cleanable filters do not need to be oiled after washing. Cleanable filters
may be replaced with disposable filters.
Venting of this furnace must comply with the unit Installation Instructions.
Be sure the installer has followed these requirements. If not, you should
request the installer to comply. 11.9- Lubrication
For your safety, please note the following: Lubrication of the bearings in the circulating air blower motor and the
combustion blower motor is not recommended. These motor are
1. Condensing furnaces must not be vented with any other permanently lubricated.
appliance. The flue (vent) system is under positive pressure
from the power venter. Connection of any other appliance to the
furnace flue may create a hazardous condition that could cause
either appliance to malfunction. 11.10- Burner flame
2. This furnace is not designed for use with a vent damper. Use of While the furnace is in operation, observe the burner flames. Compare
such a device will not improve the efficiency of this furnace. The these observations to Figure 14 to determine if proper flame adjustment
vent from your furnace may rise vertically and terminate above is present. If your observations indicate improper flame adjustment, call
the roof. The vent may also be run horizontally through an your authorized service dealer for service. Do not attempt to adjust
exterior wall. Make sure all flue product materials external to the flame! Your service representative will perform this adjustment correctly.
furnace are clear and free of any obstruction, slope upward, and
have no holes or leaks. For proper venting terminations, see
Figure 9. If this furnace is a direct vent (2 pipe) installation, it
requires that all the air necessary for combustion be supplied
from outside the dwelling through an air intake pipe. You should
inspect the air intake and flue product carrying areas external to
the furnace to determine they are clear and free of obstructions.
You should also check to see that the vent air intake system is
in place, physically sound, sealed to the furnace casing, and
terminating outside the space containing the furnace.
Check to see that the furnace cabinet is sound and firmly supported,
without sagging. There should be no cracks or gaps between the furnace
and the base or floor, which would permit entry of unfiltered air.
35
Figure 14 : Typical flame appearance 11.16.1- Clearing diagnostic fault codes from the buffer
To clear the fault codes in the fault buffer, push and hold down the “Fault
Recall” button for 3 seconds. When this is done, the right-most seven-
segment display will energize the upper and lower horizontal segments for
four seconds as confirmation that the fault codes have been cleared from
the buffer. Be sure to return the switch to the original position after clearing
the faults.
36
11.17- Active fault codes When using communicating thermostat (with the Alize system), active
faults of either level will be displayed at the thermostat in the “ACTIVE
Two levels of fault codes exist: (1) Non- critical and (2) Critical. In general FAULT” area. To enter the furnace “ACTIVE FAULT” area using a
a non-critical fault permits all (or nearly all) operations to proceed and a communication thermostat, see the installation and operation instruction
critical fault prevents all (or nearly all) operations from proceeding. provided with the thermostat.
NOTE: The text in the box shows combinations of upper-case and lower-case letters.
DISPLAYED TEXT
CODE AT DUAL 7-SEGMENT DISPLAY OF IFC& FAULT
AREA OF COMM. THERMOSTAT
STATUS
FAULT
CODE DESCRIPTION
EXPECTED OPERATION
CAUSE
SOLUTION
37
Table 18 : D1 - No shared data
38
Table 19 : D4 - Memory card
39
Table 21 : D6 - Blower horsepower conflict
40
Table 23 : D8 - old shared data
41
Table 24 : h – NO V
42
Table 26 : 11 - Failed ignition
The solutions depend on the cause. Solutions to noted causes (1) to (5) above are:
27. Clean or replace the flame sense rod or check all connections and wire between the rod and the
furnace control (or I.F.C.) Make sure furnace ground is properly connected.
28. Turn the valve on.
Solution : 29. Replace or reposition the igniter or check all connections and wire between the igniter and the
furnace control (or I.F.C.).
30. Replace the furnace control.
31. Check the manifold pressure during ignition. For natural gas it should be approx. 3.5” W.C. and for
LP gas it should be 11” W.C. If manifold pressure is good, watch the burner during ignition. If the
first burner lights, but the second, third and so on do not light, the burner may need to be replaced.
43
Table 27 : 12 - Low flame sense
32. The most common cause for low flames sense during heat operation is that the flame sense rod
may need cleaning or may not be properly connected or wiring between the rod and the furnace
Cause : control may be shorted or opened.
33. Another cause for low flame may be an improperly mounted or poorly grounded flame sensor.
34. Clean or replace the flame sense rod or check all connections and wire between the rod and the
furnace control (or I.F.C.).
Solution :
35. Reinstall or replace flame sensor and check wiring and connections. Also make sure the furnace is
properly grounded.
44
Table 28 : 13 - Flame lost
36. The most common cause for low flame sense during heat operation is that the flame sense rod
may need cleaning or may not be properly connected or wiring between the rod and the furnace
control may be shorted or opened.
Cause :
37. Another cause for low flame may be an improperly mounted or poorly grounded flame sensor.
38. Flame pattern may be unsafe.
39. Clean or replace the flame sense rod or check all connections and wire between the rod and the
furnace control (or I.F.C.).
40. Reinstall or replace flame sensor and check wiring and connections. Also make sure the furnace is
Solution : properly grounded.
41. Check that all burner assembly components are properly installed. Check for good seals between
the burner and blower compartments. Insure that the combustion door gasket is in place and the
door is properly installed and sealed.
45
Table 29 : 16 - Igniter fail
46
Table 31 : 22 - Main limit open
52. Check for proper blower operation. Is the blower turning during heat (or any other) mode? If not, a
blower motor fault should also be present. Check the wiring to the motor then check the motor. It
may need replacing.
53. Check ductwork and filters. Determine the static pressure and make sure it is not above the
published values for the furnace. Check the rate and outlet air temperature at high and low-fire
heat (use the test mode DIP switches SW2-2 and SW2-3) and compare to the nameplate
Solution : maximum values.
54. Replace the limit control.
55. Check wiring and connections. Replace and/or repair as necessary.
56. Insure properly sized burner orifices are installed. Check the manifold pressure at high fire and
compare to the nameplate values. Adjust as needed.
57. Line and neutral to the furnace have been interchanged at the furnace.
Cause :
58. Line voltage and neutral have been interchanged at the disconnect or at the breaker box.
59. Check voltage with meter and reverse line and neutral if necessary.
Solution :
60. Check voltage with meter and reverse line and neutral if necessary.
47
Table 33 : 33 - MRLC (Manually Reset Limit Control) OPEN
64. Check that the pressure switch (es) have not been welded closed or bypassed. Check that the
inducer is operating at the proper rpm. Ensure that the venting does not exceed the maximum
specified lengths. Check for obstructions in combustion venting. Check that all gaskets between
the inducer and center panel/heat exchanger are properly installed and sealed.
Solution : 65. Check wiring and connections. Replace and/or repair as necessary.
66. Check that all burner assembly components are properly installed. Check that all seals between
the burner and blower compartments are tight. Ensure that the door seals are in place and that the
burner door is properly installed and does not leak. Check to make sure that the heat exchanger
has not been damaged; i.e.: crushed tubes, breached collector box and etc.
48
Table 34 : 44 - LPC (low pressure control (switch)) Closed
49
Table 35 : 46 - LPC (low pressure control (switch)) Open
75. DISPLAYED BEFORE HEAT IS ESTABLISHED: The IBM (Indoor Blower Motor) will not be
energized. The fault code will not be displayed until the IDM (Induced Draft Motor) has been
energized for a minimum five minutes after the beginning of the pre-purge attempt. After five minutes,
the IDM is de-energized and second pressure switch closes or the heat call is lost.
Expected operation 76. DISPLAYED AFTER HEAT IS ESTABLISHED: If this fault is displayed after heat is established, the
gas valve will be de-energized, the IBM will be energized (if not already energized) at the correct
heat speed (determined by the firing rate required by the thermostat) and the IDM will remain
energized at high speed. The IBM will complete a 90 second blower off-delay and the IDM will
complete a 20 second post-purge (at high speed). After these delays, a new attempt at ignition will
be made provided the call for heat is still present.
85. Check the vent system for blockage and proper termination and repair as necessary.
86. Check the specification sheets and/or installation instructions. Remove excess venting.
87. Repair or replace inducer and/or inducer wiring and/or electrical connections.
88. Replace control board.
Solution :
89. Check wiring and connections. Replace and/or repair as necessary.
90. Replace hoses as necessary.
91. Insure proper termination.
92. Replace the pressure switch.
50
Table 36 : 55 - HPC (High Pressure Control (switch)) CLOSED
51
Table 37 : 57 - HPC (High Pressure Control (switch)) OPEN
101. DISPLAYED BEFORE HEAT IS ESTABLISHED: The IBM (Indoor Blower Motor) will not be
energized. The fault code will not be displayed until the IDM (Induced Draft Motor) has been
energized for a minimum of ten seconds. The IDM will remain energized at the high speed (high
speed is default pre-purge speed) for a period of five minutes after the beginning of the pre-purge
attempt. After five minutes, the IDM is de-energized and second attempt at pre-purge is made (as
long as the heat call is still present). This cycle is repeated indefinitely until either the pressure switch
closes or the heat call is lost.
Expected operation 102. DISPLAYED AFTER HEAT IS ESTABLISHED: if this fault is displayed after heat is established, the
IDM will remain energized at high speed and the firing rate will drop to low (40%) provided the low
pressure switch remains closed. The IBM will energize at, or switch to, the low-fire rate (also provided
the low pressure switch remains closed). Low heat is provided until the heat call ends or the high
pressure switch closes. If the high pressure switch closes, the heat rate and blower speed will be
adjusted to the correct (higher) rate required by the thermostat and the IDM will remain energized at
high speed. If the low pressure switch also will not remain closed, operation will be as described
under fault code # 46 (“LPC OPEN”) above.
111. Check the vent system for blockage and proper termination and repair as necessary.
112. Check the specification sheets and/or installation instructions. Remove excess venting.
113. Repair or replace inducer and/or inducer wiring and/or electrical connections.
114. Replace control board.
Solution :
115. Check wiring and connections. Replace and/or repair as necessary.
116. Replace hoses as necessary.
117. Insure proper termination.
118. Replace the pressure switch.
52
Table 38 : 60 - Blower fault - running
119. The motor has tripped on thermal limit because of a restriction or bearing failure.
120. The motor Power Factor Correction (P.F.C.) choke is faulty and needs replacing.
Cause : 121. The furnace shared data is faulty or corrupted.
122. Wiring to the motor and/or P.F.C. has become compromised.
123. The motor has failed catastrophically.
53
Table 40 : 66 - Blower overspeed
129. The wires between the blower motor have been disconnected or there is a poor connection.
130. There is no line voltage to the motor.
Cause :
131. The furnace shared data is faulty or corrupted.
132. The motor has failed catastrophically.
54
Table 42 : 71 - No inducer communications
137. The wires, connectors or terminals between the furnace control (or I.F.C.) have become
disconnected or there is a poor connection.
Cause :
138. The gas valve is faulty.
139. The furnace control is faulty.
140. Check the wires, connectors or terminals between the gas valve and furnace control (or I.F.C.).
Replace or repair as necessary.
Solution :
141. Replace the gas valve.
142. Replace the furnace control.
55
Table 44 : 93 - Control fault
143. 24VAC or similar voltage applied to the main gas valve solenoid circuit unexpectedly.
Cause :
144. Furnace control software test failure – failed furnace control (or I.F.C.).
56
Figure 15: Exploded View 1 Chinook Compact
57
Figure 16: Exploded View 2 Chinook Compact
58
Table 45: Parts List - Chinook Compact
# Item Description
1 B40715 Floor
2 B40794 Bottom left panel assembly
3 B40793 Top left panel assembly
4 B40791 Rear panel assembly
5 B40778 Exchanger assembly
6 B40714 Smoke box
7 B40572 Turbulator primary tube
8 B40720 Right exchanger deflector
9 R02N029 Thermodisc 125deg
10 B40702-01 Condensation box
11 G07J006 Elbow 1/2 HDPE
12 L01F009 Transformator 120/24
13 L07H001 Door switch
14 B03141-02 Inductor
15 B40788 Separator assembly
16 B40713 Separator
17 B40746 Blower slide
18 B40721 Left exchanger buffle
19 B40790 Top panel assembly
20 B40779 Blower restrictor
21 B40802 Evacuator assembly
22 Z01K005 Evacuator
23 G99Z033 Hose clamp 2-3"
24 B40580 Sleeve with drain
25 G07J006 Elbow 1/2 HDPE
26 G99Z034 Spring attache 16mm
27 B40747 Gas pipe assembly
28 R03J004 Flame sensor
29 R03K005 Lighter 24V
30 R02N022 Roll out limit switch 250F
31 B40703 Gas pipe
32 B40792 Right panel assembly
33 B30157-44 Hose 5/8
34 B30157-40 Hose 3/16
35 B30157-38 Hose 1/2
36 B40803 Bag components
37 G14F017 Grommet Kennard 1020T
38 B40535 Drain trap
39 B40568 Drain trap gasket
40 B40811 Drain trap gasket (2)
41 B40810 Drain trap (2)
42 B40573-01 Pipe PVC
43 B40567 Pipe flange gasket
44 B40533 Wall pipe flange
45 B40795-01 Front panel assembly
46 L04Z022 Clear plug #HEYCO 1299
47 R01K005 Gas valve
48 B40582-01 Electrical kit gas valve/card
49 B40675-33 Pressure detection assembly
50 B40560 Pressure switch support
51 R99F041 Pressure switch (0.9)
59
52 R99F050 Pressure switch (0.35)
53 R99F035 Pressure switch (0.2)
54 B40799 Electrical box assembly
55 R99G017 Modulating inducer fan interface board
56 B40731 Electrical box support
57 R99G014 Ignition board 24v modulating
58 B40588-02 Main harness electrical kit
59 B40634-13 Memory card programmed
60 B40586-01 Electrical kit lighter/card
61 B40585-02 Electrical kit drive/blower evacuation
62 B40798 Plastic door assembly
63 B40565 Clear plug Dettson #Heyco 1299
64 B40800 Blower assembly
65 Z01I041 Blower 90-4T
66 B40801-01 Motor, support assembly 1/3 hp
67 L06G020 Motor ECM 3.0 1/3hp
68 Z01I042 Motor bracket
69 Z01F012 Motor flange
70 B40581-03 Electrical blower kit
71 B40587-01 Electrical blower kit
72 B04435-01 Extruded gasket kit
60