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ICP Confidential Not for further publication Condensing Furnace Distributor Technical Training 1.

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Presentation on theme: "ICP Confidential Not for further publication Condensing Furnace Distributor Technical Training 1."— Presentation transcript:

1 ICP Confidential Not for further publication Condensing Furnace Distributor Technical Training 1

2 ICP Confidential Not for further publication 2 Model Nomenclature System

3 ICP Confidential Not for further publication Model Nomenclature System 3

4 ICP Confidential Not for further publication Agenda Product Line Overview New Features Installation Adjustment Servicing 4

5 ICP Confidential Not for further publication Overview 95.5 AFUE 4-way multipoise –100 & 120 size –140 size limited to Upflow & Horizontal Aluminized steel primary and stainless steel secondary heat exchangers Direct Vent or Non-Direct Venting 5

6 ICP Confidential Not for further publication New Features Lower height, now 35” Standard widths –21” for 100 and 120 sizes –24 ½” for 140 sizes Through-the-top venting Multiple venting options Internal Condensate system 6

7 ICP Confidential Not for further publication New Features Slide out blowers Ease of access for control board Two outer doors Easy door attachments –No sharp edges –Quarter-turn knobs and latches 7

8 ICP Confidential Not for further publication New Features Redesigned primary heat exchanger –More compact –No eyelets Updated tube-and-fin secondary –Better efficiency –Eliminated U-bend –Easier to service with slide-out rails 8

9 ICP Confidential Not for further publication New Technologies True installation flexibility –Venting flexibility Vent pipes can exit cabinet in three different directions –Low-profile horizontal drain trap position Easy to re-position the drain trap Fewer tubes to connect Drain trap and tubes removed from the blower compartment 9

10 ICP Confidential Not for further publication Casing 10

11 ICP Confidential Not for further publication Casing 11

12 ICP Confidential Not for further publication Casing 12

13 ICP Confidential Not for further publication Casing Combustion Air Opening Gas Entry Horizontal Drain Trap Opening Vent or Combustion Air Opening Condensate Drain K.O. J Box K.O. Return Air Opening 35” Combustion Air Opening Gas Entry Vent or Combustion Air Opening Horizontal Drain Trap Opening Condensate Drain K.O. J Box K.O. Return Air Opening 13

14 ICP Confidential Not for further publication Outer Door Assembly Two piece door design ¼ turn door knob attachment Doors are gasketed –Eliminates door rattling and leakage –Vestibule is sealed Door does NOT change with furnace orientation –Logo rotates for upflow and downflow positions 14

15 ICP Confidential Not for further publication Outer Door Assembly Vestibule functions as the burner compartment –Combustion air piped directly to the vestibule –Multiple locations to connect combustion air pipe Sealed burner box is not required Simplifies set-up 15

16 ICP Confidential Not for further publication Upflow Return Air Connections 16

17 ICP Confidential Not for further publication Downflow Return Air Connections 17

18 ICP Confidential Not for further publication Horizontal Return Air Connections 18

19 ICP Confidential Not for further publication Upflow Venting 19

20 ICP Confidential Not for further publication 100,000 BTUH & 120,000 BTUH Downflow Venting 20

21 ICP Confidential Not for further publication Horizontal Left Venting 21

22 ICP Confidential Not for further publication Horizontal Right Venting 22

23 ICP Confidential Not for further publication Direct Vent –Concentric Vent –Field-fabricated 2-pipe Ventilated Combustion Air –Vent to outdoors –Combustion air from attic or crawlspace Single Pipe –Uses indoor air for combustion Terminations 23

24 ICP Confidential Not for further publication Ventilated Combustion Air Option The combustion air pipe for the Ventilated Combustion Air Option cannot be terminated in attics or crawlspaces that use ventilation fans designed to operate during the heating season. If ventilation fans are present in these areas, the combustion air pipe must terminate outdoors as a Direct Vent / 2-Pipe system. 24

25 ICP Confidential Not for further publication Indoor Air For Combustion Option Use a (minimum) 12-inch piece of PVC –Maximum of 5 feet Tight radius elbow –Face away for better sound control Secure pipe to adapter –Pilot drill 1/8” hole –Install sheet metal screw –Seal with silicone 12” (min) 25

26 ICP Confidential Not for further publication Alternate Indoor Air For Combustion Connection 12” (min) 26

27 ICP Confidential Not for further publication Supply Air Flanges Flanges shipped flat –If flanges are not bent, nuisance limit trips could occur Bend flanges UP for upflow or horizontal coil installations Remove or bend flanges DOWN for downflow coil installations –No downflow for 140,000 input Supply opening match current coil opening sizes 27

28 ICP Confidential Not for further publication Supply Air Flanges 28

29 ICP Confidential Not for further publication Return Air Connections Upflow –Either Side –Bottom –Any combination of Sides and Bottom Downflow (100,000 BTUH & 120,000 BTUH) –Bottom only (“bottom” as referenced to furnace in upflow position) Horizontal –Bottom –Side (side facing down only) Airflow above 1800 cfm may require both side/bottom return or bottom only return Remove closure panel for bottom return air 29

30 ICP Confidential Not for further publication Return Air Connections 30

31 ICP Confidential Not for further publication Gas Piping Gas pipe can enter from either side Remove K/O on either side gas entry Install grommet in casing Flex lines must connect outside of the casing per the NFGC Sediment trap required per NFGC 31

32 ICP Confidential Not for further publication Optional Right Side Gas Entry No special fittings for left side entry Valve inlet is ½” NPT Install Street Ell, 2” nipple and 90º elbow together Install Street Ell into gas valve Remove K/O from casing Install gas pipe grommet in casing –(Required For Direct Vent) Install gas line into elbow Tighten gas line Use backup wrench on gas valve! 32

33 ICP Confidential Not for further publication J-Box Installation J-box bracket and cover shipped in loose parts bag J-box can be relocated to opposite side Other electrical knock-outs are available 33

34 ICP Confidential Not for further publication J-Box Installation Remove 7/8” knockout in casing Install J-box bracket Attach ground wire to green ground screw Install cover after all other connections are made Other electrical knock- outs are available 34

35 ICP Confidential Not for further publication Typical Disconnect At Furnace Power Cord Installation in Furnace J-Box (Where permitted) NOTE: Power cords must be able to handle the electrical requirements listed in Table 6. Refer to power cord manufacturer’s listings. 1.Remove 7/8” K.O. in casing. 2.Attach J box bracket to casing. 3. Route listed power cord through 7/8--in. (22 mm) diameter hole in casing. 4.Attach power cord to J--Box bracket with a strain relief bushing or a connector approved for the type of cord used. 5. Attach field ground wire to green ground screw on J-Box bracket. 6. Connect line voltage leads as shown in wiring diagram 7. Install cover to J--Box. Do not pinch wires between cover and bracket. 35

36 ICP Confidential Not for further publication Upflow 36

37 ICP Confidential Not for further publication Downflow - Trap Unconverted PSC Inducer Models 37

38 ICP Confidential Not for further publication Downflow - Trap Converted PSC Inducer Models 38 Route tube through Switch Tube to Port On Collector Box To 15 ib-in

39 ICP Confidential Not for further publication Horizontal Left - Trap Unconverted PSC Inducer Models 39

40 ICP Confidential Not for further publication Horizontal Left - Trap Converted PSC Inducer Models 40 Route Pressure Switch

41 ICP Confidential Not for further publication Horizontal Right - Trap Unconverted PSC Inducer Models 41

42 ICP Confidential Not for further publication Horizontal Right - Trap Converted PSC Inducer Models 42

43 ICP Confidential Not for further publication Horizontal Trap Grommet Required accessory for Direct Vent applications (only) Maintains a sealed vestibule 43

44 ICP Confidential Not for further publication Repositioning Vent Elbow Loosen the Vent Elbow Clamp. Remove the Vent Elbow. Re-install in the desired position. Torque clamp 15 lb-in. 44

45 ICP Confidential Not for further publication Condensate Trap and Drain Elbow Clear trap –Shown for clarity Production Trap –White, Opaque front/Clear back 45

46 ICP Confidential Not for further publication Condensate Trap Expanded View Outlet Relief Port Inlets Front View Back View Mounting Screw Hole 46

47 ICP Confidential Not for further publication Right Side Drain Production trap will be opaque front/clear back Connect field supplied CPVC fittings to drain tube Clamp may be located inside casing Connect condensate drain to code approved drain or condensate pump approved for furnace condensate 47

48 ICP Confidential Not for further publication Right Side Drain 48

49 ICP Confidential Not for further publication Left Side Drain Cut the tube as shown Install formed end of grommet in the left side of the casing Connect the elbow to the short end of Z pipe Slide clamps on elbow and pipe Route Z pipe behind inducer The inducer can be removed if necessary to install the Z pipe 49

50 ICP Confidential Not for further publication 50 Left Side Drain

51 ICP Confidential Not for further publication Left Side Drain 51

52 ICP Confidential Not for further publication Vent Sizing New tables based on Maximum Equivalent length –Starts with a maximum length –Deduct for type of fitting used –No restriction on number of elbows Diameters up to 4 inches on larger sizes Expanded exposed vent pipe tables –Winter design down to -40 deg. F (C) –½ inch insulation added Closed cell Armaflex type 52

53 ICP Confidential Not for further publication Maximum Equivalent Length Table 53

54 ICP Confidential Not for further publication Deductions Table and Example 54

55 ICP Confidential Not for further publication Vent Table Notes 1. Use only the vent pipe sizes shown for each furnace. It is NOT necessary to choose the smallest diameter pipe possible for venting. 2. NA – Not allowed. Pressure switch will not close, or flame disturbance may result. 3. Size both the combustion air and vent pipe independently, then use the larger size for both pipes. 4. Assume the two 45_ elbows equal one 90_ elbow. Wide radius elbows are desirable and may be required in some cases. 5. Elbow and pipe sections within the furnace casing and at the vent termination should not be included in vent length or elbow count. 6. The minimum pipe length is 5 ft. (2 M) linear feet (meters) for all applications. 7. Use 3–in. (76 m) diameter vent termination kit for installations requiring 4–in. (102 mm) diameter pipe. 55

56 ICP Confidential Not for further publication Sizing The Vent Pipe 56

57 ICP Confidential Not for further publication Sizing The Vent Pipe 57 DRAFT COPY - ICP CONFIDENTIAL

58 ICP Confidential Not for further publication Vent Pipe Support Helps support vent pipe Notches in coupling slide over buttresses on adapter Adds to unit serviceability –Provides an optional disconnect point 58

59 ICP Confidential Not for further publication Combustion Air Adapter Attach to K.O. on casing –Any unused top or side K.O. may be used Connect 2” combustion air pipe to casing Gluing is not recommended –Pilot drill 1/8” hole and secure with ½” #7 sheet metal screw –Seal with silicone 59

60 ICP Confidential Not for further publication Comparing the Two Adapters (Both fit 2” PVC pipe) Combustion Air Pipe Adapter Vent Pipe Support 2 3/8” 2” 60 Internal pipe stop No pipe stop

61 ICP Confidential Not for further publication Vent Coupling & Adapter Coupling is notched Provides for proper orientation of coupling Notches slide over buttresses on adapter 61

62 ICP Confidential Not for further publication Vent Pipe Coupling & Combustion Air Pipe Adapter 62 Gaskets

63 ICP Confidential Not for further publication Continuous Vent Pipe Vent pipe Inserts through coupling to vent elbow Vent coupling w/clamps Slides over adapter Vent coupling adapter Attaches to furnace casing Vent pipe Passes through adapter Inserts into Vent Elbow 360° Vent Elbow Connects to vent pipe 63

64 ICP Confidential Not for further publication Flush Mount Vent Pipe Vent pipe Inserts ½ way into coupling Vent coupling w/clamps Slides over adapter Vent coupling adapter Attaches to furnace casing Vent pipe from inducer Passes through adapter Inserts ½ way into coupling 360° Vent coupling Vent pipe connects to coupling 64

65 ICP Confidential Not for further publication Measure the vent pipe –Insert pipe through K.O and adapter w/gasket installed –Insert pipe into vent elbow Slide adapter down on furnace casing –Mark the pipe at the top of the adapter Remove pipe from vent elbow –Cut pipe square Flush Mount Vent Pipe 65

66 ICP Confidential Not for further publication Optional Flush Mount Vent Pipe Clean and prime vent pipe Pipe is inserted in vent elbow –Clean and prime pipe Adapter with gasket is glued to vent pipe –Insert vent pipe into vent elbow –Apply cement to pipe and adapter –Slide adapter over vent pipe If pipe is not glued to the adapter, the pipe will leak water! 66

67 ICP Confidential Not for further publication Attach vent pipe adapter to furnace casing with screws Install vent coupling –Align notches in vent coupling over stand-offs on vent pipe adapter –Push down to seat coupling Seat coupling on adapter Torque clamp 15 lb-in. Optional Flush Mount Vent Pipe 67

68 ICP Confidential Not for further publication Insert remaining vent pipe into coupling Torque clamp on coupling 15 lb-in. Torque clamp on vent elbow 15 lb-in. Optional Flush Mount Vent Pipe 68

69 ICP Confidential Not for further publication Vent Through Casing Side Install adapter/gasket Install coupling- –Align notched and fully seat on vent pipe adapter Attach remaining vent pipe Torque all clamps 15 lb-in. 69

70 ICP Confidential Not for further publication Requires a (minimum) 12-inch pipe w/tight radius elbow Pipe can be attached to any un-used 2-inch K.O. Orient elbow or pipe away from front –No combustion air disk required –Can be screened using ½” metal or plastic screening Combustion Air Pipe (Non-Direct Vent) 12” 70

71 ICP Confidential Not for further publication Single-Stage and Two-Stage PSC Inducer Assembly 360°Inducer outlet coupling PSC inducer motor Capacitor 71

72 ICP Confidential Not for further publication Single- and Two-Stage Inducer Assemblies Three unique sizes for each –PSC ball bearing motor –Provides optimum performance Adjustable vent coupling –Adjusts to 4 positions –Loosen the clamp, rotate the coupling, re-tighten the clamp Integral condensate drainage –No external hoses required Service replacement will be fully assembled 72

73 ICP Confidential Not for further publication Key Features Inducer Assembly Drain outlets with gaskets Mounting tabs Inlet gasket Flue gas inlet 73

74 ICP Confidential Not for further publication PSC Inducer Inlet Choke Factory Installed 74 Inlet Choke Plate (when used)

75 ICP Confidential Not for further publication Integrated Inducer Vent/Drain Flue gases exit through the inner opening The larger opening channels condensate from the vent through the inducer and out the drain openings in the back of the inducer. 75

76 ICP Confidential Not for further publication Vent Condensate Drainage 76 Flue gases exit through the inner opening The larger opening channels condensate from the vent through the inducer and out the drain openings in the back of the inducer. DRAFT COPY - ICP CONFIDENTIAL

77 ICP Confidential Not for further publication Collector Box-Front View Inducer drain openings Inducer attachment points w/brass inserts (red circles) Condensate trap gasket Condensate trap openings for upflow and horizontal right Condensate trap openings for downflow and horizontal left Pressure Switch/Relief port Outlet to inducer Pressure Switch/Relief port 77

78 ICP Confidential Not for further publication Single Stage Pressure Switches Single stage furnaces have 2 pressure switches –Housing Pressure Switch (HPS) Tapped into Inducer Housing Connects electrically to the CPU of the furnace control board –Collector Box Pressure Switch (LPS) Tapped into Collector Box Connects electrically to GVR via furnace control board The HPS has a lower set point than the LPS –HPS functions as a blocked vent switch –LPS functions as a blocked drain switch

79 ICP Confidential Not for further publication Single Stage Pressure Switches

80 ICP Confidential Not for further publication Single Stage Wiring Diagram Refer to the legend HPS –Inducer Housing Pressure Switch, SPST (N.O.) LPS –Collector Box Pressure Switch, SPST (N.O.)

81 ICP Confidential Not for further publication Single Stage Pressure Switches

82 ICP Confidential Not for further publication Pressure Switch Settings Single Stage Pressure Switches Input Part Number Collector Box Pressure SwitchHousing Pressure Switch Max Make-IWCNom Break-IWCMax Make-IWCNom Break-IWC 100 & 120 HK06NB030 0.450.30 +/- 0.050.450.30 +/- 0.05 140 HK06NB0310.450.30 +/- 0.050.600.45 +/- 0.05

83 ICP Confidential Not for further publication Heat Exchanger Assembly Front View 83

84 ICP Confidential Not for further publication Heat Exchanger Assembly Rear View 84 DRAFT COPY - ICP CONFIDENTIAL

85 ICP Confidential Not for further publication Primary Assembly 85 Completely redesigned heat exchanger Compact multi-pass design Aluminized Service replacement sold fully assembled to the Primary Cell Inlet Plate

86 ICP Confidential Not for further publication Condensing Heat Exchanger Fin and tube type design Stainless steel tubes Aluminum fins Tubes are straight through Turbulators are “locked” in each tube 86

87 ICP Confidential Not for further publication Burners, HSI and Flame Sensor One piece burner design for each size Burners are “ganged” together Eliminates burner misalignment –Note igniter and flame sensor locations Igniter mounts from the top of the burner assembly Flame sensor mounts through tab on burner Flame sensor is positioned underneath burner –Igniter resistance at room temp 40 to 70 ohms –Flame sensing current 4 to 6 micro amps DC 87

88 ICP Confidential Not for further publication Manifold Assembly Features (Top plate removed for clarity) Manifold is the same type for all families Four screws attach manifold here 88

89 ICP Confidential Not for further publication Burner Assembly Igniter resistance is 40 to 70 ohms @ room temperature and is stable over the life of the igniter 89

90 ICP Confidential Not for further publication Burner Assembly 90

91 ICP Confidential Not for further publication Single-Stage Gas Valve - Features 91

92 ICP Confidential Not for further publication Blower Assemblies Improved blower rails Forward-facing mounting screws Longer main harness (not shown) –Blower can be removed without harness removal Forward-facing control board 92 Mounting Screw Locations

93 ICP Confidential Not for further publication Torsion-Flex Blower Motors Mounting arms attached to motor Isolated with rubber grommets 93

94 ICP Confidential Not for further publication Typical Blower Assembly (Expanded) 94

95 ICP Confidential Not for further publication There are 2 sets of holes in the blower so if one set gets stripped, the whole motor can be rotated to the other set of holes. For example: One or more of the screws were stripped in the blower marked with a blue circle. Remove all 4 mounting screws, rotate the motor to the holes with the arrows and re-install the screws. Motor Mounting Holes 95

96 ICP Confidential Not for further publication Remember! Either set of screw holes can be used to mount the blower as long as… –The same hole position is used for each mounting arm –Do not use a left-side hole for one mounting leg then a right side hole for another mounting leg. This stresses the mounting arms and can cause them to break 96

97 ICP Confidential Not for further publication Propane Conversion Regulator spring change required for all models Low Gas Pressure Switch (LGPS) required for ALL models Burners will use “Mixing Screws” –1 screw is installed in each burner venturi –Provide better mixing of propane and combustion air –Includes drill bit to drill the correct size hole 97

98 ICP Confidential Not for further publication Converting The Gas Valve 98

99 ICP Confidential Not for further publication Spoiler Screw 99

100 ICP Confidential Not for further publication LGPS Installation –14 3/16” casing –Or, vent passes across vestibule –Install switch as shown Manifold removed Add wires to switch Install manifold 100

101 ICP Confidential Not for further publication Low Gas Pressure Switch Installation 101

102 ICP Confidential Not for further publication Low Gas Pressure Switch Installation Optional Location 102

103 ICP Confidential Not for further publication Setup and Service 103

104 ICP Confidential Not for further publication Single-stage PSC 24vac Thermostat Connections R, W, Y, GInducer Pre/Post Purge15 Sec/5 Sec Heat On Delay25 SecEACYes Heat Off Delay 90, 120, 150, 180 Hum24 vac Q.C. Cool On Delay3 SecHum MethodWhen Pressure Switch Closes Cool Off Delay90 SecBlower SpeedsUp to 4 speed taps at motor, 2 are controlled Optional Cool Off DelayCut J1 Jumper (non reversible) Heat AirflowSelectable Heat Component Self TestYesCool AirflowSelectable High Cool Only Non-Volatile MemoryYesContinuous FanSame as Heat Control Board Features 104

105 ICP Confidential Not for further publication Single-Stage PSC Control Component Layout 105

106 ICP Confidential Not for further publication Optional 3-Second Cooling Off Delay CUT J2 JUMPER TO REDUCE 90 SECOND COOLING OFF- DELAY TO 3 SECONDS (NON-REVERSIBLE) 106

107 ICP Confidential Not for further publication Single-Stage PSC Control Fan Speed Selection SELECT HEATING AND COOLING SPEEDS REQUIRED CONTINUOUS FAN SPEED IS HEATING SPEED STORE EXTRA SPEEDS ON SPARE 1 AND SPARE 2 TERMINALS 107

108 ICP Confidential Not for further publication Heating Off Delay Single-Stage Control 2 PIN JUMPER:1 TO 290 SECONDS2 TO 3120 SECONDS 3 TO 4150 SECONDS4 TO 5180 SECONDS 90 150 120 180 108

109 ICP Confidential Not for further publication Single-Stage Control Component Self Test To initiate the component last sequence, shut OFF the room thermostat or disconnect the “R” thermostat lead. Briefly short the TEST/TWIN terminal to the COM/24V terminal (Red Arrow) Once initiated the Status LED will flash the last Status Code and then turn ON the inducer The inducer motor will run for the entire component test. The hot surface igniter, blower motor FAN speed (if equipped), blower motor Heat speed and blower motor COOL speed will be turned ON for 15 seconds each. Gas Valve and Humidifier will not be turned on. 109

110 ICP Confidential Not for further publication Status Codes CodeDescription HeartbeatNO PREVIOUS CODE Stored status codes are erased automatically after 72 hours or as specified above. 2PRESSURE SWITCH DID NOT OPEN. Check for: Obstructed pressure switch tubing, Pressure switch stuck closed. 3PRESSURE SWITCH DID NOT CLOSE OR RE-OPENED. Check for: If LPS is open longer than 6 minutes, inducer shuts off for 18 minutes before re-try. If HPS remains open for 72 seconds after the gas valve closes (after 3 successive trials) the furnace control will lockout for 3 ½ hours before re-try 4LIMIT CIRCUIT FAULT. Indicates a limit or flame rollout switch is open. Blower will run for 4 minutes or until open switch remakes whichever is longer. If open longer than 3 minutes, code changes to lockout #7. If open less than 3 1/2 minutes status code #4 continues to flash until blower shuts off. Flame rollout switch requires manual reset. Check for: Dirty filter or restricted duct system-Improper limit switch or no limit gasket. Defective switch or connections- Improper gas input adjustment- Loose blower wheel 5ABNORMAL FLAME PROVING SIGNAL, Flame is proved while gas valve is de-energized. Inducer will run until fault is cleared. Check for: Leaky gas valve; Stuck-open gas valve; Dirty flame sensor insulator 6IGNITION PROVING FAULT -Control will try three more times before lockout #14 occurs. If flame signal lost during blower time limits. Thirty seconds after being turned ON or ten seconds during steady-state operation. Check for:- Oxide buildup on flame sensor (clean with fine steel wool) - Proper flame sense microamps (.5 microamps D.C. min., 4.0 - 6.0 nominal) Manual valve shut-off- Control ground continuity- Gas valve defective fumed 'OFF'- Low inlet gas pressure-Defective hot surface igniter-Flame sensor must not be grounded-Green/yellow wire MUST be connected to furnace sheet metal. 110

111 ICP Confidential Not for further publication CodeDescription 7LIMIT CIRCUIT LOCKOUT. Lockout occurs If a limit or flame rollout switch is open longer than 3 ½ minutes. Control will auto-reset in 3 hrs. Refer to Code 4. 8GAS HEATING LOCKOUT Control will NOT auto reset. Check for - Mis-wired gas valve -Defective control (valve relay) 9POLARITY Line voltage (220 VAC) polarity reversed. 1 + 2BLOWER ON AFTER POWER UP (115VAC or 24VAC)- Blower runs for 90 seconds, if unit is powered up during a call for heat (R to W/W1 closed) or (R to W/W1) opens during the blower on delay period. 6 + 1IGNITION LOCKOUT Control will auto reset in 3 ½ hours. Refer to Code 6 OFFSECONDARY VOLTAGE FUSE IS OPEN Check for - Short circuit in secondary voltage (24VAC) wiring. On (solid)CONTROL CIRCUITRY LOCKOUT Auto reset after 72 minutes. Lockout due to: Gas Valve relay stuck open. Flame sense circuitry failure. Software check error. Reset power to clear lockout. Replace control if status code repeats. Status Codes 111

112 ICP Confidential Not for further publication Sequence Of Operation NOTE: Furnace control must be grounded for proper operation or control will lock out. Control is grounded through green/yellow wire routed to gas valve and manifold bracket screw. Using the schematic diagram in Fig. 64, follow the sequence of operation through the different modes. Read and follow the wiring diagram very carefully. NOTE: If a power interruption occurs during a call for heat (W), the control will start a 108–sec blower–only ON period two sec after power is restored, if the thermostat is still calling for gas heating. The Green LED light will flash Code 1+2 during the 108–sec period, after which the LED will be flashing a heartbeat, as long as no faults are detected. After the 108–sec period, the furnace will respond to the thermostat normally. 112

113 ICP Confidential Not for further publication 113

114 ICP Confidential Not for further publication 114 Thermostat

115 ICP Confidential Not for further publication 115 Thermostat

116 ICP Confidential Not for further publication 116 Thermostat

117 ICP Confidential Not for further publication 117 Thermostat DRAFT COPY - ICP CONFIDENTI AL

118 ICP Confidential Not for further publication 118 DRAFT COPY - ICP CONFIDENTIA L

119 ICP Confidential Not for further publication Start-up Refer to the installation instructions for specific start-up details Start-up procedures are: –Verify installation is complete –Verify the correct orifices are installed –Prime the condensate trap –Purge the gas supply line –Check the inlet gas pressure 119

120 ICP Confidential Not for further publication Start-up Continued Start-up procedures (continued) are: –Adjust the manifold pressure –Set the temperature rise –Set the blower off delay –Set the cooling airflow –Check safety control operation –Review installation checklist 120

121 ICP Confidential Not for further publication Priming The Condensate Trap 1. Remove upper and middle collector box drain plugs opposite of the condensate trap. 2. Connect field-supplied 5/8--in. (16 mm) ID tube with attached funnel to upper collector box drain connection. 3. Pour one quart (liter) of water into funnel/tube. Water should run through collector box, overfill condensate trap, and flow into open field drain. 4. Remove funnel; replace collector box drain plug. 5. Connect field-supplied 5/8-in. (16 mm) ID tube to middle collector box drain port. 6. Pour one quart (liter) of water into funnel/tube. Water should run through collector box, overfill condensate trap, and flow into open field drain. 7. Remove funnel and tube from collector box and replace collector box drain plug.

122 ICP Confidential Not for further publication Start-up Continued Start-up procedures are: –Check the inlet gas pressure Use a good quality fluid-filled manometer to measure the inlet pressure at the gas valve Set the furnace to call for heat –Verify inlet gas pressure does not drop below minimum inlet pressure »4.5 IWC for Natural Gas »12.0 for Propane –Adjust the manifold pressure Manifold/orifice tables are provided Use a good quality fluid-filled manometer to measure the manifold pressure at the gas valve –Adjust manifold pressure at the regulator of the gas valve 122

123 ICP Confidential Not for further publication Single-Stage Gas Valve - Features 123

124 ICP Confidential Not for further publication Start-up Continued Start-up procedures (cont.) are: –Set the temperature rise Temperature rise shown on the unit rating plate Run the furnace at steady state Measure the temperature in the supply air and the return air –Measure supply temperature away from the line of sight of the heat exchanger Subtract the return air temperature from the supply air temperature Change blower speed to increase or decrease the temperature rise Change blower speed at the heating relay on the furnace control board –Ideal point is at the mid-point of the rise or slightly above the midpoint. 124

125 ICP Confidential Not for further publication Start-up Continued Start-up procedures (cont.) are: –Set the blower off delay Move the jumper on the control board to the desired off delay time –Set the cooling airflow Blower airflow tables are in the installation instructions. –Typical cooling speed is high speed Change motor speeds at the cooling relay on the furnace control board 125

126 ICP Confidential Not for further publication Single-Stage PSC Control Component Layout 126

127 ICP Confidential Not for further publication Single-Stage PSC Control Fan Speed Selection SELECT HEATING AND COOLING SPEEDS REQUIRED CONTINUOUS FAN SPEED IS HEATING SPEED STORE EXTRA SPEEDS ON SPARE 1 AND SPARE 2 TERMINALS 127

128 ICP Confidential Not for further publication Heating Off Delay Single-Stage Control 2 PIN JUMPER:1 TO 290 SECONDS2 TO 3120 SECONDS 3 TO 4150 SECONDS4 TO 5180 SECONDS 90 150 120 180 128

129 ICP Confidential Not for further publication Start-up Continued Start-up procedures (cont.) are: –Check safety control operation Pressure switch operation Limit switch operation Flame sensing circuit –Review installation checklist 129


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