Four Position Furnace
Transcription
Four Position Furnace
Four Position Furnace 90+ AFUE SINGLE STAGE DIRECT OR NON−DIRECT CATEGORY IV GAS FURNACE Models Dual Certified WFHR040B024A1 WFHR040B036A1 WFHR060B024A1 WFHR060B036A1 WFHR080B036A1 WFHR080B048A1 WFHR100C048A1 WFHR100C060A1 WFHR120D060A1 ama Technical Support . . . . . . . . . . . . . . . . . . . . . . Circulation Air Blower Data . . . . . . . . . . . . . . . Electrical Controls and Wiring . . . . . . . . . . . . . . Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Center . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . Service Label . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 3 4 5 5 6 7 8 9 As an Energy Star® Partner, International Comfort Products has determined that this product meets the ENERGY STAR® guidelines for energy efficiency. Ask your contractor for details or visit www.energystar .gov International Comfort Products, LLC Lewisburg, TN 37091 U.S.A. Save This Manual For Future Reference Specifications are subject to change without notice 440 04 7000 03 Sept. 2009 TECHNICAL SUPPORT UNIT SIZE - WFHR RATING AND PERFORMANCE Input Btuh* Output Capacity BTUH* ICS (Shaded capacities are specified on rating plate) AFUE%‡ Nonweatherized ICS Direct Vent (2-Pipe) Non-Direct Vent (1-Pipe) Direct Vent (2-Pipe) Non-Direct Vent (1-Pipe) Certified Temperature Rise Range Certified External Static Pressure Airflow CFM‡ Upflow Downflow Horizontal Upflow Downflow Horizontal Upflow Downflow Horizontal Upflow Downflow Horizontal °F °C Heating Cooling Heating Cooling ELECTRICAL Unit Volts - Hertz - Phase Operating Voltage Range Min-Max** Maximum Unit Amps Unit Ampacity †† Minimum Wire Size Maximum Wire Length [Measure 1 way in ft(m)]‡‡ Maximum Fuse or Ckt Bkr Size (Amps)** Transformer (24v) External Control Heating Cooling Power Available Air Conditioning Blower Relay CONTROLS Limit Control Heating Blower Control Burners (Monoport) Gas Connection Size GAS CONTROLS Manufacturer Gas Valve Min Inlet Pressure in wc/Pa (Redundant) Max Inlet pressure in wc/Pa Ignition Device BLOWER DATA Direct-Drive Motor HP(PSC) Motor Full Load Amps RPM (Nominal) speeds Blower Wheel Diameter x Width inches(mm) FILTER ARRANGEMENT 040B024 040B036 060B024 060B036 080B036 40,000 37,000 37,000 37,000 37,000 37,000 37,000 92.1 91 92.1 40,000 37,000 37,000 37,000 37,000 37,000 37,000 92.1 91 92.1 60,000 56,000 56,000 56,000 56,000 56,000 56,000 92.1 91 92.1 80,000 74,000 74,000 74,000 74,000 74,000 74,000 92.1 91 92.1 30-60 17-33 0.10 0.50 850 895 15-45 8-25 0.10 0.50 1125 1215 60,000 56,000 56,000 56,000 56,000 56,000 56,000 92.1 91 92.1 90 90 90 45-75 25-42 0.12 0.50 885 900 30-60 17-33 0.12 0.50 1065 1200 40-70 22-39 0.15 0.50 1190 1245 7.2 9.8 14 38(11.6) 15 7.7 10.4 14 36(11.0) 15 3 4 1/3 5.8 1075-4 10 x 7 6.1 8.4 14 44(13.4) 15 2 7.4 10.0 14 37(11.3) 15 115-60-1 104-127 6.1 8.4 14 44(13.4) 15 40va 12va 21va Standard SPST Selectable 90, 120, 150, or 180 3 1/2 inch NPT 2 White Rodgers 4.5/1121(Natural Gas) 13.6/3386 (Natural Gas) Hot Surface 1/5 4.9 1075-3 10 x 6 1/3 5.8 1075-4 10 x 7 1/5 4.9 1075-3 10 x 6 1/3 5.8 1075-4 10 x 7 (254x152) (254x178) (254x152) (254x178) (1) 16 x 25 x w (406.4 x 635 x 19) (254x178) (1) 20 x 25 x w (508 x 635 x 19) * Gas input ratings are certified for elevations to 2000 ft. (609.6 m) For elevations about 2000 ft. (609.6 m), reduce ratings 2% for each 1000 ft. (304.8m) above sea level. In Canada, derate the unit 5% for elevations 2000 ft. (609.6 m) to 4500 ft. (1371.6 m) above sea level. † Capacity and AFUE in accordance with U.S. Government DOE test procedures. ‡ Airflow shown is for bottom only return−air supply for the as−shipped speed tap. For air delivery above 1800 CFM, see Air Delivery table for other options. A filter is required for each return air supply. ** Permissible voltage limits for proper furnace operation. †† Unit ampacity = 125 percent of full load amps of largest components plus 100 percent full load amps of all other potential operating components (EAC, humidifier, etc.) ‡‡ Length shown in measured one way along wire path between unit and service panel for maximum 2% voltage drop. ICS Isolated Combustion System N/A Not Applicable 2 Specifications are subject to change without notice. 440 04 7000 03 TECHNICAL SUPPORT UNIT SIZE - WFHR RATING AND PERFORMANCE Input Btuh* Output Capacity BTUH* ICS (Shaded capacities are specified on rating plate) Direct Vent (2-Pipe) Non-Direct Vent (1-Pipe) Direct Vent 2-Pipe) AFUE%* Nonweatherized ICS Non-Direct Vent (1-Pipe) Certified Temperature Rise Range Certified External Static Pressure Airflow CFM‡ ELECTRICAL Unit Volts - Hertz - Phase Operating Voltage Range Maximum Unit Amps Unit Ampacity †† Minimum Wire Size Maximum Wire Length [Measure 1 way in ft(m)]‡‡ Maximum Fuse or Ckt Bkr Size (Amps)** Transformer (24v) External Control Power Available Air Conditioning Blower Relay CONTROLS Limit Control Heating Blower Control Burners (Monoport) Gas Connection Size GAS CONTROLS Gas Valve (Redund ant) 100C048 100C066 120D066 80,000 74,000 74,000 74,000 74,000 74,000 74,000 92.1 91 92.1 100,000 93,000 93,000 93,000 93,000 93,000 93,000 92.1 91 92.1 100,000 93,000 93,000 93,000 93,000 93,000 93,000 92.1 91 92.1 120,000 112,000 112,000 112,000 112,000 112,000 112,000 92.1 91 92.1 30-60 17-33 0.20 0.50 1690 1930/2130 40-70 22-39 0.20 0.50 1720 2000/2130 14.8 19.3 12 30(9.1) 20 14.6 19.1 12 30(9.1) 20 90 90 90 30-60 17-33 0.15 0.50 1285 1525 Blower Wheel Diameter x Width inches(mm) 45-75 25-42 0.20 0.50 1315 1570 115-60-1 104-127 Min-Max ** 10.1 13.4 14 28(8.5) 15 10.2 13.5 14 27(8.2) 15 40va 12va 21va Standard Heating Cooling 4 Manufacturer Min Inlet Pressure in wc/Pa Max Inlet Pressure in wc/Pa Ignition Device BLOWER DATA Direct-Drive Motor HP(PSC) Motor Full Load Amps RPM (Nominal) speeds FILTER ARRANGEMENT inches(mm) Upflow Downflow Horizontal Upflow Downflow Horizontal Upflow Downflow Horizontal Upflow Downflow Horizontal °F °C Heating Cooling Heating Cooling 080B048 SPST Selectable 90, 120, 150, or 180 5 5 1/2 inch NPT 6 White Rodgers 4.5/1121 (Natural Gas) 13.6/3386 (Natural Gas) Hot Surface 1/2 7.9 1075-4 11 x 8 (279x203) 1/2 7.9 1075-4 11 x 8 3/4 11.1 1075-4 11 x 10 (279x203) (279x254) (1) 20 x 25 x w (508 x 635 x 19) 3/4 11.1 1075-4 11 x 10 (279x254) (1) 24 x 25 x w (610 x 635 x 19) * Gas input ratings are certified for elevations to 2000 ft. (609.6 m) For elevations about 2000 ft. (609.6 m), reduce ratings 2% for each 1000 ft. (304.8m) above sea level. In Canada, derate the unit 5% for elevations 2000 ft. (609.6 m) to 4500 ft. (1371.6 m) above sea level. † Capacity and AFUE in accordance with U.S. Government DOE test procedures. ‡ Airflow shown is for bottom only return−air supply for the as−shipped speed tap. For air delivery above 1800 CFM, see Air Delivery table for other options. A filter is required for each return air supply. ** Permissible voltage limits for proper furnace operation. †† Unit ampacity = 125 percent of full load amps of largest components plus 100 percent full load amps of all other potential operating components (EAC, humidifier, etc.) ‡‡ Length shown in measured one way along wire path between unit and service panel for maximum 2% voltage drop. ICS Isolated Combustion System N/A Not Applicable 440 04 7000 03 Specifications are subject to change without notice. 3 Circulation Air Blower Data FURNACE WFHR RETURNAIR INLET 040B024 1 side or bottom 040B036 1 side or bottom 060B024 1 side or bottom 060B036 1 side or bottom 080B036 1 side or bottom 080B048 1 side or bottom 100C048 1 side or bottom 1 side or bottom 100C060 both sides or 1 side & bottom bottom only 120D060 both sides or 1 side & bottom 1 side only High Med-Low Low High Med-High Med-Low Low High Med-Low Low High Med-High Med-Low Low High Med-High Med-Low Low High Med-High Med-Low Low High Med-High Med-Low Low High Med-High Med-Low Low 0.10 CFM 1075 850 740 1470 1315 1125 930 1100 890 745 1430 1270 1070 915 1535 1395 1200 1040 1750 1495 1310 1135 1740 1500 1340 1195 2250 2020 1725 1490 25 L/s 507 401 349 694 621 531 439 519 420 352 675 599 505 432 724 658 566 491 826 706 618 536 821 708 632 564 1062 953 814 703 0.20 CFM 1040 825 700 1415 1280 1110 925 1065 865 710 1375 1260 1055 895 1470 1350 1175 1020 1685 1455 1260 1105 1705 1470 1315 1175 2175 1950 1690 1480 50 L/s 491 389 330 668 604 524 437 503 408 335 649 595 498 422 694 637 555 481 795 687 595 521 805 694 621 555 1026 920 798 698 0.30 CFM 995 780 650 1400 1235 1085 910 1005 810 670 1325 1215 1045 885 1405 1300 1125 990 1635 1405 1225 1075 1660 1445 1330 1165 2090 1900 1660 1460 EXTERNAL STATIC PRESSURE (in wc/Pa) 75 0.40 100 0.50 125 0.60 L/s CFM L/s CFM L/s CFM 470 945 446 895 422 840 368 740 349 685 323 635 307 620 293 565 267 515 661 1285 606 1215 573 1120 583 1180 557 1115 526 1035 512 1045 493 990 467 915 429 850 401 830 392 770 474 945 446 900 425 805 382 765 361 705 333 620 316 625 295 565 267 505 625 1275 602 1200 566 1135 573 1160 547 1105 521 1035 493 1015 479 975 460 920 418 865 408 840 396 800 663 1330 628 1245 588 1160 613 1225 578 1155 545 1080 531 1065 503 1030 486 970 467 960 453 940 444 860 772 1575 743 1525 720 1445 663 1355 639 1305 616 1250 578 1170 552 1125 531 1095 507 1040 491 995 470 995 783 1615 762 1570 741 1500 682 1410 665 1375 649 1330 628 1270 599 1235 583 1200 550 1130 533 1100 519 1070 986 2020 953 1930 911 1855 897 1840 868 1790 845 1710 783 1630 769 1575 743 1520 689 1440 680 1380 651 1340 149 L/s 396 300 243 529 488 432 363 380 293 238 536 488 434 378 547 510 458 406 682 590 517 470 708 628 566 505 875 807 717 632 0.70 CFM 760 560 455 995 930 830 705 730 540 425 1040 950 850 720 1065 985 890 785 1380 1185 1040 910 1425 1280 1140 1030 1760 1640 1460 1295 174 L/s 359 264 215 470 439 392 333 345 255 201 491 448 401 340 503 465 420 370 651 559 491 429 672 604 538 486 831 774 689 611 0.80 CFM 670 480 385 890 825 740 635 610 475 360 935 850 750 650 935 880 780 680 1310 1120 980 860 1355 1210 1095 975 1670 1545 1370 1230 199 L/s 316 227 182 420 389 349 300 288 224 170 441 401 354 307 441 415 368 321 618 529 462 406 639 571 517 460 788 729 647 580 High 2360 1114 2315 1092 2265 1069 2205 1041 2130 1005 2055 970 1965 927 1890 892 Med-High 1960 925 1940 916 1930 911 1900 897 1850 873 1800 849 1740 821 1660 783 High Med-High Med-Low Low 2350 2100 1770 1545 1109 991 835 729 2250 2015 1720 1520 1062 951 812 717 2160 1955 1675 1465 1019 923 790 691 2070 1875 1620 1415 977 885 765 668 2000 1810 1575 1365 944 854 743 644 1885 1710 1515 1325 890 807 715 625 1790 1650 1450 1265 845 779 684 597 1635 1540 1365 1185 772 727 644 559 High 2435 1149 2360 1114 2285 1078 2220 1048 2130 1005 2050 967 1965 927 1875 885 Med-High 2040 963 2000 944 1950 920 1905 899 1835 866 1790 845 1725 814 1650 779 High Med-High 2255 1985 1064 937 2190 1930 1034 911 2115 1890 998 892 2045 1840 965 868 1965 1780 927 840 1890 1720 892 812 1800 1645 849 776 1710 1560 807 736 SPEED Electrical Controls and Wiring ! WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death. There may be more than one electrical supply to the unit. Check accessories and cooling unit for additional electrical supplies. The electrical ground and polarity for 115−v wiring must be maintained properly. Refer to Fig. 1 for field wiring information and to Fig. 4 for unit wiring information. NOTE: If the polarity is not correct or furnace is not properly grounded, the STATUS LED on the furnace control will flash rapidly and prevent the furnace from operating. The control system also requires an earth 4 ground for proper operation of the furnace control and flame sensor. The 24−v circuit contains an automotive−type, 3−amp fuse located on the furnace control. (See Fig. 2.) Any direct shorts of the 24−v wiring during installation, service, or maintenance will cause this fuse to blow. If fuse replacement is required, use ONLY a fuse of identical size. The furnace control LED will flash status code 24 when fuse needs to be replaced. With power to the unit disconnected, check all electrical connections for tightness. Tighten all screws on electrical connections. If any smoky or burned connections are found, disassemble the connection, clean all parts, strip wire, and reassemble properly and securely. Reconnect electrical supply to unit and observe unit through one complete operating cycle and check for proper operation. Specifications are subject to change without notice. 440 04 7000 03 FIELD 24-V WIRING FIELD 115-, 208/230-, 460-V WIRING FACTORY 24-V WIRING FACTORY 115-V WIRING NOTE 2 W FIVE WIRE THREE-WIRE HEATING-ONLY C R G Y THERMOSTAT TERMINALS FIELD-SUPPLIED DISCONNECT 208/230- OR 460-V THREE PHASE BLOWER DOOR SWITCH BLK W BLK WHT C O N T R O L WHT GND GND AUXILIARY J-BOX 115-V FIELDSUPPLIED DISCONNECT R 208/230-V SINGLE PHASE G COM GND NOTE 1 CONDENSING UNIT Y/Y2 TWO WIRE 24-V TERMINAL BLOCK FURNACE NOTES: 1. Connect Y-terminal in furnace as shown for proper blower operation. 2. Some thermostats require a "C" terminal connection as shown. 3. If any of the original wire, as supplied, must be replaced, use same type or equivalent wire. A99440 Fig. 1 − Field Wiring TWINNING AND/OR COMPONENT TEST TERMINAL BLOWER OFF-DELAY BLOWER OFF-DELAY DHUM 120 180 90 150 Y1 HUMIDIFIER TERMINAL (24-VAC 0.5 AMP MAX.) G TEST/TWIN TRANSFORMER 24-VAC CONNECTIONS PLT COM W/W1 Y/Y2 24V 24-V THERMOSTAT TERMINALS R HUM 0.5 AMP@24VAC NUETRAL BLW STATUS CODE LED 3-AMP FUSE FUSE 3-AMP L2 PL1-LOW VOLTAGE MAIN HARNESS CONNECTOR 1 115-VAC(L2)NEUTRAL CONNECTIONS EAC-2 PLT LED OPERATION & DIAGNOSTIC LIGHT SEC-2 SEC-1 COOL FAN SPARE-1 SPARE-2 SPARE-1 BLOWER SPEED SELECTION TERMINALS SPARE-2 1-AMP@ EAC-1 115VAC FAN PR-1 L1 HEAT COOL HEAT PL2 1 115 VAC (L1) LINE VOLTAGE CONNECTION PL2-HOT SURFACE IGNITER & INDUCER MOTOR CONNECTOR EAC-1 TERMINAL (115-VAC 1.0 AMP MAX.) Fig. 2 − Control Center 440 04 7000 03 Specifications are subject to change without notice. A02142 5 TROUBLESHOOTING Use the troubleshooting guide, the status code LED on the furnace control and the component test to isolate furnace operation problems. STATUS CODES For an explanation of status codes, refer to service label located on back of main furnace door or Fig. 3 and the Troubleshooting Guide. The stored status code will NOT be erased from the control memory if 115− or 24−v power is interrupted. NOTE: Removing the blower access door will open the blower access door switch and terminate 115−v power to the control. To read current status code, remove main furnace door. The status code LED can be viewed through the sight glass on the blower access door. NOTE: NO thermostat signals may be present at control and all blower off delays must be completed to view previous codes. ! CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in damage to unit components. Make sure limit switch or flame rollout switch wire does not contact any metal component, such as gas valve. If wire is shorted, 3−amp fuse on furnace control board will open and unit will not operate. To retrieve previous codes, remove one of the red main limit or flame rollout switch wires for 1 to 4 sec until the LED light goes out, then reconnect it. (Do not leave red wire disconnected for longer periods of time as the control will assume an overtemperature condition exists and will respond with blower operation.) This places the control in the status recall mode and displays the last code stored in memory. Record the code. After the last code is displayed the control will perform the component test, and then return to normal standby mode. COMPONENT TEST NOTE: The furnace control component test allows all components to run for a short time; except the gas valve and humidifier terminal HUM are not energized for safety reasons. The EAC−1 terminal is energized when the blower is energized. This feature helps diagnose a system problem in case of a component failure. The component test feature will not operate if any thermostat signal is present at the control and not until all time delays are completed. NOTE: Record the status code BEFORE opening the blower access door and before shutting off power to furnace. Opening the blower access door will open the blower door switch and shut off power within the furnace. When power to the furnace is shut off by either method, the status code will be lost because the code is not stored while power is removed for any reason. To Begin Component Self−Test: 6 ! WARNING ELECTRICAL SHOCK AND UNIT MAY NOT OPERATE HAZARD Failure to follow this warning could result in electrical shock, personal injury, or death. Blower access panel door switch opens 115−v power to control board. No component operation can occur. Caution must be taken when manually closing this switch for service purposes. 1. Remove blower access door. 2. Disconnect the thermostat R lead from furnace control board. 3. Manually close blower door switch. 4. For approximately 2 sec, short (jumper) the COM−24v terminal on control to the TEST/TWIN 3/16−in. quick−connect terminal on control until LED turns off. Remove jumper from terminals. (See Fig. 2.) NOTE: If TEST/TWIN and COM−24v terminals are jumpered longer than 2 sec, LED will flash rapidly and ignore component test request. Component test sequence for single−stage furnace is as follows: a. LED will display status code 11 four times. b. Inducer motor starts and continues to run until Step f. of component test sequence. c. After 7 sec the hot surface igniter is energized for 15 sec, then off. d. Blower motor operates on HEAT speed for 10 sec. e. Blower motor operates on COOL speed for 10 sec. f. Inducer motor stops. 5. Reconnect R lead to furnace control board, remove tape from blower door switch, and reinstall blower door. 6. Operate furnace per instruction on outer door. 7. Verify furnace shut down by lowering thermostat setting below room temperature. 8. Verify that furnace restarts by raising thermostat setting above room temperature. Specifications are subject to change without notice. 440 04 7000 03 Fig. 3 − Service Label 440 04 7000 03 A02270 Specifications are subject to change without notice. 7 Fig. 4 − Wiring Diagram 8 Specifications are subject to change without notice. A02271 440 04 7000 03 INDUCED−COMBUSTION GAS FURNACE PARTS REPLACEMENT INFORMATION GUIDE HEAT EXCHANGER GROUP GAS CONTROL GROUP CASING GROUP Primary heat exchanger cell Primary heat exchanger cell panel Secondary heat exchanger assembly Limit shield Coupling box Control (outer) door Blower access panel Top filler plate Bottom encloser Condensate trap BLOWER GROUP INDUCER GROUP Pressure switch(es) Inducer motor Inducer housing Inducer motor mounting plates Inducer wheel Inducer motor capacitor FILTER GROUP Filter(s) Filter retainer wire Filter retainer wire latch Filter retainer wire pivot Media cabinet NOMENCLATURE 1, 2 WF Blower assembly Blower housing Blower cutoff Blower motor Blower wheel Capacitor Capacitor strap ELECTRICAL GROUP Control box Junction box Limit switch(es) Circuit board Door switch Transformer Wiring harness 3−amp fuse Over−temperature switch 3 4 5, 6, 7 H R 040 Manifold Burner Orifice Flame sensor Hot surface ignitor Gas valve Combustion−air intake housing ! WARNING FIRE, EXPLOSION, ELECTRICAL SHOCK AND CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in dangerous operation, personal injury, death or property damage. Improper installation, adjustment, alteration, service, maintenance, or use can cause carbon monoxide poisoning, explosion, fire, electrical shock, or other conditions which may cause personal injury or property damage. Consult a qualified installer, service agency, local gas supplier, or your distributor or branch for information or assistance. The qualified installer or agency must use only factory-authorized and listed kits or accessories when modifying this product. 8 A 9, 10 24 11 A 12 1 WF = Gas Furnace M = Mid H = High EFFICIENCY R = Regular L = Low NOx FEATURE 040 = 40,000 060 = 60,000 080 = 80,000 100 = 100,000 120 = 120,000 HEATING INPUT, MBTUH A= 14½" B = 17½" C = 21" D = 24½" CABINET WIDTH, Inches 24 = 24,000 BTU/hr, 2 Ton 30 = 30,000 BTU/hr, 2½ Ton 36 = 36,000 BTU/hr, 3 Ton 48 = 48,000 BTU/hr, 4 Ton 60 = 60,000 BTU/hr, 5 Ton COOLING SIZE SALES DIGIT EXTRA DIGIT Have available the product/model number and the serial number located on the unit rating plate to ensure correct replacement parts. TO OBTAIN INFORMATION ON PARTS: Consult your installing dealer or the classified section of your local telephone directory under the “Heating Equipment“ or “Air Conditioning Contractors and Systems” headings for dealer listing by brand name, or contact: International Comfort Products, LLC Consumer Relations Department P.O. Box 128 Lewisburg, TN 37091, USA 931−270−4100 9 440 04 7000 03 THIS PAGE LEFT BLANK INTENTIONALLY 440 04 7000 03 10