DAIKIN DD96SC0805CU (01) PDF MANUAL

-Reorient or relocate the receiving antenna.

-Increase the separation between the equipment and receiver.

-Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.

-Consult the dealer or an experienced radio/TV technician for help.

• DO NOT try to light any appliance.

• DO NOT touch any electrical switch; DO NOT use any phone in your building.

• IMMEDIATELY call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions. If you cannot reach your gas supplier, call the fire department.

– Installation and service must be performed by a qualified installer, service agency or the gas supplier.

1. Make a notation on the delivery receipt of any visible damage.

2. Notify the carrier promptly and request an inspection.

3. With concealed damage, notify the carrier as soon as possible (preferably within five days).

4. File the claim with supporting documents (Bill of Lading, freight bill, invoice, inspection report) within the nine-month statute of limitations.

1. Disconnect all power to the furnace. Do not touch the integrated control module or any wire connected to it before discharging your body’s electrostatic charge.

2. Firmly touch a clean, unpainted, metal surface of the furnace near the control. Any tools held will also be discharged.

3. Service the control module or wiring following the discharge process in step 2. Use caution not to recharge your body (e.g., shuffling feet, touching ungrounded objects). If you contact an ungrounded object, repeat step 2 before touching the control or wires.

4. Discharge your body to ground before removing a new control from its container. Follow steps 1 through 3 if installing the control. Return old or new controls to their containers before touching any ungrounded object.

• It must be installed per the installation instructions provided and per local and national codes.

• It must be installed indoors in a building constructed on site.

• It must be part of a ducted system and not used in a free air delivery application.

• It must not be used as a “make-up” air unit.

• It must be installed as a two-pipe system for combustion air.

• All other warranty exclusions and restrictions apply.

• This furnace is an ETL certified appliance and is appropriate for use with natural gas.

• Non-direct vent (single pipe): Combustion air is taken from the installation area or from air ducted from the outside.

• Direct vent (dual pipe): All combustion air is supplied directly to the furnace burners through a special air intake system.

• The furnace has a permanently installed venting system per these installation instructions.

• A room thermostat is used to control the furnace. Fixed jumpers providing continuous heating CANNOT be used.

• The furnace is attached to permanent return air ducting sealed to the furnace.

• Return air temperature is maintained between 60°F (16°C) and 80°F (27°C).

• MERV 11 air filter(s) are installed, inspected daily, and replaced as needed during construction and upon completion.

• Input rate and temperature rise settings are within furnace rating plate guidelines.

• The furnace must be installed as a two-pipe system, using 100% outside air for combustion during construction.

• The furnace heat exchanger, components, duct system, air filters, and evaporator coils are thoroughly cleaned following final construction cleanup by a qualified person.

• All furnace operating conditions are verified by a qualified person according to these installation instructions.

• Furnace doors must be in place while the furnace is operating.

• Centrally locate the furnace with respect to the air distribution system.

• Ensure return air temperature is within the specified range (55°F – 100°F while heating).

• Provide provisions for venting combustion products outdoors through a proper system, considering pipe routing limitations.

• Locate the furnace for proper condensate drainage (downward flow) and protect from freezing.

• Ensure adequate combustion air is available.

Permanent wave solutions

Chlorinated waxes or cleaners

Chlorine-based swimming pool chemicals

Carbon tetrachloride

Water softening chemicals

Swimming pool chemicals

Deicing salts or chemicals

Halogen type refrigerants

Printing inks

Cleaning solutions (such as perchloroethylene)

Paint removers

Varnishes

Hydrochloric acid

Cements and glues

Antistatic fabric softeners for clothes dryers

Masonry acid washing materials

1. Seal any unused openings in the venting system.

2. Inspect the venting system for proper size, horizontal pitch (per National Fuel Gas Code, ANSI Z223.1), blockage, restriction, leakage, corrosion, and other deficiencies.

3. Close all building doors/windows and doors between the appliance space and other spaces, as practical.

4. Close fireplace dampers.

5. Turn on clothes dryers and any appliance not connected to the venting system. Turn on exhaust fans (e.g., range hoods, bathroom exhausts) to maximum speed. Do not operate a summer exhaust fan.

6. Follow lighting instructions. Place the appliance being inspected in operation. Adjust thermostat for continuous operation.

7. If improper venting is observed, the venting system must be corrected according to the National Fuel Gas Code ANSI Z223.1/NFPA 54.

8. After determining proper venting, return doors, windows, fans, dampers, and other appliances to their previous conditions.

• Drafts, or dead spots (behind doors, in corners, under cabinets).

• Hot or cold air from registers.

• Radiant heat from the sun.

• Light fixtures or other appliances.

• Radiant heat from a fireplace.

• Concealed hot or cold water pipes, or chimneys.

• Unconditioned areas behind the thermostat (e.g., an outside wall).

• Upright Upflow: Return air ductwork may be attached to the side panel(s) and/or basepan.

• Horizontal Upflow: Return air ductwork must be attached to the blower compartment end of the furnace.

• Upright or Horizontal Downflow: Return air ductwork must be attached to the basepan (top end of the blower compartment).

1. Remove tube from front cover pressure switch and collector box cover.

2. Remove rubber plug from bottom collector box port and install on top collector box port.

3. Locate the 24″ x 1/8″ tube in the bag assembly.

4. Install one end on the front cover pressure switch.

5. Route tube to the lower port on the collector box cover and cut off excess tubing.

1. Remove the four screws from the vent pipe flange on top of the furnace.

2. Remove the internal elbow, vent pipe, and gasket.

3. Cut the internal vent pipe 2 1/2″ from the flange (Figure 11). Discard the un-flanged section.

4. Remove the 3″ plastic plug (in line with the inducer outlet) and insert it in the space vacated by the internal vent pipe.

5. Install the RF000142 drain coupling, arrow facing up, on the draft inducer outlet.

6. Insert the 2 1/2″ flanged section of pipe with gasket through the 3″ side hole and connect it to the RF000142 drain coupling. Secure with the provided gear clamp.

7. Use the four self-tapping screws removed in step 1 to secure the flange to the cabinet.

8. Connect the drain hose to the uncapped port on the RF000142 coupling (refer to page 19/20 instructions for details).

1. Remove screws, combustion air flange, and gasket from the standard cabinet location.

2. Insert the 3″ cabinet plug (from drain bag assembly) into the unused standard combustion air hole.

3. Drill a pilot hole at the locating dimple on the right side of the cabinet (1-7/8″ from the front edge, in line with knockout).

4. Use a knockout tool to create a 3″ diameter hole at the pilot hole.

5. Secure the combustion air flange and gasket (removed in step 1) to the new hole using the self-tapping screws.

• The drain trap supplied with the furnace must be used.

• The drain trap must be primed at time of installation.

• The drain line between furnace and drain location must meet local and national codes.

• The drain line must maintain a 1/4″ per foot downward slope toward the drain.

• Do not trap the drain line in any other location than at the drain trap supplied with the furnace.

• If the drain line is routed through an area which may see temperatures near or below freezing, precautions must be taken to prevent condensate from freezing.

• If an air conditioning coil is installed, a common drain may be used, but an open tee must be installed near the cooling coil to relieve positive air pressure and prevent interference with the furnace trap function.

1. Install the 45° pipe/hose drain coupling from outside the cabinet through the right-side hole (barbed end inside), secure with two #8 self-tapping screws (field supplied).

2. Locate the long drain hose #3 and cut at line “A”.

3. Install large end of hose #3 to trap outlet, secure with 1.25″ clamp.

4. Install smaller end of hose #3 onto the 45° coupling, secure with 1″ clamp.

5. Connect field-supplied drain line to the outlet of the coupling.

1. Install the 45° pipe/hose drain coupling from outside the cabinet through the left-side hole (barbed end inside), secure with two #8 self-tapping screws (field supplied).

2. Locate the long drain hose #3. Cut at “B” line for 17.5″ cabinet; cut at “C” line for 21″ cabinet; do not cut for “D” width cabinet.

3. Install large end of hose #3 to trap outlet, secure with 1.25″ clamp.

4. Install smaller end of hose #3 onto the 45° coupling, secure with 1″ clamp.

5. Connect field-supplied drain line to the outlet of the coupling.

1. Remove clamps from factory drain hoses.

2. Remove two screws holding trap to blower deck.

3. Remove trap and hoses from blower deck.

4. Remove two plugs from right side of cabinet; install them in blower deck holes.

5. Vent Elbow Drain: Locate hose #2, cut 1″ from 45° bend, discard bend. Insert hose #2 from outside through top cabinet drain hole, secure to elbow barb fitting with red clamp.

6. Collector Box Drain: Install non-grommet end of hose #11 from outside through bottom cabinet drain hole. Install on collector box port, secure with silver clamp.

7. Secure hoses #2 and #11 to drain trap inlets with silver clamps. Trap outlet faces furnace front. Secure trap to cabinet side using two screws (from step 2) through large holes in trap tabs into predrilled cabinet holes.

8. Connect field-supplied drain line to trap outlet.

1. Remove clamps from drain tubes on trap.

2. Remove two screws holding trap to blower deck.

3. Remove trap and hoses from blower deck.

4. Remove two plugs from left side of cabinet; install them in blower deck holes.

5. Vent Elbow Drain: Locate hose #6. Cut off and discard from non-grommet end: 1 1/2″ (D width), 5″ (C width), or 8 1/2″ (B width).

6. Remove rubber plug from vent-drain elbow side port. Place hose #6 onto this side port, secure with silver clamp.

7. Seal unused vent-drain elbow drip leg port by inserting rubber plug (from step 6). Use a blunt tool (e.g., 3/16″ Allen wrench) to help insert fully.

8. Locate hose #5, cut 3″ from non-grommet end. Discard section without grommet.

9. Insert cut end of hose #5 through lower cabinet drain hole.

10. Connect hose #6 & #5 using 100° elbow, secure with two red clamps.

11. Collector Box Drain: Remove cap from left side collector box drain port (bottom); install it on right side (top) port.

12. Install non-grommet end of hose #11 from outside through upper cabinet drain hole. Install on collector box port, secure with silver clamp.

13. Secure hoses #5 and #11 to drain trap inlets with silver clamps. Trap outlet faces furnace front. Secure trap to cabinet side using two screws (from step 2) through large holes in trap tabs into pre-drilled cabinet holes.

14. Connect field-supplied drain line to trap outlet.

1. RF000142 Coupling Drain: Locate hose #2 (factory installed). Cut off and discard the 45° radius end.

2. Install 90° radius end of hose #2 onto RF000142 drain outlet, secure with red clamp.

3. Insert coupling into hose #2, secure with red clamp.

4. Locate hose #5, cut 3″ from non-grommet end. Discard section without grommet.

5. Insert cut end of hose #5 through lower cabinet drain hole.

6. Insert 100° elbow into cut end of hose #5.

7. Locate hose #6. Using red clamps, connect between the coupling (from step 3) and the 100° elbow (from step 6), cutting off excess tubing.

8. Collector Box Drain: Remove cap from left side collector box drain port (bottom); install it on right side (top) port, secure with red clamp.

9. Install non-grommet end of hose #11 from outside through upper cabinet drain hole. Install on collector box port, secure with silver clamp.

10. Secure hoses from coupling/elbow (#6) and collector box (#11) to drain trap inlets with silver clamps. Trap outlet faces furnace front. Secure trap to cabinet side using two screws through large holes in trap tabs into pre-drilled cabinet holes.

1. Install a field-supplied rubber coupling (secured with 1 1/4″ clamp) or a glued PVC fitting to the trap outlet to allow for future cleaning access.

2. Install the drain line per local and National codes.

1. Remove gas manifold assembly for better access (remove four screws fastening it to bracket).

2. Remove hose clamps and hoses from trap.

3. Remove trap.

4. Vent Elbow Drain: Insert non-grommet end of hose #10 into cabinet back drain hole. Insert coupling into vent-drain elbow drip leg, secure with silver clamp. Secure hose #10 onto vent-drain elbow barb fitting with silver clamp.

5. Collector Box Drain: Insert non-grommet end of hose #9 into cabinet front drain hole. Secure onto collector box drain port with silver clamp.

6. Mate trap inlets to hoses #9 and #10, secure with silver clamps.

7. Line up trap mounting holes with pre-drilled furnace holes, secure with 2 screws (removed in step 1/gas manifold).

8. Connect field-supplied drain line to trap outlet.

*Reinstall gas manifold assembly.*

1. Remove drain trap and factory drain tube assemblies.

2. Remove two 1″ plugs from right side of cabinet.

3. Collector Box Drain: Insert non-grommet end hose #7 into back cabinet drain hole, secure to collector box port with silver clamp.

4. Vent Elbow Drain: Insert straight barbed coupling into vent-drain elbow drip leg, secure with red clamp.

5. Insert non-grommet end of hose #8 into front cabinet drain hole, secure to vent-drain elbow barb fitting (now with coupling) using red clamp.

6. Place drain hoses #7 & #8 onto trap inlets, secure with silver clamps. Trap outlet faces original furnace bottom.

7. Using two sheet metal screws (provided), secure trap to furnace.

8. Connect field-supplied drain line to trap outlet.

1. Remove factory installed drain trap and hose assemblies. Leave 100° elbow clamped in vent-drain elbow.

2. Remove two 1″ plugs from left side of cabinet.

3. Collector Box Drain: Remove cap from left side collector box port (bottom); install it on right side drain port.

4. Place radius end of hose #4 onto left collector box port, secure with silver clamp.

5. Insert hose #2 from outside cabinet into front drain hole.

6. Connect hose #4 & hose #2 together using straight barbed coupling and two gold clamps (factory installed).

7. Vent Elbow Drain: Remove rubber plug from vent-drain elbow side port.

8. Plug unused vent-drain elbow drip leg port (where 100° elbow is) with rubber plug from step 7. Use blunt tool (3/16″ Allen wrench) to help insert fully.

9. Place radius end of hose #4 (different hose #4 from step 4) onto side port of vent-drain elbow, secure with gold clamp.

10. Insert 1/2″ diameter PVC pipe (factory installed) into hose #4, secure with gold clamp.

11. Insert non-grommet end of hose #5 from outside cabinet into back drain hole.

12. Insert 100° elbow into hose #5, secure with red clamp.

13. Locate hose #4 (the one connected to PVC pipe in step 10), cut off a 4″ straight section. Discard radius end.

14. Connect 4″ straight section of hose #4 between the 100° elbow (from step 12) and the PVC pipe (from step 10), secure both ends with red clamps.

15. Connect hoses from collector box/straight coupling (#2) and vent elbow/PVC pipe assembly (#4/PVC/Hose#4/Elbow/Hose#5) to trap inlets, secure with silver clamps. Trap outlet points to original furnace bottom.

16. Using two sheet metal screws (provided), secure trap to furnace.

17. Connect field-supplied drain line to trap outlet.

1. Remove the burner compartment door.

2. Remove and save the two screws securing the junction box to the side panel.

3. Relocate the junction box and associated plugs and grommets to the opposite side panel. Secure with the screws removed in step 2.

1. Turn off electrical power.

2. Measure resistance between the neutral (white) connection in the junction box and any unpainted metal surface of the furnace.

3. Resistance should measure 10 ohms or less.

• View specific model information.

• Review active diagnostic error codes.

• Observe system status during operation.

• Make system menu adjustments.

• Add site visit notes.

• Run system testing of all operational modes (heat/cool/fan).

• Instantly update furnace software when updates are available (notified via the app when connected via Bluetooth).

1. Connect all necessary thermostat wires (R, C, W, Y, G, DH/Y2 if applicable) to the thermostat connector on the furnace control.

2. Connect the 1 & 2 wires between the indoor (furnace) board terminal connections and the outdoor board terminal connections for communicating operation.

Note: Verify if the two-stage outdoor unit requires a separate 24VAC transformer; it may not operate correctly without one. Inverter heat pumps always require their own transformer. For two-stage AC units without a built-in transformer, R & C wires can be run between indoor and outdoor units. R & C connections cannot be used for heat pumps.

1. Allow the system to remain Idle for 5 minutes.

2. Turn the system verification test on using the CoolCloud phone application OR by entering the ‘SUt’ menu via the furnace pushbuttons.

3. Wait for the test to complete.

a. Set the CR9 menu (Charge Mode) to ON through the furnace control board pushbuttons or the CoolCloud HVAC phone application.

b. The system will remain in charge mode (high speed) for 60 minutes before timing out.

c. The installer must manually shut off charge mode once complete.

a. Select the gas heat icon after entering the furnace menus in the CoolCloud app.

b. Select any value less than 50% for low stage operation and any value greater than 50% for high stage operation.

Also, confirm that standard thermostat heating and cooling calls function properly with the equipment.

1 AC for single stage Air Conditioners

1 HP for single stage heat pumps

2 AC for two-stage air conditioners

2 HP for two-stage Heat Pumps

a. Select the gas heat icon after entering the furnace menus in the CoolCloud application.

b. Select any value less than 50% for low stage operation and any value greater than 50% for high stage operation.

EXTREMELY IMPORTANT: The furnace only requires a single W input for 2-stage gas heat control. Internal algorithms will control the staging automatically.

1. Connect necessary thermostat wires to the furnace control connector as shown in Figure 42 (R to R, C to C optional, G to G optional, W to W, Y to Y, Dehum to DH/Y2).

2. Download and use the CoolCloud HVAC phone application to configure and test furnace operations.

3. Perform Gas Furnace Testing using the CoolCloud app: Select the gas heat icon, then select a value less than 50% for low stage and greater than 50% for high stage operation.

4. Confirm thermostat heating call functions correctly with the equipment.

Set to “HI” if the external dehumidistat closes on humidity rise or the thermostat energizes the DH terminal when dehumidification is required.

Set to “Lo” if the external dehumidistat opens on humidity rise or the thermostat de-energizes the DH terminal when dehumidification is required.

Use LEFT and RIGHT buttons to scroll through main menus and then through options within a specific menu.

Use the CENTER button to enter a selected main menu and then to permanently select an option within that menu.

1. Ensure the installed 24VAC thermostat can control the accessory.

2. Connect the accessory control wires from the thermostat to the accessory device (refer to thermostat manual).

3. If the thermostat provides a continuous fan call (G signal) during accessory operation, connect the thermostat G terminal to the indoor unit G terminal and set up the thermostat accordingly.

4. Select the appropriate fan-only airflow for the accessory using the indoor unit pushbuttons or the CoolCloud HVAC phone application.

5. Use the thermostat to independently test each accessory in parallel with the continuous fan mode.

Profile A (1): Provides only a one-minute OFF delay at 100% of the cooling demand airflow. (Figure 46)

Profile B (2): Ramps up to 50% of demand for 30 seconds, then ramps to 100% airflow. Provides a one-minute, post-cycle OFF delay at 100% airflow. (Figure 47)

Profile C (3): Ramps up to 85% of full cooling demand airflow for approximately 7 ½ minutes, then steps up to 100% demand airflow. Provides a one-minute, post-cycle OFF delay at 100% airflow. (Figure 48)

Profile D (4): Ramps up to 50% demand for ½ minute, then ramps to 85% of full cooling demand for 7 ½ minutes. Then runs at 100% capacity for the remainder of the cycle. Provides a post-cycle OFF delay at 50% airflow. (Figure 49)

WARNING: HIGH VOLTAGE! TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING.

• Turn OFF power to the furnace before installing the EAC.

• Follow the EAC manufacturer’s instructions for locating, mounting, grounding, and controlling.

• Use ¼” quick connect terminals for wiring connections to the furnace control module.

• Connect the hot terminal for accessory operation to the EAC terminal on the furnace control.

• Connect the neutral side of power to the NEUTRAL bus on the integrated furnace control or the neutral connection in the furnace junction box.

• Ensure all field wiring conforms to applicable codes.

• If additional line voltage wiring inside the furnace is needed, it must conform to local codes and have a minimum temperature rating of 105°C.

• Ensure all line voltage wire splices are inside the furnace cabinet.

Important Note: Wiring routing must not interfere with circulator blower operation, filter removal, or routine maintenance. The wire should not be routed near hot surfaces and should be protected from sharp edges. Route it alongside the thermostat wires through the low voltage openings in the furnace blower compartment. Refer to the electrical section for the connection point location.

1. Displays the A2L Refrigerant Leakage error code (EAL).

2. Shuts down the gas operation.

3. Energizes the optional ventilation and alarm outputs.

4. Runs the fan at maximum CFM airflow.

1. Display the A2L Refrigerant Leakage code (EAL).

2. Shut down gas operation.

3. Energize optional ventilation and alarm outputs.

4. Run the fan at max CFM airflow.

R-32 System Check: Verify the R-32 sensor wire is plugged into the control board if applicable. If the furnace is NOT paired with an R-32 system, change the default settings on the control board (disable A2L function).

Power Supply: Ensure the furnace has a 115 VAC power supply properly connected, grounded, and with correct polarity.

Furnace Cabinet Sealing: Check that all plugs, grommets, and gaskets are in place. Seal all bottom panel return duct connections and perforations to prevent air leakage. Verify door gaskets are correctly placed and replace if needed.

Drain Trap Priming: Prime the drain trap by filling both sides with water before startup. This ensures proper drainage and prevents flue gas escape.

Gas Line Purging: Purge gas lines of air prior to startup according to NFPA 54 or local codes. Do not purge into the enclosed burner compartment.

Gas Leaks: Check for gas leaks using an approved method (soap solution, electronic detector).

NOTE: The ignition device lights automatically. DO NOT try to light the burner by hand.

1. Close the manual gas shutoff valve external to the furnace.

2. Turn off electrical power to the furnace.

3. Set the room thermostat to the lowest possible setting.

4. Remove the burner compartment door.

5. Move the furnace gas valve manual control to the OFF position.

6. Wait five minutes, then smell for gas (check near the floor).

7. If you smell gas, follow safety instructions in the manual. If no gas smell after five minutes, move the gas valve manual control to the ON position.

8. Replace the burner compartment door.

9. Open the manual gas shutoff valve external to the furnace.

10. Turn on the electrical power to the furnace.

11. Adjust the thermostat to a setting above room temperature.

12. After the burners light, set the thermostat to the desired temperature.

1. Set the thermostat to the lowest setting. The control will close the gas valve. After a 15-second delay, the induced draft blower de-energizes. The main blower de-energizes after the fan OFF delay.

2. Remove the burner compartment door and move the furnace gas valve manual control to the OFF position.

3. Close the manual gas shutoff valve external to the furnace.

4. Replace the burner compartment door.

WARNING: To avoid unsatisfactory operation or damage due to underfiring, use the proper size of natural gas piping needed when running pipe from the meter/tank to the furnace.

• Size gas lines considering all appliances that will operate simultaneously. Use Table (Natural Gas Capacity of Pipe) for reference, based on pipe size, length, gas type, and required flow (CFH).

• Calculate required CFH: CFH = (BTUH Furnace Input) / (Heating Value of Gas in BTU/Cubic Foot).

• Support piping externally to avoid distorting the furnace cabinet or components.

• Use black iron or steel pipe and fittings. Ensure new pipe is clean, reamed, and free of burrs. Clean old pipe thoroughly.

• Use pipe joint compound (approved for all gases) on male threads ONLY. Do not apply to the first two threads.

• Install a ground joint union.

• Install a drip leg (min 3″ long) before the gas valve.

• Install a ½” NPT plugged tee or tapping for a test gauge connection upstream of the gas valve connection.

• Use a back-up wrench when connecting to the gas valve. Maintain valve orientation. Max torque: 375 in-lbs.

• Install a manual shutoff valve within six feet of the unit, external to the furnace.

• If a union is used, install it downstream of the manual shutoff valve.

• Tighten all joints securely.

• Comply with local codes and NFPA 54/ANSI Z223.1.

• Connection Methods: Use rigid metallic pipe, semi-rigid metallic tubing (protect if necessary), or listed gas appliance connectors (in the same room as the furnace).

• Protect tubing/connectors from damage and corrosion.

WARNING: TO AVOID THE POSSIBILITY OF EXPLOSION OR FIRE, NEVER USE A MATCH OR OPEN FLAME TO TEST FOR LEAKS.

NOTE: NEVER EXCEED SPECIFIED PRESSURES FOR TESTING. HIGHER PRESSURE MAY DAMAGE THE GAS VALVE AND CAUSE SUBSEQUENT OVERFIRING, RESULTING IN HEAT EXCHANGER FAILURE.

• For testing pressures in excess of ½ psig (3.48 kPa): Disconnect the furnace and its individual shutoff valve from the gas supply piping system.

• For testing pressures equal to or less than ½ psig (3.48 kPa): Isolate the furnace from the gas supply piping system by closing its external manual gas shutoff valve.

WARNING: NEVER ALLOW THE PRODUCTS OF COMBUSTION, INCLUDING CARBON MONOXIDE, TO ENTER THE RETURN DUCT WORK OR CIRCULATION AIR SUPPLY.

• Design duct systems and register sizes for the furnace’s CFM and external static pressure rating (recommend using ACCA Manual D).

• Install according to NFPA 90A and 90B standards.

• Use a closed return duct system connected to the furnace. Ductwork must never be attached to the back of the furnace.

• For installations requiring 1800 CFM or more, use a bottom return or two-sided return.

• Flexible joints can be used for supply/return connections to reduce noise.

• If using a central return, install a connecting duct between the unit and the utility room wall to prevent blower interference with combustion air/draft. Never use a room, closet, or alcove as a return air chamber.

1. With clean filters installed, use a manometer to measure the static pressure of the return duct at the furnace inlet (this will be a negative pressure reading).

2. Measure the static pressure of the supply duct between the furnace and the cooling coil (this will be a positive pressure reading).

3. Add the absolute values of the two readings to get the total external static pressure. Example: Return reading = -0.1″ w.c., Supply reading = +0.3″ w.c. Total ESP = |-0.1| + |0.3| = 0.4″ w.c.

NOTE: Readings can be taken simultaneously. Ensure measurements include components like A/C coils or electronic air cleaners if installed.

4. Consult airflow tables for the quantity of air at the measured ESP.

• Closed dampers or registers.

• Undersized or poorly laid out ductwork.

1. Press out the lanced sections by hand to expose the metal strips holding the sheet metal cover.

2. Use tin snips to cut the metal strips and remove the sheet metal cover.

3. In the corners of the opening, cut the sheet metal along the scribe lines to free the duct flanges.

4. Using the scribe line as a guide, use seamer pliers or tongs to unfold the duct flanges around the perimeter of the opening.

NOTE: Failure to unfold the duct flanges reduces airflow area by approximately 18% and could cause performance and noise issues.

• Filters are required and must be used with this furnace. Damage due to lack of filters is not covered by warranty.

• Filters are not shipped with the unit; the installer must provide and install them externally in the return air duct.

• Filters must comply with UL900 or CAN/ULCS111 standards.

• Discuss filter maintenance with the building owner.

• Change filters before occupants take ownership of a new home.

• Inspect filters monthly and replace/clean as needed (typically every two months or as required).

• Failure to maintain clean filters is a common cause of problems and can lead to premature heat exchanger failure.

• Use the minimum recommended filter size from the Filter Sizing Chart (Table 9). Larger filters or centrally located filters may be used.

• Consider installing an air cleaner with a deep-pleated media filter (MERV 8 minimum) for better filtration and potentially lower static pressure loss than standard 1″ filters.

• Avoid highly restrictive 1″ filters (static pressure loss > 0.25″ W.C.).

• Install the furnace in parallel with or on the upstream side of the cooling unit to prevent condensation in the heating element.

• In a parallel flow arrangement, use dampers or other means to prevent chilled air from entering the furnace. If manually operated, ensure means are in place to prevent operation of either unit unless the damper is fully in the heat or cool position.

• In a horizontal installation, the air conditioning coil must be adequately supported by proper brackets and supports to prevent furnace cabinet distortion and air leakage.

CAUTION: Inlet gas supply pressure must be as specified on the rating plate with all other household gas-fired appliances operating.

1. Turn OFF gas to the furnace at the external manual shutoff valve.

2. Access the inlet pressure test port on the gas valve (White-Rodgers 36J22Y-204 shown in Figure 56) by backing out the screw counter-clockwise (no more than one turn), OR install a field-supplied hose barb fitting in the gas piping drip leg.

3. Connect a calibrated manometer or appropriate pressure gauge to the test port or barb fitting. (If using the valve tap on a White-Rodgers 36J22, use the 36G/J Valve Pressure Check Kit, P/N 0151K00000S).

4. Turn ON the gas supply. Operate the furnace and all other gas-consuming appliances on the same supply line.

5. Measure the furnace gas supply pressure with the burners firing. It must be within the range specified in Table 7 (Natural Gas: 4.5″ – 10.0″ W.C.). If outside the range, adjust the pressure regulator, check piping size, or consult the gas utility.

6. Turn OFF gas to the furnace at the manual shutoff valve.

7. Disconnect the manometer. Reinstall the test port plug/screw and tighten securely before turning gas back on.

8. Turn OFF any unnecessary gas appliances started in step 4.

Procedure:

1. Turn OFF gas to the furnace at the external manual shutoff valve.

2. Turn off all electrical power to the system.

3. Access the outlet pressure tap: White-Rodgers 36J22 valve – back out the outlet test screw counter-clockwise (no more than one turn).

4. Connect a calibrated manometer to the gas valve outlet pressure tap (See Figure 56).

5. Turn ON the gas supply.

6. Turn on electrical power and close thermostat “R” and “W” contacts for a call for heat.

7. Measure the gas manifold pressure with burners firing. Compare to Table 10.

8. If adjustment is needed, remove the regulator cover screw. Turn the adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure.

9. After adjustment, turn off all electrical power and gas supply.

10. Remove the manometer from the outlet pressure tap.

11. Replace outlet pressure tap screw: White-Rodgers 36J22 valve – turn screw in clockwise to seal (7 in-lb minimum).

12. Turn on electrical power and gas supply.

13. Close thermostat contacts “R” and “W” to energize the valve.

14. Leak check the outlet pressure tap screw/fitting using leak detection solution. If bubbles form, SHUT OFF GAS AND REPAIR LEAKS IMMEDIATELY.

1. Turn OFF the gas supply to all other gas-burning appliances except the furnace.

2. While the furnace operates at high fire rate, time one complete revolution of the smallest quantity gas meter dial (e.g., ½ cu. ft. dial). Record the time in seconds.

3. Calculate the gas consumed per hour:

If using a ½ cu. ft. dial: Time (seconds) x 2 = Seconds per 1 cu. ft.

Gas consumption (cu. ft. per hour) = 3600 / (Seconds per 1 cu. ft.)

4. Calculate BTUH Input: BTUH = (Gas consumption cu. ft./hr) x (Gas heating value BTU/cu. ft. – typically ~1025 for natural gas, check with utility).

Example: If a ½ cu. ft. dial takes 23 seconds per revolution:

Seconds per 1 cu. ft. = 23 x 2 = 46 seconds.

Gas consumption = 3600 / 46 ≈ 78 cu. ft./hr.

BTUH Input ≈ 78 x 1025 ≈ 80,000 BTUH.

NOTE: Consult your local gas supplier if additional input rate adjustment is required beyond manifold pressure adjustment.

Procedure:

1. Operate the furnace with burners firing for approximately 10 minutes. Ensure registers are open and duct dampers are in their final position.

2. Place thermometers in the return and supply ducts close to the furnace, avoiding radiant heat influence (do not let thermometers “see” the heat exchanger, see Figure 58).

3. Allow readings to stabilize. Subtract the return air temperature from the supply air temperature to get the temperature rise.

4. If the rise is outside the rating plate range, adjust the circulator blower speed: Increase speed to reduce rise; Decrease speed to increase rise. Refer to furnace documentation for speed changing details.

• Integrated Control Module: The electronic brain that monitors safety circuits, takes precautions if hazards are detected, and provides diagnostics via an LED.

• Primary Limit: A normally closed, auto-reset sensor on the partition panel monitoring heat exchanger compartment temperature to prevent overheating from insufficient airflow.

• Auxiliary Limit: Normally closed, manual-reset sensors on or near the circulator blower monitoring blower compartment temperature to prevent overheating from insufficient airflow.

• Burner Temperature Switch: A normally closed, auto-reset sensor on the burner assembly monitoring burner box temperature to ensure proper flame draw into the heat exchanger.

• Pressure Sensor: Mounted on the induced draft blower, regulates its speed to maintain the proper air-fuel ratio for clean combustion.

• Pressure Switches: Normally open, negative pressure-activated switches monitoring airflow (combustion air/flue products) through the heat exchanger, guarding against insufficient airflow or blocked condensate drains.

• Flame Sensor: A probe that uses flame rectification to detect the presence or absence of flame.

WARNING: DO NOT BYPASS SAFETY DEVICES.

CAUTION: TO AVOID PERSONAL INJURY OR DEATH, DO NOT REMOVE INTERNAL COMPARTMENT COVERS OR ATTEMPT ANY ADJUSTMENT. CONTACT A QUALIFIED SERVICE AGENT AT ONCE IF AN ABNORMAL OPERATION SHOULD DEVELOP.

WARNING: HIGH VOLTAGE! TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, DISCONNECT ELECTRICAL POWER BEFORE PERFORMING ANY SERVICE OR MAINTENANCE.

• Annual Inspection: Have the furnace inspected by a qualified installer or service agency at least once per year, preferably at the beginning of the heating season. Checks should include:

• Flue pipe system (blockage, leakage, termination)

• Heat exchanger (corrosion, buildup)

• Burners (ignition, flame sense)

• Drainage system (blockage, leakage, hose connections)

• Wiring (tightness, corrosion, damage)

• Filters (blockage)

• R-32 Sensor Wire (connection tightness, wire damage, if applicable)

• Filter Maintenance: Inspect filters monthly. Clean or replace filters every two months or as required. Improper filter maintenance is the most common cause of inadequate heating/cooling.

• Induced Draft and Circulator Blowers: Bearings are permanently lubricated; no lubrication is needed. Check motor windings periodically for dust accumulation (which can cause overheating) and clean as necessary.

• Burner: The Ultra Low NOx burner box is sealed. Contact a qualified servicer if abnormal flame appearance develops.

• Condensate Trap and Drain System (Qualified Servicer Only): Annually inspect drain tubes, trap, and field-supplied line for proper drainage, tightness, blockage, and leaks. Clean or repair as necessary.

• Flame Sensor (Qualified Servicer Only): If flame sense signal drops too low (below 3 micro amps), the sensor may need cleaning by a qualified servicer using emery cloth or steel wool.

• Flue Passages (Qualified Servicer Only): Inspect heat exchanger flue passageways at the beginning of each heating season.

• Cycle the furnace with the thermostat at least three times.

• Verify cooling and fan-only operation.

• Review the Owner’s Manual with the homeowner, discussing proper furnace operation and maintenance.

• Leave the literature packet near the furnace.

Corrective Actions:

• Check filters for blockage, clean filters or remove obstruction.

• Check ductwork for blockage, remove obstruction and verify all registers are fully open.

• Verify ductwork is appropriately sized for system, resize and/or replace ductwork if necessary.

Corrective Action: Verify electrical connections to pressure sensor.

Corrective Action: Verify electrical connections to pressure sensor.

Corrective Action: Verify electrical connections to pressure sensor.

1. Vent blocked, pressure couldn’t reach target (too low) at max inducer RPM.

2. Vent blocked, pressure couldn’t reach target (too high) at min inducer RPM.

3. APS fault causes pressure reading lower than target at max inducer RPM.

4. APS fault causes pressure reading higher than target at min inducer RPM.

Corrective Action: Check the APS Sensor or its connection.

Voltage Ranges:

• If 2″ is selected: (0.25 – 0.06)V to (4 + 0.06)V

• If 4″ is selected: (0.5 – 0.06)V to (4.5 + 0.06)V

Corrective Action: Check the APS Sensor or its connection.

Corrective Action: Verify neutral wire connection to furnace & continuity to ground source.

Corrective Actions:

• Check for correct gas pressure.

• Check for correct burner alignment.

• Check for and correct burner restriction.

Corrective Action: Populate shared data set using CoolCloud HVAC App.

Corrective Action: Verify shared data set is correct for the specific model, re-populate data using CoolCloud HVAC App if required.

Corrective Actions:

• Locate and correct gas interruption.

• Check front cover pressure switch operation and verify proper drainage (hose, wiring, contact operation), correct if necessary.

• Replace or realign igniter.

• Check flame sense signal, sand sensor if coated/oxidized.

• Check flue piping for blockage, proper length, elbows, and termination.

• Verify proper induced draft blower performance.

Corrective Action: Replace pressure switch or repair short in wiring.

• Pressure switch hose blocked, pinched, or improperly connected.

• Blocked flue/inlet air pipe, blocked drain system, or weak induced draft blower.

• Incorrect pressure switch set point or malfunctioning switch contacts.

• Loose or improperly connected wiring.

Corrective Actions:

• Inspect pressure switch hose, repair/replace if necessary.

• Inspect flue/inlet air piping for blockage, proper length, elbows, termination.

• Check drain system, correct as necessary.

• Check induced draft blower performance, correct as necessary.

• Check pressure switch operation, replace as needed.

• Tighten or correct wiring connection.

• Insufficient conditioned air over the heat exchanger.

• Blocked filters, restrictive ductwork, improper circulator blower speed, or failed circulator blower motor.

• Loose or improperly connected wiring in high limit circuit.

Corrective Actions:

• Check filters and ductwork for blockage. Clean filters or remove obstruction.

• Check circulator blower speed and performance.

• Correct speed or replace blower motor if necessary.

• Tighten or correct wiring connection.

• Short to ground in flame sense circuit.

• Lingering burner flame / Slow closing gas valve.

Corrective Actions:

• Correct short at flame sensor or in flame sensor wiring.

• Check for lingering or lazy flame. Verify proper operation of gas valve.

Corrective Actions:

• Replace fuse.

• Locate and correct short in low voltage wiring.

• Flame sensor is coated/oxidized.

• Flame sensor incorrectly positioned in burner flame.

• Lazy burner flame due to improper gas pressure or combustion air.

Corrective Actions:

• Clean flame sensor if coated or oxidized. Inspect for proper flame sensor alignment.

• Check inlet air piping for blockage, proper length, elbows, and termination.

• Compare current gas pressure to rating plate and adjust as needed.

• Improperly connected or shorted igniter.

• Poor unit ground.

• Igniter relay fault on integrated control module.

Corrective Actions:

• Check and correct wiring from integrated control module to igniter.

• Diagnose and replace shorted igniter as needed.

• Verify and correct unit ground wiring if needed.

• Check igniter output from control, replace if necessary.

Corrective Actions:

• Correct polarity, check and correct wiring if necessary.

• Verify proper ground, correct if necessary.

Corrective Actions:

• Check Wiring in gas valve circuit.

• Replace integrated control board.

Corrective Actions:

• Check wiring in gas valve circuit.

• Replace integrated control board.

Corrective Actions:

• Check filters and ductwork for blockage, clean filters or remove obstruction.

• Check circulator blower speed and performance, correct speed or replace blower motor if necessary.

• Tighten or correct wiring connection.

Corrective Action: Check evaporator drain pan, trap, piping.

Corrective Actions:

• Verify wire connection to R-32 sensor is not loose.

• Verify that the R-32 sensor wire is not damaged.

• Replace R-32 Sensor.

Corrective Actions:

• Investigate the indoor coil for a refrigerant leak.

• Furnace will resume normal operation once a leak is not detected and the 5 minute delay period is over.

Corrective Actions:

• Investigate the R-32 sensor.

• Replace the R-32 sensor.

Corrective Actions:

• Investigate A2L relay.

• Cycle power on the furnace.

• Replace integrated control board.

• Use the HUM terminal to run the humidifier during a heat call (in Communicating or Legacy modes).

• Use the HUM-IN and HUM-OUT terminals to run the humidifier during a heat call (Communicating or Legacy mode) OR independently from a heat call (Communicating mode only – setup done via communicating thermostat).

• Electrical: Line Voltage (L1-N, N-G), Secondary Voltage (Transformer Output), Blower Amps.

• Blower External Static Pressure: Return Air, Supply Air, Total ESP.

• Temperatures: Return Air (Dry/Wet), Cooling Supply Air (Dry/Wet), Heating Supply Air, Temperature Rise, Delta T (Supply-Return difference).

• Gas Pressures: Gas Type (NG/LP), Inlet Pressure, Manifold Pressure (Low Fire), Manifold Pressure (High Fire).

• Additional Checks: Wire routings (rubbing), pressure switch tubing (kinks), flue elbow (alignment/tightness), blower wheel screw tightness, factory wiring/connections, product clearances, R-32 sensor wire connection (if applicable).