Haier GE APPLIANCES NF96US Service Manual
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Haier GE APPLIANCES NF96US Service Manual

Haier GE APPLIANCES NF96US Service Manual

96 upflow/horizontal single stage constant torque motor gas furnace
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Service
NF96US
96% Upflow/Horizontal Single Stage
Manual
Constant Torque Motor Gas Furnace
READ CAREFULLY.
.
KEEP THESE INSTRUCTIONS
31-5000728 Rev. 0 10-22 GEA
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Summary of Contents for Haier GE APPLIANCES NF96US

  • Page 1 Service NF96US 96% Upflow/Horizontal Single Stage Manual Constant Torque Motor Gas Furnace READ CAREFULLY. KEEP THESE INSTRUCTIONS 31-5000728 Rev. 0 10-22 GEA...

  • Page 2: Table Of Contents

    SERVICE MANUAL NF96US Gas Furnace - Upflow/Horizontal This is a safety alert symbol and should never be ignored. When you see this symbol on labels or in manuals, be alert to the potential for personal injury or death. Table of Contents WARNING Technical Specifications - NF96US ......3 Parts Arrangement............7...

  • Page 3: Technical Specifications - Nf96Us

    Technical Specifications - NF96US MODEL NUMBER GUIDE N F F 96 96 U U S S 5 5 C C XX BRAND MAJOR/MINOR REVISION N - GE CABINET WIDTH PRODUCT B - 17.5” F - FURNACE, GAS C - 21” D - 24.5”...
  • Page 4 BLOWER PERFORMANCE DATA NF96U045S3B PERFORMANCE (Less Filter) External Air Volume / Watts at Various Blower Speeds Static High Medium-High Medium Medium-Low Pressure in. w.g. Watts Watts Watts Watts Watts 0.00 1285 1190 1460 0.10 1430 1260 1155 0.20 1405 1235 1125 0.30 1375...
  • Page 5 NF96U110S5C PERFORMANCE (Less Filter) Air Volume / Watts at Different Blower Speeds Bottom Return Air, Side Return Air with Optional Return Air Base, Return Air from Both Single Side Return Air − Air volumes in bold require field fabricated transition to External Sides or Return Air from Bottom and One Side.
  • Page 6 ACCESSORIES System Accessory Kit Number Description 11K50 1-Stage Natural to LP Kit (See Table 16) 11K45 High Altitude 1-Stage 68W62 17.5" B Width Return Air Base 68W63 21.0" C Width Flush Mount Termination 51W11 2" & 3" Vent Version (90% Furnaces Only) (US Only) 71M80 1-1/2"...

  • Page 7: Parts Arrangement

    Parts Arrangement Figure 1. Page 7 31-5000728 Rev. 0...

  • Page 8: Electrical

    Circuit Breaker (CB8) Electrical A 24V circuit breaker is also located in the control box. The switch provides overcurrent protection to the transformer ELECTROSTATIC DISCHARGE (ESD) (T1). The breaker is rated at 3A at 32V. If the current exceeds this limit the breaker will trip and all unit operation Precautions and Procedures will shutdown.
  • Page 9 1/4” Quick Connect Terminals 120HUM Humidifier 120VAC LINE 120VAC XFMR Transformer 120VAC CIRC Indoor Blower 120VAC Indoor Air Quality Accessory 120VAC NEUTRALS Common 120VAC HUM24 Humidifier 24VAC 3/16” Quick Connect Terminals COOL Cooling Tap 24VAC HEAT Heating Tap 24VAC Continuous Blower 24VAC PARK (no power) Park terminal for unused speed taps Flame Sense...
  • Page 10 Heating Fan Off Time Fan off time (time that the blower operates after the heat demand has been satisfied) can be adjusted by moving the jumper to a different setting. The unit is shipped with a factory fan off setting of 90 seconds. For customized comfort, monitor the supply air temperature once the heat demand is satisfied.
  • Page 11 Burner Assembly Rollout Switch(s) Flame Sensor Ignitor Gas Valve Burner Box Front Figure 5. Burner Box Assembly Flame Rollout Switches (Figure 5) Flame rollout switches S47 are SPST N.C. high temperature Flame (microamp) signal is an electrical current which limits located on the left and right of the front buner box passes from the integrated control to the sensor during plate.
  • Page 12 Primary Limit Control (Figure 6) MANIFOLD PRESSURE Primary limit (S10) used on NF96US units is located in the ADJUSTMENT SCREW heating vestibule panel. When excess heat is sensed in the (under barbed fitting) MANIFOLD heat exchanger, the limit will open. Once the limit opens, PRESSURE the furnace control energizes the supply air blower and OUTLET...
  • Page 13 Flame Signal In Microamps Normal Drop Out 0.5 - 1.4 Flame Sensor Wire Remove sensor from integrated control and connect alligator clip (−) to flame sensor lead. Multi−Meter Intergrated Control Set Dial to DC MicroAmps Flame Sensor Terminal (−) T o Flame Terminal (+) To Control Sensor Terminal...
  • Page 14 Test 1 Check ignitor circuit for correct resistance. Remove 4-pin plug from control. Check ohms reading across terminals 2 and 4. Reading should be between 39 and 70 ohms. If value is correct, this is the only test needed. If the reading on the meter is not correct, (0 or infinity) then a second test is needed.
  • Page 15 Combustion Air Inducer (B6) & Cold End Header Box On start-up, the switch monitors whether the combustion air inducer is operating. It closes a circuit to the integrated All NF96US units use a combustion air inducer to move control when the difference in pressure across the air through the burners and heat exchanger during heating combustion air inducer orifice exceeds a non-adjustable operation.
  • Page 16 Black Tubing (positive +) Red and Black Tubing or Red Tubing (negative -) To Cold End Header Box To Cold End Header Box Field Provided Tubing To Pressure Switch “+” High “-” 1 - Remove thermostat demand and allow unit to 4 - Operate unit and observe manometer reading.
  • Page 17 Problem Corrective Action Check that the pressure switch is open without the combustion air inducer Pressure switch stuck closed operating. Replace if defective. Check for restricted vent. Remove all blockage. Pressure switch does not close due to obstruction in vent pipe Check for proper vent sizing.
  • Page 18 Blower Compartment Center Blower Wheel in Blower Houseing IMPORTANT Each blower is statically and dynamically balanced as an assembly before installation in the unit. NF96US units are equipped with a constant torque ECM motor. It has a DC motor coupled to an electronic control module both contained in the same motor housing.
  • Page 19 Multi−Meter (set to VAC) Multi−Meter (set to VAC) Test 1 Test 3 (if necessary) Turn on power to unit. Check for 120 volts across terminals Check for 120 volts across terminals “CIRC” and “Neutrals” “L” and “N” on input plug P48. If voltage is present continue on the integrated control.
  • Page 20 Testing the Motor (Figure 17) Scale Measurement Range in Words ohms If any motor fails the below tests, the motor is defective two megohms - two million ohms 0 - 2,000,000 and must be replaced. two hundred kil-ohms - 200 K 0 - 200,000 two hundred thousand ohms Using an ohmmeter check the resistance from any...

  • Page 21: Placement & Installation

    Placement & Installation Piping and Fittings Specifications Schedule 40 PVC (Pipe) D1785 Pipe & Fittings Specifications Schedule 40 PVC (Cellular Core Pipe) F891 All pipe, fittings, primer and solvent cement must conform Schedule 40 PVC (Fittings) D2466 with American National Standard Institute and the American Society for Testing and Materials (ANSI/ASTM) standards.

  • Page 22: Joint Cementing Procedure

    Standard Concentric Flush Mount Kit 1-1/2 inch 2 inch 3 inch Vent Pipe Dia. Field (in.) Fabricated 51W11 (US) 51W12 71M80 (US) 69M29 (US) 60L46 (US) (CA) 44W92 (CA) 44W92 (CA) 444W93 (CA) 1-1/2 2-1/2 1-1/2 3YES 3YES 2-1/2 2-1/2 2-1/2 NOTE - Standard Terminations do not include any vent pipe or elbows external to the structure.

  • Page 23: Venting Practices

    Promptly apply solvent cement to end of pipe and inside socket surface of fitting. Cement should be REPLACING FURNACE THAT CHIMNEY applied lightly but uniformly to inside of socket. Take WAS PART OF A COMMON OR GAS VENT VENT SYSTEM care to keep excess cement out of socket.

  • Page 24: Vent Piping Guidelines

    Vent Piping Guidelines Exhaust Pipe NOTE: GE Appliances has approved the use of DuraVent ® 12” Min. 12” Max. and Centrotherm manufactured vent pipe and terminations as an option to PVC. When using the PolyPro by DuraVent ® Horizontal or InnoFlue by Centrotherm venting system the vent pipe ®...
  • Page 25 Use the following steps to correctly size vent pipe diameter. 040, 060, Furnace capacity? 080, 100 btuh Standard or Which termination? Concentric? See Table 11 Which needs most Intake or elbows? Exhaust? How many? Desired pipe size? 2” or 3” What is the altitude? Use Table 12A through Table 13 to find max pipe...
  • Page 26 Maximum Allowable Intake or Exhaust Vent Length in Feet Standard Termination at Elevation 0 - 2,000 ft 1-1/2” Pipe 2” Pipe 2-1/2" Pipe 3" Pipe Number of Capacity Capacity Capacity Capacity 90° Elbows Used NOTE - Size intake and exhaust pipe length separately. Values in table are for Intake OR Exhaust, not combined total. Both Intake and Exhaust must be same pipe size.
  • Page 27 Maximum Allowable Intake or Exhaust Vent Length in Feet Concentric Termination at Elevation 0 - 2,000 ft 1-1/2” Pipe 2” Pipe 2-1/2" Pipe 3" Pipe Number of Capacity Capacity Capacity Capacity 90° Elbows Used NOTE - Size intake and exhaust pipe length separately. Values in table are for Intake OR Exhaust, not combined total. Both Intake and Exhaust must be same pipe size.
  • Page 28 Maximum Allowable Exhaust Vent Lengths With Furnace Installed in a Closet or Basement Using Ventilated Attic or Crawl Space For Intake Air in Feet Standard Termination at Elevation 0 - 2,000 ft 1-1/2” Pipe 2” Pipe 2-1/2" Pipe 3" Pipe Number of Capacity Capacity...
  • Page 29 TYPICAL EXHAUST PIPE CONNECTIONS IN UPFLOW DIRECT OR NON-DIRECT VENT APPLICATIONS Pipe size determined in Table 5 2” 2” 2” 2” 3” 2” TRANSITION EXHAUST *2” 045/070 Only 1-1/2” DO NOT transition from smaller to larger TRANSITION pipe in horizontal runs 2”...
  • Page 30 Intake Piping Follow the next two steps when installing the unit in Non- Direct Vent applications where combustion air is taken The NF96US furnace may be installed in either direct from indoors and flue gases are discharged outdoors. vent or non-direct vent applications. In non-direct vent applications, when intake air will be drawn into the furnace 1.
  • Page 31 TYPICAL INTAKE PIPE CONNECTIONS IN HORIZONTAL DIRECT OR NON-DIRECT VENT APPLICATION (RIGHT-HAND DISCHARGE SHOWN) 2” 3” 2” TRANSITION 2” 2” 2” *2” *2” INTAKE * When transitioning up in pipe size, use the shortest length of 2” PVC pipe possible. NOTE: Exhaust pipe and intake pipe must be the same diameter.
  • Page 32 In Direct Vent applications, combustion air is taken from Ventilation Louvers outdoors and the flue gases are discharged to the outdoors. Roof Inlet Air Minimum The NF96US is then classified as a direct vent, Category Terminated 12” (305mm) IV gas furnace. Exhaust Pipe above attic floor In both Non-Direct Vent and Direct Vent applications, the...
  • Page 33 Maximum Allowable Exhaust Vent Pipe Length (in ft.) without Insulation in Unconditioned Space For Winter Design Temperatures Single - Stage High Efficiency Furnace Unit Input Size Winter Design Vent Pipe Temperatures ºF (ºC) Diameter 1-1/2 in. 32 to 21 2 in. (0 to -6) 2-1/2 in.
  • Page 34 VENT TERMINATION CLEARANCES FOR DIRECT VENT INSTALLATIONS IN THE USA AND CANADA Inside Corner Detail Fixed Operable Fixed Closed Closed Operable AREA WHERE TERMINAL VENT TERMINAL AIR SUPPLY INLET IS NOT PERMITTED US Installations¹ Canadian Installations² Clearance above grade, veranda, porch, deck or 12”...
  • Page 35 Details of Intake and Exhaust Piping On field supplied terminations for sidewall exit, exhaust piping may extend a maximum of 12 inches (305 mm) Terminations for Direct Vent Installations for 2” PVC and 20 inches (508 mm) for 3” (76 mm) NOTE: In Direct Vent installations, combustion air is taken PVC beyond the outside wall.
  • Page 36 On field supplied terminations, a minimum distance 1 1/2” (38mm) accelerator between the end of the exhaust pipe and the end of provided on 71M80 & 44W92 EXHAUST the intake pipe without a termination elbow is 8” and a kits for -045 and -070 models VENT minimum distance of 6”...
  • Page 37 VENT TERMINATION CLEARANCES FOR NON-DIRECT VENT INSTALLATIONS IN THE US AND CANADA INSIDE CORNER DETAIL Fixed Operable Fixed Closed Closed Operable AREA WHERE TERMINAL AIR SUPPLY INLET VENT TERMINAL IS NOT PERMITTED US Installations Canadian Installations Clearance above grade, veranda, 12 inches (305mm) or 12 in.
  • Page 38 Details of Exhaust Piping Terminations for Non- Direct Vent Applications STRAIGHT-CUT OR * SIZE TERMINATION PIPE PER EXHAUST ANGLE-CUT IN DIRECTION PIPE TERMINATION SIZE REDUCTION TABLE Exhaust pipes may be routed either horizontally through OF ROOF SLOPE * an outside wall or vertically through the roof. In attic or closet installations, vertical termination through the roof EXHAUST VENT Minimum 12”...
  • Page 39 FIELD FABRICATED WALL TERMINATION NOTE − FIELD−PROVIDED REDUCER MAY BE 2” (51mm) 3” (76mm) REQUIRED TO ADAPT Vent Pipe Vent Pipe LARGER VENT PIPE SIZE TO TERMINATION A− Minimum clearance above grade or average 12” (305 mm) 12” (305 mm) snow accumulation B−...
  • Page 40 For the Province of Ontario, Horizontal Sidewall Vent Applications Only For exterior horizontal venting applications, the 2” X 1.5” reducer for 2” venting at the point where the exhaust pipe exits the structure is not required in direct or nondirect vent applications in the Province of Ontario. In these applications, the vent should be oriented such that the exhaust plume is unobjectionable.

  • Page 41: Condensate Piping

    above 5” may result in a flooded heat exchanger if the Condensate Piping combined primary drain line were to become restricted. NOTE: In horizontal applications it is recommended to This unit is designed for either right- or left-side exit of install a secondary drain pan underneath the unit and condensate piping in upflow applications.
  • Page 42 If unit will be started immediately upon completion of installation, prime trap per procedure outlined in Unit Evaporator drain line required Start-Up section. Condensate line must slope downward away from the (Trap at coil is optional) trap to drain. If drain level is above condensate trap, Field provided vent condensate pump must be used.
  • Page 43 Evaporator drain From evaporator coil line required Field provided vent (1” min. 2” max. above (Trap at coil is optional) condensate drain) Field provided vent (1” min. 2” max. above condensate drain connection) Condensate Furnace condensate drain connection drain connection Optional overflow switch Figure 51.
  • Page 44 Optional Condensate Drain Connection Adapter 3/4 inch slip X 3/4 inch mpt (not furnished) 90° Street Elbow 3/4 inch PVC (not furnished) Adapter 3/4 inch slip X 3/4 inch mpt (not furnished) Condensate Drain Connection In Unit 1 (25 mm) Min. Vent 2 (50 mm) Max.
  • Page 45 Optional Condensate Drain Connection Adapter 1/2 inch slip X 1/2 inch mpt (Not Furnished) 90° Street Elbow 1/2 inch PVC (Not Furnished) Adapter 1/2 inch slip X 1/2 inch mpt (Not Furnished) Condensate Drain Connection In Unit 1 (25 mm) Min. Vent 2 (50 mm) Max.

  • Page 46: Start-Up

    Start-Up WARNING If you do not follow these instructions exactly, a fire Preliminary and Seasonal Checks or explosion may result causing property damage, Inspect electrical wiring, both field and factory installed personal injury or death. for loose connections. Tighten as required. Check voltage at disconnect switch.

  • Page 47: Heating System Service Checks

    Testing Gas Piping Move gas valve switch to OFF. Replace the access panel. IMPORTANT Failure To Operate In case emergency shutdown is required, turn off the If the unit fails to operate, check the following: main shut-off valve and disconnect the main power to 1.
  • Page 48 Furnace should operate at least 5 minutes before checking Manifold Pressure Measurement gas flow. Determine time in seconds for two revolutions of Follow the steps below and use Figure 57 as a reference. gas through the meter. (Two revolutions assures a more Gas manifold Kit 10L34 provides additional components if accurate time.) Divide by two and compare to time in Table needed.
  • Page 49 Proper Combustion High Altitude Furnace should operate minimum 15 minutes with correct NOTE: In Canada, certification installations manifold pressure and gas flow rate before checking elevations over 4500 feet (1372 m) is the jurisdiction of combustion. Take combustion sample beyond the flue local authorities.
  • Page 50 Proper Ground and Voltage as a function of load indicates a poor or partial ground. Compare the readings to Table 18. If the readings exceed the maximum shown in Table 18, make repairs CAUTION before operating the furnace. In addition, measure the AC voltage from Line Hot Electric Shock Hazard.

  • Page 51: Typical Operating Characteristics

    External Static Pressure Typical Operating Characteristics 1. Tap locations shown in Figure 60. Punch a 1/4” diameter hole in supply and return air Blower Operation and Adjustment plenums. Insert manometer hose flush with inside edge of hole or insulation. Seal around the hose with NOTE: The following is a generalized procedure and does permagum.

  • Page 52: Maintenance

    Filter Size Maintenance Cabinet Width Side Return Bottom Return 17-1/2” 16 x 25 x 1 (1) 16 x 25 x 1 (1) 21” 20 x 25 x 1 (1) WARNING 24-1/2” 16 x 25 x 1 (2) 24 x 25 x 1 (1) ELECTRICAL SHOCK, FIRE, Table 19.
  • Page 53 Winterizing and Condensate Trap Care 10. Disconnect condensate drain line from the cold end header box. 1. Turn off power to the furnace. 11. Disconnect condensate drain tubing from flue collar. Have a shallow pan ready to empty condensate water. Remove screws that secures the flue collar into place.
  • Page 54 Cleaning the Burner Assembly (if needed) 30. Reinstall the cold end header box. 1. Turn off electrical and gas power supplies to furnace. 31. Reinstall the combustion air inducer. Reconnect the Remove upper and lower furnace access panels. plug to the wire harness. Disconnect the wires from the gas valve.

  • Page 55: Wiring Diagram

    Wiring Diagram 045*3B 070*3B 090*4C 110*5C Page 55 31-5000728 Rev. 0...

  • Page 56: Troubleshooting: Heating Sequence Of Operation

    Troubleshooting: Heating Sequence of Operation NORMAL HEATING MODE ABNORMAL HEATING MODE POWER ON GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. INDOOR BLOWER DELAY OFF. CONTROL SELF CHECK OKAY? LED SLOW FLASH (RESET CONTROL BY TURNING MAIN POWER OFF.) LED FLASHES CODE 1 - IS POLARITY CORRECT? POLARITY REVERSED.

  • Page 57: Troubleshooting: Heating Sequence Of Operation (Continued)

    Troubleshooting: Heating Sequence of Operation (Continued) NORMAL HEATING MODE ABNORMAL HEATING MODE 15-SECOND COMBUSTION AIR INDUCER PREPURGE INITIATED BY CLOSED PRESSURE SWITCH. LED FLASHES CODE 13 - LOW LINE VOLTAGE. ONCE VOLTAGE IS ABOVE IS VOLTAGE ABOVE 70 VOLTS? IGNITOR WARM-UP -- 20 SECONDS. 75 VOLTS, HEATING SEQUENCE RESTARTS.

  • Page 58: Troubleshooting: Cooling Sequence Of Operation

    Troubleshooting: Cooling Sequence of Operation NORMAL HEATING MODE ABNORMAL HEATING MODE POWER ON IGNITION CONTROL MAIN POWER ON. LED FLASHES STEADY - CIRCUIT BOARD FAILURE CONTROL SELF DIAGNOSTIC CHECK. IS GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. CONTROL OPERATING NORMALLY? INDOOR BLOWER OFF WITH NORMAL DELAY.

  • Page 59: Troubleshooting: Continuous Fan / Accessories Sequence Of Operation

    Troubleshooting: Continuous Fan / Accessories Sequence of Operation LED: SLOW FLASH RATE REMAINS UNCHANGED THROUGHOUT SEQUENCE. MANUAL FAN SELECTION MADE AT THERMOSTAT. CONTROL (G) ENERGIZES SYSTEM FAN AT FAN SPEED. EAC TERMINAL IS ENERGIZED. THERMOSTAT CALLS FOR HEAT (W). THERMOSTAT CALLS FOR COOLING. SYSTEM FAN CONTINUES FAN SPEED WITHOUT INTERRUPTION.
  • Page 60 All specifications and illustrations subject to change without notice and without incurring obligations. Printed in the U.S.A. Page 60 31-5000728 Rev. 0...

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