Haier GE NF96DS Service Manual
  1. Manuals
  2. Brands
  3. Haier Manuals
  4. Furnace
  5. GE NF96DS
  6. Service manual
Haier GE NF96DS Service Manual

Haier GE NF96DS Service Manual

96% downflow single stage constant torque motor gas furnace
Hide thumbs Also See for GE NF96DS:
Table of Contents

Advertisement

Quick Links

Download this manual
Service
NF96DS
96% Downflow Single Stage
Manual
Constant Torque Motor Gas Furnace
READ CAREFULLY.
.
KEEP THESE INSTRUCTIONS
31-5000729 Rev. 0 10-22 GEA

Advertisement

Table of Contents
loading

Related Manuals for Haier GE NF96DS

Summary of Contents for Haier GE NF96DS

  • Page 1 Service NF96DS 96% Downflow Single Stage Manual Constant Torque Motor Gas Furnace READ CAREFULLY. KEEP THESE INSTRUCTIONS 31-5000729 Rev. 0 10-22 GEA...

  • Page 2: Table Of Contents

    SERVICE MANUAL NF96DS Gas Furnace - Downflow 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 -NF96DS ......2 Improper installation, adjustment, alteration, service...

  • Page 3: Technical Specifications -Nf96Ds

    Technical Specifications -NF96DS MODEL NUMBER GUIDE N F F 96 96 D D S S 5 5 C C XX BRAND MAJOR/MINOR REVISION N - GE CABINET WIDTH PRODUCT B - 17.5 F - FURNACE, GAS C - 21 AFUE NOMINAL CFM 3 - 1200 CFM 96 = 96% EFFICIENCY...
  • Page 4 BLOWER PERFORMANCE DATA NF96D045S3B Performance (Less Filter) Air Volume / Watts at Different Blower Speeds External Bottom Return Air, Side Return Air with Optional Return Air Base, Return Air from Both Sides or Return Air from Static Bottom and One Side. Pressure High Medium-High...
  • Page 5 ACCESSORIES System Accessory Kit Number Description 11K50 1-Stage Natural to LP Kit 11K45 High Altitude 1-Stage 11M60 17.5" B Width Downflow Combustible Flooring Base 11M61 21.0" C Width Flush Mount Termination 51W11 2" & 3" Vent Version (90% Furnaces Only) (US Only) 71M80 1-1/2"...

  • Page 6: Parts Arrangement

    Parts Arrangement CONTROL BOX (Includes integrated control, transformer and door switch) BAG ASSEMBLY BLOWER MOTOR (hidden) BLOWER COMPARTMENT ACCESS PANEL COMBUSTION AIR INDUCER BLOWER DECK HEATING PRIMARY LIMIT COMPARTMENT ACCESS PANEL COLD END HEADER BOX HEAT EXCHANGER GAS VALVE BURNER BOX ASSEMBLY (includes flame sensor, rollout switches and ignitor) Figure 1.

  • Page 7: 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 8 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 9 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 10 IGNITOR BURNERS ROLLOUT SWITCHES FRONT BURNER BOX PLATE SENSOR GAS VALVE Figure 5. Burner Box Assembly Flame Rollout Switches (Figure 5) A microamp DC meter is needed to check the flame signal on the integrated control. Flame rollout switches S47 are SPST N.C. high temperature limits located on the left and right of the front buner box plate.
  • Page 11 Primary Limit Control (Figure 6) MANIFOLD PRESSURE Primary limit (S10) used on NF96DS 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 de- OUTLET...
  • Page 12 Flame Signal In Microamps Normal Drop Out 0.5 - 1.4 Flame Sensor Terminal Remove Sensor Wire from Intergrated Control and Intergrated Connect Alligator Clip (−) Control to Frame Sensor Lead Remove Sensor Wire from Intergrated Control and Connect Alligator Clip (+) to Terminal on Control Multi−Meter Flame Sensor...
  • Page 13 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 14 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 control All NF96DS units use a combustion air inducer to move when the difference in pressure across the combustion air air through the burners and heat exchanger during heating inducer orifice exceeds a non-adjustable factory setting.
  • Page 15 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 16 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 17 Blower Compartment Center Blower Wheel in Blower Housing IMPORTANT Each blower is statically and dynamically balanced as an assembly before installation in the unit. NF96DS 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 18 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 19 Testing the Motor (Figure 17) Scale Measurement Range in Words ohms If any motor fails the below tests, the motor is defective and two megohms - two million ohms 0 - 2,000,000 must be replaced. two hundred kil-ohms - 200 K 0 - 200,000 two hundred thousand ohms Using an ohmmeter check the resistance from any one...

  • Page 20: 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 with American National Standard Institute and the American Schedule 40 PVC (Fittings) D2466 Society for Testing and Materials (ANSI/ASTM) standards.

  • Page 21: Joint Cementing Procedure

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

  • Page 22: Venting Practices

    After assembly, wipe excess cement from pipe at end of fitting socket. A properly made joint will show a bead REPLACING FURNACE THAT CHIMNEY WAS PART OF A COMMON OR GAS around its entire perimeter. Any gaps may indicate an VENT VENT SYSTEM (Check sizing...

  • Page 23: Vent Piping Guidelines

    NOTE: It is acceptable to use any pipe size which fits within Vent Piping Guidelines the guidelines allowed in Table 10A through Table 11B. NOTE: All horizontal runs of exhaust pipe must slope back NOTE: GE Appliances has approved the use of DuraVent ®...
  • Page 24 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 Capacity Capacity Capacity Capacity Number of 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 25 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 Capacity Capacity Capacity Capacity Number of 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 26 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 Capacity Capacity Capacity...
  • Page 27 NOTE: 1-1/2” Vent Pipe Pipe size determined in table 7. Diameter Allowed Only on 045/070 Units 2” 2” 2” 2” 3” 1-1/2” 2” TRANSITION TRANSITION *2” *2” INTAKE DO NOT transition DO NOT transition EXHAUST from smaller to larger from larger to smaller TOP VIEW pipe in horizontal runs pipe in horizontal runs...
  • Page 28 Intake Piping Intake The NF96DS furnace may be installed in either direct Debris vent or non-direct vent applications. In non-direct vent Screen (Provided) applications, when intake air will be drawn into the furnace from the surrounding space, the indoor air quality must be considered and guidelines listed in Combustion, Dilution and Ventilation Air section must be followed.
  • Page 29 NOTE: See Table 12 for maximum allowed exhaust pipe length without insulation in unconditioned space during winter design temperatures below 32°F (0°C). If required Roof Terminated Exhaust Pipe exhaust pipe should be insulated with 1/2” (13mm) Armaflex or equivalent. In extreme cold climate areas, 3/4” (19mm) Armaflex or equivalent may be necessary.
  • Page 30 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 Vent Pipe Winter Design Temperatures ºF (ºC) Diameter 1-1/2 in. 32 to 21 2 in. (0 to -6) 2-1/2 in.
  • Page 31 VENT TERMINATION CLEARANCES FOR DIRECT VENT INSTALLATIONS IN THE USA 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 32 Details of Intake and Exhaust Piping Terminations 3” (76MM) MIN. SIZE PER EXHAUST PIPE for Direct Vent Installations Inches (MM) TERMINATION SIZE NOTE: In Direct Vent installations, combustion air is taken REDUCTION TABLE from outdoors and flue gases are discharged to outdoors. UNCONDITIONED ATTIC SPACE 8”...
  • Page 33 If intake and exhaust piping must be run up a side 1 1/2” (38mm) accelerator wall to position above snow accumulation or other provided on 71M80 & 44W92 EXHAUST kits for -045 and -070 models obstructions, piping must be supported. At least one VENT bracket must be used within 6”...
  • Page 34 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 35 Details of Exhaust Piping Terminations for Non- STRAIGHT-CUT OR * SIZE TERMINATION PIPE PER EXHAUST Direct Vent Applications ANGLE-CUT IN DIRECTION PIPE TERMINATION SIZE REDUCTION TABLE OF ROOF SLOPE * Exhaust pipes may be routed either horizontally through an outside wall or vertically through the roof. In attic or closet installations, vertical termination through the roof is preferred.
  • Page 36 FIELD FABRICATED WALL TERMINATION NOTE − FIELD−PROVIDED REDUCER MAY BE 2” (51mm) 3” (76mm) REQUIRED TO ADAPT LARGER VENT PIPE SIZE Vent Pipe Vent Pipe TO TERMINATION A− Minimum clearance above grade or average 12” (305 mm) 12” (305 mm) snow accumulation B−...
  • Page 37 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 38: Condensate Piping

    Condensate Piping This unit is designed for either right- or left-side exit of condensate piping. Refer to Figure 41 for condensate trap locations. Trap (same on NOTE: If necessary the condensate trap may be installed right side) up to 5 feet away from the furnace. Piping from furnace must 1-1/2 in.
  • Page 39 From Evaporator Coil Field Provided Vent 1” min. 2” max. above condensate drain. Trap can be installed a maximum of 5ft. from furnace (*PVC only) Field Provided Vent 1” min. 2” max. above FurnaceCondensate condensate drain. Drain Connection Optional 1” min. 2”...
  • Page 40 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 41 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 42: 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 43: 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 44 Tee into the gas valve regulator vent hose and connect to test gauge negative “-”. IMPORTANT Start unit and let run for 5 minutes to allow for steady For safety, connect a shut-off valve between the state conditions. manometer and the gas tap to permit shut off of gas After allowing unit to stabilize for 5 minutes, record pressure to the manometer.
  • Page 45 Gas Flow (Approximate) High Altitude NOTE: In Canada, certification for installations at elevations Gas Meter Clocking Chart over 4500 feet (1372 m) is the jurisdiction of local authorities. Seconds for One Revolution Units may be installed at altitudes up to 10,000 ft. above Natural Capacity sea level.
  • Page 46 Proper Ground and Voltage as a function of load indicates a poor or partial ground. Compare the readings to Table 19. If the readings exceed the maximum shown in Table 19, make repairs CAUTION before operating the furnace. In addition, measure the AC voltage from Line Hot to Electric Shock Hazard.

  • Page 47: Typical Operating Characteristics

    External Static Pressure Typical Operating Characteristics 1. Tap locations shown in Figure 54. 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 48: Maintenance

    Cabinet Width Filter Size Maintenance 17-1/2” 16 x 25 x 1 (1) 21” Table 20. WARNING ELECTRICAL SHOCK, FIRE, Exhaust and Air Intake Pipes OR EXPLOSION HAZARD. Check the exhaust and air intake pipes and all connections Failure to follow safety warnings exactly could result in for tightness and to make sure there is no blockage.
  • Page 49 Winterizing and Condensate Trap Care Remove four burner box screws at the vestibule panel and remove burner box. Set burner box assembly aside. 1. Turn off power to the furnace. NOTE: If necessary, clean burners at this time. Follow Have a shallow pan ready to empty condensate water. procedures outlined in Burner Cleaning section.
  • Page 50 Cleaning the Burner Assembly (if needed) 26. Route heating component wiring through hole in blower deck and reinsert strain relief bushing. Turn off electrical and gas power supplies to furnace. Remove upper and lower furnace access panels. 27. Reinstall electrical junction box. Disconnect the 2-pin plug from the gas valve.

  • Page 51: Wiring Diagram

    Wiring Diagram 045*3B 070*4B 090*4C Page 51 31-5000729 Rev. 0...

  • Page 52: 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 53: 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 54: 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 55: 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 56 All specifications and illustrations subject to change without notice and without incurring obligations. Printed in the U.S.A. Page 56 31-5000729 Rev. 0...

This manual is also suitable for:

Ge nf96d045s3bGe nf96d070s4bGe nf96d090s4c

Table of Contents