Haier GE NF96DS Installation Instructions Manual
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Haier GE NF96DS Installation Instructions Manual

Haier GE NF96DS Installation Instructions Manual

Warm air gas furnace downflow air discharge direct vent & non-direct vent
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INSTALLATION INSTRUCTIONS
NF96DS
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.
Improper installation, adjustment, alteration, service
or maintenance can cause property damage, personal
injury or loss of life. Installation and service must be
performed by a licensed professional installer (or
equivalent), service agency or the gas supplier.
As with any mechanical equipment, personal injury can
result from contact with sharp sheet metal edges. Be
careful when you handle this equipment.
GE Appliances
A Haier Company
Appliance Park
Louisville, KY 40225
507769-05G / 31-5000656
This manual must be left with the homeowner for future reference.
WARNING
CAUTION
Direct Vent & Non-Direct Vent

Table of Contents

Unit Dimensions ..........................................................2
Parts Arrangement.......................................................3
Gas Furnace ................................................................4
Shipping and Packing List ...........................................4
Safety Information .......................................................4
General ........................................................................6
Combustion, Dilution & Ventilation Air .........................6
Installation ...................................................................9
Filters .........................................................................12
Duct System ..............................................................12
Venting Practices .......................................................15
Condensate Piping ....................................................30
Gas Piping .................................................................33
Electrical ....................................................................36
Unit Start-Up ..............................................................40
Air for Non-Direct Vent Applications ..........................44
Other Unit Adjustments..............................................45
Blower Performance Data .........................................46
Service.......................................................................48
Planned Service ........................................................54
Repair Parts List ........................................................54
*P507769-05G*
Issue 2223
Warm Air Gas Furnace
Downflow Air Discharge
(P) 507769-05G
Page 1 of 55

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  • Page 1: Table Of Contents

    Be Service...............48 careful when you handle this equipment. Planned Service ............54 Repair Parts List ............54 GE Appliances *P507769-05G* A Haier Company Appliance Park (P) 507769-05G Louisville, KY 40225 507769-05G / 31-5000656 Issue 2223 Page 1 of 55...

  • Page 2: Unit Dimensions

    Unit Dimensions 9/16 (14) COMBUSTION AIR INTAKE Return Air Opening EXHAUST AIR OUTLET 2−1/16 (52) 9/16 2−1/4 (14) (57) (127) TOP VIEW 1 (25) 27−3/4 Front Panel (705) 19−7/16 9/16 9/16 (494) (14) (14) FLOW ELECTRICAL INLET (Either Side) (838) 2 (51) Either Side CONDENSATE...

  • Page 3: 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 4: Gas Furnace

    Gas Furnace Shipping and Packing List This Category IV gas furnace is shipped ready for 1 - Assembled Gas Unit installation in the downflow position. 1 - Bag assembly containing the following: 1 - Snap bushing The furnace is equipped for installation in natural gas applications.
  • Page 5 In order to ensure proper unit operation in non-direct vent Heating Unit Installed Parallell to Air Handler Unit applications, combustion and ventilation air supply must be provided according to the current National Fuel Gas Code or CSA-B149 standard. Locations and Clearances AIR HANDLER GAS UNIT This furnace is CSA International certified for installation...

  • Page 6: General

    Return air temperature range between 60°F (16°C) • When the furnace is installed in an attic or other and 80°F (27°C) must be maintained. insulated space, keep insulation away from the furnace. MERV 11 or greater air filters must be installed in the system and must be regularly inspected and •...
  • Page 7 not separated by a door. Though an area may appear to be unconfined, it might be necessary to bring in outdoor air WARNING for combustion if the structure does not provide enough air by infiltration. Insufficient combustion air can cause headaches, nausea, dizziness or asphyxiation.
  • Page 8 When communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 square inch (645 mm²) per 2,000 Btu (.56 kW) per hour of the total input rating of all equipment in the enclosure. See ROOF TERMINATED EXHAUST PIPE Figure 7.

  • Page 9: Installation

    Installation Ventilation Louvers Inlet Air Roof Terminated (Minimum 12 in. Exhaust Pipe (305mm) above Setting Equipment Attic Floor) *Intake Debris CAUTION Screen (Provided) Do not install the furnace on its front, back or in the horizontal position. See Figure 11. Do no connect the Furnace return air ducts to the back of the furnace.
  • Page 10 Front Back Horizontal NOTE - Do not install the furnace on its front, back or in the horizontal position Figure 11. Refer to Figure 13 for clearances in downflow applications. AIR FLOW AIR FLOW AIR FLOW Left Side Right Side 1/2"...
  • Page 11 Set the unit over the plenum and seal the plenum to the unit. FURNACE Ensure that the seal is adequate. Front to Rear Side to Side SUPPLY AIR Cabinet Width PLENUM PROPERLY COMBUSTIBLE B (17.5”) 19-3/4 16-5/8 SIZED FLOOR FLOORING BASE OPENING C (21”) 19-3/4...

  • Page 12: Filters

    When cooling cabinet is in place, set and secure the Duct System furnace according to the instructions that are provided with the cooling coil. Secure the furnace to the cabinet. Use industry-approved standards to size and install the Seal the cabinet and check for air leaks. supply and return air duct system.
  • Page 13 Low temperature solvent cement is recommended during cooler weather. Metal or plastic strapping may be used as CAUTION vent pipe hangers. Uniformly apply a liberal coat of PVC primer for PVC or use a clean dry cloth for ABS to clean Solvent cements for plastic pipe are flammable liquids inside socket surface of fitting and male end of pipe to and should be kept away from all sources of ignition.
  • Page 14 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 NOTE - Standard Terminations do not include any vent pipe or elbows external to the structure.

  • Page 15: Venting Practices

    Exhaust Piping NOTE: Assembly should be completed within 20 seconds after last application of cement. Hammer See Figure 22 blows should not be used when inserting pipe. In areas where piping penetrates joist or interior walls, After assembly, wipe excess cement from pipe at end hole must be large enough to allow clearance on all of fitting socket.
  • Page 16 Use the following steps to correctly size vent pipe diameter. Capacity Min. Vent Length* 15 ft. or 045, 070, 090 5 ft. plus 2 elbows or 10 ft. plus 1 elbow 045, 070, Furnace capacity? * Any approved termination may be added to the minimum length listed.
  • Page 17 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 18 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 19 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 20 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 21 Intake Piping Intake This furnace may be installed in either direct vent or non- Debris direct vent applications. In non-direct vent applications, Screen (Provided) when intake air will be drawn into the furnace from the surrounding space, the indoor air quality must be considered.
  • Page 22 At vent termination, care must be taken to maintain protective coatings over building materials (prolonged Roof Terminated exposure to exhaust condensate can destroy protective Exhaust Pipe coatings). It is recommended that the exhaust outlet not be located within 6 feet (1.8 m) of a condensing unit because the condensate can damage the painted coating.
  • Page 23 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 24 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 25 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 26 Details of Intake and Exhaust Piping 51W11 Terminations for Direct Vent Installations 2" EXTENSION NOTE: In Direct Vent installations, combustion air is taken FOR 2" PVC PIPE 1" EXTENSION from outdoors and flue gases are discharged to outdoors. FOR 3" PVC PIPE NOTE: Flue gas may be slightly acidic and may adversely FURNACE affect some building materials.
  • Page 27 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 28 71M80, 69M29 or 60L46 (US) 44W92 or 44W93 (Canada) FIELD−PROVIDED 1−1/2" (38mm) accelerator REDUCER MAY BE REQUIRED provided on 71M80 & 44W92 TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION OUTSIDE INTAKE WALL EXHAUST Inlet Air EXHAUST VENT Minimum 12 in. VENT Exhaust Furnace...
  • Page 29 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 pipe may be routed either horizontally through an outside wall or vertically through the roof. In attic or closet installations, vertical termination through the roof EXHAUST VENT Minimum 12”...

  • Page 30: Condensate Piping

    Condensate Piping This unit is designed for either right or left side exit of condensate piping in downflow applications. Refer to Figure 40 for condensate trap locations. Trap NOTE: If necessary the condensate trap may be installed (same on up to 5” away using PVC pipe from the furnace. Piping right side) from furnace must slope down a minimum of 1/4”...
  • Page 31 Field Provided Vent Field Provided Vent 1” min. 2” max. above 1” min. 2” max. above condensate drain. condensate drain. Condensate Drain Condensate Drain Connection Connection Evaporator Drain Line (vent required) Evaporator Drain Line Drain (vent required) Figure 42. Unit with Cooling Coil Using Separate Drain Figure 43.
  • Page 32 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 33: Gas Piping

    Gas Piping IMPORTANT Compounds used on threaded joints of gas piping must be resistant to the actions of liquified petroleum gases. CAUTION If a flexible gas connector is required or allowed by the authority that has jurisdiction, black iron pipe shall Leak Check be installed at the gas valve and extend outside the After gas piping is completed, carefully check all field-...
  • Page 34 Left Side Piping MANUAL (Standard) AUTOMATIC MAIN SHUT−OFF GAS VALVE MANUAL VALVE AUTOMATIC (with manual Plug MAIN SHUT−OFF (With 1/8 in. NPT GAS VALVE shut−o valve) VALVE Plugged Tap (with manual Plug (With 1/8 in. NPT Shown) shut−o valve) Plugged Tap Shown) GROUND JOINT UNION...
  • Page 35 Removal of the Furnace from Common Vent Seal any unused openings in the common venting system. In the event that an existing furnace is removed from a venting system commonly run with separate gas Inspect the venting system for proper size and appliances, the venting system is likely to be too large to horizontal pitch.

  • Page 36: Electrical

    The power supply wiring must meet Class I restrictions. Electrical Protected by either a fuse or circuit breaker, select circuit protection and wire size according to unit nameplate. ELECTROSTATIC DISCHARGE (ESD) NOTE: Unit nameplate states maximum current draw. Maximum Over-Current Protection allowed is 15 AMP. Precautions and Procedures Holes are on both sides of the furnace cabinet to facilitate wiring.
  • Page 37 Indoor Blower Speeds in the heating mode when the combustion air inducer is operating and the pressure switch is closed. Any humidifier When the thermostat is set to “FAN ON”, the indoor rated up to 0.5 amp can be connected to this terminal with blower will run continuously on the fan speed when the ground leg of the circuit connected to ground or the “C”...
  • Page 38 045*3B 070*4B 090*4C Figure 52. Typical Wiring Diagram Page 38 of 55 Issue 2223 507769-05G / 31-5000656...
  • Page 39 Red LED Flash Code Diagnostic Codes / Status of Furnace No power to control or control hardware fault detected Heartbeat Normal operation - idle, continuous fan, cool Continuous Rapid Flash Call for heat / burner operation 1 Flash Reverse line voltage polarity 2 Flashes Improper earth ground 3 Flashes...

  • Page 40: Unit Start-Up

    1/4” Quick Connect Terminal Designations 120V HUM Power for Humidifier (120VAC) LINE Incoming Power Line (120VAC) XFMR Transformer Primary (120VAC) CIRC Indoor Blower Motor (120VAC) Electronic Air Cleaner (120VAC) HUM24 Power For Humidifier (24VAC) NEUTRALS (5) Neutral 3/16” Quick Connect Terminal Designations Cool Speed From Indoor Blower Motor COOL (24VAC)
  • Page 41 Set the thermostat to the lowest setting. Turn OFF all electrical power to the unit. CAUTION This furnace is equipped with an ignition device which Before attempting perform service automatically lights the burners. Do not try to light the maintenance, turn the electrical power to unit OFF at burners by hand.
  • Page 42 Is the filter dirty or plugged? Dirty or plugged filters will Supply Pressure Measurement cause the limit control to shut the unit off. A threaded plug on the inlet side of the gas valve provides Is gas turned on at the meter? access to the supply pressure tap.
  • Page 43 Manifold and Supply Line Pressure 0-10,000 ft. Manifold Pressure in. w.g. Supply Line Pressure Capacity in. w.g. 7501-10000 0-4500 ft. 4501-5500 ft. 5501-6500 ft. 6501-7500 ft. 0-10,000 ft. Natural 13.0 All Sizes LP / Propane 10.0 10.0 11.0 13.0 NOTE: A natural to LP propane gas changeover kit is necessary to convert this unit. Refer to the changeover kit installation instruction for the conversion procedure.

  • Page 44: Testing For Proper Venting And Sufficient Combustion Air For Non-Direct Vent Applications

    Testing for Proper Venting and Sufficient Combustion Air for Non-Direct Vent Applications Seal any unused openings in the venting system. Visually inspect the venting system for proper size WARNING and horizontal pitch. Determine there is no blockage CARBON MONOXIDE POISONING HAZARD or restriction, leakage, corrosion, or other deficiencies which could cause an unsafe condition.

  • Page 45: Other Unit Adjustments

    SW2-1 SW2-2 Other Unit Adjustments Primary Limit The primary limit is located on the heating compartment vestibule panel. This limit is factory set and requires no adjustment. * Factory setting Table 20. Blower Delay Select Flame Rollout Switches (Two) These manually reset switches are located on the front of the burner box.

  • Page 46: Blower Performance Data

    Blower Speeds Connect selected speed tap at control board speed terminal. Follow the steps below to change the blower speeds. Re-secure blower access panel. 1. Turn off electrical power to furnace. Turn on electrical power to furnace. Remove blower compartment access panel. Recheck temperature rise.
  • Page 47 NF96D090S4C Performance (Less Filter) External Air Volume / Watts at Different Blower Speeds Static High Medium-High Medium Medium-Low Pressure watts watts watts watts watts in. w.c. 0.00 1760 1555 1405 1315 1190 0.10 1730 1515 1375 1280 1150 0.20 1700 1475 1350 1245...

  • Page 48: Service

    Check amp-draw on the blower motor with the blower Service compartment access panel in place. Motor Nameplate____________ Actual____________ WARNING Winterizing and Condensate Trap Care 1. Turn off power to the furnace. ELECTRICAL SHOCK, FIRE, OR EXPLOSION HAZARD. Have a shallow pan ready to empty condensate water. Remove the clean out cap from the condensate trap Failure to follow safety warnings exactly could result in dangerous operation, serious injury, death or property...
  • Page 49 Cleaning the Burner Assembly 16. Remove screws along vestibule sides and bottom which secure vestibule panel and heat exchanger 1. Turn off electrical and gas power supplies to furnace. assembly to cabinet. Remove two screws from blower Remove upper and lower furnace access panels. rail which secure bottom heat exchanger flange.
  • Page 50 Troubleshooting: Heating Sequence of Operation HEATING SEQUENCE OF OPERATION ABNORMAL HEATING MODE NORMAL 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 - POLARITY IS POLARITY CORRECT? REVERSED.
  • Page 51 Troubleshooting: Heating Sequence of Operation (continued) HEATING SEQUENCE CONTINUED 15 SECOND COMBUSTION AIR INDUCER PREPURGE INITIATED BY CLOSED PRESSURE SWITCH. LED FLASHES CODE 13 - LOW LINE VOLTAGE. ONCE VOLTAGE IS ABOVE IGNITOR WARM UP -- 20 SECONDS. IS VOLTAGE ABOVE 70 VOLTS? 75 VOLTS, HEATING SEQUENCE RESTARTS.
  • Page 52 Troubleshooting: Cooling Sequence of Operation COOLING SEQUENCE OF OPERATION POWER ON IGNITION CONTROL MAIN POWER ON. LED FLASHES STEADY - CIRCUIT BOARD FAILURE CONTROL SELF DIAGNOSTIC CHECK. GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. IS CONTROL OPERATING NORMALLY? INDOOR BLOWER OFF WITH NORMAL DELAY. INTERRUPT MAIN POWER TO RESET CONTROL.
  • Page 53 Troubleshooting: Continuous Fan Sequence of Operation 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). SYSTEM FAN CONTINUES FAN SPEED WITHOUT THERMOSTAT CALLS FOR COOLING.

  • Page 54: Planned Service

    Planned Service A service technician should check the following items during an annual inspection. Power to the unit must be shut off for safety. Fresh air grilles and louvers (on the unit and in the Operating performance - Unit must be observed during room where the furnace is installed) - Must be open and operation to monitor proper performance of the unit and unobstructed to provide combustion air.
  • Page 55 Requirements for Commonwealth of Massachusetts Modifications to NFPA-54, Chapter 10 INSPECTION. The state or local gas inspector of the side wall, horizontally vented, gas-fueled equipment Revise NFPA-54 section 10.8.3 to add the following shall not approve the installation unless, upon requirements: inspection, the inspector observes carbon monoxide For all side wall, horizontally vented, gas-fueled equipment...

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