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Haier GE APPLIANCES NF96US Installation Instructions Manual

Warm air gas furnace upflow/ horizontal left/right air discharge direct vent & non-direct vent
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INSTALLATION INSTRUCTIONS
NF96US
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
507768-05G / 31-5000655
This manual must be left with the homeowner for future reference.
WARNING
CAUTION
Warm Air Gas Furnace Upflow/
Horizontal Left/Right Air Discharge
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 .........................................................................13
Duct System ..............................................................13
Venting Practices .......................................................16
Condensate Piping ....................................................33
Gas Piping .................................................................37
Electrical ....................................................................40
Unit Start-Up ..............................................................44
Air for Non-Direct Vent Applications ..........................48
Other Unit Adjustments..............................................48
Blower Performance ..................................................50
Service.......................................................................52
Planned Service ........................................................55
Repair Parts List ........................................................55
*P507768-05G*
Issue 2223
(P) 507768-05G
Page 1 of 56

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  • Page 1: Table Of Contents

    Be Service...............52 careful when you handle this equipment. Planned Service ............55 Repair Parts List ............55 GE Appliances *P507768-05G* A Haier Company Appliance Park (P) 507768-05G Louisville, KY 40225 507768-05G / 31-5000655 Issue 2223 Page 1 of 56...

  • Page 2: Unit Dimensions

    Unit Dimensions NOTE - 5C (5 Ton) size units installed in upflow applications that Top View require air volumes of 1800 cfm (850 L/s) or greater must have one of the following: Single side return air with transition, to accommodate 20 x 25 Exhaust Air x 1 in.

  • Page 3: Parts Arrangement

    Parts Arrangement Figure 1. 507768-05G / 31-5000655 Issue 2223 Page 3 of 56...

  • Page 4: Gas Furnace

    Gas Furnace Shipping and Packing List The NF96US Category IV gas furnace is shipped ready for 1 - Assembled Gas Furnace installation in the upflow or horizontal position. The furnace 1 - Bag assembly containing the following: is shipped with the bottom panel in place. The bottom panel must be removed if the unit is to be installed in horizontal 1 - Snap bushing or upflow applications with bottom return air.
  • Page 5 In order to ensure proper unit operation in non-direct vent applications, combustion and ventilation air supply must be provided according to the current National Fuel Gas Code or CSA-B149 standard. Installation Locations This furnace is CSA International certified for installation clearances to combustible material as listed on the unit nameplate and in the table in Figure 13 and Figure 18.

  • Page 6: General

    Return air temperature range between 60°F (16°C) • When the furnace is installed in non-direct vent and 80°F (27°C) must be maintained. applications, do not block the furnace combustion air opening with clothing, boxes, doors, etc. Air is needed MERV 11 or greater air filters must be installed in for proper combustion and safe unit operation.
  • Page 7 the National Fuel Gas Code (ANSI-Z223.1/NFPA 54). This In addition to providing combustion air, fresh outdoor air reprinted material is not the complete and official position dilutes contaminants in the indoor air. These contaminants of ANSI on the referenced subject, which is represented may include bleaches, adhesives, detergents, solvents only by the standard in its entirety.
  • 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 Figure 8.

  • Page 9: Installation

    Shipping Bolt Removal Units with 1/2 hp & 3/4 hp blower motor are equipped WARNING with three flexible legs and one rigid leg. The rigid leg is equipped with a shipping bolt and a flat white plastic If this unit is being installed in an application with washer (rather than the rubber mounting grommet used combustion air coming in from a space serviced by an with a flexible mounting leg).
  • Page 10 Tilt the unit slightly (Max. 1/2”) from back to front to aid in the draining of the heat exchanger. Unit must be level side-to-side in all applications. Figure 12. Setting Equipment WARNING Improper installation of the furnace can result in personal injury or death.
  • Page 11 Return Air Guidelines Return air can be brought in through the bottom or either side of the furnace installed in an upflow application. If the 20” X 25” X 1” furnace is installed on a platform with bottom return, make (508mm X 635mm X 25mm) an airtight seal between the bottom of the furnace and the Air Filter...
  • Page 12 Right-Hand Discharge Left End Right End Flow Flow Bottom (Floor)** Left-Hand Discharge Left End Right End Flow Flow Figure 16. Removing the Bottom Panel Bottom (Floor)** Top/Plenum 1 in. (25 mm) Removing the Bottom Panel * Front Remove the two screws that secure the bottom cap to the Back furnace.

  • Page 13: Filters

    NOTE: Heavy-gauge sheet metal straps may be used to Filters suspend the unit from roof rafters or ceiling joists. When straps are used to suspend the unit in this way, support must be provided for both the ends. The straps must not This unit is not equipped with a filter or rack.
  • Page 14 unit operates properly and safely. Use fiberglass sealing the furnace, use ULC S636 approved One-Step Transition strips, caulking, or equivalent sealing method between the Cement to bond the pipe to the flue collar, or to bond plenum and the furnace cabinet to ensure a tight seal. If the 90°...
  • Page 15 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 16: Venting Practices

    Promptly apply solvent cement to end of pipe and Conduct the following test while each appliance is operating inside socket surface of fitting. Cement should be and the other appliances (which are not operating) remain applied lightly but uniformly to inside of socket. Take connected to the common venting system.
  • Page 17 Vent Piping Guidelines REPLACING FURNACE THAT This gas furnace can be installed as either a Non-Direct WAS PART OF A COMMON Vent or a Direct Vent gas central furnace. VENT SYSTEM CHIMNEY OR GAS NOTE: In non-Direct Vent installations, combustion air is VENT (Check sizing taken from indoors and flue gases are discharged outdoors.
  • Page 18 IMPORTANT Do not use screens or perforated metal in exhaust or 045, 070, Furnace capacity? intake terminations. Doing so will cause freeze-ups and 090, 110 may block the terminations. Capacity Min. Vent Length* 15 ft or 5 ft plus 2 elbows or Standard or 045, 070, 090, 110 Which termination?
  • Page 19 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 20 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 21 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 22 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 23 TYPICAL INTAKE PIPE CONNECTIONS IN UPFLOW DIRECT OR NON-DIRECT VENT APPLICATIONS 2” 3” Pipe size determined in Table 5 TRANSITION INTAKE *2” 2” 2” 2” 2” * 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 24 The air intake piping must not terminate too close to TYPICAL AIR INTAKE PIPE CONNECTIONS the flooring or a platform. Ensure that the intake air UPFLOW NON-DIRECT VENT APPLICATIONS inlet will not be obstructed by loose insulation or other items that may clog the debris screen. Intake Debris If intake air is drawn from a ventilated attic (Figure...
  • Page 25 NOTE: See Table 6A through Table 6B for maximum allowed exhaust pipe length without insulation in unconditioned space during winter design temperatures Roof Terminated Exhaust Pipe below 32°F (0°C). If required exhaust pipe should be insulated with 1/2” (13 mm) Armaflex or equivalent. In extreme cold climate areas, 3/4”...
  • Page 26 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 27 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 28 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 29 Details of Intake and Exhaust Piping 3” (76MM) MIN. SIZE PER EXHAUST PIPE Inches (MM) Terminations for Direct Vent Installations 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 30 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 31 On field supplied terminations, a minimum distance DIRECT VENT CONCENTRIC ROOFTOP TERMINATION between the end of the exhaust pipe and the end of 71M80, 69M29 or 60L46 (US) the intake pipe without a termination elbow is 8” and a 44W92 or 44W93 (Canada) minimum distance of 6”...
  • Page 32 Details of Exhaust Piping Terminations for Non- If exhaust piping must be run up a sidewall to position above snow accumulation or other obstructions, piping Direct Vent Applications must be supported every 24” (610 mm) as shown in Exhaust pipes may be routed either horizontally through Figure 47.

  • Page 33: Condensate Piping

    Figure 52 and Figure 53 show the furnace and Condensate Piping evaporator coil using a separate drain. If necessary the condensate line from the furnace and evaporator This unit is designed for either right or left side exit of coil can drain together. See Figure 54 and Figure 55. condensate piping in upflow applications.
  • Page 34 * Piping from furnace must slope down a minimum of 1/4” per ft. toward trap. Figure 50. Condensate Trap Locations (Unit shown in upflow position with remote trap) Figure 51. Condensate Trap with Optional Overflow Switch WARNING When combining the furnace and evaporator coil drains together, the A/C condensate drain outlet must be vented to relieve pressure in order for the furnace pressure switch to operate properly.
  • Page 35 * Piping from furnace must slope down a minimum of 1/4” per ft. toward trap. Figure 52. Condensate Trap Locations Figure 53. Unit with Cooling Coil Using Separate Figure 54. Evaporator Coil Using a Common Drain Drain Piping from furnace and evaporator coil must slope down a minimum 1/4” per ft. toward trap. Figure 55.
  • Page 36 Figure 56. Trap / Drain Assembly Using 1/2” PVC or 3/4” PVC Page 36 of 56 Issue 2223 507768-05G / 31-5000655...

  • Page 37: 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 38 Figure 58. Gas Piping Upflow Applications Figure 59. Gas Piping Horizontal Applications Page 38 of 56 Issue 2223 507768-05G / 31-5000655...
  • Page 39 Gas Pipe Capacity - FT³/HR (kL/HR) Nominal Length of Pipe - feet (m) Internal Iron Pipe Diameter Size - - inches inches (3.048) (6.096) (9.144) (12.192) (15.240) (18.288) (21.336) (24.384) (27.432) (30.480) (mm) (mm) .622 (12.7) (17.799) (4.96) (3.40) (2.75) (2.32) (2.07) (1.87)

  • Page 40: Electrical

    The unit is equipped with a field makeup box. The makeup Electrical box may be moved to the right side of the furnace to facilitate installation. Seal unused openings on left side with plugs removed from right side. Secure the excess wire ELECTROSTATIC DISCHARGE (ESD) to the existing harness to protect it from damage.
  • Page 41 external relay. See Figure 65 or Figure 66 for control board Install the room thermostat according to the instructions configuration. This terminal is energized in the heating provided with the thermostat. See Figure 62 for thermostat mode when the combustion air inducer is operating. designations.
  • Page 42 045*3B 070*3B 090*4C 110*5C Figure 64. Typical Wiring Diagram Page 42 of 56 Issue 2223 507768-05G / 31-5000655...
  • Page 43 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 44: 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 45 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 46 Is the filter dirty or plugged? Dirty or plugged filters will Supply Pressure Measurement cause the limit control to shut the unit off. When testing supply gas pressure, use the 1/8” N.P.T. Is gas turned on at the meter? plugged tap or pressure post located on the gas valve to facilitate test gauge connection.
  • Page 47 Table 16 or Table 17 list required pressure switch changes and orifice conversion kits at varying altitudes. The combustion air pressure switches are factory set and require no adjustment. Manifold and Supply Line Pressure 0-10,000 ft. Manifold Pressure in. w.g. Supply Line Pressure Capacity in.

  • Page 48: 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 49 Constant Torque Motor speed to maintain the temperature rise within the range shown on the unit nameplate. See Table 19 for allowable These units are equipped with a constant torque ECM heating speeds. Increase the blower speed to decrease motor. It has a DC motor coupled to an electronic control the temperature.

  • Page 50: Blower Performance

    Blower Performance NF96U045S3B Performance (Less Filter) External Air Volume / Watts at Various Blower Speeds Static High Medium - High Medium Medium - Low Pressure Watts Watts Watts Watts Watts in. w.c. 0.00 1460 1285 1190 0.10 1430 1260 1155 0.20 1405 1235...
  • Page 51 NF96U110S5C Performance (Less Filter) Air Volume / Watts at Various Blower Speeds External Bottom Return Air, Side Return Air with Optional Return Air Base, Return Air from Single Side Return Air - Air volumes in bold require field fabricated transition to Static Both Sides or Return Air from Bottom and One Side.

  • Page 52: Service

    Allowable Heating Speeds Model Yellow Blue Brown Black Allowed Factory Setting Allowed Allowed Not Allowed Not Allowed Not Allowed Factory Setting Allowed Not Allowed Allowed Factory Setting Allowed Allowed Not Allowed Not Allowed Allowed Factory Setting Allowed Not Allowed Table 19. Allowable Circulation Speeds Model Number Yellow...
  • Page 53 Remove gas supply line connected to gas valve. 24. Thoroughly rinse and drain the heat exchanger. Soap solutions can be corrosive. Take care to rinse entire Remove sensor wire from flame sensor. Disconnect assembly. 2–pin plug from the ignitor. 25. Reinstall heat exchanger into cabinet making sure Disconnect wires from flame rollout switches.
  • Page 54 Cleaning the Burner Assembly 1. Turn off gas and electrical power to the furnace. Remove heating compartment access panel. Disconnect the gas supply line from the gas valve. Disconnect and label wires from gas valve. Disconnect ignitor wiring at 2 circuit plug. Disconnect and label wires from rollout switch.

  • Page 55: Planned Service

    Planned Service Return air duct - Must be properly attached and provide A service technician should check the following items during an annual inspection. Power to the unit must be an air seal to the unit. shut off for safety. Operating performance - Unit must be observed during Fresh air grilles and louvers (on the unit and in the operation to monitor proper performance of the unit and...
  • Page 56 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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