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Haier GE NF96UV Service Manual
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Haier GE NF96UV Service Manual

Haier GE NF96UV Service Manual

96% upflow/horizontal two stage variable speed gas furnace
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Service
NF96UV
96% Upflow/Horizontal Two Stage
Manual
Variable Speed Gas Furnace
READ CAREFULLY.
.
KEEP THESE INSTRUCTIONS
31-5000726 Rev. 0 10-22 GEA

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Summary of Contents for Haier GE NF96UV

  • Page 1 Service NF96UV 96% Upflow/Horizontal Two Stage Manual Variable Speed Gas Furnace READ CAREFULLY. KEEP THESE INSTRUCTIONS 31-5000726 Rev. 0 10-22 GEA...

  • Page 2: Table Of Contents

    SERVICE MANUAL NF96UV Gas Furnace - Upflow 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 - NF96UV ......2 Parts Arrangement............5...

  • Page 3: Technical Specifications - Nf96Uv

    Technical Specifications - NF96UV MODEL NUMBER GUIDE V V 5 5 C C XX N F F 96 96 U U 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 Heating Heating CFM @ .10" - .80" w.c. Cooling CFM @ .10" - .80" w.c. Temp. Speed Model Setting Setting Setting Setting Setting Setting Setting Setting Rise Adjust. "D" "C" "B" "A" "D" "C" “B” "A" (°F) 1005 1075 1210...
  • Page 5 ACCESSORY LIST Catalog Number Description Natural to LP Kits (See Table 16) 11K48 2-Stage – 90 11K47 High Altitude 2-Stage Return Air Base 68W62 17.5" B Width 68W63 21.0" C Width 68W64 24.5” D Width Flush Mount Termination (90% Furnaces only) 51W11 2”...

  • Page 6: Parts Arrangement

    Parts Arrangement HEAT EXCHANGER ASSEMBLY BURNER BOX ASSEMBLY GAS VALVE AND MANIFOLD FLUE COLLAR COMBUSTION AIR INDUCER CABINET PRIMARY LIMIT BLOWER DECK ACCESS PANEL BLOWER ASSEMBLY CONTROL BOX Figure 1. Page 6 31-5000726 Rev. 0...

  • Page 7: Unit Components

    Unit Components WARNING NF96UV unit components are shown in Figure 1. The gas Shock hazard. valve, combustion air inducer and burners can be accessed Disconnect power before servicing. Integrated control by removing the access panel. Electrical components are is not field repairable. If control is inoperable, simply in the control box (Figure 2) found in the blower section.
  • Page 8 CFM LED Pin # Function An amber LED is provided on the control board to display Gas Valve Second Stage CFM. To determine what CFM the motor is delivering Second Stage Prove Switch at any time, count the number of times the amber LED flashes.
  • Page 9 Heat Stage Jumper (single stage shown) Air Flow Heat Jumper Taps Cool Taps TERMINAL DESIGNATIONS HUM -Humidifier (120VAC) Line - Input (120VAC) XFMR - Transformer (120VAC) EAC - Indoor Air Accessory (120VAC) Cool - Cool Speed (120VAC) Park 1 - Dead terminal for alternate speed tap Park 2 - Dead terminal for alternate speed tap Figure 3.
  • Page 10 Indoor Blower Motor MOTOR CONTROLLER Figure 5. GenTeq Blower Motor B3 Power Choke STATOR Blower Motor (WINDINGS) (4 and 5 Ton Only) (B3) BEARING Figure 4. OUTPUT SHAFT ROTOR WARNING During blower operation, the ECM motor emits Figure 6. Blower Motor Components energy that may interfere with pacemaker operation.
  • Page 11 Initial Power Up POWER CONTROL CONNECTOR J48 CONNECTOR J49 When line voltage is applied to B3, there will be a large inrush of power lasting less than 1/4 second. This inrush PIN 1 C1 PIN 2 W / W1 charges a bank of DC filter capacitors inside the controller. PIN 3 C2 If the disconnect switch is bounced when the disconnect is PIN 4 - Delay...
  • Page 12 Motor speed is determined by the size of the electrical pulse sent to the motor windings. The longer the pulse, the faster the motor. OUTPUT FROM CONTROLLER TO MOTOR WINDINGS WINDINGS TURNED OFF WINDINGS TURNED ON ON PULSE OFF PULSE The frequency of the pulses to the windings is 20KHz.

  • Page 13: Heating Components

    Burners Heating Components All units use inshot burners. Burners are factory set and require no adjustment. Always operate the unit with the burner box front panel in place. Each burner uses an orifice Ignitor that is precisely matched to the burner input. Burners can The ignitor is made of durable silicon nitride.
  • Page 14 Burner Assembly Intake Air Top Cap Sensor Rollout Switch Rollout Switch Ignitor Manifold And Gas Orifices Burner Box Cover Two-Stage Gas Valve Figure 9. Heating Components Page 14 31-5000726 Rev. 0...
  • Page 15 Test 1 Check ignitor circuit for correct resistance. Remove 4-pin plug from control. Check ohms reading across terminals 1 and 5. 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 16 Combustion Air Inducer Pressure Switch (S18) Pressure Switch Check NF96UV series units are equipped with a dual combustion To check pressure switch differential, refer to Figure 12 air pressure switch (first and second stage) located on the and use the provided fittings and tubing to follow the steps combustion air inducer orifice bracket.
  • Page 17 Black Tubing 2” long Square (positive +) Tubing Red and Black or Red Tubing (negative -) 10” Long Square Tubing Measuring Device Figure 12. Pressure Switch Check Page 17 31-5000726 Rev. 0...

  • Page 18: Placement And Installation

    Canadian Applications Only - Pipe, fittings, primer and Placement and Installation solvent cement used to vent (exhaust) this appliance must be certified to ULC S636 and supplied by a single All pipe, fittings, primer and solvent cement must conform manufacturer as part of an approved vent (exhaust) with American National Standard Institute and the American system.

  • Page 19: Joint Cementing Procedure

    STANDARD CONCENTRIC Outdoor Outdoor Exhaust Flush 1-1/2” 2” 3” Exhaust VENT PIPE Accelerator Mount Concentric Concentric Concentric Accelerator NF96UV DIA. (Dia. X Length) (Dia. X Length) (in.) 71M80 69M29 60L46 1-1/2” X 12” 2” X 12” 51W11 * or 44W93+ +44W92++ +44W92++ 1-1/2...

  • Page 20: Venting Practices

    Removal of the Furnace from Common Vent are wet with cement, forcefully insert end of pipe into socket until it bottoms out. Turn PVC pipe 1/4 turn during assembly (but not after pipe is fully inserted) to WARNING distribute cement evenly. DO NOT turn ABS or cellular core pipe.
  • Page 21 Exhaust Piping (Figure 15 and Figure 16) Close all building doors and windows and all doors between the space in which the appliances remaining Route piping to outside of structure. Continue with connected to the common venting system are located installation following instructions given in piping termination and other spaces of the building.
  • Page 22 TYPICAL EXHAUST PIPE CONNECTIONS IN HORIZONTAL DIRECT OR NON-DIRECT VENT APPLICATIONS (RIGHT-HAND DISCHARGE SHOWN) NOTE: 1-1/2” Vent Pipe Diameter Allowed Only on 045/070 Units 12” max. 2” 1-1/2” 2” 3” TRANSITION TRANSITION 2” 2” 2” 2” *2” *2” 2” EXHAUST EXHAUST EXHAUST 45°...
  • 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: Vent Piping Guidelines

    Vent Piping Guidelines CAUTION NOTE: GE Appliances has approved the use of DuraVent ® If this unit is being installed in an application with and Centrotherm manufactured vent pipe and terminations combustion air coming in from a space serviced by an as an option to PVC.
  • Page 25 Use the following steps to correctly size vent pipe diameter. Exhaust Pipe 12” Min. 12” Max. Horizontal 045, 070, Gas Furnace Furnace capacity? 090, 110 or 135 btuh NOTE - Standard or ward unit. A minimum of 1/4” (6mm) drop for each 12” (305mm) Which termination? Concentric? of horizontal run is mandatory for drainage.
  • Page 26 Maximum Allowable Intake or Exhaust Vent Length in Feet Standard Termination at Elevation 0 - 4500 ft 1-1/2" Pipe 2" Pipe 2-1/2" Pipe 3" Pipe Number of 90° Model Model Model Model Elbows Used Standard Termination Elevation 4500 - 10,000 ft Number 1-1/2"...
  • Page 27 Maximum Allowable Intake or Exhaust Vent Length in Feet Concentric Termination at Elevation 0 - 4,500 ft 1-1/2" Pipe 2" Pipe 2-1/2" Pipe 3" Pipe Number of 90° Model Model Model Model Elbows Used Concentric Termination Elevation 4,501 - 10,000 ft Number 1-1/2"...
  • 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 - 4500 ft Number 1-1/2" Pipe 2" Pipe 2-1/2" Pipe 3" Pipe of 90°...
  • Page 29 General Guidelines for Vent Terminations In Non-Direct Vent applications, combustion air is taken IMPORTANT from indoors or ventilated attic or crawlspace and the flue gases are discharged to the outdoors. The NF96UV is then Do not use screens or perforated metal in exhaust classified as a non-direct vent, Category IV gas furnace.
  • Page 30 Maximum Allowable Exhaust Vent Pipe Length (in ft.) without Insulation in Unconditioned Space for Winter Design Temperatures Winter Design Unit Input Size Temperatures ºF Vent Pipe (ºC) Diameter 1-1/2 in. 32 to 21 2 in. (0 to -6) 2-1/2 in. 3 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 Intake and exhaust pipes should be placed as close together as possible at termination end (refer to Terminations for Direct Vent Installations illustrations). Maximum separation is 3” (76MM) NOTE: In Direct Vent installations, combustion air is taken on roof terminations and 6”...
  • Page 33 On field-supplied terminations, a minimum distance STRAIGHT-CUT OR between the end of the exhaust pipe and the end of ANGLE-CUT IN DIRECTION OF ROOF SLOPE * the intake pipe without a termination elbow is 8” and a minimum distance of 6” with a termination elbow. See 3”...
  • 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 Direct Vent Applications * SIZE TERMINATION PIPE PER EXHAUST 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 EXHAUST VENT Minimum 12”...
  • 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

    Determine which side condensate piping will exit the Condensate Piping unit, location of trap, field-provided fittings and length of PVC pipe required to reach available drain. This unit is designed for either right- or left-side exit of Use a large flat head screw driver or a 1/2” drive condensate piping in upflow applications.
  • Page 39 line should be routed within the conditioned space to avoid freezing of condensate and blockage of drain line. If this is not possible, a heat cable kit may be used on the condensate trap and line. Heating cable kit is available in various lengths;...
  • Page 40 Evaporator drain From Evaporator Coil Field Provided Vent line required 1” min. 2” max. above condensate drain. (Trap at coil is optional) Field-Provided Vent (1” min. to 2” Max.above condensate drain connection) FurnaceCondensate Condensate Drain Connection Drain Connection Optional Figure 43. Furnace with Evaporator Coil Using a Common Drain Figure 44.
  • Page 41 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 42 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 43: Start-Up

    Placing the Furnace into Operation Start-Up NF96UV units are equipped with an ignition system. Do NOT attempt to manually light burners on this furnace. Preliminary and Seasonal Checks Each time the thermostat calls for heat, the burners will Inspect electrical wiring, both field and factory installed automatically light The ignitor does not get hot when there for loose connections.

  • Page 44: Heating System Service Checks

    Gas Piping This furnace is equipped with an ignition device which automatically lights the burners. Do not try to light the burners by hand. CAUTION Remove the upper access panel. If a flexible gas connector is required or allowed by Move gas valve switch to OFF.
  • Page 45 When checking piping connections for gas leaks, use Shut unit off and remove manometer as soon as an preferred means. Kitchen detergents can cause harmful accurate reading has been obtained. corrosion on various metals used in gas piping. Use of a Start unit and perform leak check.
  • Page 46 Proper Combustion High Altitude Furnace should operate minimum 15 minutes with correct The manifold pressure, gas orifice and pressure switch manifold pressure and gas flow rate before checking may require adjustment or replacement to ensure proper combustion. Take combustion sample beyond the flue operation at higher altitudes.

  • Page 47: Proper Ground And Voltage

    Proper Ground and Voltage In addition, measure the AC voltage from Line Hot A poorly grounded furnace can contribute to premature to Line Neutral (spade terminals) on the integrated ignitor failure. Use the following procedure to check for ground and voltage to the integrated control. control.

  • Page 48: Typical Operating Characteristics

    External Static Pressure Typical Operating Characteristics 1. Tap locations shown in Figure 51. Punch a 1/4” diameter hole in supply and return air Blower Operation and Adjustment plenums. Insert manometer hose flush with inside Blower operation is dependent on thermostat control edge of hole or insulation.

  • Page 49: Maintenance

    Filter Size Maintenance Furnace Cabinet Width Side Return Bottom Return 17-1/2” 16 x 25 x 1 21” 16 x 25 x 1 20 x 25 x 1 WARNING 24-1/2” 24 x 25 x 1 ELECTRICAL SHOCK, FIRE, OR EXPLOSION Table 18. HAZARD.
  • Page 50 Inspect screens and rinse with tap water if needed. 12. Mark and disconnect all combustion air pressure tubing from cold end header collector box. Reinstall screens, reconnect hoses and turn on power to unit. 13. Mark and remove wires from pressure switch assembly. Remove the assembly.
  • Page 51 33. Carefully connect combustion air pressure switch Mark and disconnect sensor wire from the sensor. tubing from pressure switches to proper ports on cold Disconnect wires from flame rollout switches. end header collector box. Disconnect combustion air intake pipe. It may be 34.

  • Page 52: Wiring And Sequence Of Operation

    Wiring and Sequence of Operation LINE VOLTAGE - FACTORY LINE VOLTAGE - FIELD LOW VOLTAGE - FACTORY LOW VOLTAGE - FIELD NOTES: PRESS AND RELEASE FAULT CODE HISTORY BUTTON TO DISPLAY FAULT CODES. TO ERASE CODES, PRESS AND HOLD BUTTON IN FOR MORE THAN 5 SECONDS IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE FURNACE MUST BE REPLACED, IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A TEMP.
  • Page 53 Sequence of Operation Cooling The unit is set up at the factory for single stage cooling. On a call for heat from the room thermostat, the control For two stage cooling operation, clip the jumper wire board performs a 1 second self check. Upon confirmation located between the Y to Y2 terminals on the integrated that the pressure switch contacts are in an open position, ignition/blower control board.

This manual is also suitable for:

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