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Carrier F96VTN User Manual

Carrier F96VTN
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. 440 01 4801 00 11/14/2019
INSTALLATION INSTRUCTIONS
Two--Stage, Non--Communicating, Variable Speed, 35” Tall
High Efficiency Condensing Gas Furnace
F96VTN and G96VTN
(Series A)
NOTE: Read the entire instruction manual before starting the installation.
SECTIONS
SAFETY CONSIDERATIONS 4.........................
INTRODUCTION 5...................................
CODES AND STANDARDS 6...........................
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS 7...
ACCESSORIES 7.....................................
LOCATION 7........................................
AIR FOR COMBUSTION AND VENTILATION 8..........
CONDENSATE TRAP 9................................
CONDENSATE DRAIN 13.............................
INSTALLATION 16...................................
AIR DUCTS 26.......................................
GAS PIPING 27......................................
ELECTRICAL CONNECTIONS 28.......................
VENTING 35........................................
START-- UP, ADJUSTMENT, AND SAFETY CHECK 56......
SERVICE AND MAINTENANCE PROCEDURES 66........
SEQUENCE OF OPERATION 76........................
PARTS REPLACEMENT GUIDE 79......................
TABLES
Loose Parts Bag Contents 6..............................
Minimum Clearances to Combustible Materials 5.............
Minimum Free Area Required 10.........................
Minimum Space Volumes 10.............................
Filter Size Information 20...............................
Opening Dimensions 20................................
Air Delivery CFM 22...................................
Maximum Capacity of Pipe 27...........................
Electrical Data 29......................................
Combustion--Air Vent Pipe, Fitting & Cement Material.. 55.....
Vent T e rmination Kit for Direct Vent (2--Pipe) Systems 38......
Hangar Spacing 52.....................................
Maximum Allowable Exposed Vent Lengths Insulation 48......
Maximum Equivalent Vent Length 44......................
Deductions from Maximum Equivalent Vent Length 44........
Altitude Derate Multiplier for U.S.A. 59....................
Blower Of f Delay Setup Switch 61........................
Gas Rate 66..........................................
Orifice Size and Manifold Pressure 63.....................
Use of the AHRI Certified TM Mark indicates a
manufacturer’s participation in the program.
For verification of certification for individual
products, go to www.ahridirectory.org .
Portions of the text and tables are reprinted from NFPA 54/ANSI Z223.1E, with permission of National Fire Protection Association,
Quincy, MA 02269 and American Gas Association, Washington DC 20001. This reprinted material is not the complete and official position
of the NFPA or ANSI on the referenced subject, which is represented only by the standard in its entirety.
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Carrier F96VTN Specifications

General IconGeneral
Fuel TypeNatural Gas
StagesTwo-Stage
Blower Motor TypeVariable-Speed ECM
Ignition TypeHot Surface Ignition
Heating Capacity60, 000 - 120, 000 BTUH
Warranty10-year parts limited warranty

Summary

Required Notice for Massachusetts Installations

SAFETY CONSIDERATIONS

WARNING: FIRE, EXPLOSION, ELECTRICAL SHOCK, AND CARBON MONOXIDE POISONING HAZARD

Critical hazards associated with improper furnace operation, installation, or maintenance.

CAUTION: CUT HAZARD

Warning about sharp metal edges and burrs on furnace parts during handling.

INTRODUCTION

NOTICE: Important Installation and Start-up Procedures

Guidance on initial installation steps to prevent nuisance smoke or odor complaints.

CODES AND STANDARDS

Safety

Compliance with national and local safety codes for gas appliances.

General Installation

Adherence to NFGC, NFPA 90B standards for general installation practices.

Combustion and Ventilation Air

Requirements for air supply for combustion and ventilation per NFPA 54/CAN/CSA B149.

Duct Systems

Standards for ductwork design and installation, including ACCA, SMACNA, ASHRAE.

Gas Piping and Gas Pipe Pressure Testing

Guidelines for gas piping installation, pressure testing, and material compliance.

Electrical Connections

Requirements for electrical connections per NEC/Canadian Electrical Code.

Condensate Drain Connection

Standards for condensate drain piping installation per plumbing codes.

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS PROCEDURE

CAUTION: FURNACE RELIABILITY HAZARD

Precautions to prevent damage to electronic components from static discharge.

ACCESSORIES

LOCATION

General

General guidelines for furnace placement, ensuring protection from water and allowing service access.

AIR FOR COMBUSTION AND VENTILATION

Introduction

Overview of air requirements for different furnace venting configurations.

Direct Vent (2-pipe) Applications

Air requirements for direct-vent systems where combustion air is supplied externally.

Non-Direct Vent (1-pipe) Applications

Air requirements for non-direct vent systems needing adequate combustion air.

Ventilated Combustion Air Applications

Air requirements for systems using ventilated combustion air from attics or crawl spaces.

CAUTION: FURNACE CORROSION HAZARD

Warning about contaminants in combustion air causing heat exchanger corrosion.

CONDENSATE TRAP

Condensate Trap - Upflow Orientation

Information on condensate trap installation for upflow furnace orientation.

Condensate Trap - Downflow Orientation.

Instructions for relocating the condensate trap for downflow furnace orientation.

Condensate Trap - Horizontal Orientation.

Details on repositioning the condensate trap for horizontal furnace installations.

CONDENSATE DRAIN CONNECTION

CAUTION: FROZEN AND BURST WATER PIPE HAZARD

Precautions to prevent freezing of condensate lines and protect against property damage.

CAUTION: PROPERTY DAMAGE HAZARD

Warning about potential property damage from condensate pump failure or drain blockage.

For Right Side Condensate Drain:

For Left Side Condensate Drain Connection:

Optional Installation of the Vent Pipe

NOTICE: FOR POLYPROPYLENE VENTING SYSTEMS

Notice regarding specific installation instructions for polypropylene venting systems.

Installing the Vent Termination

Roof Terminations

Guidelines for installing vent terminations on roofs, ensuring proper clearance and performance.

Concentric Vent

Instructions for installing concentric vent termination kits, including hole sizing and assembly.

Two-Pipe and Single-Pipe Terminations

Procedures for installing two-pipe and single-pipe vent terminations, ensuring proper spacing.

INSTALLATION

Upflow Installation

Specific instructions for installing the furnace in an upflow configuration.

Supply Air Connections

Guidelines for connecting supply-air ductwork to the furnace outlet.

Return Air Connections

Instructions for connecting return-air ductwork to the furnace, including restrictions.

Bottom Return Air Inlet

Side Return Air Inlet

Downflow Installation

CAUTION: MINOR PROPERTY HAZARD

Filter Arrangement

Filter and Return Duct Sizing

Guidance on selecting filters and sizing associated ductwork based on pressure drop.

Location Relative to Cooling Equipment

Considerations for installing the furnace in relation to cooling equipment to prevent issues.

Platform Furnace Support

Methods for providing proper support for the furnace installation on a platform.

GAS PIPING

WARNING: FIRE OR EXPLOSION HAZARD

Critical safety warning regarding gas line purging, leak testing, and handling.

CAUTION: FURNACE DAMAGE HAZARD

Caution to avoid damaging gas controls or misaligning the burner during piping connections.

Gas Pressure

Specifications for natural gas and propane inlet gas pressures for furnace operation.

ELECTRICAL CONNECTIONS

WARNING: ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

Critical safety warning regarding electrical connections, wiring, and disconnects.

115-V Wiring

Detailed instructions for connecting the 115-volt power supply to the furnace.

J-Box Installation

Procedures for installing the junction box for field electrical connections.

24-V Wiring

Instructions for making 24-volt connections for thermostat and accessories.

WARNING: FIRE, EXPLOSION, ELECTRICAL SHOCK, AND CARBON MONOXIDE POISONING HAZARD

Thermostats

Air Conditioning (A/C) Setup Switches (SW2-6, 7, 8)

Configuration of switches for matching furnace airflow to cooling unit tonnage.

Continuous Fan (CF) Setup Switches (SW2-3, 4, 5)

Configuration of switches for selecting continuous fan or low-cooling airflow.

Setup Switches (SW2-1, 2)

Configuration of additional setup switches for twinning and airflow adjustments.

Accessories

1. Electronic Air Cleaner (EAC)

Installation instructions for connecting an optional Electronic Air Cleaner.

2. Humidifier (HUM)

Instructions for connecting an optional humidifier to the furnace control.

3. Twinning Connector

Information on the use of the twinning connector for multiple furnaces.

Alternate Power Supplies

Guidelines for operating the furnace with alternate power sources like generators.

VENTING

Special Venting Requirements for Installations in Canada

Specific venting requirements and material compliance for installations in Canada.

General

General considerations for furnace venting, including replacement of existing systems.

Materials

Approved materials for combustion air and vent piping in the USA and Canada.

Venting System Length Calculations

Methodology for calculating total equivalent vent length and comparing it to maximum allowable lengths.

WARNING: CARBON MONOXIDE POISONING HAZARD

Venting Systems

General information and recommendations for vent system installation and support.

Direct Vent / 2-Pipe System

Installation requirements for direct-vent (2-pipe) systems, including termination locations.

Ventilated Combustion Air Systems

Installation requirements for systems using ventilated combustion air, including termination and air source.

Locating the Vent Termination

General

Guidelines for selecting appropriate locations for vent and combustion air terminations.

Inside Corner Terminations

NOTICE: RECOMMENDED SUPPORT FOR VENT TERMINATIONS

Termination Requirements for the Provinces of Alberta and Saskatchewan

Size the Vent and Combustion Air Pipes

General

General guidance on sizing vent and combustion air pipes based on furnace requirements.

OPTIONAL CONFIGURATION FOR COMBUSTION AIR INLET PIPE

Information on adding a moisture trap to the combustion air inlet pipe for protection.

ELBOW CONFIGURATIONS

VENT TERMINAL CONFIGURATIONS

Recommended Combustion Air Inlet Moisture Trap

Venting System Length Calculations

Example 1

A worked example demonstrating venting system length calculations for a specific furnace model.

Configure the Furnace

WARNING: CARBON MONOXIDE POISONING HAZARD

Critical safety warning regarding proper sealing of vent and air pipes through the furnace casing.

Near Furnace Vent Connections

Guidelines for making vent pipe connections near the furnace, emphasizing elbow types.

Install the Vent and Combustion Air Pipes

Step-by-step instructions for installing the vent and combustion air pipes through the furnace casing.

Installing the Vent Pipe Adapter and Combustion Air Pipe Adapter

WARNING: CARBON MONOXIDE POISONING HAZARD

Critical safety warning regarding proper sealing of vent and air pipes through the furnace casing.

NOTICE: THE FOLLOWING INSTRUCTIONS ARE FOR PVC/ABS DWV VENT PIPING ONLY.

CAUTION: FURNACE RELIABILITY HAZARD

WARNING: CARBON MONOXIDE POISONING HAZARD

Optional Installation of the Vent Pipe

Installing the Vent Termination

Guidelines for installing vent terminations on roofs, ensuring proper clearance and performance.

Sidewall Terminations

Concentric Vent

Instructions for installing concentric vent terminations on sidewalls, following manufacturer guidelines.

2-Pipe and 1-Pipe Vent Termination

Guidelines for installing two-pipe and one-pipe vent terminations on sidewalls.

Inducer Outlet Restrictor

To install the outlet restrictor:

Instructions for installing an inducer outlet restrictor to improve furnace efficiency on short vent systems.

Venting System Length Calculations

Example 1

A worked example demonstrating venting system length calculations for a specific furnace model.

START-UP, ADJUSTMENT, AND SAFETY CHECK

NOTICE: Important Installation and Start-up Procedures

Procedures to follow after installation to ensure proper operation and prevent initial issues.

General

General requirements for furnace power supply, grounding, and thermostat connections.

CAUTION: UNIT OPERATION HAZARD

Warning about potential intermittent operation or performance issues due to improper setup.

Setup Switches

Description and configuration of DIP switches for furnace setup and airflow.

Air Conditioning (A/C) Setup Switches (SW2-6, 7, 8)

Prime Condensate Trap with Water

WARNING: CARBON MONOXIDE POISONING HAZARD

Warning that improper trap priming can allow vent gases into the structure.

Purge Gas Lines

Instructions for purging gas lines and checking for leaks after connections are made.

Adjustments

CAUTION: FURNACE DAMAGE HAZARD

Caution against improper adjustments that could lead to excessive burner noise or flame issues.

WARNING: FIRE HAZARD

NOTICE

Notice regarding natural gas manifold pressure adjustments and altitude derates.

Check Inlet Gas Pressure

Procedures for checking the furnace inlet gas pressure to ensure proper operation.

Adjust Temperature Rise

CAUTION: FURNACE DAMAGE HAZARD

Warning about potential furnace damage or shortened life from incorrect temperature rise.

To lock the furnace in low heat:

Steps to lock the furnace in low-heat mode for temperature rise adjustments.

To lock the furnace in high heat:

Steps to lock the furnace in high-heat mode for temperature rise adjustments.

Adjust Blower Off Delay (Heat Mode)

Instructions for setting the blower off-delay time using dip switches for heat mode.

Adjust Cooling Airflow – High-Speed and Low-Speed Cooling

Procedures for adjusting cooling airflow based on unit tonnage and setup switch configurations.

Check Safety Controls

1. Check Main Limit Switch

Procedure to test the main limit switch for proper operation during overheat conditions.

2. Check Pressure Switch(es)

Procedure to test pressure switches that verify inducer blower operation.

Checklist

A final checklist of items to verify before completing the installation or service.

SERVICE

LED CODE

Explanation of the LED status codes for furnace diagnostics and troubleshooting.

STATUS

Description of furnace status indicators and their meanings.

COMPONENT TEST

Procedure to initiate and perform component tests for diagnosing furnace issues.

Electrical Controls and Wiring

Troubleshooting

Retrieving Stored Status Codes

Instructions on how to retrieve and interpret stored diagnostic status codes from the furnace control.

Component Self-Test

Steps to initiate and perform the furnace's built-in component self-test for diagnostics.

Cleaning and/or Replacing Air Filter

WARNING: CARBON MONOXIDE POISONING AND FIRE HAZARD

Critical safety warning regarding furnace operation without a filter or with access doors removed.

Blower Motor and Wheel Maintenance

Clean blower motor and wheel as follows:

Step-by-step instructions for cleaning the blower motor and wheel for optimal performance.

Cleaning Burners and Flame Sensor

WARNING: ELECTRICAL SHOCK AND FIRE HAZARD

Critical safety warning regarding electrical and gas supplies before performing burner maintenance.

Servicing Hot Surface Ignitor

Flushing Collector Box and Drainage System

Cleaning Condensate Drain and Trap

Procedures for cleaning the condensate drain and trap to ensure proper drainage.

Cleaning Heat Exchangers

Primary Heat Exchangers

Instructions for cleaning primary heat exchangers and identifying issues requiring professional service.

WINTERIZATION

CAUTION: UNIT AND PROPERTY DAMAGE HAZARD

Precautions to take when installing the furnace in areas susceptible to freezing temperatures.

CAUTION: UNIT COMPONENT DAMAGE HAZARD

Warning about using incompatible antifreeze solutions that can damage plastic components.

Troubleshooting Guide

Troubleshooting Guide (Continued)

SEQUENCE OF OPERATION

1. Two-Stage Heating (Adaptive Mode) with Single-Stage Thermostat

Detailed explanation of the furnace's operation in two-stage heating with a single-stage thermostat.

a. Inducer Prepurge Period

Description of the inducer prepurge period before ignition in heating modes.

b. Igniter Warm-Up

Explanation of the ignitor warm-up sequence before the trial-for-ignition period.

c. Trial-For-Ignition Sequence

Description of the trial-for-ignition sequence and flame proving process.

d. Flame-Proving

Explanation of how the furnace proves the presence of a flame after ignition.

e. Blower-On delay

Explanation of the blower-on delay sequence after flame is proven.

f. Switching from Low- to High-Heat

Process for switching between low-heat and high-heat operation based on thermostat demand.

g. Switching from High- to Low-Heat

Process for switching from high-heat back to low-heat operation.

h. Blower-Off Delay

Explanation of the blower-off delay sequence after the heating cycle completes.

2. Two-Stage Thermostat and Two-Stage Heating

PARTS REPLACEMENT INFORMATION GUIDE

Casing Group

List of replacement parts related to the furnace casing components.

Electrical Group

List of replacement parts for the furnace's electrical system.

Blower Group

List of replacement parts for the furnace's blower assembly.

Filter Group

List of replacement parts related to the furnace's air filter system.

Gas Control Group

List of replacement parts for the furnace's gas control system.

Heat Exchanger Group

List of replacement parts for the furnace's heat exchanger assemblies.

Inducer Group

List of replacement parts for the furnace's inducer assembly.

MODEL NOMENCLATURE

Explanation of the model number designation for identifying furnace specifications.

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