F80CTL & G80CTL: Installation, Start–Up, Operating and Service and Maintenance Instructions
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
38
GENERAL
These instructions are written as if the furnace is installed in an upflow
application. An upflow furnace application is where the blower is
located below the combustion and controls section of the furnace, and
conditioned air is discharged upward. Since this furnace can be installed
in any of 4 positions, see in Fig. 65, you must revise your orientation to
component location accordingly.
Electrical Controls and Wiring
The electrical ground and polarity for 115-v wiring must be properly
maintained. See Fig. 24 for field wiring information, and see Fig. 53 in
the Wiring Diagram section for furnace wiring information.
NOTE: If the polarity is not correct, the STATUS LED on the control
will flash status code 10 and prevent the furnace from heating. The
control system also requires an earth ground for proper operation of the
control and flame-sensing electrode.
The 24-v circuit contains an automotive-type, 3-amp. fuse located on the
control, see Fig. 32. Any shorts of the 24-v wiring during installation,
service, or maintenance will cause this fuse to blow. If fuse replacement
is required, use ONLY a 3-amp. fuse. The control LED will display turn
off when fuse needs to be replaced.
Proper instrumentation is required to service electrical controls. The
control in this furnace is equipped with a Status Code LED
(Light-Emitting Diode) to aid in installation, servicing, and
troubleshooting. Status codes can be viewed at the sight glass in blower
access door. The amber furnace control LED is either flashing a
heartbeat (bright-dim), on solid, or flash a status code.
For an explanation of status codes, refer to service label located on
blower access door (also on Fig. 49), and the troubleshooting guide
which can be obtained from your distributor.
See the brief Troubleshooting Guide, see Fig. 54.
For 2-Stage Variable Speed ECM Controls the stored status codes will
NOT be erased from the control memory, when 115- or 24-v power is
interrupted. The control will store up to the last 7 Status Codes in order
of occurrence.
1. To retrieve status codes, proceed with the following:
NOTE: NO thermostat signal may be present at control, and all
blower-OFF delays must be completed.
a. Leave 115-v power to furnace turned on.
b. Remove outer access door.
c. Look into blower access door sight glass for current LED status.
d. Remove blower access door.
NOTE: The Status Codes cannot be retrieved by disconnecting the limit
switch or draft safeguard switch. To retrieve Status Codes, follow the
procedure below.
2. Turn Setup Switch, SW1-1 “ON.”
3. Manually close blower access door switch.
4. Control will flash up to 7 Status Codes.
5. The last Status Code, or 8th Code, will be flashing heartbeat.
6. Turn SW1-1 “OFF.”
7. The Amber LED will flash heartbeat (bright-dim) continuously
which indicates proper operation.
8. Release blower access door switch, install blower access door and
replace outer door, or refer to the SERVICE label on the front of the
blower access door for more information.
Component Self-Test
Component Test can ONLY be initiated by performing the following:
1. Remove outer access door.
2. Remove blower access door.
3. Remove the wire from the “R” terminal of the control board.
4. Turn Setup Switch, SW-1-6 “ON.”
5. Manually close blower access door switch.
Blower access door switch opens 115-v power to control. No component
operation can occur unless switch is closed. Caution must be taken when
manually closing this switch for service purposes.
6. Component Test sequence will function as follows:
a. Inducer motor starts on high-speed and continues to run until
Step (d.) of component test sequence.
b. Hot surface igniter is energized for 15 sec, then de-energized.
c. Blower operates for 10 sec, then turns off.
d. Inducer motor goes to low-speed for 10 seconds, then turns off.
CAUTION
!
ENVIRONMENTAL HAZARD
Failure to follow this caution may result in environmental pollution.
Remove and recycle all components or materials (i.e. oil, refrigerant,
control board, etc.) before unit final disposal.
WARNING
!
ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal injury or death,
or property damage.
Before installing, modifying, or servicing system, main electrical
disconnect switch must be in the OFF position and install a lockout tag.
There may be more than one disconnect switch. Lock out and tag
switch with a suitable warning label. Verify proper operation after
servicing.
CAUTION
!
ELECTRICAL OPERATION HAZARD
Failure to follow this caution may result in improper furnace operation
or failure of furnace.
Label all wires prior to disconnection when servicing controls. Wiring
errors can cause improper and dangerous operation.
WARNING
!
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury or death.
There may be more than one electrical supply to the furnace. Check
accessories and cooling unit for additional electrical supplies that must
be shut off during furnace servicing. Lock out and tag switch with a
suitable warning label.
WARNING
!
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury, or death.
Blower access door switch opens 115-v power to furnace control. No
component operation can occur unless switch is closed. Exercise
caution to avoid electrical shock from exposed electrical components
when manually closing this switch for service purposes.
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