Tappan iQ Drive Furnace Blower Kit Installation guide

Type
Installation guide
Installation Instructions
WARNING:
To avoid the risk of electrical shock, personal
injury, or death, disconnect electrical power
before installing this kit or performing
maintenance.
Before beginning installation, read these instructions
thoroughly and follow all warning and cautions in these
instructions and on the unit. These instructions are primar-
ily intended to assist qualified individuals experienced in
the proper installation of this appliance. Some local codes
require licensed installation/ service personnel for this type
of equipment. Improper installation, service, adjustment,
or maintenance can cause fire, electrical shock or other
conditions which may result in personal injury or property
damage. Unless otherwise noted in the instructions, only
factory authorized kits or accessories may be used when
modifying this product.
1. SPECIFICATIONS
The variable speed blower kit number 904621 is designed
for installation in all “B” and “C” cabinet upflow *G6 and
*GF1 furnaces only. This kit is not intended for use on
downflow furnaces.
2. INSTALLATION REQUIREMENTS
Check Equipment - After unpacking, inspect the kit
thoroughly for concealed damage. If damage is found,
notify the transportation company immediately and file a
concealed damage claim. All installations shall be made
as described in the installation instructions and in accor-
dance with applicable national and local codes including
the requirements of local utilities.
3. INSTALLATION
Conversion of Single Stage Upflow
Furnace
1. Disconnect electrical power to the furnace.
2. Remove the upper and lower access doors from the
furnace.
3. Remove the electrical plug containing the blower
wires from the receptacle located on the left side of
the blower deck.
4. Remove the screws that hold the blower assembly
and remove the blower.
5. Attach the blower mounting brackets, supplied in the
kit, to the blower housing.
6. Slide the variable speed blower kit into the furnace.
Be sure that the sides of the blower are captured by
all of the blower mounting tabs in the blower deck.
Secure with the two screws removed in step 4.
Blower Kit for Gas Furnace Applications
7. Remove the front cover from the control panel. Con-
nect the thermostat wires from the auxiliary board to
the integrated control board in the furnace.
IMPORTANT NOTE: All wires should be routed
through a strain relief bushing. All signal wires
(shielded wires) should be routed separately from
the single conductor wires.
8. Connect the pressure transducer from the coil to 4
pin terminal labeled "P3" on the EXV Board.
9. Connect the temperature sensor from the evapora-
tor coil to the 3 pin terminal labeled "P2" on the EXV
Board.
10. Connect the 1/4 inch coil thermister leads from the
evaporator coil to the indicated location on the auxiliary
board.
11. Connect the EXV coil from the evaporator coil to the
6 pin terminal on the EXV Board labeled "P1".
12. Replace the transformer on the furnace with the
60VA transformer (Part No. 622057) that is provided
in the kit, and connect to the furnace control board.
Self tapping screws may be required to install the
transformer.
13. Connect the Black wire from the noise filter to "L1"
on the furnace control board, and the White wire to
the neutral terminal on the control board. Use the
piggy back connector to re-attach the Black wire to
the board.
14. Connect the Blue wire that is placed on the "Twin"
terminal on the interface board to the "Twin" terminal
on the integrated control board on the furnace.
15. A set of thermostat wires is furnished with the kit.
These 4 wires are connected to the "Thermostat"
terminals on the interface board. These wires include
a noise filter ring. DO NOT REMOVE THE FILTER
RING. This has been supplied by the factory to avoid
electrical interference. Field supplied wire shall be
used to connect the Red wire to "R" on the thermostat
control, the Yellow wire to "A", the White wire to "B",
and the Green wire to "C".
16. A set of wires is furnished to connect the outdoor
condensing unit to the interface board. These 3 wires
are connected to the "O.D. Unit" terminals on the in-
terface board. These wires include a noise filter ring.
DO NOT REMOVE THE FILTER RING. Refer to the
outdoor unit installation instructions for connection.
IMPORTANT NOTE: The use of shielded cable
is required for the connection to the thermostat
controller. This wire is field supplied. Ground the
shielded cable at the furnace end only on the
grounding lug on the interface board bracket.
2
Conversion of 2-Stage Upflow Furnaces
with Factory Installed Variable Speed
Blower (See Figures 1 & 3)
1. Disconnect electrical power to the furnace
2. Remove the upper and lower access doors from the
furnace.
3. Remove the screws that hold the blower assembly.
4. Remove the factory installed variable speed blower
including the wires connected to the integrated control
board in the furnace.
5. Remove all three wires that are fastened to the closed
end connector. Please note that one of the brown wires
is secured between the closed end connector and
the white wire on pin 13 of the variable speed motor.
These wires will not be used with the IQ Drive.
6. Remove the yellow wire from the Y-connector that
is attached to the gas valve. These wires will not be
used with the IQ Drive.
7. Connect the yellow wire from the W2 terminal of the
auxiliary board in the IQ Drive blower kit to the high
side terminal of the gas valve. (See Figure 2)
8. Install the IQ Drive blower kit as described in the
installation section for single stage furnaces, making
the conversions in steps 5 through 16.
Figure 2. Conversion of 95+ *TE Furnace
R
C
W2
WH
INTERFACE
BOARD
GAS VALVE
CONTROL
BOARD
ADD-ON
BOARD
RCYGW
W2 Y2
TWIN
TWIN
LOW
CONDENSATE
PRESSURE SWITCH
LOW
WHITE
BLUE
RED
YELLOW
BLUE
YELLOW
BROWN
BROWN
YELLOW
YELLOW
BROWN
HI
HI
C
1
2
3
4
5
6
7
8
9
123
456
FIGURE 2. 95+ FURNACE GAS VALVE WIRING
C
R
Y
INTERFACE
BOARD
R
C
W2
W
H
7
8
9
4
5
6
1
2
3
FURNACE
CONTROL
BOARD
GAS VALVE
HI LO C
YELLOW
YELLOW
BROWN
Figure 1. Wiring for furnaces with 2-stage gas valve.
Conversion of 2-stage Upflow Furnace with
Factory Installed Fixed Speed Blower
1. Disconnect electrical power to the furnace
2. Remove the upper and lower access doors from the
furnace.
3. Remove the screws that hold the blower assembly
and remove the blower.
4. Remove the DPST relay from the furnace and the
wires that connect to it. The relay and the wiring will
not be used with the IQ Drive.
5. Remove the brown wire that connects between the
DPST relay and the closed end connector in the fur-
3
nace. Also remove all three wires that are fastened
by the closed end connector. These wires will not be
used with the IQ Drive.
6. Remove the yellow Y-connector that is attached to
the gas valve. These wires will not be used with the
IQ Drive.
7. Install the IQ Drive blower kit as described in the
installation section for single stage furnaces, making
the conversions in steps 5 through 16.
8. Connect the yellow wire from the W2 terminal of the
auxiliary board in the IQ Drive blower kit to the high
side terminal of the gas valve. (See Figure 1)
Conversion of 92+ 2-stage Upflow Furnace
Models *TE Series with Factory Installed Vari-
able Speed Blower (See Figures 2 & 4)
1. Disconnect electrical power to the furnace
2. Remove the upper and lower access doors from the
furnace.
3. Remove the screws that hold the blower assembly
and remove the blower.
4. Install the IQ Drive blower kit as described in the
installation section for single stage furnaces, making
the conversions in steps 5 through 16.
5. Find wires that are fastened to the closed end connec-
tor. Please not that one of the brown wires is secured
between the closed end connector and the white wire
on pin 13 of the variable speed motor.
6. Remove the factory installed variable speed blower
including the wires connected to the integrated control
board in the furnace.
7. Cut and remove the brown wire from the variable speed
motor attached to the closed end connector. Insulate
the other end brown wire with insulation tape.
8. Disconnect the yellow wire from the low fire side
terminal on the gas valve that leads to the variable
speed motor.
9. Attach the W2 wire from the Interface board to
the W2 terminal on Add-on combustion board.
(See Figure 2)
Figure 3. IQ Wiring Diagram
MOTOR
NOISE
FILTER
INTERFACE
BOARD
R
C
W2
W
H Y
R
P3
3
2
1
O.D. UNIT
I.D. BLOWER
THERMOSTAT
TWIN
DX+
DX-
GND
GND
C R
DX-
DX+
TO
OUTDOOR
UNIT
THERMISTOR
THRU CORE
RING
TEMP
SENSOR
COIL
THRU CORE
RING
POWER
CABLE
PLUG
CONNECTOR
GREEN
WHITE
RED
RED
YELLOW
WHITE
GREEN
EXV
BOARD
ON
R
Y
SW2
P2
THERM
P3
THERM
SW1
COMM
P4
EXV
P1
C
OFF
SUCTION TEMP.
SENSOR
SUCTION PRESS.
SENSOR
PLUG
CONNECTOR
CONTROL
CABLE
R
C
Y
G
W
HUM
7
8
9
4
5
6
1
2
3
EAC
C
W2
RH
R
W1
H
0
Y2
Y1
G
L
V
A
B
GD
OD
ID
GD
THERMOSTAT
CONTROL
3 Amp Fuse
TWIN
COM
24 V
Neutrals
41
52
63
EAC
HUM
M1
M2
M3
HEAT
COOL
L1
XFMR
Unused Motor
Leads
120V
24V
WHITE
BLOWER OFF
180
120
90
60
FURNACE
BOARD
CONNECT TO
GAS VALVE
(TWO-STAGE
FURNACES ONLY)
RED
BLACK
BLACK
RED
BLACK
WHITE
GREEN
BLACK
WHITE
RED
RED
WHITE W/BLACK STRIPE
BLACK W/WHITE STRIPE
GREEN
GREEN
WHITE
BLACK
BLACK
WHITE
GREEN
YELLOW
WHITE
BLUE
BLUE
RED
RED
GRAY
YELLOW
710677 (Replaces 7106220)
Furnace Kit for System
Legend
Field Wiring
Factory Wiring:
Low Voltage
High Voltage
03/07
7106770
Figure 4. Wiring for 95+ 2-Stage Furnace
7106800
5. SELECTING BLOWER-OFF TIME
DELAY.
The blower off time delay can be adjusted through the
programming screen. The time delay can be adjusted
from 60 to 180 seconds. To enable this feature, the blower
off delay on the furnace board must be positioned to 60
seconds in order for the desired delay to be active. The
default setting on the thermostat is 120 seconds.
4. SELECTING THE GAS HEATING
AIRFLOW
To select the airflow, enter into the programming screen
on the controller thermostat. Select the input rate of the
gas furnace, then select the desired temperature rise.
PLEASE NOTE: Improper selection of the temperature
rise may result in limit operation. It is recommended that
a full furnace cycle is witnessed before the furnace is
placed in operation.
For 95+ 2-Stage Model Furnaces (2-Stage Inducer)
CR
FLAME SENSOR
PRESSURE
LOW
HI HI
LOW
SWITCH
PRESSURE
SWITCH
BLOWER DOOR
SWITCH
TRANSFORMER
24 V
120 V
WHITE W/BLK STRIPES
BLK W/ WHITE STRIPES
IGNITO
2-PIN
HOUSING
6-PIN PLUG
3-PIN PLUG
3-PIN HOUSING
(SUPPLIED W/ INDUCER)
R
INDUCER
PRIMARY
GAS
VALV E
COM
24 V
3 AMP FUSE
BLOWER OFF
TWIN
FLAMESTATUS
1
1
2
2
1
2
1
2
3
3
VENT SAFETY SWITCH
HILOWC
SUPPLY AIR
LIMIT SWITCH
FLAME ROLL-OUT
SWITCH
ADD ON BOARD
Y2
Y2 W2
CONDENSAT E
BLOCKED VENT
EAC
HUM
HUM
M1
M2
M3
HEAT
COOL
EAC
XFMR
L1
NEUTRALS
R C
Y G W
MOTOR
NOISE
FILTER
1
2
3
45
1
2
345
R
C
W2
W
HY
R
P
O.D. UNIT
I.D. BLOWER
THERMOSTAT
TWIN
CR
DX+
DX-
GND
DX-
DX+
GRD
COIL
THERMISTOR
TEMP
SENSOR
COIL
THR
4-PIN
HARNESS
U CORE
RING
THRU CORE
RING
POWER
BUSHING
CABLE
CONTROL
CABLE
INTERFACE
BOARD
BLACK
BLACK
BLACK
BLACK
BLACK
RED
YELLOW
WHITE
WHITE
GREEN
GREEN
RED
PLUG
3-PIN HARNESS
3-PIN HARNESS
CONNECTOR
C
W2
RH
R
W1
H
0
Y2
Y1
G
L
V
A
B
GD
OD
ID
GD
THERMOSTAT
CONTROL
TO
OUTDOOR
UNIT
TO
OUTDOOR
UNIT
9-PIN PLUG
1
2
3
4
5
6
7
8
9
3
4
5
1
2
3
6
2
1
3
2
31
456
RED
WHITE
GREEN
HARNESS
EXV
BOARD
ON
R
Y
SW2
P2
THERM
P3
THERM
SW1
COMM
P4
EXV
P1
C
OFF
SUCTION TEMP.
SENSOR
SUCTION PRESS.
SENSOR
GREEN
BLACK
WHITE
RED
RED
EXV
6-WIRE CABLE
CABLE
WHITE
GREEN
GREEN
BLACK
3-PIN PLUG
6-PIN PLUG
WHITE
BLACK
FURNACE
BOARD
GREEN
RED
RED
YELLOW
GRAY
RED
RED
BLUE
BLUE
WHITE
BLACK
BLACK
BLUE
BLUE
BLUE
ORANGE
WHITE
GREEN
BLACK
BLACK
BLACK
RED
BROWN
GREEN
ORANGE
YELLOW
YELLOW
BROWN
BROWN
YELLOW
WHITE
BLACK
BLACK
BLACK
VIOLET
BLACK
RED
BLACK
WHITE
VIOLET
VIOLET
FIELD WIRING
LEGEND:
LOW VOLTAGE
HIGH VOLTAGE
STATUS
RED LIGHT
Power On ON
Limit Circuit Open or External Load On "W"1 FLASH
Pressure Switch is Open with Inducer On 2 FLASHES
Hi Pressure Switch is Open (Add-on board LED) 2 FLASHES
Pressure Switch is Closed with Inducer Off3 FLASHES
Ignition Failure (Check Ground) 4 FLASHES
115 VAC & Neutral Reversed or no Ground 5 FLASHES
False Flame or Gas Valve Relay ShortedContinuous
Power Of
OFF
FAULT CONDITION
FLAME
YELLOW
LIGHT
Low Flame Sensor Signal
Continuous
Flash
Flame Presen
ON
NOTES:
1. Use copper conductors only.
2. If any of the original wires as supplied with the furnace must be replaced,
it must be replaced with wiring material having a temperature rating of at
least 105˚ C.
3. Refer to the Installation Instructions provided with the furnace for the
appropriate heating and cooling settings for your application.
4. Ensure that wires from the blower remain connected to the board thermo-
stat terminals after making the field thermostat connections.
708751A (Replaces 7087510)
Specifications & illustrations subject to change without notice or incurring obligations (05/15).
O’Fallon, MO, © Nortek Global HVAC LLC 2015. All Rights Reserved.
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Tappan iQ Drive Furnace Blower Kit Installation guide

Type
Installation guide

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