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 install-
ing 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 qualifi ed 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 fi re, 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 904492 is designed
for installation in all “B” and “C” cabinet upfl ow *G6 and
*GF1 furnaces only.
2. INSTALLATION REQUIREMENTS
Check Equipment - After unpacking, inspect the kit
thoroughly for concealed damage. If damage is found,
notify the transportation company immediately and fi le 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 Upfl ow
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 conduc-
tor wires.
8. Connect the pressure transducer from the coil to
terminals 22, 23, 24 on the Kelvin Controller. The
White wire connects to Terminal #22, the Green wire
connects to terminal #23, and the Black wire connects
to Terminal #24.
9. Connect the temperature sensor from the evaporator
coil to terminals 20 and 21.
10. Connect the 1/4 inch coil thermister leads from the
evaporator coil to the indicated location on the auxiliary
board.
11. Connect the ESX coil from the evaporator coil to the
Kelvin Controller. The Gray wire connects to terminal
#8, the Black wire connects to #9, the Red wire to
#10, the Yellow wire to #11, and the Brown wire to
#12.
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 fi lter 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 fi lter 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 fi lter ring.
DO NOT REMOVE THE FILTER RING. Refer to the
outdoor unit installation instructions for connection.
2
Conversion of 95+ 2-stage Upfl ow Furnace
Models *TE Series 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
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 con-
nector. 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.
6. Remove the factory installed variable speed blower
including the wires connected to the integrated control
board in the furnace.
7. Cut and remove brown wire from the variable speed
motor attached to the closed end connector. Insulate
the other end brown wire with insulation tape.
8. Disconnect yellow wire from the low fi re side terminal
on the gas valve that leads to the variable speed mo-
tor.
9. Attach the W2 wire from the Interface board to the W2
terminal on Add-on combustion board. (See Figure 1)
Replacing IQ Drive Furnace Blower
Assembly
NOTE: IQ Drive furnace blower assembly can be replaced
with this kit.
Please check the wiring using Figure 3 and check fur-
nace operation according to the main furnace Installation
Instructions after replacing the blower assembly.
Conversion of 92+ 2-stage Upfl ow Furnace
Models *TC Series with Factory Installed
Variable 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.
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.
Figure 1. 95+ Furnace Gas Valve Wiring
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
3
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.
Conversion of 2-stage Upfl ow 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-
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 2)
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 2. 92+ Furnace Gas Valve Wiring
Figure 3. 95+ IQ Drive 2-Stage Furnace Wiring
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
WHITE
BLACK
IGNITOR
INDUCER
PRIMARY
GAS
VALV E
COM
24 V
3 AMP FUSE
BLOWER OFF
TWIN
FLAME STATUS
WHITE BLACK
GREEN
1
1
2
2
1
2
1
2
3
3
GREEN
RED
BROWN
WHITE
BLACK
BLACK
BLUE
BLUE
VENT SAFETY SWITCH
HILOW C
SUPPLY AIR
LIMIT SWITCH
FLAME ROLL-OUT
SWITCH
BLUE
VIOLET
BLACK
RED
ADD ON BOARD
GREEN
BLACK
Y2
Y2
W2
RED
BLACK
YELLOW
BROWN
RED
BLUE
WHITE
WHITE
BLACK
BLUE
CONDENSATE
BLOCKED VENT
VIOLET
ORANGE
ORANGE
VIOLET
EAC
HUM
HUM
M1
M2
M3
HEAT
COOL
EAC
XFMR
L1
NEUTRALS
YELLOW
YELLOW
YELLOW
BROWN
BLACK
RCYGW
KELVIN
CONTROLLER
MOTOR
20
123 4567891011
12
21
22
23
24
NOISE
FILTER
1
2
3
45
1
2
345
R
C
W2
W
H
R
P
O.D. UNIT
I.D. BLOWER
THERMOSTAT
TWIN
DX+
DX-
GND
24 VAC
DX-
DX+
GRD
COIL
THERMISTOR
TEMP
SENSOR
COIL
ESX COIL
PRESSURE
TRANSDUCER
TEMP.
SENSOR
SUCTION
(I.D. COIL)
THRU CORE
RING
THRU CORE
RING
POWER
CABLE
CONTROL
CABLE
CABLE
INTERFACE
BOARD
BLACK
BLACK
BLACK
BLACK
BLACK
RED
YELLOW
WHITE
WHITE
GRAY
BLACK
WHITE
GREEN
BLACK
BLACK
RED
BLACK
YELLOW
ORANGE
WHITE
GREEN
GREEN
GREEN
GREEN
BLACK
RED
RED
PLUG
CONNECTOR
BLACK
BROWN
BROWN
BLACK
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
Field Wiring
Low Voltage
High Voltage
Legend
Factory Wiring:
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.
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 Off 3 FLASHES
Ignition Failure (Check Ground) 4 FLASHES
115 VAC & Neutral Reversed or no Ground 5 FLASHES
False Flame or Gas Valve Relay Shorted Continuous
Power Off OFF
FAULT CONDITION
FLAME
YELLOW
LIGHT
Low Flame Sensor Signal
Continuous
Flash
Flame Present ON
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
7106440
O'Fallon, MO
7087430 (Replaces 7086110)
Specifi cations and illustrations subject to change
without notice and without incurring obligations.
Printed in U.S.A. (02/07)
¢7087436¤
7087430
Figure 4. 92+/80+ 2-Stage Furnace Wiring
KELVIN
CONTROLLER
MOTOR
20
21
22
23
24
1
2
3
4
5
6 7 8 9 10 11 12
NOISE
FILTER
INTERFACE
BOARD
R
C
W2
W
H
R
P3
O.D. UNIT
I.D. BLOWER
THERMOSTAT
TWIN
DX+
DX-
GND
GND
24 VAC
DX-
DX+
COIL
THERMISTOR
TO
OUTDOOR
UNIT
THRU CORE
RING
R
C
Y
G
W
3 Amp Fuse
TWIN
COM
24 V
HUM
Neutrals
41
52
63
7
8
9
4
5
6
1
2
3
EAC
HUM
M1
M2
M3
HEAT
COOL
L1
XFMR
Unused Motor
Leads
EAC
TEMP
SENSOR
COIL
ESX COIL
TEMP.
SENSOR
SUCTION
(I.D. COIL)
120V
24V
CONNECT TO
GAS VALVE
(TWO-STAGE
FURNACES ONLY)
Legend
Field Wiring
Factory Wiring:
Low Voltage
High Voltage
BLACK
GREEN
WHITE
RED
BLACK
BLACK
BLACK
RED
YELLOW
YELLOW
WHITE
WHITE
GRAY
BLACK
WHITE
GREEN
BLACK
BLACK
RED
BLACK
YELLOW
ORANGE
WHITE
WHITE
WHITE W/BLACK STRIPE
BLACK W/ WHITE STRIPE
GREEN
GREEN
GREEN
WHITE
GREEN
RED
C
W2
RH
R
W1
H
0
Y2
Y1
G
L
V
A
B
GD
OD
ID
GD
THRU CORE
RING
WHITE
BLUE
BLUE
BROWN
BROWN
RED
POWER
CABLE
CABLE
BLOWER OFF
180
120
90
60
FURNACE
BOARD
PRESSURE
TRANSDUCER
PLUG
CONNECTOR
PLUG
CONNECTOR
CONTROL
CABLE
RED
THERMOSTAT
CONTROL
BLACK
BLACK
TO
OUTDOOR
UNIT
BLACK
7106220
4. SELECTING THE GAS HEATING
AIRFLOW
To select the airfl ow, 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.
5. SELECTING BLOWER-OFF TIME
DELAY.
The blower off time delay can be adjusted through the
programming screen. The time delay can be adjusted to
go 120 or 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.
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Tappan iQ Drive Furnace Blower Kit Installation guide

Type
Installation guide

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