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Haier GE NF97DM Service Manual

97% downflow modulating variable speed gas furnace
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Service
NF97DM
97% Downflow Modulating
Manual
Variable Speed Gas Furnace
READ CAREFULLY.
.
KEEP THESE INSTRUCTIONS
31-5000724 Rev. 0 11-22 GEA

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  • Page 1 Service NF97DM 97% Downflow Modulating Manual Variable Speed Gas Furnace READ CAREFULLY. KEEP THESE INSTRUCTIONS 31-5000724 Rev. 0 11-22 GEA...

  • Page 2: Table Of Contents

    SERVICE MANUAL NF97DM Gas Furnace 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. NF97DM series units are high-efficiency upflow, horizontal right and left) gas furnaces equipped with variable capacity gas valve, variable speed combustion air inducer and Table of Contents...

  • Page 3: Technical Specifications - Nf97Dm

    Technical Specifications - NF97DM MODEL NUMBER GUIDE N F F 97 97 D D M M 5 5 C C XX BRAND MAJOR/MINOR REVISION N - GE CABINET WIDTH PRODUCT B - 17.5 F - FURNACE, GAS C - 21.0 AFUE NOMINAL CFM 97 - 97% EFFICENCY...
  • Page 4 BLOWER PERFORMANCE: RETURN INLET Heating Cooling Motor Temp CFM @ 0" - 0.8" w.c. CFM @ 0" - 0.8" w.c. Blower Cooling Speed Model Size Rise Size Stages Adjustment 100% Medium Medium High (hp) F° Input Input Input High Default +15% 1118 +10%...
  • Page 5 ACCESSORY LIST Catalog Number Description Natural to LP Kits 68W77 Modulating 97% (including gas valve) Downflow Combustible Flooring Base 11M60 17.5" B Width 11M61 21.0" C Width Flush Mount Termination (90% Furnaces only) US Only 51W11 2” & 3.0” Vent Concentric Vent Kit (90% Furnaces only) US Only 71M80 1-1/2”...

  • Page 6: Parts Arrangement

    Parts Arrangement Blower Deck Blower Assembly Control Blower Access Cabinet Panel Burner Access Heat Exchanger Panel Assembly Combustion Primary Air Inducer Limit Gas Valve Burner Box and Manifold Assembly Figure 1. Page 6 31-5000724 Rev. 0...

  • Page 7: Unit Components

    Circuit Breaker (CB8) Unit Components A 24V circuit breaker is also located in the control box. The switch provides overcurrent protection to the transformer NF97DM unit components are shown in Figure 1. The gas (T1). The breaker is rated 3A at 32V. If the current exceeds valve, combustion air inducer and burners can be accessed this limit the breaker will trip and all unit operation will by removing the access panel.
  • Page 8 Thermostat Selection Modes Pin # Function See Table 3 for DIP switch settings Not Used High Fire Pressure Switch The control can be made to operate in three modes: variable capacity, three-stage timed or two-stage. The variable Rollout Switch In capacity and two-stage modes are only operational with Ground a two-stage thermostat.
  • Page 9 NEUTRAL TERMINALS COMBUSTION AIR INDUCER CONNECTOR IGNITOR CONNECTOR FLAME SENSE DIAGNOSTIC LINE VOLTAGE PUSH BUTTON TERMINALS DIP SWITCHES INDOOR BLOWER CONNECTOR OUTDOOR AIR SENSOR TERMINALS 7-SEGMENT DIAGNOSTIC LED W915 Y1 TO Y2 DISCHARGE AIR SENSOR W951 R TO O TERMINALS W914 R TO DS FACTORY TEST W915...
  • Page 10 Figure 5. Integrated Control Configuration Guide Page 10 31-5000724 Rev. 0...
  • Page 11 Operation Thermostat Switch 1 Switch 2 Switch 3 Variable Capacity Heat Two Stage (40% to 100%) 2nd stage delay OFF = 7 minutes Three Stage Heat Single Stage ON = 12 minutes (40%, 70%, 10%) 3rd stage delay 10 minutes fixed Two Stage Heat Single Stage (W1 70%, W2 100%)
  • Page 12 to operate as normal. This mode is used to check motor Ramping Option C operation. • Motor runs at 100% until demand is satisfied. • Once demand is met, motor runs at 100% for 45 seconds Adjustment Switch 10 Switch 11 then ramps down to stop.
  • Page 13 +15% Airflow Determination Identify blower speed adjustment points at low and high fire +7.5% Airflow will lie on straight line between these two points and will fall within the shaded area as shown EXAMPLE -7.5% at low fire +7.5% at high fire Nominal High Fire -7.5%...
  • Page 14 • Initiate furnace ignition sequence and move to and hold During Field Test mode operation, all safety switches mid-fire rate by applying a jumper to R and W2. are still in the circuit (they are not by-passed) and indoor blower performance and timings will match DIP switch •...

  • Page 15: Configuring Unit Size Codes

    Configuring Unit Size Codes Power-Up - Number displayed by integrated control represents unit size code (furnace model and capacity). If three horizontal bars are displayed followed by continuous E203, furnace control does not recognize unit size code. Configure per the following: Turn room thermostat to OFF.
  • Page 16 LED Diagnostic Codes Code Diagnostic Codes / Status of Equipment Action Required to Clear and Recover Idle mode (Decimal blinks at 1 Hertz - 0.5 seconds ON, 0.5 seconds OFF). Cubic feet per minute (cfm) setting for indoor blower (1 second ON, 0.5 seconds OFF) / cfm setting for current mode displayed.
  • Page 17 Code Diagnostic Codes / Status of Equipment Action Required to Clear and Recover E202 Indoor blower motor mismatch - indoor motor Incorrect appliance capacity code selected. Check for horsepower does not match unit capacity proper configuring under Unit Size Code for Furnace/ Air Handler on configuration guide or in installation instructions.
  • Page 18 Code Diagnostic Codes / Status of Equipment Action Required to Clear and Recover E240 Low flame current - Run mode- Refer to Check micro-amperes of flame sensor using control troubleshooting diagnostics or field installed mode. Clean or replace sensor. Measure voltage of neutral to ground to ensure good unit ground.
  • Page 19 Code Diagnostic Codes / Status of Equipment Action Required to Clear and Recover E292 Indoor blower motor unable to start due to Indoor blower motor unable to start (seized bearing, obstructed wheel seized bearings. stuck wheel, etc.) Replace motor or wheel if assembly does not operate or meet performance standards.
  • Page 20 Operating Sequence System Demand System Response Thermostat Relative Humidity Blower Demand System Step Compressor Comments Condition (COOL) Status Stage NO CALL FOR DEHUMIDIFICATION Compressor and indoor Normal Operation Acceptable 24 VAC High 100% blower follow thermostat demand BASIC MODE (only active on a Y1 thermostat demand) Normal Operation Acceptable 24 VAC...
  • Page 21 Operating Sequence System Demand System Response Thermostat Demand Relative Humidity Blower System Step Compressor Comments Condition (COOL) Status Stage Stage NO CALL FOR DEHUMIDIFICATION Normal Operation Acceptable Compressor and indoor - Y1 blower follow thermostat Normal Operation demand Acceptable High 100% - Y2 ROOM THERMOSTAT CALLS FOR FIRST STAGE COOLING...
  • Page 22 Indoor Blower Motor STATOR (WINDINGS) BEARING OUTPUT SHAFT Figure 8. Blower Motor Components The controller uses sensing devices to sense what position Figure 7. the rotor is in at any given time. By sensing the position of the rotor and then switching the motor windings on and off in sequence, the rotor shaft turns the blower.
  • Page 23 Remove Blower from Unit Motor Start-Up 1. Remove unit access panels, control box, bolts and When B3 begins start-up, the motor gently vibrates back wiring jackplugs. and forth for a moment. This is normal. During this time the electronic controller is determining the exact position 2.
  • Page 24 P48 5 Pin P48 5 Pin P49 4 Pin SHAFT SHAFT P49 4 Pin MOTOR with INTEGRATED MOTOR with INTEGRATED CONTROLLER CONTROLLER J48 5 Pin J49 4 Pin P48 5 Pin P49 4 Pin J49 4 Pin Control Connector J48 5 Pin Line Voltage Connector J48 Connector 120v Figure 9.
  • Page 25 Troubleshooting Motor Windings TEST B Ensure that motor windings are not damaged by performing Use an ohmmeter to measure the motor phase-to-phase the following tests: resistance by checking these combinations of the the 3-pin motor plug. For the purpose of this test, start at either end NOTE: If your ohm meter is not an auto-ranging type, set of the connector as lead 1.
  • Page 26 Flame Rollout Switches that is precisely matched to the burner input. Burners can be removed as a one piece assembly for service. If burner Flame rollout switch S47 is a high temperature limit located assembly has been removed, it is critical to align center inside the burner box.
  • Page 27 Primary Limit Control (S10) Figure 15 shows the primary limit (S10) used on NF97DM DANGER units located in the heating vestibule panel. When excess Danger of explosion. heat is sensed in the heat exchanger, the limit will open. Once the limit opens, the furnace control energizes the There are circumstances in which odorant supply air blower and de-energizes the gas valve.
  • Page 28 Finally, the switch interrupts the combustion process if • Venting conditions change (affecting high and low the condensate drainage system becomes blocked to the pressure switch operation) point the condensate level builds up in the cold end header • Ramp down low fire switch check failed (calibration will box/ secondary coil or vent system.
  • Page 29 5. If low pressure switch opens turn off inducer. No further The CAI is installed on the cold end header box. The cold action. end header box is a single piece made of hard plastic. The box has an internal channel where the combustion 6.
  • Page 30 Intake Air Pipe Exhaust Pipe Cold End Header Box Pipe Clamp Exhaust Connector Blower Deck Seal with Alignment Tabs Exhaust Coupling Drain Cap Exhaust Elbow Tubing Combustion Air Inducer (CAI) Clamp Intake Air Coupling CAI Embossment Figure 19. Combustion Air Inducer / Cold End Header Box / Vent Pipe Assembly Page 30 31-5000724 Rev.

  • Page 31: 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 32: Joint Cementing Procedure

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

  • Page 33: Venting Practices

    • In areas where piping penetrates joists or interior Venting Practices walls, hole must be large enough to allow clearance on all sides of pipe through center of hole using a hanger. SCHEDULE 40 • When furnace is installed in a residence where unit PVC - 5' is shut down for an extended period of time, such all other pipe* - 3'...
  • Page 34 Pipe Length 4” Maximum (Not Furnished) 3” 2” 2” TRANSITION *2” 2” Plate (Furnished) 90° Elbow (Not Furnished) TOP VIEW * When transitioning up in pipe size, use the shortest length of 2” PVC pipe possible. NOTE Intake pipe and exhaust pipe must be the same diameter. Figure 23.

  • Page 35: Vent Piping Guidelines

    Vent Piping Guidelines IMPORTANT NOTE: GE Appliances has approved the use of DuraVent ® Do not use screens or perforated metal in exhaust or and Centrotherm manufactured vent pipe and terminations intake terminations. Doing so will cause freeze-ups and as an option to PVC. When using the PolyPro by DuraVent ®...
  • Page 36 Maximum Allowable Intake or Exhaust Vent Length (feet) Standard Termination at Elevation 0 - 4,500 ft 1-1/2” Pipe 2” Pipe 2-1/2” Pipe 3” Pipe Number of Model Model Model Model 90° Elbows Used Standard Termination at Elevation 4,501 - 10,000 ft 1-1/2”...
  • Page 37 Maximum Allowable Intake or Exhaust Vent Length (feet) Concentric Termination at Elevation 0 - 4,500 ft 1-1/2” Pipe 2” Pipe 2-1/2” Pipe 3” Pipe Number of Model Model Model Model 90° Elbows Used Concentric Termination Elevation 4,501 - 10,000 ft 1-1/2”...
  • Page 38 General Guidelines for Vent Terminations In Direct Vent applications, combustion air is taken from IMPORTANT outdoors and the flue gases are discharged to the outdoors. The NF97DM is then classified as a direct vent, Category For Canadian Installations Only: IV gas furnace. In accordance to CSA International B149 installation codes, the minimum allowed distance between the In Direct Vent applications, the vent termination is limited...
  • Page 39 Maximum Allowable Vent Pipe Length without Insulation in Unconditioned Space for Winter Design Temperatures Modulating High Efficiency Furnace Vent Pipe Winter Design Temperatures ºF (ºC) Diameter 1-1/2 in. 32 to 21 2 in. (0 to -6) 2-1/2 in. 3 in. 1-1/2 in.
  • Page 40 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 41 Details of Intake and Exhaust Piping 2. 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 42 6. 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 43 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 44: For The Province Of Ontario, Horizontal Sidewall Vent Applications Only

    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 45: Condensate Piping

    2. For furnaces with a 1/2” drain connection use a 3/8 Condensate Piping allen wrench and remove plug (Figure 44) from the cold end header box at the appropriate location on This unit is designed for either right- or left-side exit of the side of the unit.
  • Page 46 From Evaporator Coil CAUTION Field Provided Vent 1” min. 2” max. above Do not use copper tubing or existing copper condensate condensate drain. lines for drain line. 6. If unit will be started immediately upon completion of Furnace Condensate installation, prime trap per procedure outlined in Unit Drain Condensate Start-Up section.
  • Page 47 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 48 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 49: Start-Up

    Each time the thermostat calls for heat, the burners will Start-Up automatically light The ignitor does not get hot when there is no call for heat on units with an ignition system. Preliminary and Seasonal Checks Priming Condensate Trap 1. Inspect electrical wiring, both field and factory installed The condensate trap should be primed with water prior for loose connections.

  • Page 50: Heating System Service Checks

    4. This furnace is equipped with an ignition device which off power to unit. All access panels and covers must be in automatically lights the burners. Do not try to light the place and secured. burners by hand. 5. Remove the upper access panel. Heating System Service Checks 6.
  • Page 51 Operating Pressure Signal (Delta P) When checking piping connections for gas leaks, use preferred means. Kitchen detergents can cause harmful Measurement (Figure 48) corrosion on various metals used in gas piping. Use of a Operating pressure signal can be taken while the specialty Gas Leak Detector is strongly recommended.
  • Page 52 Gas Valve Field Installed Figure 47. Manifold Pressure Measurement Negative Port Positive Port Red and Black Tubing or Red Tubing - Black Tubing + Gas Valve Field Installed Measuring Device Figure 48. Operating Signal (Delta P) Measurement Page 52 31-5000724 Rev. 0...
  • Page 53 Proper Combustion High Altitude NOTE: In Furnace should operate minimum 15 minutes with correct Canada, certification installations manifold pressure and gas flow rate before checking elevations over 4500 feet (1372 m) is the jurisdiction of combustion. Take combustion sample beyond the flue local authorities.

  • Page 54: Typical Operating Characteristics

    External Static Pressure Typical Operating Characteristics 1. Tap locations shown in Figure 49. Blower Operation and Adjustment 1. Blower operation is dependent on thermostat control system. filter 2. Generally, blower operation is set at thermostat subbase fan switch. With fan switch in ON position, blower operates continuously.

  • Page 55: Maintenance

    Exhaust and Air Intake Pipes Maintenance Check the exhaust and air intake pipes and all connections for tightness and to make sure there is no blockage. NOTE: After any heavy snow, ice or frozen fog event the WARNING furnace vent pipes may become restricted. Always check ELECTRICAL SHOCK, FIRE, OR EXPLOSION the vent system and remove any snow or ice that may be HAZARD.
  • Page 56 Condensate Hose Screens (Figure 50) 10. Disconnect condensate drain tubing from flue collar. Remove screws that secures the flue collar into place. Check the condensate hose screens for blockage and Remove flue collar. It may be necessary to cut the clean if necessary.
  • Page 57 Cleaning the Burner Assembly 30. Reinstall pressure switches and reconnect pressure switch wiring. 1. Turn off electrical and gas power supplies to furnace. Remove upper and lower furnace access panels. 31. Carefully connect combustion air pressure switch hosing from pressure switches to proper stubs on cold 2.

  • Page 58: Wiring And Sequence Of Operation

    Wiring and Sequence of Operation Figure 51. NF97DM Typical Field Wiring Diagram Page 58 31-5000724 Rev. 0...
  • Page 59 Sequence of Operation 7. When the demand for first- and second-stage heat is satisfied, the gas valve is de-energized and the NOTE: The ignition control thermostat selection DIP switch field-selected indoor blower off delay begins. The is factory-set in the “TWO-STAGE” position. combustion air inducer begins a 20-second post-purge period.
  • Page 60 Applications Using a Two-Stage Thermostat C - Heating Sequence -- Control Thermostat Selection DIP switch in “Two-Stage” Position (Factory Setting) 1. On a call for heat, thermostat first-stage contacts close sending a signal to the integrated control. The integrated control runs a self-diagnostic program and checks high temperature limit switches for normally closed contacts and pressure switches for normally open contacts.

  • Page 61: Field Wiring Applications With Conventional Thermostat

    Field Wiring Applications with Conventional Thermostat DIP Switch Settings and On-Board Links W915 W914 W951 Thermostat Wiring Connections DIP Switch 1 (Y1 to Y2) (DS to R) (O to R) Two-Stage Cooling Dehumidification Heat Pumps CONTROL OUTDOOR T'STAT TERM. STRIP UNIT 1 Heat / 1 Cool NOTE:...
  • Page 62 DIP Switch Settings and On-Board Links W915 W914 W951 Thermostat Wiring Connections DIP Switch 1 (Y1 to Y2) (DS to R) (O to R) Two-Stage Cooling Dehumidification Heat Pumps CONTROL OUTDOOR T'STAT TERM. STRIP UNIT 2 Heat / 2 Cool Intact Intact CONTROL...
  • Page 63 DIP Switch Settings and On-Board Links W915 W914 W951 Thermostat Wiring Connections DIP Switch 1 (Y1 to Y2) (DS to R) (O to R) Two-Stage Cooling Dehumidification Heat Pumps CONTROL T'STAT TERM. STRIP HEAT PUMP 67M41** Dual Fuel Single- Stage Heat Pump thermostat w/dual Intact Intact...

  • Page 64: Sequence Of Operation And Troubleshooting Flow Chart

    Sequence of Operation and Troubleshooting Flow Chart Safety Check Verify There Is No Main Burner Flame Indoor blower OFF After Heat OFF Delay (Low Heat Speed) Combustion Air Limit Limit Indoor Blower De−Energize Error Code Inducer On Switch Closes Within 3 Gas Valve Flashes ON (100%)
  • Page 65 2 Stage Thermostat 1st Call for High Fire? 2nd Stage Recognition Delay (30 Seconds) Combustion Air Inducer ON (100% Rate Speed) High Pressure Switch Increase Combustion Error Code Wait 5 Closes Within Air Inducer Speed Flashes Minutes 10 Seconds? if Not at 100% Rate Speed Adjust Indoor Blower to...
  • Page 66 RUN MODE (2 STAGE THEREMOSTAT) RUN MODE (SINGLE STAGE THERMOSTAT) 1ST OR 2ND STAGE CALL FOR HEAT ALL ALL INPUTS MONITORED (LIMIT, PRESSURE, INPUTS MONITORED (LIMIT, PRESSURE, CALL FOR HEAT / COOL, FLAME LEVEL) CALL FOR HEAT / COOL, FLAME LEVEL) 2nd Stage Heat 2nd Stage Call for Heat...
  • Page 67 Safety Check Verify There Is No Main Burner Indoor Blower OFF After Flame Heat OFF Delay (Low Heat Speed) Indoor Blower Limit Limit De−Energize Combustion Air Error Code Switch Closes Within 3 Gas Valve Flashes Inducer ON (100% Speed) Closed? Minutes? (100%) Indoor Blower OFF...
  • Page 68 1st Stage Cooling Request Received Energize 1st Stage Cooling Contactor (Compressor & Fan) Indoor Blower On After 2−second delay Energize Indoor Blower (Per Ramping Profile) 1st Stage 2nd Stage Cooling Request Cooling Still Active? Request? Energize 2nd Stage Energize Indoor Blower Cooling Contactor (High Cooling mode) (Compressor &...
  • Page 69 Call for Continuous Blower Indoor Blower On (Speed Determined by Dip Switch settings) Request Maintain Indoor for Cooling Go to Call for Cooling Blower at set speed Received? Go to Call for Heat - 2 Stage Thermostat Request Maintain Indoor for Heat Blower at set speed Received?
  • Page 70 All specifications and illustrations subject to change without notice and without incurring obligations. Printed in the U.S.A.

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