THIS KIT MUST BE INSTALLED BY A QUALIFIED TECHNICIAN.
For Use with Item 1302140 (1/2HP) and 1302141 (3/4HP)
1041562 KIT INCLUDES
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Mounting plate, mounting screws and standoffs
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Strain relief for 7/8” Knockout
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Black/Yellow jumper wire to bypass high speed relay on Base I/O Relay Board
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Blue extension wire and yellow extension wire for circuit board “R” and “C” if needed.
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2 Yellow extension wires for Discharge Air
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Wire Ties
WARNING
HAZARDOUS VOLTAGE: RISK OF ELECTRIC SHOCK. CAN CAUSE INJURY OR DEATH. DISCONNECT ALL REMOTE ELECTRIC POWER SUPPLIES BEFORE SERVICING.
INSTALLATION
Deenergize
De-energize the heating system.
Remove Blower
Remove existing supply air blower assembly by disconnecting the wiring harnesses at the blower and sliding the supply air blower assembly out of the plenum.
Replace Plenum
Replace the air plenum assembly re-using existing mounting bracket on the heater. (Figure 5)
Figure 5
Remove Cover
Remove the electrical panel cover.
Remove T-stat wires
Disconnect the field wires connected to the 6 and 12-position low voltage terminal blocks. For ease of installation, label the wires with the terminal designation as they are disconnected.
Disconnect Transformer
Disconnect the blue and yellow wires (16 awg) coming from the “R” and “C” terminals at the quick disconnects shown in Figure 1.
Figure 1
Disconnect Harnesses
At the processor control (display) board, disconnect the two low voltage wiring harnesses (one 9-pin and one 15-pin).
Disconnect Sensor
Disconnect the two brown wires at the quick disconnects. (Figure 2).
Figure 2
Jumper Fan Relay
At the base I/O relay board (Figure 3), disconnect the two wires connected to the high-speed relay and install the black/yellow jumper wire with two male quick disconnects across these two wires.
Figure 3
Install Blower
Slide the new supply air blower assembly into the plenum. (Figure 4)
NOTE: Verify that the blower is installed in the plenum with the motor facing away from the system to ensure maximum air flow.
Figure 4
Connect Harness
Route the 9-pin wiring harness in the base of the furnace (Figure 5) to the 9-pin wiring harness from the blower and connect them.
Figure 5
Remove Plate
Remove the existing mounting plate with 6 and 12-position low voltage terminal blocks. Be sure to remove the spare fuses so they can be left with the furnace.
Remove Knockout
Locate new mounting plate and remove the 7/8” knockout from the lower right corner (some plates may not have a knock-out, only a 7/8" hole).
Mount Circuit Board
Mount the low voltage circuit board to the new mounting plate with screws and standoffs provided.
Route Harness
Route the 7-pin wiring harness from the blower assembly into the electrical compartment through the knockout/hole on the lower right corner of the mounting plate.
Connect Harness
Attach the 7-pin wiring harness to the “Blower” terminal and install the strain relief (Figure 7) around the harness, securing it in the knockout on the mounting plate.
Figure 7
Secure Plate
Secure the new mounting plate to the electric panel.
Connect Harness
Connect ECM motor harness to motor.
Connect Sensor
Connect the two yellow discharge air sensor wires to the “Air” terminals (Figure 8).
Figure 8
Connect Harnesses
Connect both the 9-pin and the 15-pin wiring harnesses included in the variable speed kit to the processor control (display) board and the ports labeled “To Control Board” on the LV circuit board.
Connect Transformer
Connect the blue transformer wire to LV circuit board “R” terminal and the yellow transformer wire to the “C” terminal. Use extension wires as needed.
Select CFM
Using the chart below and the blower speed selection jumper (Figure 8), select the desired blower speed.
|
Jumper |
3/4 HP Variable Speed CFM |
|
|---|---|---|
|
A |
1000 |
1200 |
|
B |
1200 |
1400 |
|
C |
1400 |
1600 |
|
D |
1600 |
2000 |
NOTE: Generally, 400 CFM of air flow is recommended per ton of cooling. Therefore, a 3-ton heat pump or air conditioner would require 1200 CFM.
Set Jumper
The “W/E” jumper (Figure 9) MUST be in the “ON” position.
NOTE: If the W/E jumper is in the "OFF" position when installed in a forced air heating system, the blower will NOT run with an "E" call from the thermostat and the core blower will cycle on and off on limit. If receiving a "G" and an "E" call from the thermostat, the system will operate at 600 CFM (earlier models 400 CFM).
Figure 9
Set Jumper
If installing the system with a two stage heat pump, the Y1/Y2 jumper (Figure 8) must be placed in the “OFF” position.
NOTE: When using a two stage heat pump, a "Y1" signal will yield 70% of the maximum CFM selected. A "Y2" signal will yield maximum CFM selected. Install a relay if 50% Stage 1 airflow is desired.
|
Jumper |
No Heat Pump or Single Stage Heat Pump |
Two Stage Heat Pump |
|---|---|---|
|
Y1-Y2 |
ON |
OFF |
Connect Sensor
If applicable, connect the outdoor sensor wires which used to be connected to “OS” and “SC” to the two terminals labeled “Outdoor” on the LV circuit board.
Connect Peak
If applicable, connect the peak control device which used to be connected to “RP” and “P” to the Peak Inputs “RP” and “P” on the LV circuit board.
Connect Thermostat
Re-connect the field thermostat wires removed from 12-position terminal block to the LV circuit board (Figure 9).
Connect Relay
If applicable, connect the auxiliary load control wires which used to be connected to “COM”, “NC”, and “NO” to the auxiliary relay contacts “Com”, “NC”, and “NO” on the LV board.