electric furnace - relay installation...
TRANSCRIPT
The p/n 903091 2-wire and p/n 902987 A/CHeat Pump (4 to 7 wire) Relay Boxes install withcurrent models of the E2 and current models ofthe E(1,2) NORDYNE electric furnaces respec-tively. The 2-wire Relay Box has control switchesthat are operable through an opening in thefurnace door, where applicable.
Important InformationRead all instructions carefully before startingthe installation. Specifications or designs aresubject to change or to discontinuance withoutnotice and without incurring obligations.
! WARNING:Improper installation may damageequipment, can create a hazard, andwill void the warranty.
Installation Instructions2 Wire: For models E2E(H,B) Series4-7 Wire: For models E(1,2)EH Series
Electric Furnace - Relay
! DANGER:Shut off electrical supply to the fur-nace at the household breaker box toprevent electrical shock which couldcause personal injury.
These instructions are primarily intended toassist qualified individuals experienced in theproper installation of heating and/or air condi-tioning appliances. Some local codes requirelicensed installation/service personnel for thistype of equipment. Read all instructions care-fully before starting the installation.
2
CircuitBreakersRelay Box
Wiring Harness plugs here onFurnace ControlPanel
Blowerand
Relay
DecorativeDoor Insert
Door ControlFrame (used w/2 wire relay box)
FurnaceDoor
Wiring Harness
Low VoltageWiring
Blower ConnectorConnects
Here
Connect8 PinConnectoron WiringHarnessHere
BlowerConnector(Connect toRelay Box)
Wiring Harness
Connectto RelayBox
Connectto FurnaceControl Panel
Figure 1. E1E(-) Series Electric Furnace
CircuitBreakers
Relay BoxWiring Harness plugs here onFurnace ControlPanel
Blowerand
Relay
FurnaceDoor
Wiring Harness
Low VoltageWiring
Figure 2. E2E(-) Series Electric Furnace, manufactured prior to 1999
Figure 2a. E2E(-) Series Electric Furnace, manufactured 1999 or later
Connect BlowerConnector Here
Blower Connector (Connect to Relay Box)
CircuitBreakers
Relay BoxWiring Harness plugs here onFurnace ControlPanel
Blowerand
Relay
NameplateInsert
Door ControlFrame (used w/2 wire relay box)
FurnaceDoor
Wiring Harness
Low VoltageWiring
Connect 8 PinConnector on
Wiring HarnessHere
Connect BlowerConnector Here
Blower Connector (Connect to Relay Box)
Connect 8 PinConnector on
Wiring HarnessHere
3
Installation Sequence for ModelsE(1,2) E(H,B) Series ElectricFurnace (See Figure 1, 2, or 2a)Prior to installing a relay box in the NORDYNEfurnace, be sure to install the correct A/C sys-tem equipment as outlined on the furnace op-tions label.
Remove the furnace door by pulling outwardeither from the top or the top side of the door.Switch the circuit breaker(s) to the OFF posi-tion. (See Figure 1, 2, or 2a for the circuitbreaker location.)
Before installing the relay box remove the blowerand install the cabinet insulation kit for furnacesthat are not factory equipped with this package.Refer to the instructions supplied with the kit forproper installation.
E(1,2)EH Models: All E(1,2)EH models requirea relay box when adding an air conditioner orheat pump.E2EB Models: E2EB models using a 2-wirethermostat require a relay box (2-wire) whenadding an air conditioner.Blower Selection: See the furnace InstallationInstructions for the correct air conditioning orheat pump available with the factory installedfurnace blower. Change out the blower whenneeded.
Remove the cover from the relay box by remov-ing the screw from each side.
Blower Speed Selection: • HEATING - Move the orange wire on the
circuit board to one of the four quick-connectslabeled with heating blower speeds.
• COOLING - Move the violet wire on the circuitboard to one of the three quick-connectslabeled with cooling blower speeds.
• TWO SPEED BLOWER - Connect the or-ange wire (heating) to the L (low) quick-connect for low speed. Connect the violetwire (cooling) to the ML (medium low) quick-connect for high speed.
• THREE OR FOUR SPEED BLOWER - SeeTable 1 for the appropriate speed connec-tions for the E1E(-) and Table 2 for the E2E(-).
Reattach the relay box cover using the twoscrews previously removed.
IMPORTANT: For the 2-wire relay box (onlyafter the cover has been reattached):
a. Attach two red caps (provided in plasticbag) to the switches that stick through thebezel on the sheet metal cover (see Figure3, items 7 and 8).
b. E1 and E2 furnace models manufacturedprior to 1999 only: Attach the appropriatebrand label to the sheet metal cover so thatit may be seen through the door controlframe (see Figure 2) in the furnace doorwhen it is replaced.
c. E1 and E2 furnace models manufacturedprior to 1999 only: Attach the foam “stand-off” to the bottom corner on the back side
Furnace Operation (orange wire)
Furnace Model # -010, 012-015, -017, -020, -023
Relay Box Speed Terminal (min.)
L ML
Air Conditioning/Heat Pump Operation (violet wire)
Air Conditioning Model # -024 -030, -036-042, -046,
-048
Heat Pump Model # -018 -024, 030-036, -042,
-048
Relay Box Speed Terminal (min.)
ML MH HNote: See furnace installation instruc-tions for nominal air deliveries.
Table 1. E1E(-) Heating and Cooling Speed Setting Positions – 4 Speed Blower
Table 2. E2E(-) Heating and Cooling Speed Setting Positions – 3 or 4 Speed Blower
Air Conditioning/Heat Pump Operation (violet wire)
SEE FURNACE BLOWER LABEL OR FURNACEINSTALLATION INSTRUCTIONS FOR
APPROPRIATE SPEED CONNECTIONS
Note: See furnace installation instructionsfor nominal air deliveries.
Furnace Operation (orange wire)
Furnace Model #Relay Box Speed
Terminal (min.)L-3 spd ML-4 spd
-010, -012, -015, -017, -020, -023
4
of the relay box opposite the side wherethe bracket is attached (See Figure 2b).This standoff will prevent movement of therelay box when the homeowner adjuststhe switches.
Relay Box Attachment(See Figure 1, 2, or 2a)Attach the mounting bracket to the appropriateside of the relay box. Attach the relay box to theside of the blower housing. For E2 furnacesmanufactured 1999 or later, bracket should beattached by self tapping 2 screws into the sideof the blower housing approximately 1/2” backfrom the mounting holes.
Insert the relay/blower assembly into the fur-nace by sliding it into the furnace and under themounting tabs. Secure the blower in place byusing the blower screws previously removed.
Relay Box Connection (See Figure 1, 2, or 2a): • Unplug the blower connector and the thermo-
stat pigtail leads connector from the furnacecontrol panel.
• Plug the two different 6-circuit connec-tors onthe relay box wiring harness into their corre-sponding locations on the furnace controlpanel (where the blower and thermostat leadsconnectors were just removed).
• Plug the 8-circuit connector on the other end ofthe wiring harness into the side of the relay box.
• Plug the 6-circuit blower connector into thebottom of the relay box.
Low Voltage Wiring(See Figure 1, 2, or 2a)Bring in the low voltage field wires from thethermostat and air conditioning or heat pumpunit and attach them to the screw terminalslocated at the top of the relay box. See Figure 5for System Wiring.
Switch the circuit breaker(s) to the ON position.The unit is now ready for operation.
SYSTEM OPERATIONFor the AC/Heat Pump Relay Box
Heating: Set the furnace system switch toAUTO (where applicable), the thermostat sys-tem switch to HEAT, and the thermostat fanswitch to AUTO.
Cooling: Set the furnace system switch toAUTO (where applicable), the thermostat sys-tem switch to COOL, and the thermostat fanswitch to AUTO.
Emergency Heat: (Used with a heat pumponly.) Set the furnace system switch to AUTO(where applicable), the thermostat system switchto EMERGENCY HEAT, and the thermostat fanswitch to AUTO.
Continuous Air Circulation: Set the thermo-stat fan switch to ON.
Shut off System: Set the thermostat systemswitch to OFF and set it to the lowest tempera-ture setting. Set the furnace system switch toOFF and shut off all power to the air conditioner.
For the 2-Wire Relay BoxHeating: Set the furnace system switch toAUTO (where applicable), the temperatureswitch (on the relay box) to HEAT, and the fanswitch (on the relay box) to AUTO.
Cooling: Set the furnace system switch toAUTO (where applicable), the temperatureswitch (on the relay box) to COOL, and the fanswitch (on the relay box) to AUTO.
Continuous Air Circulation: Set the fan switch(on the relay box) to ON.
Shut off System: Set the temperature switch(on the relay box) to OFF and set the thermostatto the lowest temperature setting. Set thefurnace system switch to OFF and shut off allpower to the air conditioner.
Attach foam "standoff" here
Figure 2b. E2E(-) (Pre-1999 manufacture)Electric Furnace w/2 wire Relay Box
5
Blower and Relay Replacement Parts List
1
2
3
4 6
7
8
1
2
3
4
5
6
Figure 3. 2 Wire Relay Box, Exploded View
Figure 3. A/C Heat Pump Relay Box, Exploded View
Model p/n 903091
Model p/n 902987
ITEM # PART # DESCRIPTION 903091 9029871 375952 Cover (2 Wire) 1
376431 Cover (AC/HP) 12 378700 Box, Relay 1 13 624567 2 Wire Relay Circuit Board 1
624625 AC/HP Relay Circuit Board 14 259200 Wire Harness 1 15 376050 Mounting Bracket, E1 - 16 380790 Mounting Bracket, E2 1 17 669084 Bezel 1 -8 632278 Switch Cap 2 -
6
Figure 5. System Wiring
Blo
wer
Mo
tor
LMLM
HH
C
12
34
56
12
34
56
R
Y
W
G
A/C
O.D
. Sec
tio
n4
Wir
e A
/C
T-S
tat
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
Blo
wer
Mo
tor
R
C
Y
O
W2
W/E
G
1 2 3 4 5 61 2 3 4 5 6
LO
WM
ED
-LO
ME
D-H
IH
IGH
240V
L1
240V
L2
Fu
rnac
e co
ntr
ol p
anel
SE
Q 1
(W
2)
24V
CO
M24
V H
OT
SE
Q 2
(W
2)
1 2 3 4 5 6
1 2 3 4 5 6
GO
PE
N
LMLM
HH
C
Fu
rnac
e W
ith
th
e A
C/H
eat
Pu
mp
R
elay
Bo
x an
d a
4 W
ire
Th
erm
ost
at
12
34
56
12
34
56
RC
RH
Y W
G
A/C
O.D
. Sec
tio
n5
Wir
e A
/C
T-S
tat
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
Blo
wer
Mo
tor
R
C
Y
O
W2
W/E
G
1 2 3 4 5 6
1 2 3 4 5 6
LO
WM
ED
-LO
ME
D-H
IH
IGH
240V
L1
240V
L2
Fu
rnac
e co
ntr
ol p
anel
SE
Q 1
(W
2)
24V
CO
M24
V H
OT
SE
Q 2
(W
2)1 2 3 4 5 6
1 2 3 4 5 6
GO
PE
N
LMLM
HH
C
Fu
rnac
e W
ith
th
e A
C/H
eat
Pu
mp
R
elay
Bo
x an
d a
5 W
ire
Th
erm
ost
at
12
34
56
12
34
56
R
W
A/C
O.D
. Sec
tio
n2
Wir
e H
eat
O
nly
T-S
tat
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
Y
R
C
W
1 2 3 4 5 6
1 2 3 4 5 6
LO
WM
ED
-LO
ME
D-H
IH
IGH
240V
L1
240V
L2
Fu
rnac
e co
ntr
ol p
anel
SE
Q 1
(W
2)
24V
CO
M24
V H
OT
SE
Q 2
(W
2)
1 2 3 4 5 6
1 2 3 4 5 6
GO
PE
N
Fu
rnac
e W
ith
th
e 2
Wir
e R
elay
B
ox
and
a 2
Wir
e T
her
mo
statH
EA
T
CO
OL
OF
FO
N
AU
TO
FA
N
12
34
56
12
34
56
H/P
O.D
. Sec
tio
nH
/PT
-Sta
t
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
Blo
wer
Mo
tor
R C
Y
O
W2
W/E
G
1 2 3 4 5 61 2 3 4 5 6
LO
WM
ED
-LO
ME
D-H
IH
IGH
240V
L1
240V
L2
Fu
rnac
e co
ntr
ol p
anel
SE
Q 1
(W
2)
24V
CO
M24
V H
OT
SE
Q 2
(W
2)
1 2 3 4 5 6
1 2 3 4 5 6
GO
PE
N
LMLM
HH
C
Fu
rnac
e W
ith
th
e A
C/H
eat
Pu
mp
R
elay
Bo
x an
d a
Hea
t P
um
p
R C
Y
O
E
W2
R
C
Y
O W
2 E
G
12
34
56
12
34
56
Po
wer
mis
er
Co
mp
ress
or
Sec
tio
n
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
Blo
wer
Mo
tor
R
C
Y
O W
2 W
/E G
1 2 3 4 5 61 2 3 4 5 6
LO
WM
ED
-LO
ME
D-H
IH
IGH
240V
L1
240V
L2
Fu
rnac
e co
ntr
ol p
anel
SE
Q 1
(W
2)
24V
CO
M24
V H
OT
SE
Q 2
(W
2)
1 2 3 4 5 6
1 2 3 4 5 6
GO
PE
N
LMLM
HH
C
Fu
rnac
e W
ith
th
e A
C/H
eat
Pu
mp
Rel
ay B
ox
and
a P
ow
erm
iser
C W
2 G
R
G
Y
W2
O
P
R
Po
wer
mis
erT
-Sta
t
C W
1 G
Y
E
F
O
P
R
X
Fan
Co
il
T-S
tat
OD
T
LE
GE
ND
Fie
ld W
irin
g
Fac
tory
Wir
ing
Wir
e H
arn
ess
Su
pp
lied
wit
h R
elay
Bo
xW
ire
Har
nes
s S
up
plie
dw
ith
Rel
ay B
ox
Wir
e H
arn
ess
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pp
lied
wit
h R
elay
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Wir
e H
arn
ess
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pp
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wit
h R
elay
Bo
xW
ire
Har
nes
s S
up
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d w
ith
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ay B
ox
NO
TE
: a
jum
per
w
ire
mu
st c
on
nec
t th
e tw
o R
ter
min
als
on
th
e th
erm
ost
at.
Op
tio
nal
Hea
t P
um
p
Inte
rco
nn
ect
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le
7
Figure 6. Wiring Schematics
P1
H(H)* MH(M)* ML(L)* L
COOL
HEAT
K1
K2
P2
K3
K3
K4
COOL
OFF
HEAT
AUTO
FAN ON
K1
Cooling Speed Selector (violet wire)
Heating Speed Selector (orange wire)
K2
K4
BlowerSwitch
Temperature Switch
2 Wire Circuit Board (used in relay box 903091)
AC/Heat Pump Circuit Board (used in relay box 902987)
P2
K1
K2
P1
COOL
HEAT
K1
K2
Cooling Speed Selector (violet wire)
Heating Speed Selector(orange wire)
6 5 4 3 2 1
6 5 4 3 2 1
6
5
4
3
2
1
7
8
6
5
4
3
2
1
7
8
Y R C W
R C Y O W2 W/E G
* - 3 speed motor
* - 3 speed motor
H(H)* MH(M)* ML(L)* L
O’Fallon, MO
7081360 (Replaces 7078340)Specifications and illustrations subject to change without
notice and without incurring obligations. Printed inU.S.A. (03/02)
��������708136R R