Electric Furnace - Relay Installation Instructions

Electric Furnace - RelayInstallation Instructions2 Wire: For models E2E(H,B) Series4-7 Wire: For models E(1,2)EH SeriesThe 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 respectively. 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.! DANGER:Shut off electrical supply to the furnace 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 conditioning appliances. Some local codes requirelicensed installation/service personnel for thistype of equipment. Read all instructions carefully before starting the installation.

DecorativeDoor InsertBlowerandRelayLow VoltageWiringWiring HarnessWiringHarnessConnectto RelayBoxDoor ControlFrame (used w/2 wire relay box)Relay BoxWiring Harnessplugs here onFurnace ControlPanelCircuitBreakersConnectto FurnaceControl PanelBlowerConnector(Connect toRelay Box)Connect8 PinConnectoron WiringHarnessHereFurnaceDoorFigure 1. E1E(-) Series Electric FurnaceLow rnessDoor ControlFrame (used w/2 wire relay box)Relay BoxWiring Harnessplugs here onFurnace ControlPanelCircuitBreakersFurnaceDoorConnect 8 PinConnector onWiring HarnessHereConnect BlowerConnector HereBlower Connector(Connect to Relay Box)Figure 2. E2E(-) Series Electric Furnace, manufactured prior to 1999Low VoltageWiringBlowerandRelayWiringHarnessRelay BoxWiring Harnessplugs here onFurnace ControlPanelCircuitBreakersFurnaceDoorConnect 8 PinConnector onWiring HarnessHereConnect BlowerConnector HereBlower Connector(Connect to Relay Box)Figure 2a. E2E(-) Series Electric Furnace, manufactured 1999 or later2BlowerConnectorConnectsHere

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 system equipment as outlined on the furnace options 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 position. (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 removing the screw from each side.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 “standoff” to the bottom corner on the back sideAir Conditioning/Heat Pump Operation (violet wire)Furnace Operation (orange wire)Furnace Model #Relay Box SpeedTerminal (min.)Blower Speed Selection: HEATING - Move the orange wire on thecircuit 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 orange wire (heating) to the L (low) quickconnect for low speed. Connect the violetwire (cooling) to the ML (medium low) quickconnect for high speed. THREE OR FOUR SPEED BLOWER - SeeTable 1 for the appropriate speed connections for the E1E(-) and Table 2 for the E2E(-).-010, 012-015, -017,-020, -023LMLAir Conditioning Model #-024-030, -036-042, -046,-048Heat Pump Model #-018-024, 030-036, -042,-048Relay Box SpeedTerminal (min.)MLMHHNote: See furnace installation instructions for nominal air deliveries.Table 1. E1E(-) Heating and Cooling Speed Setting Positions – 4 Speed BlowerFurnace Operation (orange wire)Furnace Model #Relay Box SpeedTerminal (min.)Air Conditioning/Heat Pump Operation (violet wire)-010, -012, -015,-017, -020, -023L-3 spdML-4 spdSEE FURNACE BLOWER LABEL OR FURNACEINSTALLATION INSTRUCTIONS FORAPPROPRIATE SPEED CONNECTIONSNote: See furnace installation instructionsfor nominal air deliveries.Table 2. E2E(-) Heating and Cooling Speed Setting Positions – 3 or 4 Speed Blower3

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 furnace 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 thermostat pigtail leads connector from the furnacecontrol panel. Plug the two different 6-circuit connec-tors onthe relay box wiring harness into their corresponding 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.Cooling: Set the furnace system switch toAUTO (where applicable), the thermostat system 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 thermostat fan switch to ON.Shut off System: Set the thermostat systemswitch to OFF and set it to the lowest temperature 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.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 BoxHeating: Set the furnace system switch toAUTO (where applicable), the thermostat system switch to HEAT, and the thermostat fanswitch to AUTO.4Attach foam "standoff" hereFigure 2b. E2E(-) (Pre-1999 manufacture)Electric Furnace w/2 wire Relay Box

Blower and Relay Replacement Parts ListITEM#12345678PART 69084632278DESCRIPTIONCover (2 Wire)Cover (AC/HP)Box, Relay2 Wire Relay Circuit BoardAC/HP Relay Circuit BoardWire HarnessMounting Bracket, E1Mounting Bracket, E2BezelSwitch Cap903091 9029871111111111112-6413827Model p/n 903091Figure 3. 2 Wire Relay Box, Exploded View564132Model p/n 902987Figure 3. A/C Heat Pump Relay Box, Exploded View5

6RCOOLOFFHEATC1 2 3 4 5 61 2 3 4 5 61 2 3 4 5 61 2 3 4 5 6Figure 5. System Wiring1 2 3 4 5 61 2 3 4 5 61 2 3 4 5 6 7 81 2 3 4 5 6 7 81 2 3 4 5 61 2 3 4 5 61 2 3 4 5 61 2 3 4 5 61 2 3 4 5 6R C Y O W2 W/E GODTLOWMED-LOMED-HIHIGH240V L1240V L25 Wire A/CT-StatWire Harness Suppliedwith Relay BoxBlowerMotorMH HMLCL1 2 3 4 5 61 2 3 4 5 6FFurnace With the AC/Heat Pump Relay Box and a PowermiserFactory WiringField WiringLEGENDO P R XPowermiserT-StatC W1 G Y ET-StatG Y W2 O P RGRC RH Y W GR C Y O W2 W/EA/C O.D. SectionFurnace With the AC/Heat PumpRelay Box and a 5 Wire ThermostatSEQ 1 (W2)SEQ 2 (W2)24V COM24V HOTGOPENFurnacecontrol panelPowermiserCompressor SectionFan CoilC W2 G RMH HMLCLWire Harness Supplied with Relay Box BlowerMotor1 2 3 4 5 6Furnace With the AC/Heat PumpRelay Box and a Heat PumpBlowerMotorMH HMLCLSEQ 1 (W2)SEQ 2 (W2)24V COM24V HOTGOPENFurnacecontrol panelLOWMED-LOMED-HIHIGH240V L1240V L21 2 3 4 5 6 7 81 2 3 4 5 6 7 8Wire Harness Suppliedwith Relay Box1 2 3 4 5 61 2 3 4 5 6R C Y O W2 W/E GMH HMLCL BlowerMotor1 2 3 4 5 6GFurnace With the AC/Heat PumpRelay Box and a 4 Wire Thermostat1 2 3 4 5 61 2 3 4 5 6SEQ 1 (W2)SEQ 2 (W2)24V COM24V HOTGOPENFurnacecontrol panelLOWMED-LOMED-HIHIGH240V L1240V L2R C Y O W2 E G1 2 3 4 5 61 2 3 4 5 6R C Y O E W21 2 3 4 5 6 7 81 2 3 4 5 6 7 8H/PT-StatO2 W/EW1 2 3 4 5 6H/P O.D. SectionY1 2 3 4 5 6CNOTE: a jumperwire must connectthe two R terminalson the thermostat.1 2 3 4 5 61 2 3 4 5 6Wire Harness Suppliedwith Relay BoxRR Y W G4 Wire A/CT-Stat1 2 3 4 5 6Furnace With the 2 Wire RelayBox and a 2 Wire ThermostatMH HMLCLBlowerWire Harness Supplied with Relay BoxMotor1 2 3 4 5 6 7 81 2 3 4 5 6 7 81 2 3 4 5 6SEQ 1 (W2)SEQ 2 (W2)24V COM24V HOTGOPENFurnacecontrol panelLOWMED-LOMED-HIHIGH240V L1240V L2A/C O.D. Section1 2 3 4 5 6 7 8OptionalHeat PumpInterconnectCableFANONAUTOW1 2 3 4 5 6YR W2 Wire HeatOnly T-Stat1 2 3 4 5 61 2 3 4 5 6SEQ 1 (W2)SEQ 2 (W2)24V COM24V HOTGOPENFurnacecontrol panelLOWMED-LOMED-HIHIGH240V L1240V L2A/C O.D. Section1 2 3 4 5 6 7 8

2 Wire Circuit Board (used in relay box EATFAN ON5TemperatureSwitchK343K22Cooling SpeedSelector (violet wire)COOLHEATH(H)* MH(M)* ML(L)*L1Heating SpeedSelector(orange wire)K16* - 3 speed motor54321P1AC/Heat Pump Circuit Board (used in relay box 902987)RCYOW2W/EGP287K16K2Cooling SpeedSelector (violet wire)54K2COOL3HEATH(H)* MH(M)* ML(L)*L2K11Heating SpeedSelector(orange wire)654321P1* - 3 speed motorFigure 6. Wiring Schematics7

708136 RR7081367081360 (Replaces 7078340)O’Fallon, MOSpecifications and illustrations subject to change withoutnotice and without incurring obligations. Printed inU.S.A. (03/02)

System Wiring Blower Motor L ML MH H C R Y W G 123456 123456 A/C O.D. Section 4 Wire A/C T-Stat 12345678 12345678 R C Y O W2 Blower Motor W/E G 123456 123456 LOW MED-LO MED-HI HIGH 240V L1 240V L2 Furnace control panel SEQ 1 (W2) SEQ 2 (W2) 24V COM 24V HOT 123456 123456 G OPEN L ML MH H C Furnace With the AC/Heat Pump Relay Box and a 4 Wire .