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1. Size Cooling Switch Settings External Static Pressure ESP in w c SW2 3 SW2 2 SW2 1 0 1 0 2 0 3 0 4 0 5 0 6 0 7 2 1 0 OFF OFF OFF 1075 1065 OFF OFF ON 505 495 490 OFF ON OFF 680 660 665 OFF ON ON 905 900 900 ON OFF 1080 1075 1065 ON ON 1255 1255 1260 ON ON OFF 1255 1255 1260 ON ON ON 1255 1255 1260 Maximum Clg Airflow2 1450 1415 1375 Maximum Heat Airflow 1450 1415 1375 Intermediate Heat Airflow 755 755 765 inimum Heat Airflow 630 620 610 Cooling Switch Settings External Static Pressure ESP in w c OFF OFF OFF 1815 1810 1805 1800 1785 1765 1745 1720 1710 1685 OFF OFF ON 765 775 755 730 710 OFF ON OFF 930 940 935 930 935 OFF ON ON 1095 1120 1120 1105 1095 1100 1085 1075 1055 1050 ON OFF OFF 1245 1270 1275 1280 1290 1280 1285 1270 1260 1245 ON OFF ON 1440 1445 1455 1445 1450 1440 1440 1425 1415 1405 ON ON OFF 1815 1810 1805 1800 1785 1765 1745 1720 1710 1685 ON ON ON 1815 1810 1805 1800 1785 1765 1745 1720 1710 1685 Maximum Clg Airflow2 2055 2055 2050 2045 2030 2015 1995 1940 1870 1805 Maximum Heat Airflow 1495 1515 1515 1520 1525 1520 1515 1505 1490 1480 Intermediate Heat Airflow 900 905 900 900 890 Minimum Heat Airflow 725 725 720 690 670 SERVICE AND TECHNI
2. f FLAME SENSOR BELow BURNER L11F064 Representative drawing only some models may vary in appearance E NIV L p2 1 2 in 64 4 9 Attach the wires to the roll out switches 10 Align the burner assembly with the openings in the primary cell inlet panel and attach the burner assembly to the cell panel 11 Connect the wire for the flame sensor 12 Connect the wire for the Hot Surface Igniter NOTE Use propane resistant pipe dope to prevent leaks Do not use Teflon tape 13 Install the gas pipe to the gas valve a WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage Never purge a gas line into a combustion chamber Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of leaks to check all connections A fire or explosion may result causing property damage personal injury or loss of life 14 Check for gas leaks with a soap and water solution 15 Turn gas on at electric switch on gas valve and at external shut off or meter 16 17 18 Gas Furnace F G 9MAC Figure 11 Igniter Position Side View A11272 Turn power on at external disconnect fuse or circuit breaker Run the furnace through two complete heating cycles to check for proper operation Install outer door when complete Servicin
3. Refer to 4 GAS HEATING LOCKOUT Control will NOT auto reset Check for Mis wired gas valve Defective control valve relay MEDIUM PRESSURE SWITCH HIGH PRESSURE SWITCH OR PSR RELAY DID NOT CLOSE OR REOPENED Indicates the medium or high pressure switch failed to close on a call for intermediate or maximum heat or opened during a heat cycle PSR relay may be defective Refer to status code 3 10 POLARITY Check for correct line voltage polarity If units are twinned check for proper low voltage 24V transformer phasing 1 2 BLOWER ON AFTER POWER UP 115VAC or 24VAC Blower runs for 90 seconds if unit is powered up during a call for heat R WAV1 closed or R WIW1 opens during blower on delay period 1 5 BLOWER MOTOR LOCKOUT Indicates the blower failed to reach 250 RPM or the blower failed to communicate within 30 seconds after being tured ON in two successive heating cycles Control will auto reset after 3 hours Refer to status code 4 1 2 5 MODEL SELECTION OR SETUP ERROR Either indicates the model plug PL4 is missing or incorrect or setup switch SW1 1 or SW1 6 is positioned improperly If code flashes only 4 times on power up control is defaulting to model selection stored in memory Check the following Thermostat call with SW1 1 ON Thermostat call with SW1 6 ON SW1 1 and SW1 6 both ON together Two different furnace models twinned See Rating Plate for model plug number and resistance values if cod
4. or maximum heat The furnace will operate in minimum heat after starting and operating for 1 minute at intermediate heat before transitioning to minimum heat The wall thermostat calls for heat closing the R to W1 circuit for minimum heat or closing the R to W1 and W2 circuits for maximum heat The furnace control performs a self check and verifies the low medium and high pressure switch contacts LPS MPS and HPS are open then de energizes the PSR relay to close the NC contact The start up and shut down functions and delays described above apply to the two stage minimum maximum heating mode as well except for switching from maximum to minimum heat 1 Switching from Maximum to Minimum Heat If the thermostat R to W2 circuit opens and the R to W1 circuit remains closed the furnace control CPU will gradually decrease the inducer motor speed to the required intermediate heat RPM When the inducer motor IDM reduces pressure sufficiently the high pressure switch Specifications subject to change without notice 29 SERVICE AND TECHNICAL SUPPORT MANUAL HPS will open and the gas rate will be changed to intermediate heat The gas valve solenoid GV will remain energized as long as the low pressure switch LPS remains closed When the inducer motor speed gets within 15 of the required intermediate heat RPM the furnace control CPU will start a 5 second blower airflow change delay After the 5 second blower airflow change delay is
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6. 0 55 3 6 0 60 3 5 0 55 3 7 0 60 3 8 0 60 3 4 0 55 8000 3 3 0 55 3 4 0 55 3 5 0 55 3 7 0 60 2438 3 8 0 60 3 2 0 50 3 3 0 55 3 4 0 55 3 7 0 60 3 8 0 60 3 8 0 60 3 2 0 50 3 4 0 55 3 5 0 55 3 6 0 55 3 7 0 60 8001 3 8 0 60 3 2 0 50 3 3 0 55 3 4 0 55 2439 3 5 0 55 3 6 0 60 3 7 0 60 3 2 0 50 3 7 0 60 3 4 0 55 3 5 0 55 3 6 0 55 3 5 0 55 3 6 0 60 3 7 0 60 3 8 0 60 3 3 0 50 3 4 0 55 3 5 0 55 3 6 0 55 3 7 0 60 3 2 0 50 3 3 0 50 3 4 0 55 3 3 0 55 3 4 0 55 3 6 0 55 3 7 0 60 2744 3 7 0 60 3 2 0 50 3 3 0 55 3 4 0 55 3 5 0 55 3 6 0 55 3 7 0 60 3 8 0 60 3 7 0 60 3 8 0 60 3 4 0 55 3 5 0 55 3 4 0 55 3 5 0 55 3 7 0 60 3 8 0 60 3 2 0 50 3 3 0 55 3 4 0 55 3 5 0 55 to to Orifice numbers shown in BOLD are factory installed A11251B 12 Specifications subject to change without notice 440 04 4201 01 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace F G 9MAC Table 4 COOLING4 AND HEATING AIR DELIVERY CFM Bottom Return with Filter SW1 5 and SW4 3 set to OFF except as indicated See notes 1 and 2 Unit Cooling Switch Settings External Static Pressure ESP in w c Size SW2 3 SW2 2 SW2 1 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 0 0601 iw uma me aa y gt i m i sisa OFF OFF OFF ON OFF ON OFF ON ON OFF ON ON Maximum Clg Airflow2 Maximum Heat Airflow Intermediate Heat Airflow inimum Heat Airflow Unit
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8. MULTIPLIER FT M OF DERATE FACTOR 5 ao 0 1 00 TAR 086 eee 6 8 0 98 o TE os s tote o oo a7 aR on TE 08 ee s om Derate multiplier factors are based on midpoint altitude for altitude range NOTE For Canadian altitudes of 2000 to 4500 ft 610 to 1372 M use USA altitudes of 2001 to 3000 ft 610 to 914 M NOTE If orifice hole appears damaged or it is suspected to have been redrilled check orifice hole with a numbered drill bit of correct size Never redrill an orifice A burr free and squarely aligned orifice hole is essential for proper flame characteristics The inlet gas pressure must be checked with the furnace operating in maximum heat This is necessary to make sure the inlet gas pressure does not fall below the minimum pressure of 4 5 in w c for natural gas The maximum inlet gas pressure is 13 6 in w c If the inlet pressure is too low you will not be able to adjust the manifold pressure to obtain the proper input rate To check the inlet gas pressure 1 Make sure the gas supply is turned off to the furnace and at the electric switch on the gas valve 2 Remove the 1 8 inch NPT plug from the inlet pressure tap on the gas valve 3 Connect a manometer to the inlet pressure tap on gas valve Turn on furnace power supply Turn gas supply manual shutoff valve to ON position Turn furnace gas valve switch to ON position Jumper the R to W W1 and W2 thermostat connections at the furna
9. Mode SW1 2 and SW4 2 are both OFF with a two stage thermostat is the same as with a single stage thermostat EXCEPT for the following If the two stage thermostat R to W2 circuit closes along with the R to W W1 circuit while the furnace is operating at any capacity less than maximum the furnace will switch to the maximum heating capacity At this point the furnace control heating algorithm is overridden and the two stage thermostat takes control of staging until BOTH R to W W1 and R to W2 circuits are opened The furnace will transition back to the lower heating capacity if the two stage thermostat opens the R to W2 circuit but leaves R to WAW1 circuit closed The furnace control will continue to follow the commands from the two stage thermostat for W W1 and W2 until the R to W W1 circuit is opened After the two stage thermostat opens both the R to W W1 and R to W2 circuits the adaptive algorithm will set the beginning capacity of the next heating cycle to the same value as the heating cycle that most recently completed Two Stage Thermostat and Two Stage Minimum Maximum Heating NOTE In this mode the minimum heat only switch SW1 2 must be ON to select the minimum heat only operation mode in response to closing the thermostat R to W1 circuit Closing the thermostat R to Wt and W2 circuits always causes maximum heat operation regardless of the setting of the minimum heat only switch The furnace will start up in either intermediate
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12. and Y1 circuit starts the furnace blower motor BLWM at low cooling airflow which is the true on board CF selection as shown in Figure 4 The R to Y1 and Y2 circuits start the outdoor unit on high cooling speed 30 Specifications subject to change without notice Gas Furnace F G 9MAC and the R to G and Y Y2 circuits start the furnace blower motor BLWM at high cooling airflow High cooling airflow is based on the A C selection shown in Figure 4 The electronic air cleaner terminal EAC 1 is energized with 115 vac whenever the blower motor BLWM is operating When the thermostat is satisfied the R to G and Y1 or R to G and Y1 and Y2 circuits are opened The outdoor unit stops and the furnace blower BLWM and electronic air cleaner terminal EAC 1 will remain energized for an additional 90 seconds Jumper Y1 to DHUM to reduce the cooling off delay to 5 seconds See Figure 3 Dehumidify Mode The dehumidification output H on the Thermostat should be connected to the furnace control thermostat terminal DHUM When there is a dehumidify demand the DHUM input is activated which means 24 vac signal is removed from the DHUM input terminal In other words the DHUM input logic is reversed The DHUM input is turned ON when no dehumidify demand exists Once 24 vac is detected by the furnace control on the DHUM input the furnace control operates in Thermostat mode If the DHUM input is low for more than 48 hours the furnace control reverts back
13. and blower motor tested OK Visual check of hot surface igniter required 2 5 SETUP ERROR Same as code 2 5 above 3 5 GAS VALVE FAULT same as code 3 5 above T 4 1 BLOWER MOTOR FAULT Indicates blower motor failed test Check blower wiring and furnace control To repeat component test turn setup switch SW1 6 OFF and then back ON After component test is completed put setup switch SW1 6 in the OFF position and reconnect the R thermostat lead 338316 2 Rev E SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace F G MAC Wiring Diagram CONNECTION DIAGRAM SCHEMATIC DIAGRAM NTED CIRCUIT BOARD orsvac _ L2 rh EQUIPMENT GROUND gt 440 440 330 330 Q 9 2 2 mMm ei re 8L BL 8 swi AURAURAA 53 3353 HUM 61 N0110313S AV130 430 383M018 S LIMS IHI LOR e r 3 0901s eoo JZS OSS 1300N 18 NOLINI9 OSE NO 03SV8 LYVHO NOILOSTAS MOTIUIV 49 YO OW jrm aay elses cpu alee J TUE 18 loz 430 0009015 00 1 ACRDJ z N 030 SMIWLS Y MA LWM W09 9 WAHO LA ZM Ma PL12 e M pgi NOTE 7 4 u Seah SZ
14. be retrieved by disconnecting the limit switch To retrieve Status Codes follow the procedure below 2 Turn Setup Switch SW1 1 ON Manually close blower door switch Control will flash up to 7 Status Codes The last Status Code or 8th Code will be a heartbeat Turn SW1 1 OFF A heartbeat amber LED will appear and indicates proper operation 8 Release blower door switch install blower door and or refer to the SERVICE label for more information Component Self Test Component Test can ONLY be initiated by performing the following 1 Remove blower door 2 Remove the wire from the R terminal of the control board 3 Turn Setup Switch SW1 6 ON 4 Manually close blower door switch Blower door switch opens 115 v power to control No component operation can occur unless switch is closed O OQ G 16 Specifications subject to change without notice TERMINALS FUSED DISCONNECT 208 230 OR 460 VOLT THREE _ PHASE ___ VOLT SINGLE J PHASE CONDENSING UNIT o NOTES 1 Connect Y Y2 terminal as shown for proper operation 2 Some thermostats require a C terminal connection as shown 3 If any of the original wire as supplied must be replaced use same type or equivalent wire A11401 Caution must be taken when manually closing this switch for service purposes 4 amp WARN
15. for continuous fan speeds different than heating or cooling fan speed See Table 4 Air Delivery CFM With Filter Select the required continuous fan airflow from Figure 4 and Table 4 The continuous fan speed is also the fan speed for low speed cooling when furnace is used with a 2 speed cooling unit Adjust the Continuous Fan CFM to match the airflow required for low speed cooling Select the required airflow from Figure 4 and Table 4 For airflow at 400 CFM per ton turn Setup SW1 5 ON See Figure 4 and Table 4 The airflow selected for low speed cooling will also be the airflow used for continuous fan 440 04 4201 01 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace F G HMAC Furnace Setup Switch Description Furnace Setup Switch Description SETUP SWITCH SWITCH NAME NORMAL POSITION DESCRIPTION OF USE Turn ON to retrieve up to 7 stored status codes for troubleshooting assistance when R thermostat lead is disconnected When SW1 2 is OFF allows low heat operation with a single stage thermostat Turn ON when using two stage thermostat to allow Low Heat operation when R to W W1 closes and High Heat operation when R to W W1 and W2 close Status Code Recovery Low Heat Only Adaptive Heat Mode when SW1 2 is OFF Turn ON to increase Minimum Heat and Intermediate Heat airflow by 18 percent This compensates for increased return air temperature caused with bypass humidifier This also increases the low heat inducer speed 15 pe
16. gas valve 3 Connect a manometer to the outlet pressure tap on gas valve Turn on furnace power supply Turn gas supply manual shutoff valve to ON position Turn furnace gas valve switch to ON position Jumper the R to W W1 and W2 thermostat connections at the furnace control board 8 After the main burners ignite and the blower starts confirm Maximum Heat manifold pressure is correct based on the manifold pressure tables in the installation instructions 9 To adjust the Maximum Heat manifold pressure slowly turn adjusting screw counterclockwise out to decrease manifold pressure or clockwise in to increase manifold pressure Turn adjustment no more than one click per second until you obtain the required manifold pressure 10 Main burner flame should be clear blue almost transparent 11 After adjusting the Maximum Heat manifold pressure remove jumpers across thermostat connections to terminate the call for heat 12 Wait for blower off delay to finish then reset 115 v power to furnace To adjust manifold pressure to obtain input rate for Minimum Heat 1 Turn SW1 2 ON at the furnace control Set up switch SW4 2 must be OFF 2 Jumper R and W W1 thermostat connections on control to start furnace 3 After the main burners ignite and the blower starts confirm Minimum Heat manifold pressure is correct based on the manifold pressure tables in the installation instructions 4 To adjust the Minimum Heat mani
17. locations are shown and described on Figure 4 The set up switches are also shown on the unit wiring label Setup Switches SW1 The furnace control has 8 setup switches that may be set to meet the application requirements To set these setup switches for the appropriate requirement e Remove blower door e Locate setup switches on furnace control e Configure the set up switches as necessary for the application e Replace blower door NOTE If a bypass humidifier is used setup switch SW1 3 Minimum Heat Rise Adjust should be in ON position This compensates for the increased temperature in return air resulting from bypass NOTE If modulating dampers are used blower motor automatically compensates for modulating dampers Air Conditioning A C Setup Switches SW2 The air conditioning setup switches are used to match furnace airflow to cooling unit used To set the desired cooling airflow 4 Specifications subject to change without notice Gas Furnace F G 9MAC 1 Remove blower door 2 Locate A C setup switches on furnace control 3 Determine air conditioning tonnage used 4 Configure the switches for the required cooling airflow NOTE Excessive airflow caused by improper A C switch setup may cause condensate blow off in cooling mode 5 Replace blower door Continuous Fan CF Setup Switches SW3 The CF setup switches are used to select desired airflow when thermostat is in continuous fan mode or to select low cool
18. or intermediate heat only switches This furnace can operate as a modulating furnace with a single stage thermostat because the furnace control CPU includes a programmed adaptive sequence of controlled operation which selects a modulated rate between minimum and maximum heat This selection is based upon the stored history of the length of previous gas heating periods of the single stage thermostat 28 Specifications subject to change without notice Gas Furnace F G 9MAC The furnace will start up in either intermediate or maximum heat The furnace will transition and operate at minimum heat or the calculated modulating rate after starting and operating for 45 seconds at intermediate heat The furnace control CPU defaults to minimum heat on the first thermostat cycle and calculates the modulating rate that the furnace should run at for 19 minutes on subsequent heat cycles If the power is interrupted the stored modulating rate is erased and the furnace control will select intermediate heat for 45 seconds minimum heat for 19 minutes and then switch to maximum heat as long as the thermostat continues to call for heat The furnace control CPU then uses this information to calculate the modulating rate the furnace will operate at on the next heating cycle If the calculated modulating rate is between 40 99 then the furnace control CPU will operate for 45 seconds at intermediate heat and then operate at the calculated modulating ra
19. plate Operation is within a few degrees of midpoint of rise range when setup switch SW1 4 is OFF Figue3 Variable Speed Furnace Control for ECM Blower Motor Modulating COMMUNICATION CONNECTOR CONTINUOUS FAN CF AIRFLOW MODEL PLUG SETUP SWITCHES CONNECTOR SW1 SETUP OUTDOOR AIR TEMP CONNECTOR SW4 SETUP SWITCHES PL8 MODULATING GAS VALVE CONNECTOR SWITCHES AND BLOWER OFF DELAY OAT yz ee ES AIR CONDITIONING AC AIRFLOW gt q SETUP SWITCHES ov D l 8 PL 24 V THERMOSTAT TERMINALS Ave ZAIALMIM W09 9 WMH LA ZM od STATUS AND COMM 3 LED LIGHTS 5 a N FUSE 3 AMP 3 AMP FUSE SEC 2 SEC 1 co HWOo0o0o00 0000000 TRANSFORMER 24 VAC CONNECTIONS HUMIDIFIER TERMINAL 24 VAC 0 5 AMP MAX O FLASH UPGRADE CONNECTOR FACTORY ONLY PL3 ECM BLOWER HARNESS CONNECTOR TAMP 115 VAC EAC 1 PL2 EAC 2 oo r qUOOU 21 IWYLNAN V17 HK42FZ0443411 VS HSI HI LO CONNECTIONS 115 VAC L2 NEUTRAL i PART NUMBER AND PL1 LOW VOLTAGE MAIN DATE CODE WWYY HARNESS CONNECTOR SOFTWARE VERSION Adjust Temperature Rise When setup switch SW1 4 is ON operation will be near the high end of the rise range for improved comfort Furnace must operate within ranges of temp
20. the appropriate communicating control for this furnace When a communicating control is used the furnace will modulate through its full operation range or can be limited via the minimum and maximum heating capacity configurations Operation of the furnace at the beginning and end of each heating cycle will be the same as detailed below in the Single Stage Thermostat section EXCEPT that the communicating control will activate the W W1 W2 etc command signals through the communication bus rather than through the 24 v thermostat terminals Note that the R to W W1 circuit signal will be controlled by the COMMR relay on the furnace control See the wiring diagram in Figure 15 Single Stage Thermostat and Modulating Heating Adaptive Mode NOTE Minimum heat only switch SW1 2 selects the minimum heat only operation mode when ON Intermediate heat only switch SW4 2 selects intermediate heat only operation mode when ON If both switches are ON the furnace control will default to intermediate heat If either or both switches are ON the furnace control will operate at two stages only as referenced in Two Stage Thermostat section below If both switches are OFF the furnace control will operate in the adaptive heating mode in response to a call for heat See Figure 15 When the W2 thermostat terminal is energized it will always cause maximum heat operation as long as the R to W circuit is closed regardless of the setting of the minimum heat
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22. 1 and National standards of Canada CAN CSA B149 1 and 2 Natural Gas and Propane Installation Codes a WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could cause personal injury or death Before performing service or maintenance operations on unit always turn off main power switch to unit and install lockout tag Unit may have more than one power switch 4 amp WARNING CARBON MONOXIDE POISONING AND FIRE HAZARD Failure to follow safety warnings could result in personal injury death and or property damage This furnace is not designed for use in mobile homes trailers or recreational vehicles A CAUTION CUT HAZARD Failure to follow this caution may result in damage personal injury Sheet metal parts may have sharp edges or burrs Use care and wear appropriate protective clothing safety glasses and gloves when handling parts and servicing furnaces 2 Specifications are subject to change without notice 440 04 4201 01 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace F G 9MAC START UP CHECK SHEET For Variable Speed Models F G 9MAC This sheet is optional Keep for future reference Date of Start Up Heating Check Dealer Name Measured Line Pressure During High Heat Address Measured Manifold Pressure High Heat City State Province Zip or Postal Code Low Heat Temperature of Supply Air High Heat Phone Low Heat Owner Name Temperature of Retu
23. 100 200 500 92 39 78 196 37 97 195 486 94 38 76 192 38 95 189 474 96 38 75 188 39 92 185 462 98 37 74 184 40 90 180 450 100 36 72 180 41 88 176 439 102 35 71 178 42 86 172 429 104 35 69 173 43 84 167 419 106 34 68 170 44 82 164 409 108 33 67 167 45 80 160 400 110 33 65 164 46 78 157 391 112 32 64 161 47 76 153 383 116 31 62 155 48 75 150 375 120 30 60 150 49 73 147 367 14 Specifications subject to change without notice 440 04 4201 01 SERVICE AND TECHNICAL SUPPORT MANUAL SERVICE AND MAINTENANCE PROCEDURES a WARNING FIRE INJURY OR DEATH HAZARD Failure to follow this warning could result in personal injury death and or property damage The ability to properly perform service and maintenance on this equipment requires certain knowledge mechanical skills tools and equipment If you do not possess these do not attempt to perform any service and maintenance on this equipment other than those procedures recommended in the User s Manual A CAUTION ENVIRONMENTAL HAZARD Failure to follow this caution may result in environmental pollution Remove and recycle all components or materials i e oil refrigerant control board etc before unit final disposal 4 amp WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury or death or property damage Before installing modifying or servicing system main electrical disconnect switch must be in the OFF
24. 1000 CFM max 14 1400 CFM max 16 1600 CFM max 20 2000 CFM max 22 2200 CFM max COOLING AIRFLOW ALES MAJOR REVISION DIGIT ENGINEERING MINOR REVISION DIGIT International Comfort Products LLC Consumer Relations Department P O Box 128 Lewisburg TN 37091 USA 931 270 4100
25. 27 PUB 118 AGI 3134 SI pino Huljooysajqnol L saysey Buol JO Jaquunu y SI uis snid y saye Jaquinu puoo s y pue seysey ous JO Jaquunu y Aq p uluu l p Jaquunu 1S1lJ y YIM JaquINU 1651p om 10 lBuis e s po2 sns BY po2 sns sulWa eq ON Ie que u e y ulp iuBuq uiip luBuq Buyse Ajayeuseye 346i snes q31 HIANY SI pIIOS NO U snes q31 Y39NY SI 440 pue NO Bulusel 40 yeaquesy e y wip 4ybLq wip ybBug Buyse Ajeyeusaye pilos NO f snes q31 HAAN SI 25 Specifications subject to change without notice 440 04 4201 01 F G 9MAC Gas Furnace SERVICE AND TECHNICAL SUPPORT MANUAL Troubleshooting Guide Figure 16 CONT Jo1JUOD BOBUINy 5p d ti pono l aoer day uolleoo Josuas Owe pue saoe Jauing yooyo YO JI inss id pjoyiuew yOoyo e u leIp uulul 0 yous UY 1e u uunuuiixeuu ul ayesado suauing Jl 01 U09 oe d 1 uo LIS JOU JINS IIIA sSi uunq J 1e u uunuuixeui u yoayo yeadai uo LIS JOU JIA sJauINg pue EUILWOU 0 9 0 t anyea jeoidA Jeau SI 1u uuno J a pue suonoauuoo y99uo uone_ do 1lu llluu lui 10 398Uu2 0 1s 1 yeeday ainssaud p ojlueui yoayo pue Jeoay ulwW 0 dop 0 pun moj ayes Bully sedolg ainssoud sef 1 U A01 uoniuBi uBnoi 10 Janokueo awe jenb peul 10 YOOUD uo Keys pue lluBi siauing ureu IIM anjen jeoidAy seau lu uino s sdweosoIW 0 9 0 O t
26. 3 5 0 55 3 8 0 60 3 7 0 60 3 2 0 50 3 3 0 55 3 2 0 50 3 3 0 55 3 4 0 55 3 5 0 55 5001 3 7 0 60 3 8 0 60 3 2 0 50 3 3 0 55 1525 3 4 0 55 3 5 0 55 3 7 0 60 3 8 0 60 3 7 0 60 3 8 0 60 3 4 0 55 3 5 0 55 3 5 0 55 3 6 0 55 3 7 0 60 3 8 0 60 6000 3 3 0 50 3 4 0 55 3 5 0 55 3 6 0 60 1829 3 7 0 60 3 2 0 50 3 3 0 55 3 4 0 55 3 7 0 60 3 8 0 60 3 8 0 60 3 2 0 50 3 4 0 55 3 5 0 55 3 6 0 60 3 8 0 60 6001 3 2 0 50 3 3 0 50 3 4 0 55 3 5 0 55 1830 3 6 0 60 3 7 0 60 3 8 0 60 3 3 0 50 3 4 0 55 3 5 0 55 3 6 0 55 3 7 0 60 3 6 0 60 3 7 0 60 3 4 0 55 3 5 0 55 7000 3 4 0 55 3 5 0 55 3 6 0 60 3 7 0 60 2133 3 2 0 50 3 3 0 55 3 4 0 55 3 5 0 55 3 8 0 60 3 8 0 60 3 2 0 50 3 3 0 55 U S A and Canada U S A and Canada to to U S A Only to U S A Only to U S A Only A11251A SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace F G 9MAC Table 3 CONT Orifice Size and Manifold Pressure in w c for Gas Input Rate Modulating MODULATING FURNACE TABULATED DATA BASED ON 20 000 BTUH MAX HEAT 8 000 BTUH MIN HEAT PER BURNER DERATED 2 1000 FT 305M ABOVE SEA LEVEL ALTITUDE AVG GAS SPECIFIC GRAVITY OF NATURAL GAS RANGE ft m 3 4 0 55 3 5 0 55 3 6 0 60 3 7 0 60 3 8 0 60 3 2 0 50 3 3 0 55 3 4 0 55 2134 3 5 0 55 3 7 0 60 3 8 0 60 3 2 0 50 3 8 0 60 3 4 0 55 3 5
27. CAL SUPPORT MANUAL Gas Furnace F G 9MAC Table 4 CONT COOLING AND HEATING AIR DELIVERY CFM Bottom Return with Filter SW1 5 and SW4 3 set to OFF except as indicated See notes 1 and 2 Unit Cooling Switch Settings External Static Pressure ESP in w c 0 1 OFF OFF OFF 1850 1855 1860 1855 1850 1830 1805 1775 1750 1730 OFF OFF ON 765 745 740 705 680 OFF ON OFF 930 925 915 900 885 OFF ON ON 1095 1100 1110 1105 1085 ON OFF OFF 1265 1255 1265 1280 1275 1285 1270 1260 1250 1230 ON OFF ON 1465 1455 1470 1465 1465 1470 1455 1450 1435 1415 ON ON OFF 1850 1855 1860 1855 1850 1830 1805 1775 1750 1730 ON ON ON 2200 2200 2200 2190 2185 2170 2145 2085 1990 1890 Maximum Clg Airflow2 2200 2200 2200 2190 2185 2170 2145 2085 1990 1890 Maximum Heat Airflow 1815 1820 1825 1820 1815 1795 1775 1745 1720 1700 Intermediate Heat Airflow 1095 1100 1110 1105 1085 Minimum Heat Airflow 905 900 890 875 855 a Nominal 350 CFM ton cooling airflow is delivered with SW1 5 and SW4 2 set to OFF Set SW1 5 to ON for nominal 400 CFM ton 15 airflow Set SW4 3 to ON for nominal 325 CFM ton 7 airflow Set both SW1 5 and SW4 3 to ON for nominal 370 CFM ton 7 airflow 2 Maximum cooling airflow is achieved when switches SW3 1 SW3 2 SW3 3 and SW1 5 are set to ON and SW4 3 is set to OFF 3 All heating CFM s are when minimum intermediate heat rise a
28. CM Blower motors Gas Valve Relay DPST N O 6 Circuit Pressure Sw Assy Connector High Pressure Switch SPST N O 3 Circuit Inducer Control Connector Factory connected when LGPS not used Pressure Switch Relay SPST NC L 5 Circuit Modulating Gas Valve Connector Blower off delay gas heating selections are 90 120 150 180 Hot Surface Igniter 115VAC 4 Manual Switch Status Code Recall seconds cooling or heat pump 90 seconds or 5 seconds when Hot Surface Igniter Relay SPST N O 2 Manual Switch Minimum Heat Only dehumidify call is active ZA Harieta C ee 0 5 Amp Max We Manual Sieh Mit reat Rie Ad iti i j Humidifier Relay SPST N O lanual Switch Comfort Effy Adj Ignition lockout will occur after four consecutive usuccessful Induced Draft Motor ECM 5 Manual Switch Cooling CFM Ton trials for ignition Control will auto reset after three hours DR Inducer Motor Relay SPST N O Manual Switch Component Test Any of the 5 wires shown within the NEUTRAL L2 box can be Inducer Motor Speed Change Relay SPDT 7 8 Manual Switches Blower Off Delay connected to any terminal within the box K Blower Na ieo Switch SPST N O 3 Pin el trata Man Si Sec Inductor Note 7 lanual Switch Intermediate Hea Blower motor BLWM and Inducer motor IDM are locked rotor Light Emiting Diode for Status Codes 3 Manual Switch Future Use overload protected by redundant electronic control circuits Low Gas Pressure Switch SPST NO Transfo
29. DENSATE DRAIN AND TRAP N are WINTERIZATION enc ceteeee ieee eee qas wagusaaqqaqwaquaqqas 22 SERVICE LABEL uya anam pana am ayipasaaykatuqtuwa w bq a dy 23 TROUBLESHOOTING GUIDE 25 Printed in U S A manufacturer s participation in the program For verification of certification for individual products go to www ahridirectory org IS0 9001 QMI SAI Global CERTIFIED 440 04 4201 01 Aug 2011 SAFETY CONSIDERATIONS Improper installation adjustment alteration service maintenance or use can cause explosion fire electrical shock or other conditions which may cause death personal injury or property damage Consult a qualified installer service agency or your distributor or branch for information or assistance The qualified installer or agency must use factory authorized kits or accessories when modifying this product Refer to the individual instructions packaged with the kits or accessories when installing Follow all safety codes Wear safety glasses protective clothing and work gloves Use quenching cloth for brazing operations Have fire extinguisher available Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the unit Consult local building codes the current editions of the National Fuel Gas Code NFCG NFPA 54 ANSI Z223 1 and the National Electrical Code NEC NFPA 70 In Canada refer to the current editions of t
30. Failure to follow this caution may result in reduced furnace life Recheck temperature rise It must be within limits specified on the rating plate Recommended operation is at the mid point of rise range or slightly above Adjust Blower Off Delay Heat Mode a Remove blower door if installed b Turn Dip switch SW 7 or SW 8 ON or OFF for desired blower off delay See Table 2 Figure 3 and Figure 4 Table 2 Blower Speed Taps DESIRED HEATING MODE SETUP SWITCH POSITION BLOWER OFF DELAY SEC SW1 7 SW1 8 90 OFF OFF 120 ON OFF 150 OFF ON 180 ON ON Adjust Cooling Airflow Single Stage and High Stage Cooling The ECM blower can be adjusted for a range of airflow for Low Speed or High Speed cooling See Table 4 Air Delivery CFM With Filter Depending on the model size the cooling airflow can be adjusted from 1 5 tons to 6 tons of nominal cooling based on 350 CFM ton The cooling airflow is adjusted by turning Setup switches SW2 1 SW2 2 and SW2 3 either ON or OFF Select the required airflow from Table 4 Table 4 is based on 350 CFM per ton For other CFM per ton set up switch selections see Figure 4 or Figure 15 NOTE 6 ton airflow will truncate at 2200 CFM on applicable models For a complete explanation of cooling airflow refer to the section titled Sequence of Operation Adjust Continuous Fan Airflow Low Speed Cooling Airflow The ECM blower motor can be adjusted
31. H GROUND FIELD WIRING SCREW TERMINAL 77 EQUIPMENT GROUND PLUG RECEPTACLE Air Conditioning Adjustable Airflow CFM Low Pressure Switch SPST N O Air Conditioning Relay SPST N O Limit Switch Auto Reset SPST N C Air Conditioning Relay Defeat Jumper Medium Pressure Switch SPST N C NOTES WM Blower Motor ECM Printed Circuit Board a Dai CF Continuous Fan Adjustable Airflow CFM 2 Circuit Connector If any of the original equipment wire is replaced use wire rated for 105 C OMMR Communication Relay SPDT P 4 Circuit HSI amp IDM Connector Use only copper wire between the disconnect switch and the PU Microprocessor Circuitry 4 Circuit ECM BLWM Connector furnace junction box JB HUM DHUM Connection 24VAC eer Hee Plug Connector This wire must be connected to furnace sheet metal for control r ke poker Communication Cohhectar to prove flame 2 Electronic Air Cleaner Connection Common 2 Circuit OAT Connector Symbols are electrical representation only Flame Rollout Switch Man Reset SPST N C L 2Circuit HSI Connector Solid lines inside PCB are printed circuit board conductors and Flame Proving Sensor Electrode Circuit Inducer Power Connector t included in legend Fuse 3 Amp Automotive Blade Type 1 Circuit Inductor Splice Connector ae MOLING gena Factory Installed 4 Circuit ECM Blower Ctrl Connector Replace only with a 3 amp fuse Gas Valve 5 Circuit ECM Blower Power Connector Inductor is used with 3 4 hp and 1 hp E
32. IC GRAVITY OF NATURAL GAS RANGE ft m 3 8 0 60 3 2 0 50 3 3 0 55 3 4 0 55 3 6 0 55 3 7 0 60 3 8 0 60 3 2 0 50 3 4 0 55 3 5 0 55 3 6 0 60 3 7 0 60 3 7 10 60 3 8 0 60 3 4 0 55 3 6 0 55 3 5 0 55 3 6 0 60 3 8 0 60 3 4 0 55 3 3 0 55 3 5 0 55 3 6 0 55 3 7 0 60 3 2 0 50 3 3 0 55 3 4 0 55 3 5 0 55 3 7 0 60 3 8 0 60 3 3 0 50 3 4 0 55 3 7 0 60 3 8 0 60 3 8 0 60 3 2 0 50 U S A 3 4 0 55 3 5 0 55 3 6 0 55 3 7 0 60 2001 611 3 8 0 60 3 3 0 50 3 4 0 55 3 5 0 55 to 3 6 0 60 3 7 0 60 3 2 0 50 3 3 0 55 3000 914 3 4 0 55 3 5 0 55 3 7 0 60 3 8 0 60 3 7 0 60 3 8 0 60 3 5 0 55 3 6 0 55 Canada 3 5 0 55 3 6 0 60 3 8 0 60 3 4 0 55 2001 611 3 3 0 55 3 4 0 55 3 6 0 55 3 7 0 60 to 3 2 0 50 3 3 0 50 3 4 0 55 3 5 0 55 4500 1372 3 8 0 60 3 8 0 60 3 2 0 50 3 3 0 55 3 3 0 55 3 4 0 55 3 5 0 55 3 6 0 60 3001 3 8 0 60 3 2 0 50 3 3 0 55 3 4 0 55 915 3 6 0 55 3 7 0 60 3 8 0 60 3 2 0 50 3 8 0 60 3 5 0 55 3 6 0 55 3 7 0 60 3 6 0 60 3 7 0 60 3 4 0 55 3 5 0 55 4000 3 4 0 55 3 5 0 55 3 7 0 60 3 8 0 60 1219 3 2 0 50 3 4 0 55 3 5 0 55 3 6 0 55 3 7 0 60 3 2 0 50 3 3 0 55 3 4 0 55 3 3 0 50 3 4 0 55 3 5 0 55 3 6 0 55 4001 3 7 0 60 3 8 0 60 3 3 0 50 3 4 0 55 1220 3 5 0 55 3 6 0 60 3 7 0 60 3 8 0 60 3 8 0 60 3 4 0 55 3 5 0 55 3 6 0 60 3 5 0 55 3 7 0 60 3 8 0 60 3 4 0 55 5000 3 3 0 55 3 5 0 55 3 6 0 55 3 7 0 60 1524 3 2 0 50 3 3 0 50 3 4 0 55
33. ICAL SUPPORT MANUAL Gas Furnace F G 9MAC PARTS REPLACEMENT INFORMATION GUIDE Casing GROUP Control door Blower door Top filler plate Bottom filler plate Door Knob Assembly Electrical group Control box Junction box Limit switch es Circuit board Door switch Transformer 3 Amp fuse Flame Rollout Switch Main Wiring Harness Blower Motor Harness when used Filter Group Filter s Blower group Cut off Plate Blower housing Blower motor Blower wheel Capacitor when used Capacitor strap when used Power choke where used Gas Control Group Manifold Burner Orifice Flame sensor Hot surface igniter Gas valve Heat exchanger group Primary Heat Exchanger assembly Primary Heat Exchanger cell panel Secondary Heat Exchanger assembly Coupling box Containment Plate Tubing Gaskets Inducer group Pressure switch es Inducer assembly Inducer Inducer motor Motor Module when used Inducer motor capacitor when used Collector box Condensate trap Condensate trap elbow Gaskets A WARNING FIRE EXPLOSION ELECTRICAL SHOCK AND CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in dangerous operation personal injury death or property damage Improper installation adjustment alteration service maintenance or use can cause carbon monoxide poisoning explosion fire electrical shock or other conditions which may cause personal injury or property damage Consult a qualif
34. ING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Blower door switch opens 115 v power to furnace control No component operation can occur unless switch is closed Exercise caution to avoid electrical shock from exposed electrical components when manually closing this switch for service purposes Component Test sequence will function as follows 1 The furnace control CPU turns the inducer motor IDM ON at medium speed and keeps it ON through step 3 2 The furnace control CPU will test communication with the modulating gas valve GV 3 After waiting 15 seconds the furnace control CPU turns the hot surface igniter ON for 15 seconds then OFF 4 The furnace control CPU then turns the blower motor BL WM ON at mid range airflow for 15 seconds then OFF 5 After shutting the blower motor BLWM OFF the furnace control CPU shuts the inducer motor IDM OFF NOTE The EAC terminals are energized when the blower is operating After the component test is completed 1 or more status codes heartbeat 2 5 3 5 4 1 4 2 will flash See Service label on control door or Service status Code instructions for explanation of status codes NOTE To repeat component test turn setup switch SW1 6 to OFF and then back ON 6 RELEASE BLOWER DOOR SWITCH reattach wire to R terminal on furnace control board replace blower door 440 04 4201 01 SERVICE AND TECHNICAL SUPPORT MANUAL Care and Maint
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36. MANUAL SEQUENCE OF OPERATION A CAUTION UNIT OPERATION HAZARD Failure to follow this caution may result in intermittent unit operation Furnace control must be grounded for proper operation or control will lock out Control is grounded through green yellow wire routed to gas valve and manifold bracket screw Using the schematic diagram See Figure 15 follow the sequence of operation through the different modes Read and follow the wiring diagram very carefully NOTE If a power interruption occurs during a call for heat W W1 or WAW1 and W2 the control will start a 90 second blower only ON period two seconds after power is restored if the thermostat is still calling for gas heating The amber LED light will flash code 1 2 during the 90 second period after which the LED will be ON continuous as long as no faults are detected After the 90 second period the furnace will respond to the thermostat normally The blower door must be installed for power to be conducted through the blower door interlock switch ILK to the furnace control CPU transformer TRAN inducer motor IDM blower motor BLWM hot surface igniter HSI and gas valve GV Communicating Control and Modulating Heating Adaptive Mode Best comfort will be attained when a communicating wall control is used with this product Wiring and setup instructions are provided with the communicating control See the furnace data sheet accessory section for help in selecting
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38. SERVICE AND TECHNICAL SUPPORT MANUAL Modulating Variable Speed Blower Motor 35 Tall High Efficiency Condensing Gas Furnace F G 9MAC Save this manual for future reference Safety Labeling and Signal Words Signal Words in Manuals The signal word WARNING is used throughout this manual in the following manner 4 WARNING DANGER WARNING CAUTION and NOTE The signal words DANGER WARNING CAUTION and NOTE are used to identify levels of hazard seriousness The signal word DANGER is only used on product labels to signify an immediate hazard The signal words WARNING CAUTION and NOTE will be used on product labels and throughout this manual and other manual that may apply to the product DANGER Immediate hazards which will result in severe personal injury or death WARNING Hazards or unsafe practices which could result in severe personal injury or death CAUTION Hazards or unsafe practices which may result in minor personal injury or product or property damage NOTE Used to highlight suggestions which will The signal word CAUTION is used throughout this manual in the following manner CAUTION Signal Words on Product Labeling Signal words are used in combination with colors and or pictures or product labels A Safety alert symbol When you see this symbol on the unit and in instructions or manuals be alert to the FLUSHING COLLECTOR BOX AND DRAINAGE SYSTEM N are U
39. Trials For Ignition before going to Ignition Lockout Lockout will be reset automatically after three hours or by momentarily interrupting 115 vac power to the furnace or by interrupting 24 vac power at SEC1 or SEC2 to the furnace control CPU not at W W1 G R etc If flame is proved when flame should not be present the furnace control CPU will lock out of Gas Heating mode and operate the inducer motor IDM at full speed until flame is no longer proved 5 Inducer Speed Change If the cycle starts in intermediate heat the furnace control CPU reduces the inducer speed slightly after flame sense If cycle starts in maximum heat the furnace control CPU increases the inducer speed after flame sense 6 Blower On delay If the burner flame is proven the blower ON delay for intermediate heat and maximum heat are as follows Intermediate heat 45 seconds after the gas valve GV is opened the blower motor BLWM is turned ON at the modulating heat airflow Maximum heat 25 seconds after the gas valve GV is opened the BLWM is turned ON at maximum heat airflow Simultaneously the humidifier terminal HUM and electronic air cleaner terminal EAC 1 are energized and remain energized throughout the heating cycle 7 Switching from Intermediate Heat to a Low Range Input If the furnace control CPU switches from intermediate heat to a low range input low range input is an input rate less than or equal to 51 of full rate the furnace cont
40. YIO LINN did Buib6es jq ssod Buidid 1u A ul Jaye urep ayesuapuod p nid p ds Jaonpul 1sooq 0 NO LMS yous dnjes uan sjsisuod walqoud J Pulm eAIsseoxy SOUOIIMS inss 1d POJIMSILW JO 9AI D9j9q Buigny nss d pajonsjsqo 10 p lo uuoosiq JU9A p louls u p sn SqD7 J aunssaud sef eju A01 juawpedwoo JaMo q pue nqils9A UZEMjag yea UIV Buizis uaa Jadolg 10 49949 1e u uinuuixeuu 0 p919l11S 1 aq IIIA ajoAO Bune u 1x u y uous Jaye s lnului S u UlA suado J e p JJO J9MO G p 99 s y 104 uo BOD JIM Jamo ponad Aejap uo Jamojq Buunp su do J q3N3dO3ti HO IS079 LON aid HOLIMS SYNSSAYd LVWAH MO1 p so o YONIS YOIMS INSS Id qn1 ainsseid p lonilsqO 140 YOOYD N3dO LON GIG HOLIMS SYNSS3Yd 440 04 4201 01 Specifications subject to change without notice 26 F G 9MAC Gas Furnace SERVICE AND TECHNICAL SUPPORT MANUAL Troubleshooting Guide Figure 16 CONT p sn 1 ullloA y uo Bulpuadap Area Aew pnyubew y pue abe OA u uonenioni z nq e moys IIIA 11 4 1 uioA Ie1IBip piepuels e aAeY NOA J puo2o s e s ull ej A 8s ude 6 eq y uo pniiuBeui u eBueYyo Bue e moys IIM 1 ydes6 seq e uA aawo elb e aney NOA J puo2o s e s uu eJaAeS uBiu oB Ayaug IIIA p u y 19 8uullOA Bo eue ue aney no J puo5 s e sowy jesanas Ayauig ayenjonyy IM 1 1nq OdA 0 Jeau aq pinoys eyoa ay
41. age For continuing high performance and to minimize possible furnace failure periodic maintenance must be performed on this furnace Consult your local dealer about proper frequency of maintenance and the availability of a maintenance contract a WARNING Before installing modifying or servicing system main electrical disconnect switch must be in the OFF position and install a lockout tag There may be more than one disconnect switch Lock out and tag switch with a suitable warning label Verify proper operation after servicing 1 Turn off electrical supply to furnace ELECTRICAL SHOCK AND FIRE HAZARD 2 Remove filter cabinet door Failure to follow this warning could result in personal injury 3 Slide filter out of cabinet death and or property damage 4 If equipped with permanent washable filter clean filter by spraying cold tap water through filter in opposite direction Turn off the gas and electrical supplies to the furnace and I ae S install lockout tag before Bia any maintenance or of airflow Rinse filter and let dry Oiling or coating of the service Follow the operating instructions on the label filter is not recommended R ee attached to the furnace 5 If equipped with factory specified disposable media filter replace only with a factory specified media filter of the same size A WAR N l N G 6 Slide filter into cabinet 7 Replace filter cabinet door CARBON MONOXIDE POISONING AND FIRE HAZARD epilace
42. ain burners ignite then shut OFF and remain OFF for the blower ON delay 45 seconds in intermediate heat and 25 seconds in maximum heat allowing the furnace heat exchangers to heat up more quickly then restarts at the end of the blower ON delay period at modulating or maximum heat airflow respectively The blower motor BLWM will revert to continuous blower airflow after the heating cycle is completed When the thermostat satisfies the furnace control CPU will drop the blower motor BLWM to minimum heat airflow during the selected blower OFF delay period before transitioning to continuous blower airflow When the thermostat calls for low cooling the blower motor BLWM will operate at low cooling airflow When the thermostat is satisfied the blower motor BLWM will operate an additional 90 seconds at low cooling airflow before transitioning back to continuous blower airflow 440 04 4201 01 SERVICE AND TECHNICAL SUPPORT MANUAL When the thermostat calls for high cooling the blower motor BLWM will operate at high cooling airflow When the thermostat is satisfied the blower motor BLWM will operate an additional 90 seconds at high cooling airflow before transitioning back to continuous blower airflow When the R to G circuit is opened the blower motor BLWM will continue operating for an additional 5 seconds if no other function requires blower motor BLWM operation Heat Pump See Thermostat Instructions for thermostat conn
43. alance will be affected 7 If greasy residue is present on blower wheel remove wheel from the blower housing and wash it with an appropriate degreaser To remove wheel a Mark blower wheel location on shaft before disassembly to ensure proper reassembly b Loosen setscrew holding blower wheel on motor shaft NOTE Mark blower mounting arms and blower housing so each arm is positioned at the same hole location during reassembly c Mark blower wheel orientation and cutoff plate location to ensure proper reassembly d Remove screws securing cutoff plate and remove cutoff plate from housing e Remove bolts holding motor mounts to blower housing and slide motor and mounts out of housing f Remove blower wheel from housing g Clean wheel per instructions on degreaser cleaner Do not get degreaser in motor 8 Reassemble motor and blower wheel by reversing items 7b through 7f Ensure wheel is positioned for proper rotation 9 Torque motor mounting bolts to 40 10 Ib in when reassembling 10 Torque blower wheel set screw to 160 20 Ib in when reassembling 11 Verify that blower wheel is centered in blower housing and set screw contacts the flat portion of the motor shaft Loosen set screw on blower wheel and reposition if necessary 12 Spin the blower wheel by hand to verify that the wheel does not rub on the housing 13 Reinstall blower assembly in furnace 14 Reinstall two 2 screws securing blower assembl
44. ap is removed a new gasket between the trap and collector box is required Verify a condensate trap gasket is included in the service kit or obtain one from your local distributor 1 Disconnect power at external disconnect fuse or circuit breaker Turn off gas at external shut off or gas meter Remove outer doors and set aside Turn electric switch on gas valve to OFF Disconnect external drain from condensate drain elbow or drain extension pipe inside the furnace and set aside 6 Disconnect the condensate trap relief hose from collector box port and condensate trap NOTE If condensate has a heat pad attached to the trap trace the wires for the pad back to the connection point and disconnect the wires for the heat pad 7 Remove the screw that secures the condensate trap to the collector box remove the trap and set aside 8 Remove the trap gasket from the collector box if it did not come off when the trap was removed 9 Discard the old trap gasket 10 Rinse condensate trap in warm water until trap is clean 11 Flush condensate drain lines with warm water Remember to check and clean the relief port on the collector box 12 Shake trap dry 13 Clean port on collector box with a small wire To re install Condensate Drain and Trap 1 Remove adhesive backing from condensate trap gasket 2 Install gasket on collector box 3 Align the condensate trap with the drain opening on the collector box and secure the tra
45. burrs Use care and wear appropriate protective clothing safety glasses and gloves when handling parts and servicing furnaces The minimum maintenance on this furnace is as follows 1 Check and clean air filter each month or more frequently if required Replace if torn 2 Check blower motor and wheel for cleanliness each heating and cooling season Clean as necessary 3 Check electrical connections for tightness and controls for proper operation each heating season Service as necessary 4 Inspect burner compartment before each heating season for rust corrosion soot or excessive dust If necessary have furnace and burner serviced by a qualified service agency Specifications subject to change without notice 1 7 440 04 4201 01 SERVICE AND TECHNICAL SUPPORT MANUAL d Separate the pipes from the blower compartment and set aside e Remove the couplings from the pipe adapters and set aside f After servicing the blower reverse steps a through e g Tighten all clamps 15 Ib in See Figure 8 for steps 5 through 14 5 Remove screws securing blower assembly to blower shelf and slide blower assembly out of furnace Detach ground wire and disconnect blower motor harness plugs from blower motor NOTE Blower wheel is fragile Use care 6 Clean blower wheel and motor by using a vacuum with soft brush attachment Be careful not to disturb balance weights clips on blower wheel vanes Do not bend wheel or blades as b
46. ce control board 8 When main burners ignite confirm inlet gas pressure is Between 4 5 in w c and 13 6 in w c 9 Remove jumper across thermostat connections to terminate call for heat Wait until the blower off delay is completed 10 Turn furnace gas valve electric switch to OFF position 11 Turn gas supply manual shutoff valve to OFF position 12 Turn off furnace power supply 13 Remove manometer from the inlet pressure tap of the gas valve 14 Apply pipe dope sparingly to end of inlet gas pipe plug and re install in the gas valve For proper operation and long term reliability the manifold pressure must be adjusted within 2 percent of input rate on furnace rating plate The modulating furnace manifold pressure is set at two points The first point is Maximum Heat The second point is Minimum 6 Specifications subject to change without notice Gas Furnace F G 9MAC Heat Do not adjust Intermediate Heat manifold pressure Intermediate Heat manifold pressure is checked as part of the temperature rise but is not adjustable Always adjust Maximum Heat first then Minimum Heat NOTE DO NOT set Maximum Heat manifold pressure less than 3 2 in w c or more than 3 8 in w c for natural gas To adjust manifold pressure to obtain input rate for Maximum Heat 1 Make sure the gas supply is turned off to the furnace and at the electric switch on the gas valve 2 Remove the 1 8 inch NPT plug from the outlet pressure tap on the
47. code composed of 1 or 2 digits The first digit is the number of short flashes the second digit is the number of long flashes Specifications subject to change without notice 1 5 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace F G 9MAC Typical Two Stage Field Wiring Diagram FIELD 24 VOLT WIRING FIELD 115 208 230 460 VOLT WIRING FACTORY 24 VOLT WIRING FACTORY 115 VOLT WIRING FIVE 1 STAGE THERMOSTAT FIELD SUPPLIED WIRE THREE WIRE HEATING ONLY BLOWER DOOR SWITCH BK ge WHT JUNCTION BOX 115 VOLT FIELD SUPPLIED FUSED DISCONNECT TODAZOO O GH 24 VOLT TERMINAL BLOCK FURNACE For an explanation of status codes refer to service label located on blower access door or Figure14 and the troubleshooting guide which can be obtained from your distributor Retrieving Stored Fault Codes The stored status codes will NOT be erased from the control memory when 115 or 24 v power is interrupted The control will store up to the last 7 Status Codes in order of occurrence 1 To retrieve status codes proceed with the following NOTE NO thermostat signal may be present at control and all blower OFF delays must be completed a Leave 115 v power to furnace turned on b Look into blower door sight glass for current LED status c Remove blower door NOTE The Status Codes cannot
48. completed the blower airflow will transition to minimum heat airflow At this point the furnace control CPU will energize the PSR relay to open the NC contact and slowly decrease the inducer motor speed to the required minimum heat RPM When the PSR relay is energized and the NC contact opens the furnace control CPU will reduce the gas rate to minimum heat RPM Two Stage Thermostat and Two Stage Intermediate Maximum Heating NOTE In this mode the intermediate heat only switch SW4 2 must be ON to select the intermediate heat only operation mode in response to closing the thermostat R to W1 circuit Closing the thermostat R to W1 and W2 circuits always causes maximum heat operation regardless of the setting of the intermediate heat only switch The wall thermostat calls for heat closing the R to W1 circuit for intermediate heat or closing the R to W1 and W2 circuits for maximum heat The furnace control performs a self check and verifies the low medium and high pressure switch contacts LPS MPS and HPS are open then de energizes the PSR relay to close the NC contact The start up and shut down functions and delays described above apply to the 2 stage intermediate maximum heating mode as well except for switching from maximum to intermediate heat 1 Switching from Maximum to Intermediate Heat If the thermostat R to W2 circuit opens and the R to W1 circuit remains closed the furnace control CPU will gradually decrease the
49. djustment switch SW1 3 and comfort efficiency adjustment switch SW1 4 are both set to OFF 4 Ductwork must be sized for maximum heating CFM within the operational range of ESP Operation within the blank areas of the chart is not recommended because maximum heat operation will be above 1 0 ESP 5 All airflows on 21 casing size furnaces are 5 less on side return only installations 6 Side returns for 24 5 casing sizes require two sides or side and bottom to allow sufficient airflow at the return of the furnace Table 5 Gas Rate CU ft hr SECONDS G SIZE OF TEST DIAL SECONDS SIZE OF TEST DIAL FOR 1 REVOLUTION 1 Cu Ft 2 Cu Ft 5 Cu Ft FOR 1 REVOLUTION 1 Cu Ft 2 Cu Ft 5 Cu Ft 10 360 720 1800 50 72 144 360 11 327 655 1636 51 71 141 355 12 300 600 1500 52 69 138 346 13 277 555 1385 53 68 136 340 14 257 514 1286 54 67 133 333 15 240 480 1200 55 65 131 327 16 225 450 1125 56 64 129 321 17 212 424 1059 57 63 126 316 18 200 400 1000 58 62 124 310 19 189 379 947 59 61 122 305 20 180 360 900 60 60 120 300 21 171 343 857 62 58 116 290 22 164 327 818 64 56 112 281 23 157 313 783 66 54 109 273 24 150 300 750 68 53 106 265 25 144 288 720 70 51 103 257 26 138 277 692 72 50 100 250 27 133 267 667 74 48 97 243 28 129 257 643 76 47 95 237 29 124 248 621 78 46 92 231 30 120 240 600 80 45 90 225 31 116 232 581 82 44 88 220 32 113 225 563 84 43 86 214 33 109 218 545 86 42 84 209 34 106 212 529 88 41 82 205 35 103 206 514 90 40 80 200 36
50. does not operate if polarity is incorrect 2 Thermostat wire connections at terminals R W W1 G Y Y2 etc must be made at 24 v terminal block on furnace control See communicating wall control instructions for proper wiring of communicating controls 3 Natural gas service pressure must not exceed 0 5 psig 14 in w c but must be no less than 0 16 psig 4 5 in W C 4 Blower door must be in place to complete 115 v electrical circuit to furnace A CAUTION UNIT OPERATION HAZARD Failure to follow this caution may result in intermittent unit operation or performance satisfaction These furnaces are equipped with a manual reset limit switch in burner assembly This switch opens and shuts off power to the gas valve is an overheat condition flame rollout occurs in burner assembly Correct inadequate combustion air supply or improper venting condition before resetting switch DO NOT jumper this switch Before operating furnace check flame rollout manual reset switch for continuity If necessary press button to reset switch EAC 1 terminal is energized whenever blower operates HUM terminal is only energized when blower is energized in heating Select Setup Switch Positions There are four 4 sets of setup switches on the furnace control board These switches configure the furnace for correct application requirement They also select the airflow settings for Air Conditioning and Continuous Fan CFM The Setup Switch
51. e flashes continuously 3 5 GAS VALVE FAULT Indicates the modulating gas valve failed to communicate Check connection to furnace control and gas valve 4 1 BLOWER MOTOR FAULT Indicates the blower failed to reach 250 RPM or the blower failed to communicate within the prescribed time limits Thirty seconds after being turned ON or ten seconds during steady state operation 4 3 LOW OR MEDIUM PRESSURE SWITCH OPEN WHILE MEDIUM OR HIGH PRESSURE SWITCH IS CLOSED Check for Plugged condensate drain low inlet gas pressure if LGPS used Improper pressure switch wiring Water in vent piping possibly sagging pipe Stuck open low or medium pressure switch Disconnected or obstructed pressure tubing HPS closes before LPS HPS closes before MPS MPS closes before LPS 6 1 IGNITION LOCKOUT Control will auto reset after 3 hours Refer to 6 COMPONENT TEST To initiate the component test sequence shut OFF the room thermostat or disconnect the R thermostat lead Reset power and Men pu setup switch SW1 6 in the ON position to start the component test sequence Once initiated the furnace control will turn the inducer ON The inducer motor will run for the entire test The hot surface igniter and blower motor will be turned ON for 15 seconds each When the blower is turned OFF the inducer will be turned OFF When the component test is completed one or more of the following codes will flash CODE DESCRIPTION HEARTBEAT Indicates the inducer
52. ections When installed with a heat pump the furnace control automatically changes the timing sequence to avoid long blower off times during demand defrost cycles Whenever W W1 is energized along with Y1 or Y Y2 the furnace control CPU will transition to or bring on the blower motor BLWM at cooling airflow minimum heat airflow or the mid range airflow whichever is lowest The blower motor BLWM will remain on until the main 440 04 4201 01 Gas Furnace F G 9MAC burners ignite then shut OFF and remain OFF for 25 seconds before coming back on at modulating heat airflow When the W W1 input signal disappears the furnace control begins a normal inducer post purge period while changing the blower airflow If Y Y2 input is still energized the furnace control CPU will transition the blower motor BLWM airflow to cooling airflow If Y Y2 input signal disappears and the Y1 input is still energized the furnace control CPU will transition the blower motor BLWM to low cooling airflow If both the Y1 and Y Y2 signals disappear at the same time the blower motor BLWM will remain on at minimum heat airflow for the selected blower OFF delay period At the end of the blower OFF delay the blower motor BLWM will shut OFF unless G is still energized in which case the blower motor BLWM will operate at continuous blower airflow Component Self Test Refer to page 16 for instructions Specifications subject to change without notice 31 SERVICE AND TECHN
53. elects desired cooling or high stage cooling two stage units airflow See Air Delivery Tables for specific switch settings CONTINUOUS FAN CF SETUP SWITCHES SW 3 CF Continuous Fan SETUP SWITCHES The CF setup switch selects desired Continuous Fan Airflow The CF switch position is the low cooling airflow selection for two stage cooling units The CFM values in the Air Delivery Tables for SW 3 settings are the same as SW 2 settings SW 3 cannot be set for airflow higher than SW 2 See Air Delivery Tables for specific switch settings A11365 440 04 4201 01 Specifications subject to change without notice 9 SERVICE AND TECHNICAL SUPPORT MANUAL Adjust Thermostat Heat Anticipator a Mechanical thermostat Set thermostat heat anticipator to match the amp draw of the electrical components in the R WAW1 circuit Accurate amp draw readings can be obtained at the wires normally connected to thermostat subbase terminals R and W The thermostat anticipator should NOT be in the circuit while measuring current 1 Set SW1 2 switch on furnace control board to ON 2 Remove thermostat from subbase or from wall 3 Connect an amp meter as shown in Figure 5 across the R and W subbase terminals or R and W wires at wall 4 Record amp draw across terminals when furnace is in minimum heat and after blower starts 5 Set heat anticipator on thermostat per thermostat instructions and install on subbase or wall 6 Tu
54. en the medium pressure switch closes inducer motor RPM is noted by the furnace control CPU and a 25 second prepurge period begins The RPM is used to evaluate vent system restriction This evaluation is then used to determine the required RPM necessary to operate the inducer motor in maximum heat pre purge or maximum heat The high pressure switch HPS should be closed before ignition but the furnace control ignores this input until after ignition occurs 2 Igniter Warm Up At the end of the prepurge period the Hot Surface Igniter HSI is energized for a 17 second igniter warm up period 3 Trial For Ignition Sequence When the igniter warm up period is completed the main gas valve relay contact GVR closes to energize the gas valve solenoid GV The gas valve solenoid GV permits gas flow to the burners where it is ignited Five seconds after the GVR closes a 2 second Flame Proving period begins The HSI igniter will remain energized until flame is sensed or until the 2 second flame proving period begins 4 Flame Proving When the burner flame is proved at the flame proving sensor electrode FSE the furnace control CPU begins the blower ON delay period and continues to hold the gas valve GV open If the burner flame is not proved within two seconds the furnace control CPU will 440 04 4201 01 SERVICE AND TECHNICAL SUPPORT MANUAL close the gas valve GV and the furnace control CPU will repeat the ignition sequence for up to three more
55. enance a WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage Gas Furnace F G 9MAC 5 Inspect the vent pipe vent system before each heating season for water leakage sagging pipes or broken fittings Have vent pipes vent system serviced by a qualified service agency 6 Inspect any accessories attached to the furnace such as a humidifier or electronic air cleaner Perform any service or maintenance to the accessories as recommended in the accessory instructions Cleaning and or Replacing Air Filter Never store anything on near or in contact with the furnace such as The air filter arrangement will vary depending on the 1 Spray or aerosol cans rags brooms dust mops application vacuum cleaners or other cleaning tools NOTE If the filter has an airflow direction arrow the arrow 2 Soap powders bleaches waxes or other cleaning compounds plastic or plastic containers gasoline kerosene cigarette lighter fluid dry cleaning fluids or other volatile fluids Paint thinners and other painting compounds paper bags or other paper products Exposure to these materials could lead to corrosion of the heat exchangers must point towards the blower To clean or replace filters proceed as follows a WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury or death or property dam
56. erature rise specified on the furnace rating plate Determine air temperature rise as follows 1 Place thermometers in return and supply ducts as near furnace as possible Be sure thermometers do not see heat exchanger so that radiant heat does not affect readings This practice is particularly important with straight run ducts 2 When thermometer readings stabilize subtract return air temperature from supply air temperature to determine air temperature rise NOTE Temperature rise can be determined for Minimum Heat Intermediate Heat and Maximum Heat operation by locking the furnace in each mode of operation The mode of operation is 440 04 4201 01 EAC 1 TERMINAL 115 VAC 1 0 AMP MAX PL2 HOT SURFACE GNITER amp INDUCER MOTOR CONNECTOR 115 VAC L1 LINE VOLTAGE CONNECTIONS L11F061 based on the position of Set up switch SW1 2 and SW4 2 on the furnace control board The furnace is capable of automatically providing proper airflow to maintain the temperature rise within the range specified on furnace rating plate If temperature rise is outside this range proceed as follows a Check gas input for Maximum heat operation b Check derate for altitude if applicable c Check all return and supply ducts for excessive restrictions causing static pressure greater than 0 5 in W C d Ensure Min Int Heat Rise Adjust switch SW1 3 on furnace control is in ON position when a bypass humidifier is used See Figure 3 fo
57. es have been provided in the furnace installation instructions to match the required orifice to the manifold pressure to the heat content and specific gravity of the gas To do this a Obtain average heat value at installed altitude from local gas supplier b Obtain average specific gravity from local gas supplier c Find installation altitude range for your installation in the manifold pressure tables See Table 3 d Find closest natural gas heat value and specific gravity in Table 3 e Follow heat value and specific gravity lines to point of intersection to find orifice size and maximum and minimum manifold pressure settings for proper operation f Check and verify burner orifice size in furnace Never assume orifice size Always check and verify g Replace orifice with correct size if required by Table 3 Use only factory supplied orifices See EXAMPLE EXAMPLE 0 2000 ft 0 609 6M altitude Heating value 1050 Btu cu ft Specific gravity 0 62 Therefore Orifice No 44 Manifold pressure 3 4 in w c for maximum heat 0 55 in w c for minimum heat Furnace is shipped with No 44 orifices In this example all main burner orifices are the correct size and do not need to be changed to obtain proper input rate Specifications subject to change without notice 5 SERVICE AND TECHNICAL SUPPORT MANUAL Table 1 Altitude Derate Multiplier for U S A ALTITUDE PERCENT DERATE
58. filter cabinet door Fail fol j id i 8 Turn on electrical supply to furnace ailure to follow this warning could result in personal injury death and or property damage Blower Motor and Wheel Maintenance i Sai i To ensure long life economy and high efficiency clean Area RN race WN OMI UNL Or AN ME ACESS accumulated dirt and grease from blower wheel and motor annually The inducer and blower motors are pre lubricated and require A CAUTIO N no additional lubrication These motors can be identified by the absence of oil ports on each end of the motor CUT HAZARD The following items should be performed by a qualified service Failure to follow this caution may result in personal injury technician Clean blower motor and wheel as follows 1 Turn off electrical supply to furnace 2 Remove blower door 3 All factory wires can be left connected but field thermostat and accessory wiring may need to be disconnected depending on their length and routing 4 If the vent and combustion air pipe passes through the blower compartment it will be necessary to remove the pipes from the blower compartment Disconnect the vent and combustion air pipe by a Loosen the clamps on the vent couplings and combustion air pipe external to the furnace b Separate the pipes from the couplings and move them aside c Loosen the clamps on the vent couplings and combustion air pipe located on the blower shelf Sheet metal parts may have sharp edges or
59. fold pressure slowly turn adjusting screw counterclockwise out to decrease manifold pressure or clockwise in to increase manifold pressure Turn adjustment no more than one click per second until you obtain the required manifold pressure 5 After adjusting the manifold pressure remove jumpers across thermostat connections to terminate the call for heat Wait until the blower off delay is completed Move setup switch SW1 2 to the OFF position Turn gas supply manual shutoff valve to OFF position Turn off furnace power supply Remove manometer from the inlet pressure tap of the gas valve 10 Apply pipe dope sparingly to end of inlet gas pipe plug and re install in the gas valve 11 Re install cap over adjustment screw on the top of the gas valve O Q O ON O 440 04 4201 01 SERVICE AND TECHNICAL SUPPORT MANUAL A CAUTION FURNACE OVERHEATING HAZARD Failure to follow this caution may result in shortened furnace life Set air temperature rise within limits specified on the rating plate to prevent reduced life of furnace components Operation is within a few degrees of the mid point of rise range when setup switch SW1 4 is OFF Gas Furnace F G 9MAC A CAUTION FURNACE DAMAGE HAZARD Failure to follow this caution may result in overheating the heat exchangers or condensing flue gases in heat exchanger areas not designed for condensate Temperature rise must be within limits specified on unit rating
60. g Hot Surface Igniter The igniter does NOT require annual inspection Check igniter resistance before removal Refer to Figure 9 Figure 10 and Figure 11 1 Turn off gas and electrical supplies to furnace 2 Remove control door 3 4 Check igniter resistance Igniter resistance is affected by Disconnect igniter wire connection temperature Only check resistance when the igniter is at room temperature a Using an ohm meter check resistance across both igniter leads in connector b Cold reading should be between 40 ohms and 70 ohms Resistance reading will increase as igniter temperature increases Remove igniter assembly a Using a 1 4 in driver remove the two screws securing the igniter mounting bracket to the burner assembly See Figure 9 b Carefully withdraw the igniter and bracket assembly through the front of the burner assembly without striking the igniter on surrounding parts c Inspect igniter for signs of damage or failure d If replacement is required remove the screw that secures the igniter on igniter bracket and remove the igniter To replace igniter and bracket assembly reverse items 5a through 5e Reconnect igniter harness to the igniter dressing the igniter wires to ensure there is no tension on the igniter itself See Figure 9 Turn on gas and electrical supplies to furnace Verify igniter operation by initiating control board self test feature or by cycling ther
61. he valve from rotating on the manifold or damaging the mounting to the burner assembly Refer to Figure 9 1 Disconnect power at external disconnect fuse or circuit breaker 440 04 4201 01 Gas Furnace F G 9MAC Turn off gas at external shut off or gas meter Remove outer doors and set aside Turn electric switch on gas valve to OFF Disconnect the gas pipe from gas valve and remove pipe from the furnace casing Disconnect the connector harness from gas valve Disconnect Hot Surface Igniter HSI wires from HSI Disconnect Flame Sensor wire from Flame Sensor Support the manifold and remove the four 4 screws that secure the manifold assembly to the burner assembly and set aside Note the location of the green yellow wire and ground terminal 10 Inspect the orifices in the manifold assembly for blockages or obstructions Remove orifice and clean or replace orifice 11 Remove the four 4 screws that attach the top plate of the casing to the furnace 12 Raise top plate up slightly and prop it up with a small piece of wood or folded cardboard 13 Support the burner assembly and remove the screws that attach the burner assembly to the heat exchanger cell panel 14 Remove wires from both rollout switches 15 Slide one piece burner assembly out of slots on sides of burner assembly 16 Remove the flame sensor from the burner assembly 17 Optional Remove the Hot Surface Igniter HSI and brac
62. he National standards of Canada CAN CSA B149 1 and 2 Natural Gas and Propane Installation Codes and Canadian Electrical Code CSA C22 1 Recognize safety information This is the safety alert symbol AN when you see this symbol on the unit and in instructions or manuals be alert to the potential for personal injury Understand these signal words DANGER WARNING and CAUTION These words are used with the safety alert symbol DANGER identifies the most serious hazards which will result in severe personal injury or death WARNING signifies hazards which could result in personal injury or death CAUTION is used to identify unsafe practices which may result in minor personal injury or product and property damage NOTE is used to highlight suggestions which will result in enhanced installation reliability or operation a WARNING PERSONAL INJURY AND OR PROPERTY DAMAGE HAZARD Failure to carefully read and follow this warning could result in equipment malfunction property damage personal injury and or death Installation or repairs made by unqualified persons could result in equipment malfunction property damage personal injury and or death The information contained in this manual is intended for use by a qualified service technician familiar with safety procedures and equipped with proper tools and test instruments Installation must conform with local building codes and with the Natural Fuel Gas Code NFCG NFPA 54 ANSI Z223
63. his warning could result in personal injury death and or property damage DO NOT bottom out gas valve regulator adjusting screw This can result in unregulated manifold pressure and result in excess overfire and heat exchanger failures A CAUTION FURNACE DAMAGE HAZARD Failure to follow this caution may result in reduced furnace life DO NOT redrill orifices Improper drilling burrs out of round holes etc can cause excessive burner noise and misdirection of burner flames This can result in flame impingement of heat exchangers causing failures See Figure 2 440 04 4201 01 Gas Furnace F G 9MAC Figue2 Orifice Hole BURNER ORIFICE A93059 For proper operation and long term reliability the Furnace input rate must be within 2 percent of input rate on furnace rating plate The gas input rate on rating plate is for installations at altitudes up to 2000 ft 609 6M In the USA the input rating for altitudes above 2000 ft 610 M must be reduced by 2 percent for each 1000 ft 304 8M above sea level refer to Table 1 In Canada the input rating must be derated by 5 percent for altitudes of 2000 ft 610 M to 4500 ft 1372 M above sea level To adjust manifold pressure to obtain the proper input rate first determine if the furnace has the correct orifice installed At higher altitudes or different gas heat contents it may be necessary to change the factory orifice to a different orifice Tabl
64. hours or as specified LED CODE STATUS CONTINUOUS OFF a We y VAC at Neutral and 24VAC at SEC 1 and SEC 2 BRIGHT DIM Control has 24VAC power one uto reset after 1 hour lockout due to Gas valve relay stuck open Flame sense circuit failure Software check error Reset power to clear lockout Replace control if status code repeats EACH OF THE FOLLOWING STATUS CODES IS A SINGLE OR TWO DIGIT NUMBER WITH THE FIRST NUMBER DETERMINED BY THE NUMBER OF SHORT FLASHES AND THE SECOND NUMBER AFTER THE PLUS SIGN IS THE NUMBER OF LONG FLASHES OFF SECONDARY VOLTAGE FUSE IS OPEN Check for Short circuit in secondary voltage 24VAC wiring 2 PRESSURE SWITCH DID NOT OPEN Check for Obstructed pressure tubing Pressure switch stuck closed j LOW PRESSURE SWITCH DID NOT CLOSE OR REOPENED Indicates the low pressure switch input failed to close on a call for heat or opened during minimum heat If opens during 5 minutes after ignition the next heating cycle will be restricted to maximum heat Check for Proper vent sizing Plugged condensate drain Excessive wind Low inlet gas pressure if LGPS used Improper pressure switch wiring Restricted vent Disconnected or obstructed pressure tubing Walerin vent piping possible sagging pipe Failed or Out of Calibration pressure switche LIMIT CIRCUIT FAULT Indicates a limit or flame rollout is open or the furnace is operating at maximum heat due to 2 successive low or medi
65. ied installer service agency local gas supplier or your distributor or branch for information or assistance The qualified installer or agency must use only factory authorized and listed kits or accessories when modifying this product Have available the product model number and the serial number located on the unit rating plate to ensure correct replacement parts TO OBTAIN INFORMATION ON PARTS Consult your installing dealer or the classified section of your local telephone directory under the Heating Equipment or Air Conditioning Contractors and Systems headings for dealer listing by brand name or contact 32 Specifications subject to change without notice 440 04 4201 01 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace F G 9MAC PRODUCT NOMENCLATURE T x ofo NW A C 0117F 14 A f Mainline Look 1 F Mainline Look 2 N Entry 9 90 100 EFFICIENCY M Multiposition H Horizontal U Upflow D Downflow FEATURE A Modulating Variable Speed ECM V Variable Speed X ECM S Single stage T Two stage FEATURE B Base AFUE Efficiency E Extra AFUE Efficiency C Communicating D Dual Certified 2 pipe or 1 pipe R 2 pipe only S Single stage T Two stage N Standard L Low Nox FEATURE 040 40 000 BTU hr 060 60 000 BTU hr 080 80 000 BTU hr 100 100 000 BTU hr 120 120 000 BTU hr INPUT HEAT 14 14 316 17 17 1 2 21 21 24 24 1 2 CABINET WIDTH 10
66. inducer motor speed to the required intermediate heat RPM When the inducer motor IDM reduces pressure sufficiently the high pressure switch HPS will open and the gas rate will be changed to intermediate heat When the inducer motor speed gets within 15 of the required intermediate heat RPM the furnace control CPU will start a 5 second blower airflow change delay After the 5 second blower airflow change delay is completed the blower airflow will transition to intermediate heat airflow Cooling Mode The thermostat calls for cooling 1 Single Speed Cooling The thermostat closes the R to G and Y circuits The R to Y circuit starts the outdoor unit and the R to G and Y Y2 circuits start the furnace blower motor BLWM on cooling airflow Cooling airflow is based on the A C selection shown in Figure 4 The electronic air cleaner terminal EAC 1 is energized with 115 vac when the blower motor BLWM is operating When the thermostat is satisfied the R to G and Y circuits are opened The outdoor unit will stop and the furnace blower motor BLWM will continue operating at cooling airflow for an additional 90 seconds Jumper Y Y2 to DHUM to reduce the cooling off delay to 5 seconds See Figure 3 Two Stage Thermostat and Two Speed Cooling The thermostat closes the R to G and Y1 circuits for low cooling or closes the R to G and Y1 and Y2 circuits for high cooling The R to Y1 circuit starts the outdoor unit on low cooling speed and the R to G
67. ing airflow for two speed cooling units This setup feature allows continuous fan airflow or low cooling airflow to be adjusted To set desired continuous fan airflow or low cooling airflow 1 Remove blower door 2 Locate CF setup switches on furnace control 3 Determine desired continuous fan airflow or low cooling airflow 4 Configure the switches for the required continuous fan or low cooling airflow 5 Replace blower door Additional Setup Switches SW4 The furnace control has 3 additional setup switches labeled SW4 Setup switch SW4 2 can be used to lock the furnace into intermediate heat When setup switch SW4 2 is ON it will over ride setup switch SW1 2 if it is ON SW4 3 is used to adjust airflow See communicating control instructions for use of SW4 1 To activate setup switch SW4 2 and SW4 3 1 Remove blower door 2 Locate setup switch SW4 on furnace control 3 Configure the switches for the required heat stages air flow if necessary 4 Replace blower door Prime Condensate Trap with Water A CAUTION UNIT OPERATION HAZARD Failure to follow this caution may result in intermittent unit operation or performance satisfaction Condensate trap must be PRIMED or proper draining may not occur The condensate trap has two internal chambers which can ONLY be primed by pouring water into the inducer drain side of condensate trap 1 Remove upper and middle inducer housing drain plugs opposite of the condensa
68. ion of Set up switch SW1 3 When set to ON airflow is raised 18 for Minimum Heat and for Intermediate Heat Factory default position is OFF 5 Turn 115 VAC power on 6 Re check Minimum Heat Temperature Rise To lock the furnace in Maximum Heat 7 Connect a jumper across R and W W1 and W2 at the thermostat terminals at the furnace control 8 Allow the burners to ignite and the blower to turn on 9 Allow the supply temperature to stabilize and verify the proper rise range If the temperature rise is too high or too low in Maximum Heat 1 Remove jumpers from R and W W1 2 Wait until the blower off delay is completed 3 Turn 115 VAC power off 4 Check the position of Set up switch SW1 4 When set to ON airflow is raised 9 for Minimum Heat 7 for Intermediate Heat and 15 for Maximum Heat Factory default position is ON 5 Turn 115 VAC power on 6 Re check Minimum Heat Temperature Rise After the temperature rise has been verified 1 Remove jumpers from thermostat terminals 2 Allow the blower off delay to complete 3 Turn Set up switches SW1 2 and SW4 2 to the OFF position 4 Install blower door 8 Specifications subject to change without notice Gas Furnace F G 9MAC A WARNING FIRE HAZARD Failure to follow this warning could result in personal injury death and or property damage Reinstall manifold pressure tap plug in gas valve to prevent gas leak A CAUTION FURNACE OVERHEATING HAZARD
69. ity for 115 v wiring must be properly maintained Refer to Figure 7 for field wiring information and to Figure 15 for furnace wiring information NOTE If the polarity is not correct the STATUS LED on the control will flash code 10 and prevent the furnace from heating The control system also requires an earth ground for proper operation of the control and flame sensing electrode The 24 v circuit contains an automotive type 3 amp fuse located on the control See Figure 3 Any shorts of the 24 v wiring during installation service or maintenance will cause this fuse to blow If fuse replacement is required use ONLY a 3 amp fuse The control LED display will be off when fuse needs replacing Troubleshooting Refer to the service label See Figure 14 Service Label The Troubleshooting Guide See Figure 16 can be a useful tool in isolating furnace operation problems Beginning with the word Start answer each question and follow the appropriate arrow to the next item The Guide will help to identify the problem or failed component After replacing any component verify correct operation sequence Proper instrumentation is required to service electrical controls The control in this furnace is equipped with a Status Code LED Light Emitting Diode to aid in installation servicing and troubleshooting Status codes can be viewed at the sight glass in blower access door The amber furnace control LED is either heartbeat off or a
70. ket from the burner assembly 18 Check igniter resistance Nominal resistance is 40 to 70 ohms at room temperature and is stable over the life of the igniter 19 Clean burner assembly with a brush and a vacuum 20 Clean the flame sensor with fine steel wool 0000 grade Do not use sand paper or emery cloth To reinstall burner assembly 1 Install the Hot Surface Igniter HSI and bracket in burner assembly 2 Install flame sensor on burner assembly 3 Align the edges of the one piece burner assembly with the slots in the burner assembly and slide the burners forward until they are fully seated in the burner assembly 4 Align the orifices in the manifold assembly with the support rings on the end of the burner 5 Insert the orifices in the support rings of the burners NOTE If manifold does not fit flush against the burner assembly do not force the manifold on the burner assembly The burners are not fully seated forward in the burner assembly Remove the manifold and check burner positioning in the burner assembly before re installing the manifold 6 Attach the green yellow wire and ground terminal to one of the manifold mounting screws 7 Install the remaining manifold mounting screws a G Pf Oo ON O Specifications subject to change without notice 19 SERVICE AND TECHNICAL SUPPORT MANUAL 8 Check the igniter alignment See Figure 9 Figure 10 and Figure 11 Figue9 Burner Assembly BURNER SUPT ASSY
71. mostat 20 Specifications subject to change without notice 440 04 4201 01 SERVICE AND TECHNICAL SUPPORT MANUAL 10 Replace control door Flushing Collector Box and Drainage System 1 Turn off gas and electrical supplies to furnace 2 Remove control door 3 Disconnect pressure switch tube from pressure switch port NOTE Ensure the pressure switch tube disconnected from the pressure switch is higher than the collector box opening or water will flow out of tube 4 Remove one of the collector box plugs from a port on the upper corner of the collector box See Figure 1 5 Attach a funnel with a flexible tube to port on the collector box 6 Flush inside of collector box with water until discharge from condensate trap is clean and runs freely 7 Repeat steps 4 through 6 with middle plug on upper corner of collector box 8 Remove the pressure switch tube from the collector box NOTE Do Not blow into tube with tube connected to the pressure switch 9 Clean pressure switch port on collect box with a small wire Shake any water out of pressure switch tube 10 Reconnect tube to pressure switch and pressure switch port 11 Remove the relief tube from the port on the collector box and the trap 12 Clean the relief port on collect box and the trap with a small wire Shake any water out of the tube 13 Reconnect relief tube to trap and collector box ports Cleaning Condensate Drain and Trap NOTE If the condensate tr
72. ndary heat exchanger CANNOT be serviced or inspected without complete removal of the heat exchanger assembly Detailed information on heat exchanger removal can be obtained from your Distributor 22 Specifications subject to change without notice Gas Furnace F G 9MAC Winterization A CAUTION UNIT AND PROPERTY DAMAGE HAZARD Failure to follow this caution may result in unit component or property damage If the furnace is installed in an unconditioned space where the ambient temperatures may be 32 F 0 C or lower freeze protection measures must be taken to prevent property or product damage Since the furnace uses a condensing heat exchanger some water will accumulate in the unit as a result of the heat transfer process Therefore once it has been operated it cannot be turned off and left off for an extended period of time when temperatures will reach 32 F 0 C or lower unless winterized Follow these procedures to winterize your furnace A CAUTION UNIT COMPONENT DAMAGE HAZARD Failure to follow this caution may result in damage to the furnace and other property damage Do not use ethylene glycol automotive antifreeze coolant or equivalent Failure of plastic components 1 Obtain propylene glycol RV swimming pool antifreeze or equivalent 2 Turn off gas and electrical supplies to your furnace 3 Remove furnace control door 4 Remove the top unused rubber plug from the port on the collector b
73. ols down Check Pressure Switch es This control proves operation of the draft inducer blower a Turn off 115 v power to furnace b Disconnect inducer motor lead wires from wire harness c Turn on 115 v power to furnace d Set thermostat to call for heat and wait 1 minute When pressure switch is functioning properly hot surface igniter should NOT glow and control diagnostic light flashes a status code 3 If hot surface igniter glows when inducer motor is disconnected shut down furnace immediately e Determine reason pressure switch did not function properly and correct condition f Turn off 115 v power to furnace g Reconnect inducer motor wires replace blower door and turn on 115 v power h Blower will run for 90 seconds before beginning the call for heat again i Furnace should ignite normally Checklist 1 2 Put away tools and instruments Clean up debris Verify that switches SW1 1 and SW1 6 are OFF and other setup switches are set as desired Verify that switches SW1 7 and SW1 8 for the blower OFF DELAY are set as desired per Table 2 Verify that blower and control doors are properly SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace F G 9MAC Orifice Size and Manifold Pressure in w c for Gas Input Rate Modulating MODULATING FURNACE TABULATED DATA BASED ON 20 000 BTUH MAX HEAT 8 000 BTUH MIN HEAT PER BURNER DERATED 2 1000 FT 305M ABOVE SEA LEVEL ALTITUDE AVG GAS SPECIF
74. ored insulation is evident replace heat tape 3 Check that heat tape power supply circuit is on Cleaning Heat Exchangers The following items must be performed by a qualified service technician Primary Heat Exchangers If the heat exchangers get an accumulation of light dirt or dust on the inside they may be cleaned by the following procedure Figure 12 Cleaning Heat Exchanger Cell NOTE If the heat exchangers get a heavy accumulation of soot and carbon both the primary and secondary heat exchangers should be replaced rather than trying to clean them thoroughly due to their intricate design A build up of soot and carbon indicates that a problem exists which needs to be corrected such as improper adjustment of manifold pressure insufficient or poor quality combustion air improper vent termination incorrect size or damaged manifold orifice s Specifications subject to change without notice 21 SERVICE AND TECHNICAL SUPPORT MANUAL improper gas or a restricted heat exchanger primary or secondary Action must be taken to correct the problem 1 Turn off gas and electrical supplies to furnace 2 Remove control door 3 Disconnect wires or connectors to flame rollout switch gas valve igniter and flame sensor 4 Using backup wrench disconnect gas supply pipe from furnace gas control valve 5 Remove two screws attaching top filler panel and rotate upwards to gain access to screws attaching b
75. ox opposite the condensate trap See Figure 1 5 Connect a field supplied 3 8 in 9 5 mm ID tube to the open port on the collector box 6 Insert a field supplied funnel into the tube 7 Pour one quart of anti freeze solution into the funnel tube Antifreeze should run through the collector box overfill condensate trap and flow to an open drain 8 Replace the rubber plug in the port on the collector box 9 Remove the middle unused rubber plug from the port on the collector box opposite the condensate trap See Figure 1 10 Repeat Steps 5 through 8 11 If a condensate pump is used check with pump manufacturer to verify pump is safe for use with antifreeze used Allow pump to start and pump anti freeze to open drain 12 Replace main door 13 When furnace is re started flush condensate pump with clear water to check for proper operation before re starting furnace 14 Propylene glycol need not be removed before re starting furnace 440 04 4201 01 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace F G 9MAC Figure 14 ServiceLabel S SERVICE If status code recall is needed disconnect the R thermostat lead reset power and put setup switch SW1 1 in the ON position To clear the status code history put setup switch SW1 1 in the ON position and jumper thermostat terminals R W W1 and Y Y2 simultaneously until heartbeat is flashed Stored status codes are erased automatically after 72
76. p with the screw Q G NS 440 04 4201 01 Gas Furnace F G 9MAC 4 Attach the relief hose to the relief port on the condensate trap and collector box 5 Secure tubing to prevent any sags or traps in the tubing 6 Connect condensate drain elbow or drain extension elbow to the condensate trap 7 Connect the leads of the condensate heat pad if used 8 Connect external drain piping to the condensate drain elbow or drain extension pipe 9 Turn gas on at electric switch on gas valve and at external shut off or meter 10 Turn power on at external disconnect fuse or circuit breaker 11 Run the furnace through two complete heating cycles to check for proper operation 12 Install outer door when complete Checking Heat Pad Operation If Applicable In applications where the ambient temperature around the furnace is 32 F or lower freeze protection measures are required If this application is where heat tape has been applied check to ensure it will operate when low temperatures are present NOTE The Heat Pad when used should be wrapped around the condensate drain trap There is no need to use heat tape within the furnace casing Most heat tapes are temperature activated and it is not practical to verify the actual heating of the tape Check the following 1 Check for signs of physical damage to heat tape such as nicks cuts abrasions gnawing by animals etc 2 Check for discolored heat tape insulation If any damage or discol
77. plnoo2 noy907 uNOY Jaye Jase O Ne IM pue JNO p yx20 SI O4JUOD y L opuunj 0 Jayeosq JINOIIO WO 34M u AlInulluo2 40 YOBYD SJA D so 2 18X281 4N911 S YOUMS JOOP ay so O JOWJOJSUBI BOe dey YOUMS 100p soR day EYOUMs o ButoB ASI 3194 SI p SOJ YAMS 100P S ON Eyeaqueay y uey 19440 po2 SNIS SNOJ Jd e 9194 SEM p usel sem yey po2 SNIS y 10 MOJ q UOND S 0 09 uolllsod 440 4 u LMS youms dn s nd auop u uA s usel yeaquesy y Inun Ajsnosueynwis ZA A pue WN Y Bunadwnf pue uolisod NO 84 u MS yams dnyes Bund Aq p se1 jenuew aq ued JO sinou Zz saye p se1 ale s poo snjejg yeadal jm S pO9 snlels y s uu L1 A S s use J ye que y Jayy s use j Ie que u UN s poo snes P1odsyY 959u uinooo JO 1 p10 y u s po2 SNJEJS Y use Mm G31 H38NV y uonisod NO y ul L LMS Yyoums dn s nd pue amod JOS9J uono uuoo ezsow y H OY 19 uuoosip pod SNIS snolA 81d Ee L991 OL paseajo seu poo snes sej OY 1d Bnid japow aved y Pp lle1su 6njd poui 3991109 y S adeUINY SIU 404 Bnd japouw 399100 By SMOS ejd Buyer ayy p llelsu S 1q Bnid jepow 1991109 ay yey ans yew 0 Y99049 104 u09 oguinj 5e d tJ YN Uous lelosi 0 spe 1Jelsouuu 199uuo5sip u u asny 5e d tJ u do asn AtZ au S O3S pue O3S 18 Ave 3194 S amp
78. position and install a lockout tag There may be more than one disconnect switch Lock out and tag switch with a suitable warning label Verify proper operation after servicing A CAUTION ELECTRICAL OPERATION HAZARD Failure to follow this caution may result in improper furnace operation or failure of furnace Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation General These instructions are written as if the furnace is installed in an upflow application An upflow furnace application is where the blower is located below the combustion and controls section of the furnace and conditioned air is discharged upward Since this furnace can be installed in any of the four positions shown in Figure 6 you must revise your orientation to component location accordingly 440 04 4201 01 Gas Furnace F G 9MAC Multipoise Orientations AIRFLOW cH HORIZONTAL RIGHT Q HORIZONTAL LEFT AIRFLOW DOWNFLOW AIRFLOW v AIRFLOW A93041 Electrical Controls and Wiring 4 amp WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death There may be more than one electrical supply to the furnace Check accessories and cooling unit for additional electrical supplies that must be shut off during furnace servicing Lock out and tag switch with a suitable warning label The electrical ground and polar
79. r switch location e Check Troubleshooting Guide for Variable Speed Step Modulating Condensing Furnaces Minimum Intermediate and Specifications subject to change without notice 7 SERVICE AND TECHNICAL SUPPORT MANUAL To lock the furnace in Minimum Heat 1 Turn SW1 2 ON at the furnace control Set up switch SW4 2 must be OFF 2 Connect a jumper across R and W W1 at the thermostat terminals at the furnace control 3 Allow the burners to ignite and the blower to turn on 4 Allow the supply temperature to stabilize and verify the proper rise range If the temperature rise is too high or too low in Minimum Heat 1 Remove jumpers from R and W W1 2 Wait until the blower off delay is completed 3 Turn 115 VAC power off 4 Check the position of Set up switch SW1 3 When set to ON airflow is raised 18 for Minimum Heat and for Intermediate Heat Factory default position is OFF 5 Turn 115 VAC power on 6 Re check Minimum Heat Temperature Rise To lock the furnace in Intermediate Heat 7 Connect a jumper across R and W W1 at the thermostat terminals at the furnace control 8 Allow the burners to ignite and the blower to turn on 9 Allow the supply temperature to stabilize and verify the proper rise range If the temperature rise is too high or too low in Intermediate Heat 1 Remove jumpers from R and W W1 2 Wait until the blower off delay is completed 3 Turn 115 VAC power off 4 Check the posit
80. rcent Low Heat Rise Adjustment Comfort Efficiency Adjustment CFM per ton adjust Component Self Test Turn ON to decrease low heat airflow by 9 percent Intermediate Heat airflow 7 percent and high heat airflow 15 percent for maximum comfort Turn ON for 400 CFM per ton Turn OFF for 350 CFM per ton See also SW4 Turn ON to initiate Component Self Test for troubleshooting assistance when R thermostat lead is disconnected Turn OFF when Self Test is completed Blower Off Delay time adjustable 90 seconds to 180 seconds See table in Adjustments section or refer to unit wiring diagram When SW1 2 is OFF allows Modulating operation from a single stage thermostat Turn ON when using two stage thermostat to allow Intermediate Heat operation when R to W W1 closes and Maximum Heat operation when R to W W1 and R to W2 close SW1 7 amp SW1 8 Blower OFF delay Intermendiate Heat Only Adaptive Heat Mode when both SW1 2 and SW4 2 are OFF Allows additional CFM per ton selections when used with SW 1 5 325 CFM per ton nominal when SW 4 3 ON and SW 1 5 OFF 350 CFM per ton nominal when SW 4 3 OFF and SW 1 5 OFF Intermediate CFM per ton Adjust 370 CFM per ton nominal when SW4 3 ON and SW 1 5 ON 400 CFM per ton nominal when SW 1 5 ON and SW 4 3 OFF See Air Delivery Tables for model specific CFM vs static pressure AIR CONDITIONING A C SETUP SWITCHES SW 2 AC Cooling Airflow SETUP SWITCHES The AC setup switch s
81. red RPM necessary to operate the inducer motor at maximum heat The blower motor BLWM will transition to maximum heat airflow five seconds after the furnace control CPU switches from a low range input to maximum heat As the inducer RPM increases the high pressure switch HPS should close Switching from Medium Range Input to Maximum Heat If the furnace control CPU switches 440 04 4201 01 Gas Furnace F G 9MAC from medium range input to maximum heat the furnace control CPU will increase the inducer motor speed to the maximum heat inducer motor RPM The blower motor BLWM will transition to the maximum heat airflow five seconds after the furnace control CPU switches froma medium range input to maximum heat As the inducer RPM increases the high pressure switch HPS should close 8 Blower Off Delay When the thermostat is satisfied the R to W circuit is opened de energizing the gas valve GV stopping gas flow to the burners and humidifier terminal HUM The inducer motor IDM will remain energized for a 15 second post purge period The blower motor BLWM and air cleaner terminal EAC 1 will remain energized at minimum heat airflow or transition to minimum heat airflow for 90 120 150 or 180 seconds depending on selection at blower OFF delay switches The furnace control CPU is factory set for a 120 second blower OFF delay Two Stage Thermostat and Modulating Heating Adaptive Mode Operation of Modulating Heating Adaptive
82. rmer 115VAC 24VAC LINDYID YO Gasnd ILON a03Y NIHM HOLIMS LOANNOOSIC i3yv3ug 338316 2 Rev E 24 Specifications subject to change without notice 440 04 4201 01 F G 9MAC Gas Furnace SERVICE AND TECHNICAL SUPPORT MANUAL Troubleshooting Guide yeJSOWJOU y ade da 10 yeJSOWAUY 94 O Jeu 1elsouu ul APZWOD ay JOOUUOD 10 S S 1 1selleq jesu Jay lonuoo BoeUINY y YIM lqileduuo2 Jou si 1e souu u1 y L JoyJUOD soeUUN Boe deYy ON am Jaduunf e Buisn uaym yeadas wajqoid y s oq JoyJUOD BoeUINY y WOJ SOIM 1P1SOulI U AU L JW UUODSIG SHA 101 U09 ogulnj y uo s puluu ye soway D 10 ZA A LA ZM LMM asad AtZ SI ON qe5 Buno uuoo1u lu JO ye soway WOOL y99uO LYVLS 0 yorq oB pue Jayeaig YN so O s use J ye que y y Inun Isno uel nuiis ZA A pue AVA H Buu dun pue uonisod NO 8ulu LANS Youms dnjes Bund Aq p seu jenuew aq ued Jo sinou ZZ Jaye pasese ase s poo sneg uoneiodo yoayd 0 lo o Bullooo Jo ye y wnu xew yeay winwiulw e yno ui ls s uny SIeu6is 1elsouu ul Atz PUB ZA A LA SM LM M 0 puodsai olluo2 34 s oq syeadad po2 Jl Ioluoo ejd y 1noyoo 123 9 0 1SAod Jasay 1011 YOOYD BIEMYOS u do yonjs Aejau A PA Se un iey 1ino1o su s Owe Bulmo o au Jo Aue 0 np aq
83. rn Air Address Temperature Rise Supply Return High Heat City State Province Zip or Postal Code Low Heat In Rise Range see furnace rating plate d Model Number Static Pressure Ducts High Heat Supply Serial Number Return t heck setup eirck Optional Check CO Check the box when task is complete CO2 ee All Electrical Connections Tight Cooling Check have noses been relocated for furnace U D H Temperature of Supply Air application Temperature of Return Air Condensate Drain Connected p Temperature Difference Condensate Drain Trapped Static Pressure Ducts Cooling Supply Manual Gas Shut off Upstream of Furnace Drip Leg Return L L L L L L Gas Valve turned ON Dealer Comments Type of Gas Natural Propane LI Filter Type and Size Shade in Final Furnace Settings Below PL4 swt HHHBBHBH Sw2 gt Sw3 ARAS BBB F Calculated Input BTU Rate See Checks and Adjustments Section 440 01 4201 01 Specifications subject to change without notice SERVICE AND TECHNICAL SUPPORT MANUAL START UP ADJUSTMENT AND SAFETY CHECK General 1 Furnace must have a 115 v power supply properly connected and grounded NOTE Proper polarity must be maintained for 115 v wiring Control status indicator light flashes code 10 and furnace
84. rn SW1 2 switch OFF 7 Install blower door b Electronic thermostat Set cycle rate for three cycles per hr Figures Amp Draw Check with Ammeter THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED ANITICIPATOR CLOCK ETC MUST BE OUT OF CIRCUIT HOOK AROUN AMMETER T FROM UNIT 24 V CONTROL TERMINALS installed 4 Cycle test furnace with room thermostat EXAMPLE 50 aad ae 5 Check operation of accessories per manufacturer s instructions 6 Review Home Owner s Information with owner 7 Attach literature packet to furnace 10 Specifications subject to change without notice 440 04 4201 01 Gas Furnace F G 9MAC Check Safety Controls The flame sensor gas valve and pressure switch were all checked in the Start up procedure section as part of normal operation 1 Check Main Limit Switch This control shuts off combustion system and energizes air circulating blower motor if furnace overheats By using this method to check limit control it can be established that limit is functioning properly and will operate if there is a restricted return air supply or motor failure If limit control does not function during this test cause must be determined and corrected a Run furnace for at least five minutes b Gradually block off return air with a piece of cardboard or sheet metal until the limit trips c Unblock return air to permit normal circulation d Burners will re light when furnace co
85. rol CPU will turn the blower ON or switch to the modulating heat airflow energize the PSR relay to open the NC contact and slowly decrease the inducer motor speed to the desired inducer RPM Switching from a Intermediate Heat to a Medium Range Input If the furnace control CPU switches from intermediate heat to a different medium range input medium range input is an input rate between 52 and 71 of full rate the furnace control CPU will turn the blower ON or switch to the modulating heat airflow and continue to maintain the inducer motor speed or change it further if required Switching from a Intermediate Heat to a High Range Input If the furnace control CPU switches from intermediate heat to a high range input high range input is an input rate greater than or equal to 72 of full rate the furnace control CPU will turn the blower ON or switch to the modulating heat airflow and increase the inducer motor speed to the desired inducer motor RPM Switching from Low Range Input to Maximum Heat If the furnace control CPU switches from a low range input to maximum heat the furnace control CPU will de energize the PSR relay to close the NC contact and slowly increase the inducer motor speed until the medium pressure switch MPS closes When the medium pressure switch MPS closes the inducer motor RPM is noted by the furnace control CPU The RPM is used to evaluate vent system resistance This evaluation is then used to determine the requi
86. se of the AHRI Certified TM Mark indicates a result in enhanced installation reliability or i ra operation potential for personal injury SEQUENCE OF OPERATION 28 TABLE OF CONTENTS PARTS REPLACEMENT INFORMATION GUIDE 32 START UP ADJUSTMENT AND SAFETY CHECK 4 PRODUCT NOMENCLATURE 33 SELECT SETUP SWITCH POSITIONS 4 PRIME CONDENSATE TRAP WITH WATER 4 M O D E LS PURGE GAS LINES 5 ADJUSTMENTS 5 ADJUST TEMPERATURE RISE 7 F G 9MACO601 714A ADJUST BLOWER OFF DELAY HEAT MODE 8 F G 9MACO801 714A ADJUST COOLING AIRFLOW 8 ADJUST CONTINUOUS FAN AIRFLOW 8 F G 9 MAC1002122A ADJUST THERMOSTAT HEAT ANTICIPATOR 10 CHECK SAFETY CONTROLS 10 F G 9MAC1 202422A CHECKLIST 10 COOLING AND HEATING AIR DELIVERY 13 SERVICE AND MAINTENANCE PROCEDURES 15 E ELECTRICAL CONTROLS AND WIRING 15 pA R LD CLEANING AND OR REPLACING AIR FILTER 17 2 man nal CERTIFIED CLEANING BURNERS AND FLAME SENSOR 19 3 www ahridirectory org SERVICING HOT SURFACE IGNITER 20 o CLEANING CON
87. te for up to 19 minutes and then switch to maximum heat as long as the thermostat continues to call for heat If the calculated modulating rate is 100 then the furnace control will only operate at maximum heat until the thermostat is satisfied The wall thermostat calls for heat closing the R to W circuit The furnace control CPU performs a self check verifies the low medium and high pressure switch contacts LPS MPS and HPS are open then de energizes the PSR relay to close the NC contact 1 Inducer Prepurge Period The furnace control CPU turns on inducer motor IDM and slowly increases the inducer motor speed After the low pressure switch LPS closes the furnace control CPU continues to increase the inducer motor speed until the medium pressure switch MPS closes When the medium pressure switch MPS closes inducer motor RPM is noted by the furnace control CPU and a 25 second prepurge period begins The RPM is used to evaluate vent system resistance This evaluation is then used to determine the required RPM necessary to operate the inducer motor during pre purge the first 45 seconds of intermediate heat or any modulating rate that the furnace will transition to after the blower on delay is completed NOTE The heat cycle can start in either intermediate or maximum heat If a maximum heat cycle is initiated the furnace control CPU will continue to increase the inducer motor speed after the medium pressure switch MPS closes Wh
88. te trap See Figure 1 2 Connect field supplied 1 2 in 13 mm OD tube to upper inducer housing drain connection 3 Insert field supplied funnel into tube 4 Pour one quart of water into funnel tube Water should run through inducer housing overfill condensate trap and flow into open field drain 5 Remove funnel replace inducer drain plug 6 Connect field supplied 1 2 in 13 mm OD tube to middle inducer housing drain port 7 Pour one quart of water into funnel tube Water should run through inducer housing overfill condensate trap and flow into open field drain 8 Remove funnel and tube from inducer housing and replace inducer drain plug 440 04 4201 01 SERVICE AND TECHNICAL SUPPORT MANUAL Priming Condensate Drain lt SS Representative drawing only some models may vary in appearance L11F065 Purge Gas Lines If not previously done purge the lines after all connections have been made and check for leaks A WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage Never purge a gas line into a combustion chamber Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of leaks to check all connections A fire or explosion may result causing property damage personal injury or loss of life Adjustments A WARNING FIRE HAZARD Failure to follow t
89. to hold switch closed Check for proper rotation and speed changes between heating and cooling by jumpering R to G and R to Y Y2 on furnace control thermostat terminals Turn outdoor circuit breaker on after completing cooling cycle See Figure 3 NOTE If R W W1 thermostat terminals are jumpered at the time blower access door switch is closed blower will run for 90 seconds before beginning a heating cycle a Perform component self test as shown at the bottom of the SERVICE label located on the front of blower access door b Verify blower is rotating in the correct direction 18 If furnace is operating properly RELEASE BLOWER ACCESS DOOR SWITCH Remove any jumpers or reconnect any disconnected thermostat leads Replace blower access door 19 Downflow or horizontal furnaces with vent pipe through furnace only a Install and connect short piece of vent pipe inside furnace to existing vent b Connect vent connector to vent elbow 20 Reinstall outer door 21 Turn on gas supply and cycle furnace through one complete heating cycle Verify the furnace temperature rise as shown in Adjustments Section Adjust temperature rise as shown in Adjustments Section Cleaning Burners and Flame Sensor The following items must be performed by a qualified service technician If the burners develop an accumulation of light dirt or dust they may be cleaned by using the following procedure NOTE Use a back up wrench on the gas valve to prevent t
90. to non Thermostat mode The cooling operation described above in the Cooling Mode section also applies to operation with a Thermostat The exceptions are listed below 1 Low cooling When the R to G and Y1 circuit is closed and there is a demand for dehumidification the furnace blower motor BLWM will drop the blower airflow to 86 of low cooling airflow which is the true on board CF selection as shown in Figure 4 2 High cooling When the R to G and Y Y2 circuit is closed and there is a demand for dehumidification the furnace blower motor BLWM will drop the blower airflow to 86 of high cooling airflow High cooling airflow is based on the A C selection shown in Figure 4 3 Cooling off delay When the call for cooling is satisfied and there is a demand for dehumidification the cooling blower off delay is decreased from 90 seconds to 5 seconds Continuous Blower Mode When the R to G circuit is closed by the thermostat the blower motor BLWM will operate at continuous blower airflow Continuous blower airflow selection is initially based on the CF selection shown in Figure 4 Factory default is shown in Figure 4 Terminal EAC 1 is energized as long as the blower motor BLWM is energized During a call for heat the furnace control CPU will transition the blower motor BLWM to continuous blower airflow minimum heat airflow or the mid range airflow whichever is lowest The blower motor BLWM will remain ON until the m
91. um range limit trips Blower will run for 4 minutes or until open switch remakes whichever is longer open longer than 3 minutes code changes to lockout 7 If open less than 3 minutes status code 4 continues to flash until lower shuts off Flame rollout switch requires manual reset Check for Improper limit switch or no limit gasket Defective switch or connections Improper gas input adjustment Loose blower wheel Stuck high heat solenoid in gas valve BNORMAL FLAME PROVING SIGNAL Flame is proved while gas valve is de energized Inducer will run until fault is cleared heck for Leaky gas valve Stuck open gas valve GNITION PROVING FAULT Control will try three more times before lockout 6 1 occurs If flame signal lost during blower on delay period blower will come on for the selected blower off delay Check for Oxide buildup on flame sensor clean with fine steel wool Proper flame sense microamps 9 microamps D C min 4 0 6 0 nominal Manual valve shut off Control ground continuity Gas valve defective tured OFF Low inlet gas dae Inadequate flame carryover or rough ignition Defective Hot Surface Ignitor Flame sensor must not be grounded Green yellow wire MUST be connected to furnace sheet metal LIMIT CIRCUIT LOCKOUT Lockout occurs if a limit or flame rollout switch is open longer than 3 minutes or 10 successive limit trips occurred during maximum heat Control will auto reset after 3 hours
92. urner assembly to cell panel 6 Remove screws attaching burner assembly to cell panel See Figure 9 NOTE Burner assembly cover manifold gas valve and burner assembly should be removed as one assembly 7 Clean heat exchanger openings with a vacuum and a soft brush See Figure 12 NOTE After cleaning inspect the heat exchangers to ensure they are free of all foreign objects that may restrict flow of combustion products 8 Reverse items 6 through 1 for reassembly 9 Refer to furnace wiring diagram and reconnect wires to flame rollout switch gas valve igniter and flame sensor 10 Turn on gas and electrical supplies to furnace 11 Check furnace operation through 2 complete heat operating cycles Look through sight glass in burner enclosure to check burners Burner flames should be clear blue almost transparent See Figure 13 Burner Flame Burner Manifold A11461 a WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage Never purge a gas line into a combustion chamber Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of leaks to check all connections A fire or explosion may result causing property damage personal injury or loss of life 12 Check for gas leaks 13 Replace control door Secondary Heat Exchangers The condensing side inside of the seco
93. y to blower deck 15 Reconnect blower leads to furnace control Refer to furnace wiring diagram and connect thermostat leads if previously disconnected NOTE Be sure to attach ground wire and reconnect blower harness plugs to blower motor 18 Specifications subject to change without notice Gas Furnace F G 9MAC Blower Assembly MOTOR SHAFT FLAT BLOWER WHEEL HUB SET SCREW TORQUE GROMMET MOTOR ARM COLLAR WASHER SEE DETAIL A A Ze SCREW LOCATION BLO HSG ASSY WHEEL BLOWER CHOKE POWER WHEN REQ D BLOWER Representative drawing only some models may vary A11347 440 04 4201 01 SERVICE AND TECHNICAL SUPPORT MANUAL a WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Blower access door switch opens 115 v power to furnace control No component operation can occur unless switch is closed Exercise caution to avoid electrical shock from exposed electrical components when manually closing this switch for service purposes 16 Downflow or horizontal furnaces with vent pipe through furnace only a Install and connect short piece of vent pipe inside furnace to existing vent b Connect vent connector to vent elbow 17 Turn on electrical supply If outdoor temperature is below 70 F turn off circuit breaker to outdoor unit before running furnace in the cooling cycle Manually close blower access panel door switch Use a piece of tape

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