ICP G9MAE0601714A Service And Technical Support Manual Download

Page: 1 / 39

Printed in U.S.A.

440 04 4700 00

Aug. 2012

SERVICE AND TECHNICAL

SUPPORT MANUAL

Modulating, Variable Speed Blower Motor

35” Tall, High Efficiency Condensing Gas Furnace

(F/G)9MAE

Save this manual for future reference.

Safety Labeling and Signal Words

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

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

result in enhanced installation, reliability, or

operation.

WARNING

Signal Words in Manuals

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.

The signal word

WARNING

is used throughout

this manual in the following manner:

Safety

−

alert symbol

When you see this symbol on the unit and in

instructions or manuals, be alert to the

potential for personal injury.

TABLE OF CONTENTS

START

−

UP, ADJUSTMENT, AND SAFETY CHECK

. . . . . . . . . . .

SELECT SETUP SWITCH POSITIONS

. . . . . . . . . . . . . . . . . . . . .

PRIME CONDENSATE TRAP WITH WATER

. . . . . . . . . . . . . . . . .

PURGE GAS LINES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTMENTS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUST TEMPERATURE RISE

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUST BLOWER OFF DELAY (HEAT MODE)

. . . . . . . . . . . . . .

ADJUST COOLING AIRFLOW

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUST CONTINUOUS FAN AIRFLOW

. . . . . . . . . . . . . . . . . . . .

ADJUST THERMOSTAT HEAT ANTICIPATOR

. . . . . . . . . . . . . . .

CHECK SAFETY CONTROLS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKLIST

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING AND HEATING AIR DELIVERY - CFM

. . . . . . . . . . . . .

SERVICE AND MAINTENANCE PROCEDURES

. . . . . . . . . . . . .

ELECTRICAL CONTROLS AND WIRING

. . . . . . . . . . . . . . . . . . .

CLEANING AND/OR REPLACING AIR FILTER

. . . . . . . . . . . . . .

CLEANING BURNERS AND FLAME SENSOR

. . . . . . . . . . . . . . .

SERVICING HOT SURFACE IGNITER

. . . . . . . . . . . . . . . . . . . . . .

FLUSHING COLLECTOR BOX AND DRAINAGE SYSTEM

. . . .

CLEANING CONDENSATE DRAIN AND TRAP

. . . . . . . . . . . . . .

WINTERIZATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE LABEL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING CHART

−

FLOW CHART

. . . . . . . . . . . . .

TROUBLESHOOTING GUIDE

−

FLOW CHART

. . . . . . . . . . . . . .

SEQUENCE OF OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PARTS REPLACEMENT INFORMATION GUIDE

. . . . . . . . . . . . .

PRODUCT NOMENCLATURE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MODELS

(F/G)9MAE0601714A

(F/G)9MAE0602120A

(F/G)9MAE0801714A

(F/G)9MAE0802120A

(F/G)9MAE1002122A

(F/G)9MAE1202422A

Use of the AHRI Certified TM Mark indicates a

manufacturer’s participation in the program.

For verification of certification for individual

products, go to www.ahridirectory.org .

Summary of Contents for G9MAE0601714A

Page 1: ...rs and or pictures or product labels The signal word WARNING is used throughout this manual in the following manner Safety alert symbol When you see this symbol on the unit and in instructions or manuals be alert to the potential for personal injury TABLE OF CONTENTS START UP ADJUSTMENT AND SAFETY CHECK 4 SELECT SETUP SWITCH POSITIONS 4 PRIME CONDENSATE TRAP WITH WATER 4 PURGE GAS LINES 5 ADJUSTME...

Page 2: ...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 WARNING PERSONAL INJURY AND OR PROPERTY DAMAGE HAZARD Failure to carefully read and follow this w...

Page 3: ...ensate Drain Connected Condensate Drain Trapped Manual Gas Shut off Upstream of Furnace Drip Leg Gas Valve turned ON Type of Gas Natural Propane Filter Type and Size Shade in Final Furnace Settings Below Calculated Input BTU Rate See Checks and Adjustments Section Heating Check Measured Line Pressure During High Heat Measured Manifold Pressure Max Heat Min Heat Temperature of Supply Air Max Heat M...

Page 4: ...s 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 required cooling airflow or high stage cooling airflow when a two stage outdoor unit is used Refer to Figure 4 and the Ad...

Page 5: ...o 2000 ft 610 M NOTICE The NATURAL GAS manifold pressure adjustments in Table 4 and Table 5 compensate for BOTH altitude AND gas heating value DO NOT apply an additional de rate factor to the pressures shown in Table 4 or Table 5 The values in these Tables are NOT referenced to sea level they are AS MEASURED AT ALTITUDE The heating content of natural gas at altitude may already provide for a reduc...

Page 6: ...de 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 Check Inlet Gas Pressure 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 1...

Page 7: ...revent gas leak WARNING 9 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 Clocking the Meter Verify natural gas input rate by clocking meter NOTE Contact your HVAC distributor or gas supplier for metric gas meter Tables if requ...

Page 8: ...range for improved comfort 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 ...

Page 9: ...lve to prevent gas leak WARNING FURNACE OVERHEATING HAZARD 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 CAUTION 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 ...

Page 10: ...eshooting assistance when R thermostat lead is disconnected Turn OFF when Self Test is completed Bl Off D l i dj bl d SW1 7 SW1 8 Blower OFF delay ON or OFF Blower Off Delay time adjustable 90 seconds to 180 seconds See table in Adjustments section or refer to unit wiring diagram SW4 2 Intermediate Heat Only Adaptive Heat Mode when both SW1 2 and SW4 2 are OFF OFF Allows additional CFM per ton sel...

Page 11: ...CH POSITIONS 1600 2000 2100 2000 1000 800 1000 1200 1400 1600 2000 800 800 1000 1200 1400 2000 800 800 1000 1200 1400 1600 2000 2000 2000 800 800 1000 1200 1400 1600 2000 2000 1400 1400 1400 600 600 800 1000 1200 1400 600 600 800 1000 1200 1400 1400 1400 1750 2100 NOMINAL AIRFLOW BASED ON 400 CFM TON SW1 5 ON SW4 3 OFF Model Size SW2 Clg Default SW3 CF Default COOLING SW2 AND CONTINUOUS FAN SW3 AI...

Page 12: ...ormal circulation d Burners will re light when furnace cools down 2 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 NO...

Page 13: ... 43 3 8 0 60 42 3 2 0 50 850 44 3 8 0 60 43 3 5 0 55 43 3 6 0 55 43 3 7 0 60 875 44 3 6 0 60 44 3 7 0 60 43 3 4 0 55 43 3 5 0 55 4000 900 44 3 4 0 55 44 3 5 0 55 44 3 7 0 60 44 3 8 0 60 1219 925 44 3 2 0 50 44 3 4 0 55 44 3 5 0 55 44 3 6 0 55 950 45 3 7 0 60 44 3 2 0 50 44 3 3 0 55 44 3 4 0 55 750 42 3 3 0 50 42 3 4 0 55 42 3 5 0 55 42 3 6 0 55 4001 775 43 3 7 0 60 43 3 8 0 60 42 3 3 0 50 42 3 4 0...

Page 14: ...0 750 44 3 5 0 55 44 3 7 0 60 44 3 8 0 60 43 3 4 0 55 8000 775 44 3 3 0 55 44 3 4 0 55 44 3 5 0 55 44 3 7 0 60 2438 800 45 3 8 0 60 44 3 2 0 50 44 3 3 0 55 44 3 4 0 55 825 46 3 7 0 60 46 3 8 0 60 45 3 8 0 60 44 3 2 0 50 625 42 3 4 0 55 42 3 5 0 55 42 3 6 0 55 42 3 7 0 60 8001 650 43 3 8 0 60 42 3 2 0 50 42 3 3 0 55 42 3 4 0 55 2439 675 43 3 5 0 55 43 3 6 0 60 43 3 7 0 60 42 3 2 0 50 700 44 3 7 0 6...

Page 15: ... 3 2 0 50 42 3 3 0 50 850 43 3 4 0 55 43 3 5 0 55 43 3 6 0 55 43 3 8 0 60 875 44 3 7 0 60 44 3 8 0 60 43 3 4 0 55 43 3 6 0 55 4000 900 44 3 5 0 55 44 3 6 0 55 44 3 7 0 60 43 3 4 0 55 1219 925 44 3 3 0 50 44 3 4 0 55 44 3 5 0 55 44 3 6 0 55 950 45 3 8 0 60 44 3 2 0 50 44 3 4 0 55 44 3 5 0 55 750 42 3 3 0 50 42 3 4 0 55 42 3 6 0 55 42 3 7 0 55 4001 775 43 3 8 0 60 42 3 2 0 50 42 3 3 0 50 42 3 4 0 55...

Page 16: ...50 44 3 6 0 55 44 3 7 0 60 43 3 4 0 55 43 3 5 0 55 8000 775 44 3 4 0 55 44 3 5 0 55 44 3 6 0 55 44 3 7 0 60 2438 800 44 3 2 0 50 44 3 3 0 50 44 3 4 0 55 44 3 5 0 55 825 46 3 8 0 60 45 3 7 0 60 44 3 2 0 50 44 3 3 0 50 625 42 3 4 0 55 42 3 5 0 55 42 3 7 0 55 42 3 8 0 60 8001 650 42 3 2 0 50 42 3 3 0 50 42 3 4 0 55 42 3 5 0 55 2439 675 43 3 6 0 55 43 3 7 0 60 43 3 8 0 60 42 3 2 0 50 700 44 3 8 0 60 4...

Page 17: ...370 1335 1300 1260 1225 1190 1155 Heating SW1 Maximum Heat Airflow 3 1075 1085 1095 1095 1090 1080 1065 1050 1035 1020 Intermediate Heat Airflow 3 535 515 505 515 495 See note 4 Minimum Heat Airflow 3 420 410 415 400 380 See note 4 Unit Size Clg CF Switch Settings External Static Pressure ESP SWx 3 SWx 2 SWx 1 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 0 060 20 Clg Default OFF OFF OFF 1735 1735 1725 17...

Page 18: ...eating SW1 Maximum Heat Airflow 3 1520 1485 1450 1415 1375 1335 1300 1265 1225 1190 Intermediate Heat Airflow 3 755 745 755 755 765 See note 4 Minimum Heat Airflow 3 620 625 630 620 610 See note 4 Unit Size Clg CF Switch Settings External Static Pressure ESP SWx 3 SWx 2 SWx 1 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 0 080 20 Clg Default OFF OFF OFF 1745 1755 1755 1760 1755 1750 1745 1725 1705 1685 CF...

Page 19: ... 745 740 705 680 See note 4 OFF ON OFF 930 925 915 900 885 See note 4 OFF ON ON 1095 1100 1110 1105 1085 See note 4 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 Clg SW2 Maximum Clg Airflow 2 2200 2200 2200...

Page 20: ...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 8...

Page 21: ...o component location accordingly Figure 6 Multipoise Orientations A93041 Electrical Controls and Wiring 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 ta...

Page 22: ... Status Code or 8th Code will be a heartbeat 6 Turn SW1 1 OFF 7 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 ...

Page 23: ... 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 The air filter arrangement will vary depending on th...

Page 24: ...per 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 f...

Page 25: ...ging the mounting to the burner assembly Refer to Figure 9 1 Disconnect power at external disconnect fuse or circuit breaker 2 Turn off gas at external shut off or gas meter 3 Remove outer doors and set aside 4 Turn electric switch on gas valve to OFF 5 Disconnect the gas pipe from gas valve and remove pipe from the furnace casing 6 Disconnect the connector harness from gas valve 7 Disconnect Hot ...

Page 26: ...iew L12F041 2ïin 2 5 mm 3 8ïin 3 16ïin 0 8 ï1 5 mm 50 mm 9 6 mm 4 6 mm 1 10ïin 1 32 ï 1 16ïin 16 Turn power on at external disconnect fuse or circuit breaker 17 Run the furnace through two complete heating cycles to check for proper operation 18 Install outer door when complete Servicing Hot Surface Igniter The igniter does NOT require annual inspection Check igniter resistance before removal Refe...

Page 27: ... 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 ad...

Page 28: ...Heat Exchangers The condensing side inside of the secondary 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 Winterization UNIT AND PROPERTY DAMAGE HAZARD Failure to follow this caution may result in unit component or property damage If the furnace is installed...

Page 29: ...SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace F G 9MAE Specifications subject to change without notice 440 04 4700 00 29 Figure 14 Service Label 338316 2 Rev I ...

Page 30: ...SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace F G 9MAE Specifications subject to change without notice 30 440 04 4700 00 Figure 15 Wiring Diagram 338316 2 Rev I ...

Page 31: ...When done put setup switch SW1 1 in the OFF position Was there a previous status code other than the heartbeat Go to section below for the status code that was flashed Does the control respond to W W1 W2 Y1 Y Y2 and G 24V thermostat signals Run system through a minimum heat maximum heat or cooling cycle to check operation Status codes are erased after 72 hours or can be manually erased by putting ...

Page 32: ...heck in maximum heat If burners will still not stay on replace control If burners operate in maximum heat then switch to intermediate heat check manifold pressure If OK check burner carryover and flame sensor location Clean flame sensor with fine steel wool and recheck current Nominal current is 4 0 to 6 0 microamps Is current near typical value Replace electrode Will main burners ignite and stay ...

Page 33: ...nd If you have a digital voltmeter with a bar graph it will show a large change in magnitude on the bar graph several times a second If you have a standard digital voltmeter it will show a brief fluctuation in voltage and the magnitude may vary depending on the voltmeter used Does the voltage fluctuate as described in the previous step Connect a DC voltmeter across PL3 4 BLUE and PL3 2 GREEN Does ...

Page 34: ...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 modulat...

Page 35: ...igh pressure switch HPS should close Switching from Medium Range Input to Maximum Heat If the furnace control CPU switches 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 from a medium range...

Page 36: ...starts the furnace blower motor BLWM at low cooling airflow which is the true on board CF selection as shown in Figure 4 Table 3 and Table 6 The R to Y1 and Y2 circuits start the outdoor unit on high cooling speed 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 Table 3 and Table 6 The ...

Page 37: ...nergized 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 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 furna...

Page 38: ...Module when used Inducer motor capacitor when used Collector box Condensate trap Condensate trap elbow Gaskets 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 poisoni...

Page 39: ...le 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 060 60 000 BTU hr 080 80 000 BTU hr 100 100 000 BTU hr 120 120 000 BTU hr INPUT HEAT 14 14 3 16 17 17 1 2 21 21 24 24 1 2 CABINET WIDTH 10 1000 CFM max 14 1400 CFM max 16 1600 CFM max 20 2000 CFM max 22 2...

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