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SERVICE AND TECHNICAL SUPPORT MANUAL

Gas Furnace: (F/G)9MAC

Specifications  subject to change without notice.

440 04 4201 01

11

Table 3

Orifice Size and Manifold Pressure (in. w.c.) for Gas Input Rate 

 Modulating

S

A

G

L

A

R

U

T

A

N

F

O

Y

T

I

V

A

R

G

C

I

F

I

C

E

P

S

S

A

G

.

G

V

A

HEAT VALUE

0.58

0.60

0.62

0.64

AT ALTITUDE

Orifice Mnfld Press Orifice Mnfld Press Orifice Mnfld Press Orifice Mnfld Press

(Btu/cu ft)

No.

Max/Min

No.

Max/Min

No.

Max/Min

No.

Max/Min

900

43

3.8 /0.60

42

3.2 /0.50

42

3.3 /0.55

42

3.4 /0.55

0

925

43

3.6 /0.55

43

3.7 /0.60

43

3.8 /0.60

42

3.2 /0.50

(0)

950

43

3.4 /0.55

43

3.5 /0.55

43

3.6 /0.60

43

3.7 /0.60

975

44

3.7 /0.60

44

3.8 /0.60

43

3.4 /0.55

43

3.6 /0.55

to

1000

44

3.5 /0.55

44

3.6 /0.60

44

3.8 /0.60

43

3.4 /0.55

1025

44

3.3 /0.55

44

3.5 /0.55

44

3.6 /0.55

44

3.7 /0.60

2000

1050

44

3.2 /0.50

44

3.3 /0.55

44

3.4 /0.55

44

3.5 /0.55

(610)

1075

45

3.7 /0.60

45

3.8 /0.60

44

3.3 /0.50

44

3.4 /0.55

1100

46

3.7 /0.60

46

3.8 /0.60

45

3.8 /0.60

44

3.2 /0.50

U.S.A.

800

42

3.4 /0.55

42

3.5 /0.55

42

3.6 /0.55

42

3.7 /0.60

2001 (611)

825

43

3.8 /0.60

42

3.3 /0.50

42

3.4 /0.55

42

3.5 /0.55

to

850

43

3.6 /0.60

43

3.7 /0.60

42

3.2 /0.50

42

3.3 /0.55

3000 (914)

875

43

3.4 /0.55

43

3.5 /0.55

43

3.7 /0.60

43

3.8 /0.60

900

44

3.7 /0.60

44

3.8 /0.60

43

3.5 /0.55

43

3.6 /0.55

Canada

925

44

3.5 /0.55

44

3.6 /0.60

44

3.8 /0.60

43

3.4 /0.55

2001 (611)

950

44

3.3 /0.55

44

3.4 /0.55

44

3.6 /0.55

44

3.7 /0.60

to

975

44

3.2 /0.50

44

3.3 /0.50

44

3.4 /0.55

44

3.5 /0.55

4500 (1372)

1000

46

3.8 /0.60

45

3.8 /0.60

44

3.2 /0.50

44

3.3 /0.55

775

42

3.3 /0.55

42

3.4 /0.55

42

3.5 /0.55

42

3.6 /0.60

3001

800

43

3.8 /0.60

42

3.2 /0.50

42

3.3 /0.55

42

3.4 /0.55

(915)

825

43

3.6 /0.55

43

3.7 /0.60

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 /0.55

(1220)

800

43

3.5 /0.55

43

3.6 /0.60

43

3.7 /0.60

43

3.8 /0.60

825

44

3.8 /0.60

43

3.4 /0.55

43

3.5 /0.55

43

3.6 /0.60

850

44

3.5 /0.55

44

3.7 /0.60

44

3.8 /0.60

43

3.4 /0.55

5000

875

44

3.3 /0.55

44

3.5 /0.55

44

3.6 /0.55

44

3.7 /0.60

(1524)

900

44

3.2 /0.50

44

3.3 /0.50

44

3.4 /0.55

44

3.5 /0.55

925

46

3.8 /0.60

45

3.7 /0.60

44

3.2 /0.50

44

3.3 /0.55

725

42

3.2 /0.50

42

3.3 /0.55

42

3.4 /0.55

42

3.5 /0.55

5001

750

43

3.7 /0.60

43

3.8 /0.60

42

3.2 /0.50

42

3.3 /0.55

(1525)

775

43

3.4 /0.55

43

3.5 /0.55

43

3.7 /0.60

43

3.8 /0.60

800

44

3.7 /0.60

44

3.8 /0.60

43

3.4 /0.55

43

3.5 /0.55

825

44

3.5 /0.55

44

3.6 /0.55

44

3.7 /0.60

44

3.8 /0.60

6000

850

44

3.3 /0.50

44

3.4 /0.55

44

3.5 /0.55

44

3.6 /0.60

(1829)

875

45

3.7 /0.60

44

3.2 /0.50

44

3.3 /0.55

44

3.4 /0.55

900

46

3.7 /0.60

46

3.8 /0.60

45

3.8 /0.60

44

3.2 /0.50

675

42

3.4 /0.55

42

3.5 /0.55

42

3.6 /0.60

42

3.8 /0.60

6001

700

42

3.2 /0.50

42

3.3 /0.50

42

3.4 /0.55

42

3.5 /0.55

(1830)

725

43

3.6 /0.60

43

3.7 /0.60

43

3.8 /0.60

42

3.3 /0.50

750

43

3.4 /0.55

43

3.5 /0.55

43

3.6 /0.55

43

3.7 /0.60

775

44

3.6 /0.60

44

3.7 /0.60

43

3.4 /0.55

43

3.5 /0.55

7000

800

44

3.4 /0.55

44

3.5 /0.55

44

3.6 /0.60

44

3.7 /0.60

(2133)

825

44

3.2 /0.50

44

3.3 /0.55

44

3.4 /0.55

44

3.5 /0.55

850

46

3.8 /0.60

45

3.8 /0.60

44

3.2 /0.50

44

3.3 /0.55

(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

RANGE

ft (m)

U.

S

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a

n

d

C

a

n

a

d

a

U

.S

.A

.

an

d

C

an

ad

a

U.

S

.A.

On

ly

to

U.

S

.A.

On

ly

to

U.

S

.A.

On

ly

to

U.

S

.A.

On

ly

to

MODULATING FURNACE

A11251A

Summary of Contents for (F/G)9MAC0601714A

Page 1: ...nal 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 4 SELECT SETUP SWITCH POSITIONS 4 PRIME CONDENSATE T...

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: ...nsate 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 High Heat Low Heat Temperature of Supply Air High Heat ...

Page 4: ...ng 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 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 se...

Page 5: ...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 ...

Page 6: ... second point is Minimum 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...

Page 7: ...SWITCHES SOFTWARE VERSION PART NUMBER AND DATE CODE WWYY PL8 MODULATING GAS VALVE CONNECTOR L11F061 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 temperature rise specified on the furnace rating plate Determine air temperature rise as follows 1 Place thermometers in return and s...

Page 8: ... 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 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 WARNING FURNACE OVERHEATI...

Page 9: ... 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 Intermendiate Heat Only Adaptive Heat Mode when both SW1 2 and SW4 2 are OFF OFF When SW1 2 is OFF allows Modulating operation from a single stage thermostat Turn ON when using two ...

Page 10: ...imit 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 pe...

Page 11: ...50 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 55 1220 800 43 3 5 0 55 4...

Page 12: ... 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 60 43 3 4 0 55 43 3 5 0 55 ...

Page 13: ...075 1065 1050 1045 1035 1025 1005 OFF OFF ON 520 505 505 495 490 OFF ON OFF 665 685 680 660 665 OFF ON ON 885 895 905 900 900 895 885 875 860 845 ON OFF OFF 1055 1065 1080 1075 1065 1050 1045 1035 1025 1005 ON OFF ON 1245 1245 1255 1255 1260 1255 1250 1235 1220 1185 ON ON OFF 1245 1245 1255 1255 1260 1255 1250 1235 1220 1185 ON ON ON 1245 1245 1255 1255 1260 1255 1250 1235 1220 1185 Maximum Clg Ai...

Page 14: ... 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 suff...

Page 15: ...ientation to 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...

Page 16: ... 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 Turn Setup Switch S...

Page 17: ... 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 18: ...oned 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 ...

Page 19: ...otating 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 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 f...

Page 20: ... 2 5 mm 75 mm 3 8 in 3 16 in 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 Refer to Figure 9 Figure 10 and Figure 11 1 Turn off gas and electric...

Page 21: ... 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...

Page 22: ...rviced 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 in an unconditioned space where the ambient temperatures may be 32_ F 0_ C or lower fr...

Page 23: ...SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace F G 9MAC Specifications subject to change without notice 440 04 4201 01 23 Figure 14 Service Label 338316 2 Rev E ...

Page 24: ...SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace F G 9MAC Specifications subject to change without notice 24 440 04 4201 01 Figure 15 Wiring Diagram 338316 2 Rev E ...

Page 25: ...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 setup...

Page 26: ...ay on repeat check 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 ig...

Page 27: ...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 the vo...

Page 28: ...aximum 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 modulati...

Page 29: ...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 30: ... 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 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 w...

Page 31: ...r 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 furnace control begins a normal inducer post purge period while changing the blo...

Page 32: ...e 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 poisoning ex...

Page 33: ...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 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...

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