ICP 9MAC/E series Скачать руководство пользователя

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Replaces: New

Form: ICP Eng

3-12

Variable Speed, Modulating

Electronic Condensing

Four-Way Multipoise Gas Furnace

*9MAC

(

TROUBLESHOOTING GUIDE

INDEX

PAGE

Safety Considerations.............................................................................. 1

Instructions .............................................................................................. 1

Example ................................................................................................... 2

General..................................................................................................... 2

Sequence of Operation ............................................................................ 2

Communicating Control and Modulating Heating......................... 2

Single-Stage Thermostat and Modulating Heating (Adaptive

Mode)...................................................................................... 3

Two-Stage Thermostat and Two-Stage Minimum/Maximum

Heating.................................................................................... 4

Two-Stage Thermostat and Two-Stage Intermediate/Maximum

Heating.................................................................................... 4

Cooling Mode.................................................................................. 5

Single-Speed Cooling ..................................................................... 5

Two-Stage Thermostat and Two-Speed Cooling............................ 5

Dehumidification Mode.................................................................. 5

Super-Dehumidify Mode ................................................................ 5

Continuous-Blower Mode............................................................... 6

Heat Pump Defrost.......................................................................... 6

Component Test .............................................................................. 6

Service/Status Code Instructions............................................................. 7

Start Here................................................................................................. 9

Amber LED On Solid............................................................................10

Improper Cooling Air Flow...................................................................11

Minimum and/or Maximum Heat Temperature Rise Too Low............13

Secondary Voltage Fuse Open ..............................................................14

Status Code 2 - Pressure Switch Did Not Open....................................16

Status Code 3 - Low Pressure Switch Did Not Close or Reopened .....17

Status Code 4 - Limit Circuit Fault .......................................................19

Status Code 5 - Abnormal Flame-Proving Signal.................................21

Status Code 6 - Ignition-Proving Fault .................................................21

Status Code 7 - Limit Circuit Lockout..................................................23

Status Code 8 - Gas Heating Lockout ...................................................24

Status Code 9 - Medium Pressure Switch, High Pressure Switch, or

PSR Relay did not Close or Reopened .........................................24

Status Code 10 - Polarity.......................................................................27

Status Code 1 + 2 - Blower On After Power Up...................................28

Status Code 1 + 5 - Blower Motor Lockout..........................................28

Status Code 2 + 5 - Model Selection or Setup Error ............................29

Status Code 3 + 5 - Gas Valve Fault.....................................................30

Status Code 4 + 1 - Blower Motor Fault...............................................32

Status Code 4 + 2 - Inducer Motor Fault ..............................................34

Status Code 4 + 3 - Low or Medium Pressure Switch Open While

Medium or High Pressure Switch Is Closed.................................36

Status Code 6 + 1 - Ignition Lockout....................................................37

Cleanup and Start-Up Instructions........................................................37

APPENDIX A - Board Layout & Wiring Schematic ...........................38

APPENDIX B - ECM Blower Motor Description & Operation..........40

APPENDIX C - Pressure Check Diagram............................................42

APPENDIX D - Static Pressure Reading Location Diagrams..............43

APPENDIX E - Quick Reference Information..................................... 45

APPENDIX F - Furnace Staging Algorithm ........................................ 46

SAFETY CONSIDERATIONS

Installing and servicing heating equipment can be hazardous due to

gas and electrical components. Only trained and qualified personnel

should install, repair, or service heating equipment.

Untrained personnel can perform basic maintenance functions such

as cleaning coils, or cleaning and replacing filters. All other

operations should be performed by trained service personnel. When

working on heating equipment, observe precautions in literature, on

tags, and on labels attached to or shipped with the unit, and other

safety precautions that may apply.

Follow all safety codes. In the United States, follow all safety codes

including the National Fuel Gas Code (NFGC) NFPA 54-2006/ANSI

Z223.1-2006. In Canada, refer to the National Standard of Canada

Natural Gas and Propane Installation Codes (NSCNGPIC), CSA

B149.1-05.

Wear safety glasses and work gloves. Have a fire extinguisher

available during start-up, adjustment procedures, and service calls.

Recognize safety information. This is the safety-alert symbol

When you see this symbol on the furnace and in instructions or

manuals, be alert to the potential for personal injury.

Understand the signal words DANGER, WARNING, and

CAUTION, and NOTE. The words DANGER, WARNING, and

CAUTION 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.

INSTRUCTIONS

This guide uses your expertise and observations to lead you to the

trouble spot as efficiently as possible. This is only intended as a

guide and should not be used blindly. Your experience and expertise

are of high value when troubleshooting this unit. Do not disregard

all of your instincts.

The modulating furnace control was designed with diagnostic

capabilities built in. A AMBER LED is used to flash a status code

which will lead you to one of the sections as listed in the Index.

440 08 4001 00

Содержание 9MAC/E series

Страница 1: ...hm 46 SAFETY CONSIDERATIONS Installing and servicing heating equipment can be hazardous due to gas and electrical components Only trained and qualified personnel should install repair or service heati...

Страница 2: ...in wc Thermostat wire connections to the furnace at R and W W1 are the minimum required for gas heating operation W2 must be connected for 2 stage heating thermostats Y Y2 and G are required to be co...

Страница 3: ...ted 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...

Страница 4: ...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 minimum heat only switch...

Страница 5: ...is based on the A C selection shown in Table 1 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 t...

Страница 6: ...us blower airflow When the thermostat calls for high cooling the blower motor BLWM will switch to high cooling airflow When the thermostat is satisfied the blower motor BLWM will operate an additional...

Страница 7: ...Failed or Out of Calibration pressure switches Water in vent piping possible sagging pipe Disconnected or obstructed pressure tubing 4 LIMIT CIRCUIT FAULT Indicates the limit or flame rollout is open...

Страница 8: ...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...

Страница 9: ...status code other than the heartbeat Note Status codes are erased after 72 hours or can be manually erased by putting setup switch SW1 1 in the ON position and jumpering R W W1 and Y Y2 simultaneousl...

Страница 10: ...C terminal to COM 24V Isolate the W W1 input with a relay Install ballast resistor across W W1 and COM 24V Replace the thermostat with a compatible model 18 32 Turn power off Remove secondary voltage...

Страница 11: ...ce the modulating furnace control 7 13 Reconnect the G thermostat lead or jumper and observe operation of furnace in cooling mode for 10 minutes 14 14 Does the furnace operate properly in cooling mode...

Страница 12: ...116 1302 1488 18601 DEF 5T 60 4882 6512 651 814 976 814 6512 814 976 9761 1139 1139 1139 1302 1302 1139 16271 16271 1139 1627 1953 DEF DEF DEF 3 5T 60 80 5T 80 100 BASED ON 325 CFM TON SETUP SWITCH SW...

Страница 13: ...d on furnace rating plate External static pressure in maximum heat should be less then 7 in w c If return temperature is below 60 deg F condensation may form on heat exchangers If left uncorrected fai...

Страница 14: ...energized Note On the modulating furnace control the HUM terminal is energized when the blower turns ON 3 18 18 Disconnect jumper wire across R and W W1 thermostat terminals and wait until blower stop...

Страница 15: ...r stops 49 49 Jumper R G and Y Y2 thermostat terminals 50 50 Does the AMBER LED turn off when G and Y Y2 are energized 3 51 51 Reconnect communication connector PL7 if used or all thermostat leads if...

Страница 16: ...on modulating furnace control 11 12 11 The main harness is miswired 7 12 Is 24 vac across VIOLET wire on the medium pressure switch MPS and COM 24V on modulating furnace control 15 13 13 Is 24 vac acr...

Страница 17: ...Is 24 vac across YELLOW wire on the low pressure switch LPS and COM 24V on modulating furnace control 14 10 10 Is 24 vac across connector terminal PL1 2 and COM 24V on modulating furnace control 11 13...

Страница 18: ...blem still persists and wind conditions are not excessive turn setup switch SW1 3 ON to boost inducer speed On the Communicating Wall Control select MIN INT RISE ADJ 8 45 Check for partially clogged d...

Страница 19: ...power off 15 15 Do you have continuity across limit switch LS 19 16 16 Wait for unit to cool then recheck for continuity across limit switch LS 17 17 Do you have continuity across limit switch LS 19 1...

Страница 20: ...The setpoint is 170 deg F but the switch opens at a temperature below 160 deg F 18 56 56 The problem may be related to poor air distribution or excessive pressure drop across filter Check filter and r...

Страница 21: ...ex for the section covering the status code INDEX 8 Go to page number indicated in Index for CLEANUP AND START UP INSTRUCTIONS INDEX 9 Turn off the power and disconnect the jumper across the R and W W...

Страница 22: ...heat 37 8 40 Turn off the power and disconnect the jumper across the R and W W1 thermostat terminals 41 41 Turn power on and jumper R W W1 and W2 thermostat terminals 42 42 Do the main burners ignite...

Страница 23: ...10 17 Do you have continuity across each flame rollout switch FRS 25 18 18 Can flame rollout switch FRS be reset 20 19 19 Replace flame rollout switch FRS 10 20 Reset flame rollout switch FRS install...

Страница 24: ...PUT OPERATION 40 51 OF MAXIMUM HEAT 40 45 OF MAXIMUM HEAT ON 5T 060 1 STEADY STATE If the medium pressure switch input turns ON the modulating furnace control begins flashing status code 9 and continu...

Страница 25: ...ating furnace control ramps inducer RPM up until the high pressure switch HPS remakes When the high pressure switch HPS remakes the modulating furnace control continues the heating cycle If high press...

Страница 26: ...and disconnect jumper wire across R and W W1 thermostat terminals 38 38 Connect 1 side of slope manometer with a tee to collector box pressure tap Refer to pressure check diagram in Appendix C 39 39 T...

Страница 27: ...akers or manual disconnects to the problem unit correctly set 11 10 10 Fix problem 5 11 Are the Auxiliary Limit switches properly set 12 10 12 Do you have 115 vac across L1 and L2 in the problem unit...

Страница 28: ...iter HSI come on during the cycle 15 24 15 Disconnect the humidifier lead from HUM terminal on modulating furnace control 16 16 Does the furnace still alternately cycle induced draft motor IDM and blo...

Страница 29: ...p switch SW1 6 in the ON position 9 10 9 Put setup switch SW1 6 in the OFF position 5 10 Is this a new service replacement control 19 13 11 You need to remove the model plug PL4 from the old control a...

Страница 30: ...from the furnace control board 2 2 Turn the power on and depress the door switch Use a piece of tape to hold it closed 3 3 Jumper the R and W W1 thermostat terminals 4 4 Observe the operation of the f...

Страница 31: ...30 Does the voltage drop as described in step 29 31 17 31 Put setup switch SW1 6 in the OFF position 32 32 Connect a DC voltmeter across terminals PL8 3 ORANGE and COM 24V then run COMPONENT TEST by t...

Страница 32: ...door switch Use a piece of tape to hold it closed 19 19 Do you have 115 vac across the BLACK blower motor wire connected to L1 and the WHITE blower motor wire connected to L2 21 20 20 Replace the mod...

Страница 33: ...rminals PL13 3 BLUE and PL13 4 GREEN Does the voltage fluctuate as described in step 28 15 32 32 You have an open wire or bad terminal on the BLUE wire between connectors PL3 and PL13 Repair it or rep...

Страница 34: ...ex for the section covering the status code INDEX 8 Go to page number Indicated in Index for CLEANUP AND START UP INSTRUCTIONS INDEX 9 Does the inducer motor turn on 27 10 10 Hook an AC voltmeter acro...

Страница 35: ...ng in direction shown on inducer housing 41 25 41 Turn power off and disconnect jumper from the R and W W1 thermostat terminals 49 42 Connect 1 side of slope manometer with a tee to collector box pres...

Страница 36: ...the furnace until ignition 5 5 Does status code 4 3 flash 9 6 6 Does a different status code flash 7 8 7 Go to page number indicated in the Index for the section covering the status code INDEX 8 Go to...

Страница 37: ...or is not running during lockout refer to status code 6 If the inducer motor is running at full speed during lockout this indicates that flame sense was lost 3 times within 60 minutes of cumulative ga...

Страница 38: ...ECTOR PL3 ECM BLOWER HARNESS CONNECTOR TRANSFORMER 24 VAC CONNECTIONS 3 AMP FUSE STATUS AND COMM LED LIGHTS SW1 SETUP SWITCHES AND BLOWER OFF DELAY MODEL PLUG CONNECTOR AIR CONDITIONING A C AIRFLOW SE...

Страница 39: ...39 Fig 2 Wiring Schematic 440 08 4001 00...

Страница 40: ...ines motor speed Setting up the desired airflow CFM for an ECM blower motor is done by setting the A C or CF selections on the modulating furnace control shown in figure 1 The ECM blower motor then de...

Страница 41: ...41 Figure 3 ECM Blower Motor 440 08 4001 00...

Страница 42: ...c max 0 70 in wc 0 05 0 62 in wc max 0 47 in wc 0 05 60 000 21 casing 1 46 in wc max 1 29 in wc 0 07 1 00 in wc max 0 85 in wc 0 05 0 64 in wc max 0 49 in wc 0 05 80 000 1 58 in wc max 1 40 in wc 0 08...

Страница 43: ...43 APPENDIX D STATIC PRESSURE READING LOCATION DIAGRAMS Figure 5 Upflow Total Static Pressure Reading Locations Figure 6 Downflow Total Static Pressure Reading Locations 440 08 4001 00...

Страница 44: ...20 in w c Coil Static Pressure Drop Wet 0 20 in w c Total ESP 0 60 in w c Both Examples 1 and 2 are correct Example 1 ESP readings were taken as laid out in static pressure reading location diagrams F...

Страница 45: ...amps Hot Surface Igniter Reading The Silicon Nitride igniter in this furnace is not voltage sensitive and will work within the voltage range of 102 to 132 VAC Hence there is no voltage regulation circ...

Страница 46: ...um heat operation EXAMPLE 1 Furnace ran for 45 seconds in intermediate heat 19 minutes in minimum heat MOD 40 and 5 minutes at maximum heat during previous call for heat MOD 40 MODT 19 MAXT 5 Calculat...

Страница 47: ...m Heat if the call for heat still exists The Modulating rate MOD for this cycle will be as determined Thermostat is satisfied Yes Yes Unit will start the next cycle in Maximum Heat and will remain run...

Страница 48: ...48 Replaces New Form ICP Eng 3 12 440 08 4001 00...

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