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Service Manual

Single Stage Multi Position Furnace

TABLE OF CONTENTS

INTRODUCTION

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

UNIT IDENTIFICATION

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

FURNACE THEORY OF OPERATION

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

ELECTRICAL SUPPLY

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

INTERLOCK SWITCH

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

GAS SUPPLY

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

BURNERS

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

L.P. PRESSURE SWITCH

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

HIGH ALTITUDE OPERATION

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

10.

CHECKING TEMPERATURE RISE

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

11.

ROOM THERMOSTATS

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

12.

CONTROL WIRING

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

13.

TWINNING KITS

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

14.

LIMIT SWITCHES

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

15.

PRESSURE SWITCHES

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

16.

VENT/COMBUSTION AIR PIPING

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

17.

STANDARD VENT TERMINATION

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

18.

CONCENTRIC VENT TERMINATION

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

19.

EXHAUST BLOWER

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

20.

CONDENSATE DRAIN TRAP

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

21.

HONEYWELL ST9160B FAN TIMER/FURNACE CONTROL

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

22.

ST9160B TESTING SEQUENCE

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

23.

ST9160B -- UNIQUE CONTROL FUNCTIONS/RESPONSES

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

24.

HONEYWELL SV9541M GAS VALVE/IGNITION SYSTEM

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

25.

HONEYWELL SV9541M SYSTEM OPERATION

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

26.

CHECKING FLAME CURRENT

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

27.

CAPACITORS

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

28.

BLOWER ASSEMBLY

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

29.

BLOWER ROTATION

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

30.

HEAT EXCHANGER REMOVAL/REPLACEMENT

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

SV9541M “SMART VALVE” -- Sequence of Operation

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

SV9541M “SMART VALVE” -- Trouble shooting

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

SV9541M “SMART VALVE” -- Electrical Variation

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

WIRING DIAGRAM

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

TECHNICAL SERVICE DATA (N9MP1 or 2)

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

TECHNICAL SERVICE DATA (*9MPD/A1)

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

TECHNICAL SERVICE DATA (*9MPD/A2)

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

BLOWER PERFORMANCE DATA (N9MP1 or 2 & *9MPD)

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

APPENDIX OF HELPFUL INFORMATION

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Содержание N9MP1

Страница 1: ...INGLE STAGE GAS FURNACES Part Number 440 08 2001 02 N9MP1 N9MP2 9MPD A1 A2 Manufactured by This manual supports condensing gas furnaces manufactured in 2001 2001 International Comfort Products Corpora...

Страница 2: ...N9MP1 Indoor combustion air 1 pipe only N9MP2 Direct Vent ONLY 2 pipe only 9MPD Dual Certified Venting 1 or 2 pipes Denotes Brand T C or H...

Страница 3: ...ER 17 20 CONDENSATE DRAIN TRAP 17 21 HONEYWELL ST9160B FAN TIMER FURNACE CONTROL 18 22 ST9160B TESTING SEQUENCE 19 23 ST9160B UNIQUE CONTROL FUNCTIONS RESPONSES 19 24 HONEYWELL SV9541M GAS VALVE IGNIT...

Страница 4: ...pairs made by the unqualified persons can result in hazards subjecting the unqualified person making such repairs to the risk of injury or electrical shock which can be serious or even fatal not only...

Страница 5: ...ow of flue products through the heat exchanger 2 The serpentine heat exchanger design does not lend itself well to the ribbon type or slotted port type burner found in more traditional design furnaces...

Страница 6: ...HECKING GROUNDING AND POLARITY Grounding may be verified as follows 1 Turn the power supply OFF 2 Using an Ohmmeter check for continuity between the Neutral white wire and Ground wire green of the sup...

Страница 7: ...se conditions MUST be a minimum of 4 5 W C Water Column If the inlet pressure is less it may be an indication of undersized piping or regulator problems L P GAS Inlet Supply pressure to the furnace sh...

Страница 8: ...the gas supplier 7 For ALL UNITS ABOVE 8 000 contact the factory for SPECIFIC de rating information MANIFOLD PRESSURE AND ORIFICE SIZE FOR HIGH ALTITUDE APPLICATIONS Table 2 NATURAL GAS Heat Value Ele...

Страница 9: ...ing under low line pressure conditions can create problems such as in complete combustion flashback sooting etc The switch is a Normally Open pressure operated switch that is wired in series with the...

Страница 10: ...a thermometer in the return air duct within 6 of furnace Place a second ther mometer in the supply duct at lease two 2 ft away from the furnace This will prevent any false readings caused by radi ati...

Страница 11: ...he R termi nal 3 Turn power on and wait approximately 1 minute then read meter 4 Divide meter reading by 10 to obtain correct anticipator setting If an ammeter is not available a setting of 0 30 amps...

Страница 12: ...ed electrical switches de signed to open when their predetermined limit setting has been reached It should also be remembered that when a limit switch opens it more than likely is not due to a bad swi...

Страница 13: ...rrect one is used Typical Roll Out Limit Switch Figure 12 CAUTION NEVER use an automatic reset roll out switch to replace a manual reset type roll out switch Doing so may cause potentially unsafe and...

Страница 14: ...en Part Upflow 1 40 W C 1 18 0 10 W C Downflow 1 40 W C 1 18 0 10 W C CHECK CURRENT TECHNICAL SUPPORT MANUAL FOR PART NOS Under normal operating conditions sufficient negative pres sure will be create...

Страница 15: ...e Combustion Blower may be caused by 1 Restriction on the Inlet side of the combustion blower I E Plugged Heat Exchanger air inlet orifice too small Inlet Pipe not used on Single Pipe models Vent Pipe...

Страница 16: ...000 Btuh Furnaces 40 5 90 elbows with 2 PVC pipe or 70 5 90 elbows with 3 PVC pipe or 100 000 Btuh Furnace 70 5 90 elbows with 3 PVC pipe 125 000 Btuh Furnace 40 5 90 elbows with 3 PVC pipe Elbows are...

Страница 17: ...let Figure 19 Sidewall Inlet Vent and Exhaust Air Termination Dimension A is touching or 2 maximum separation 12 Min Grade or Snow Level 18 Min for Cold Climates Sustained Below 0 F 8 Min 20 Max 8 Min...

Страница 18: ...pipe 100 000 Btuh Furnace NAHA001CV 65 4 90 elbows with 3 PVC pipe 125 000 Btuh Furnace NAHA001CV 35 4 90 elbows with 3 PVC pipe 1 Do not include the field supplied 45 elbow in the total elbow count...

Страница 19: ...d from the furnace and routed to a remote drain or conden sate pump The combustion blower creates a negative pressure in ex cess of 2 W C while operating Without a condensate drain trap of sufficient...

Страница 20: ...23 63 FUSE The Honeywell ST9160B Electronic Fan Timer Furnace Control contains NO USER SERVICEABLE COM PONENTS It is as its name implies a fan timer and a fur nace control of sorts In addition to cont...

Страница 21: ...IGNITION SYSTEM ACTIVATION 4 WHEN MAIN BURNER LIGHTS CHECK HEATING FAN ON DELAY 5 CHECK HEATING SPEED FAN OPERATION 6 REMOVE JUMPER 7 CHECK POST PURGE DELAY 8 CHECK HEATING FAN OFF DELAY 23 ST9160B UN...

Страница 22: ...omposite material It operates on 24 Volts A C The Igniter Flame Rod assembly can be replaced independently from the pilot burner assembly The system operation is quite simple and forgiving I E nui san...

Страница 23: ...SV9541Q Ignition system used in this furnace series proves verifies flame via the Flame Rectification method Flame Rectification is a process of converting Alternating Current A C into Direct Current...

Страница 24: ...l static pressure of 0 2 W C with a dry coil 67 500 or 67 500 50 X 1 08 54 1250 CFM Checking the blower performance data for this model see Figure 36 indicates that 0 2 W C E S P medium high speed wil...

Страница 25: ...rain side of the condensate trap Connect a section of the 5 8 OD hose with a funnel to the drain stub and pour eight 8 ounces of wa ter into the trap Remove the hose and replace the plastic cap and cl...

Страница 26: ...itting Securely attach vent fitting to combustion blower NOTE The vent fitting MUST be installed with the airflow marking arrow pointed toward the vent pipe with the drain stub ata 20 to30 downward sl...

Страница 27: ...ed horizontally on the left side If needed remove the hole plugs from the furnace side panel and relocate to the open set of holes in the opposite side panel Drill two 7 64 diameter holes in the casin...

Страница 28: ...and the 90 elbow to the combustion blower using the rubber coupling and clamps NOTE The vent fitting MUST be installed with the airflow marking arrow pointed toward the vent pipe with the drain stubat...

Страница 29: ...nt stripping out of the plastic mounting holes For right side venting remove vent fitting assembly from combus tion blower Remove 90 elbow and rubber tubing from the vent fit ting by loosening the cla...

Страница 30: ...20 to30 downward slope This configuration allows left side venting from the furnace If right side venting is required the combustion blower must be relocated on the plastic transition box Remove the f...

Страница 31: ...using the condensate trap as the template Relocate the combustion blower on the plastic transition box Re move the four 4 screws that secure the blower to the transition box Rotate the blower 180 so...

Страница 32: ...e 90 elbow is securely attached to the combustion blower using the rubber coupling and clamps NOTE The vent fitting MUST be installed with the airflow marking arrow pointed toward the vent pipe Plug t...

Страница 33: ...enting is required the combustion blower must be relo cated on the plastic transition box Remove the four 4 screws that secure the blower transition box Rotate the blower 180 and secure with the four...

Страница 34: ...ears on the drain stub through the hole in the casing and push the condensate trap into position Secure with the two screws Reconnect the drain hoses to the stubs on the vent fitting and the plastic t...

Страница 35: ...ottom of the plastic transition box and secure with a 3 4 clamp Route the hose to the large drain stub on the condensate pump Cut off excess hose and discard Connect the hose to the drain stub on the...

Страница 36: ...that are provided Note The condensate trap will belocated underthe furnacein aver tical position when the furnace is placed horizontally on the left side If needed remove the hole plugs from the furn...

Страница 37: ...sate trap will be located under the furnace in a vertical position when the furnace is placed horizontally on the right side If needed remove the hole plugs from the furnace side panel and relocated t...

Страница 38: ...wnward 20 to 30 NOTE TRAP MUST BE PRIMED BEFORE OPERATION Preassemble and insert into furnace Trap Connection Clamp ears Pointed OUT AIR FLOW Combustion Blower Mounting Screws 4 Downflow Installations...

Страница 39: ...ubs to the upper stubs and secure tightly with the clamps Route the pressure switch hose to the lower stub on the plastic tran sition box Cut off excess hose and discard Connect the pressure switch ho...

Страница 40: ...to the condensate trap follow the directions outlined below except do not make any clamp connections to any of the drain stubs and hoses until the hose routing and lengths have been determined Remove...

Страница 41: ...ed condensate trap connect the 3 4 OD rubber hose with the 90 bend to the bottom of the plastic transition box and secure with a 3 4 clamp Route the hose to the large drain stub on the condensate pump...

Страница 42: ...bs to the horizontal drain stubs Secure the clamps tightly to prevent condensate leakage Mount the condensate drain trap in a vertical position to the left side of the furnace using the two screws and...

Страница 43: ...furnace using the two screws and gasket that are pro vided Note The condensate trap will be located under the furnace in a vertical position when the furnace is placed horizontally on the right side...

Страница 44: ...ecure with the two screws Reconnect the drain hoses to the stubs on the vent fitting and the plastic transition and secure with the clamps Mount the condensate drain trap in a vertical position to eit...

Страница 45: ...nt fitting and secure with a 5 8 clamp Route the hose to the smaller stub on the condensate trap Cut off excess hose and discard Connect the hose to the drain stub on the trap and secure with a 5 8 cl...

Страница 46: ...Primary Heat Exchanger 1 Turn OFF electrical power and gas supply to furnace 2 Disconnect vent pipe to furnace at flexible coupling 3 Disconnect combustion air inlet pipe at top panel if needed 4 Rem...

Страница 47: ...ize and light Timed from the opening of the main gas valve the control will delay 30 seconds before switching the fan to Heat speed W signal removed from EFT The gas valve de energizes and the main bu...

Страница 48: ...RCULATING BLOWER OFF AFTER DELAY PILOT AND MAIN VALVE CLOSE COMBUSTION AIR BLOWER OFF AFTER POST PURGE FLAME SENSE LOST MORE THAN FIVE TIMES IN THIS CALL FOR HEAT THERMOSTAT CALL FOR HEAT ENDS COMBUST...

Страница 49: ...nt piping 4 Flashes Main Limit or Roll Out Switch is open Combustion blower is energized Circulating blower is energized heat speed Main limit switch Manual reset burner rollout switch Limit and rollo...

Страница 50: ...tion tubing and wiring Restrictions in furnace air intake or vent piping High winds blowing against vent 6 Flashes 4 Flashes Soft Lockout Last failure was limit circuit opened during run Combustion ai...

Страница 51: ...witch is closed This signal is the same as the C1 pin 1 C1 pin 3 Pressure Switch return 1 2 wave rectified AC Present when the door interlock switch is closed This AC voltage decreases when the Low Pr...

Страница 52: ...APS FOR PROPER HEATING COOLING CIRCULATING SPEEDS COLOR CODE 6 3 5 BLACK BK BLUE BL BROWN BR GREEN G ORANGE O RED R WHITE W YELLOW Y PURPLE P 1 SPEED TAP CODE BLACK HI BLUE MLO ORANGE MHI RED LO LINE...

Страница 53: ...ROPER HEATING COOLING CIRCULATING SPEEDS COLOR CODE 6 3 5 BLACK BK BLUE BL BROWN BR GREEN G ORANGE O RED R WHITE W YELLOW Y PURPLE P 1 SPEED TAP CODE BLACK HI BLUE MLO ORANGE MHI RED LO LINE VOLTAGE F...

Страница 54: ...L P 5 54 Combustion Flue Outlet Size Inches Std Outlet Temp F 2 140 2 140 3 140 3 140 3 140 Blower Transition Box Std Pressures of WC 5 No Elbows 40 5 90 DWV Elbows 1 80 2 60 1 30 2 30 1 80 2 60 1 30...

Страница 55: ...6 2 3 2 6 2 3 2 6 2 5 1 8 1 7 2 6 2 5 1 8 1 7 2 6 2 5 1 8 1 7 2 6 2 5 Limits Controls Rollout Switch F Limit Control Setting F 300 240 300 210 300 230 300 230 300 220 300 190 Standard Pressure Sw Par...

Страница 56: ...ize Inches Std Outlet Temp F 2 140 2 140 3 140 3 140 3 140 Blower Transition Box Std Pressures of WC 5 No Elbows 40 5 90 DWV Elbows 1 80 2 60 1 30 2 30 1 80 2 60 1 30 2 30 1 80 2 60 1 70 2 50 1 80 2 6...

Страница 57: ...DWV Elbows WC 2 6 2 3 2 6 2 3 2 6 2 5 1 8 1 7 2 6 2 5 1 8 1 7 2 6 2 5 1 8 1 7 2 6 2 5 Limits Controls Rollout Switch F Limit Control Setting F 300 260 300 240 300 220 300 220 300 220 300 190 Standard...

Страница 58: ...2 677 979 1247 Static es of W 0 7 608 909 1161 rrnal S Inche 0 8 528 827 1058 Exterr I 0 9 733 932 E 1 0 624 778 For 080 Models 4 Ton 19 223 4 Units Speed Tap Low Med L Med H Hi 0 1 823 1109 1527 1850...

Страница 59: ...Blower Data 56 Combustion Air Vent Piping 14 17 Combustion Blower See Exhaust Blower Condensate Drain Trap 17 18 Control Wiring 10 D DIP Switch Settings ST9160 19 Drain Trap Condensate 18 E Electrica...

Страница 60: ...itch DIP ST9140 19 Switch Auxiliary Limit 11 Switch Transition Pressure 12 Switch L P Gas Pressure 7 Switch Main Limit 10 Switch Pressure 12 13 Switch Roll Out Limit 11 Switches Limit 10 T Technical S...

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