AHRI 9MVE0401410A2, 9MVE0401712A2, 9MVE0601412A2, 9MVE0601714A2, 9MVE0801716A2 Technical

...

Download

SERVICE AND TECHNICAL

SUPPORT MANUAL

Two−Stage, Variable Speed ECM Blower Motor

35” Tall, High Efficiency Condensing Gas Furnace

(F/G)9MVE ’A2’ Series

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 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 result in enhanced installation, reliability, or operation.

Signal Words in Manuals

The signal word WARNING is used throughout this manual in the following manner:

WARNING

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.

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...........

SETUP SWITCHES 4......................................

PRIME CONDENSATE TRAP WITH WATER 4.................

PURGE GAS LINES 5......................................

ADJUSTMENTS 5.........................................

ADJUST TEMPERATURE RISE 11............................

ADJUST BLOWER OFF DELAY (HEAT MODE) 12..............

ADJUST COOLING AIRFLOW 12.............................

ADJUST CONTINUOUS FAN AIRFLOW 12....................

ADJUST THERMOSTAT HEAT ANTICIPATOR 14...............

CHECK SAFETY CONTROLS 14.............................

CHECKLIST 14.............................................

COOLING AND HEATING AIR DELIVERY - CFM 15.............

SERVICE AND MAINTENANCE PROCEDURES 17.............

ELECTRICAL CONTROLS AND WIRING 17...................

CLEANING AND/OR REPLACING AIR FILTER 19..............

BLOWER MOTOR AND WHEEL MAINTENANCE 20............

CLEANING BURNERS AND FLAME SENSOR 21...............

SERVICING HOT SURFACE IGNITER 22......................

FLUSHING COLLECTOR BOX AND DRAINAGE SYSTEM 23....

CLEANING CONDENSATE DRAIN AND TRAP 23..............

CLEANING HEAT EXCHANGERS 23..........................

SERVICE LABEL 26.........................................

WIRING DIAGRAM 27.......................................

TROUBLESHOOTING GUIDE − FLOW CHART 28..............

SEQUENCE OF OPERATION 30.............................

PARTS REPLACEMENT INFORMATION GUIDE 35.............

PRODUCT NOMENCLATURE 36.............................

MODELS

(F/G)9MVE0401410A2 (F/G)9MVE0401712A2 (F/G)9MVE0601412A2 (F/G)9MVE0601714A2 (F/G)9MVE0801716A2 (F/G)9MVE0802120A2 (F/G)9MVE1002120A2 (F/G)9MVE1202422A2

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 .

Printed in U.S.A. 440 04 4801 00 7/3/2014

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 the 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

. 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.

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 Z223.1, and National standards of Canada CAN/CSA−B149.1 and .2 Natural Gas and Propane Installation Codes.

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.

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.

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.

Specifications are subject to change without notice.

440 04 4801 00

SERVICE AND TECHNICAL MANUAL Gas Furnace: (F/G)9MVE

START−UP CHECK SHEET

For Variable Speed Models (F/G)9MVE

(This sheet is optional. Keep for future reference.)

Date of Start−Up:

Dealer Name:

Address:

City, State(Province), Zip or Postal Code:

Phone:

Owner Name:

Address:

City, State(Province), Zip or Postal Code:

Model Number:

Serial Number:

Setup Checks

Check the box when task is complete.

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

Low Heat

Temperature of Return Air:

Temperature Rise (Supply − Return): High Heat

Low Heat

In Rise Range (see furnace rating plate)?

Static Pressure (Ducts) High Heat: Supply

Return

All Electrical Connections Tight?

Have hoses been relocated for furnace U/D/H application?

Condensate 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:

O N

Optional Check: CO?

CO2?

Cooling Check

Temperature of Supply Air:

Temperature of Return Air:

Temperature Difference:

Static Pressure (Ducts) Cooling: Supply

Return

Dealer Comments:

O N

440 01 4801 00 3

Specifications subject to change without notice.

SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE

START−UP, ADJUSTMENT, AND SAFETY CHECK

NOTICE

IMPORTANT INSTALLATION AND START−UP PROCEDURES

Failure to follow this procedure may result in a nuisance smoke or odor complaint.

The manifold pressure, gas rate by meter clocking, temperature rise and operation must be checked after installation. Minor smoke and odor may be present temporarily after start−up from the manufacturing process. Some occupants are more sensitive to this minor smoke and odor. It is recommended that doors and windows be open during the first heat cycle.

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 does not operate if polarity is incorrect or if the furnace is not grounded.

2. Thermostat wire connections at terminals R, W/W1, G, and Y/Y2 must be made at 24-v terminal block on furnace control.

3. Natural gas service pressure must not exceed 0.5 psig (14- in. w.c., 350 Pa), but must be no less than 0.16 psig (4.5-in. w.c., 1125 Pa).

4. Blower door must be in place to complete 115-v electrical circuit and supply power to furnace components.

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 if 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.

Setup Switches

There are four 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 locations are shown and described on Figure 4, Figure 5 and Table 5. The setup 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:

1. Remove blower door.

2. Locate setup switches on furnace control.

3. Configure the set-up switches as necessary for the application.

4. Replace blower door.

NOTE: If a bypass humidifier is used, setup switch SW1-3 (Low Heat Rise Adjust) should be in ON position. This compensates for the increased temperature in return air resulting from bypass.

Setup Switch (SW2)

Setup switches SW2 are used for applications used for Twinning two furnaces of the same model and BTU’s and to adjust airflow. SW2−2 is used to adjust airflow. Refer to the Adjustments section for set up switch configurations. Refer to Figure 5 for configuration of SW2 airflow options.

1. Remove blower door.

2. Locate setup switch SW2 on furnace control.

3. Configure the switches as necessary for the application.

4. Replace blower door.

Continuous Fan (CF) Setup Switches (SW2−5, SW2−4, SW2−3)

The CF setup switches are used to select desired airflow when thermostat is in continuous fan mode or to select low-cooling airflow for two-speed cooling units. Refer to the Adjustments section for set up switch configurations.

To set the desired cooling airflow:

1. Remove blower door.

2. Locate CF setup switches on furnace control.

3. Determine air conditioning tonnage used for low cooling (when used) or desired continuous fan airflow.

4. Configure the switches for the required airflow.

5. Replace blower door.

Air Conditioning (A/C) Setup Switches (SW2−6, SW2−7, SW2−8)

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 the Adjustments section for set up switch configurations.

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.

5. Replace blower door.

NOTE: Incorrect airflow caused by improper A/C switch setup may cause condensate blow-off or frozen indoor coil in the cooling mode.

4 440 04 4801 00

Specifications subject to change without notice.

SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE

Prime Condensate Trap with Water

! WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow these warnings could result in personal injury or death.

Failure to use a properly configured trap or NOT water-priming trap before operating furnace may allow positive pressure vent gases to enter the structure through drain tube. Vent gases contain carbon monoxide which is tasteless and odorless.

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 collector box drain plugs

opposite of the condensate trap. (See Figure 1)

2. Connect field-supplied 5/8-in. (16 mm) ID tube with

attached funnel (see Figure 1) to upper collector box drain connection.

3. Pour one quart (liter) of water into funnel/tube. Water should run through collector box, overfill condensate trap, and flow into open field drain.

4. Remove funnel; replace collector box drain plug.

5. Connect field-supplied 5/8-in. (16 mm) ID tube to middle collector box drain port.

6. Pour one quart (liter) of water into funnel/tube. Water should run through collector box, overfill condensate trap, and flow into open field drain.

7. Remove funnel and tube from collector box and replace collector box drain plug.

Figure 1 Priming Condensate Drain

Purge Gas Lines

If not previously done, purge the lines after all connections have been made and check for leaks.

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.

WARNING

Adjustments

FIRE HAZARD

Failure to follow this 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.

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)

Figure 2 Orifice Hole

WARNING

CAUTION

BURNER

ORIFICE

For proper operation and long term reliability the furnace input

Representative drawing only, some models may vary in appearance.

L11F065

440 04 4801 00 5

Specifications subject to change without notice.

rate must be within +/− 2 percent of input rate on furnace rating plate, or as adjusted for altitude.

A93059

SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE

The gas input rate on rating plate is for installation at altitudes up to 2000 ft. (610 M).

NOTICE

The NATURAL GAS manifold pressure adjustments in Table 3 compensate for BOTH altitude AND gas heating value. DO NOT apply an additional de−rate factor to the pressures shown in Table 3. The heating content of natural gas at altitude may already provide for a reduction in capacity or altitude. Refer to Table 3. No adjustments to the furnace may be necessary at altitude for certain gas heating values. Refer to the instructions provided in the factory-specified Propane conversion kit for instructions for setting gas manifold pressures for Propane applications.

In the USA, the input rating for altitudes above 2000 ft. (610 M) must be reduced by 2 percent for each 1000 ft. (305 M) above sea level refer to Table 1. The natural gas manifold pressures in Table 3 adjust for BOTH altitude and natural gas heating value.

In Canada, the input rating must be reduced by 5 percent for altitudes of 2000 ft. (610 M) to 4500 ft. (1372 M) above sea level. The natural gas manifold pressures in Table 3 adjust for BOTH altitude and natural gas heating value.

Table 1 Altitude Derate Multiplier for U.S.A.

ALTITUDE

FT. (M)

0–2000 (0−610)

2001–3000

(610−914)

3001–4000

(914−1219)

4001–5000

(1219−1524)

5001–6000

(1524−1829)

6001–7000

(1829−2134)

7001–8000

(2134−2438)

8001–9000

(2438−2743)

9001–10,000

(2743−3048)

* 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) in Table 3.

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.

Tables have been provided in the furnace Service and Technical Manual to match the required orifice to the manifold pressure to the heat content and specific gravity of the gas. to do this:

1. Obtain average yearly gas heat value (at installed altitude) from local gas supplier.

2. Obtain average yearly gas specific gravity from local gas supplier.

3. Find installation altitude in Table 3.

4. Find closest natural gas heat value and specific gravity in Table 3. Follow heat value and specific gravity lines to point of intersection to find orifice size and low−and

6 440 04 4801 00

PERCENT

OF DERATE

0 1.00

4−6 0.95

6−8 0.93

8−10 0.91

10−12 0.89

12−14 0.87

14−16 0.85

16−18 0.83

18−20 0.81

DERATE MULTIPLIER

FACTOR*

Specifications subject to change without notice.

high−heat manifold pressure settings for proper operation.

5. Check and verify burner orifice size in furnace. NEVER ASSUME ORIFICE SIZE. ALWAYS CHECK AND VERIFY.

NOTICE

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.

6. Replace orifice with correct size, if required by Table 3. Use only factory−supplied orifices. See EXAMPLE.

EXAMPLE 1:

0 - 2000 ft. (0 - 609.6M) altitude Heating value = 1050 Btu/cu ft. Specific gravity = 0.62

Therefore: Orifice No. 44 (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.) Manifold pressure: 3.4-in. w.c. (847 Pa) for high heat, 1.4-in. w.c. (349 Pa) for low heat

NOTE: To convert gas manifold Table pressures to Pascals, multiply the in.w.c. value by 249.1 Pa/in. w.c. (1 in. wc. = 249.1 Pa).

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. (1121 Pa).

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 in. NPT plug from the inlet pressure tap on the gas valve.

3. Connect a manometer to the inlet pressure tap on gas valve.

4. Turn on furnace power supply.

5. Turn gas supply manual shutoff valve to ON position.

6. Turn furnace gas valve switch to ON position.

7. Jumper the R to W/W1 and W2 thermostat connections at the furnace control board.

8. When main burners ignite, confirm inlet gas pressure is between 4.5 in. w.c. (1125 Pa) and 13.6 in. w.c.(3388 Pa).

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.

FIRE HAZARD

Failure to follow this warning could result in personal injury, death, and/or property damage.

Re−install manifold pressure tap plug in gas valve to prevent gas leak.

14. Apply pipe dope sparingly to end of inlet gas pipe plug and re−install in the gas valve.

WARNING

SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE

Adjust Manifold Pressure

1. Adjust manifold pressure to obtain low fire input rate.

(See Figure 3) a. Turn gas valve ON/OFF switch to OFF. b. Remove manifold pressure tap plug from gas valve. c. Connect a water column manometer or similar device

to manifold pressure tap. d. Turn gas valve ON/OFF switch to ON. e. Move setup SW1—2 on furnace control to ON

position to lock furnace in low−heat operation. (See

Figure 4 and Figure 5)

f. Manually close blower door switch.

g. Jumper R and W/W1 thermostat connections on

control to start furnace. (See Figure 4) h. Remove regulator adjustment cap from low heat gas

valve pressure regulator (See Figure 3) and turn

low−heat adjusting screw (3/16 or smaller flat−tipped

screwdriver) counterclockwise (out) to decrease input

rate or clockwise (in) to increase input rate.

NOTICE

DO NOT set low−heat manifold pressure less than 1.3−in. w.c. (324 Pa) or more than 1.7−in. w.c. (423 Pa) for natural gas. If manifold pressure is outside this range, change main burner orifices.

i. Install low−heat regulator adjustment cap. j. Re−install manifold pressure tap plug from gas valve.

k. Move setup switch SW1−2 to OFF position after

completing low−heat adjustment.

l. Leave manometer or similar device connected and

proceed to Step 2.

2. Adjust manifold pressure to obtain high fire input rate.

(See Figure 3) a. Jumper R to W/W1 and W2 thermostat connections

on furnace control. This keeps furnace locked in

high−heat operation. b. Remove regulator adjustment cap from high−heat

gas valve pressure regulator (See Figure 3) and turn

high heat adjusting screw (3/16−in. or smaller

flat−tipped screwdriver) counterclockwise (out) to

decrease input rate or clockwise (in) to increase input

rate.

Figure 3

1/2” NPT Inlet

1/8” NPT Inlet Pressure Tap

Redundant Automatic Gas Control Valve (2−Stage)

ON/OFF Switch

Regulator Seal Cap

Regulator Adjustment Regulator Seal Cap under Cap

1/8” NPT Manifold Pressure Tap

1/2” NPT Outlet

A11152

NOTICE

DO NOT set high−heat manifold pressure less than 3.2−in. w.c. (797 Pa) or more than 3.8 in. w.c. (947 Pa) for natural gas. If required manifold pressure is outside this range, change main burner orifices to obtain manifold pressure in this range.

c. When correct input is obtained, replace caps that

conceal gas valve regulator adjustment screws. Main burner flame should be clear blue, almost transparent. (See Figure 14)

d. Re−install manifold pressure tap plug to gas valve. e. Remove jumpers R to W/W1 and R to W2.

FIRE HAZARD

Failure to follow this warning could result in personal injury, death, and/or property damage.

Re−install manifold pressure tap plug in gas valve to prevent gas leak.

3. Verify natural gas input rate by clocking meter.

NOTE: Contact your HVAC distributor or gas supplier for metric gas meter Tables, if required.

a. Turn off all other gas appliances and pilots served by

the meter.

b. Move setup switch SW1−2 to ON position. This

keeps furnace locked in low−heat operation when

only W/W1 is energized. c. Jumper R to W/W1. d. Run furnace for 3 minutes in low−heat operation. e. Measure time (in sec) for gas meter to complete 1

revolution and note reading. The 2 or 5 cubic feet dial

provides a more accurate measurement of gas flow.

f. Refer to Table 2 for cubic ft. of gas per hr.

g. Multiply gas rate cu ft./hr by heating value (Btuh/cu

ft.) to obtain input. h. If clocked rate does not match required input from

Step 1, increase manifold pressure to increase input

or decrease manifold pressure to decrease input.

Repeat steps b through e until correct low−heat input

is achieved. Re−install low heat regulator seal cap on

gas valve.

i. Jumper R to W/W1, and W2. This keeps furnace

locked in high−heat operation when both W/W1 and

W2 are energized.

j. Repeat items (d) through (h) for high−heat operation,

repeating Step 2 and adjusting the high−heat regular

screw, as required.

4. Restore furnace to normal operating condition. a. Turn gas valve On/Off switch to OFF. b. Remove water column manometer or similar device

from manifold pressure tap. c. Replace manifold pressure tap plug to gas valve. d. Turn gas valve On/Off switch to ON. e. Move setup SW1−2 on furnace control to position

required for attached thermostat (OFF for

single−stage thermostats, ON for two−stage

thermostats).

f. Check for gas leaks and verify furnace operation.

WARNING

440 04 4801 00 7

Specifications subject to change without notice.

SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE

(

)

Figure 4 Example of Variable Speed Furnace Control for Variable Speed ECM Blower Motor

SW1 SETUP

SWITCHES AND

BLOWER OFF-

DELAY

COMMUNICATION

CONNECTOR

24-V THERMOSTAT

TERMINALS

STATUS AND COMM

LED LIGHTS

MODEL PLUG CONNECTOR

OUTDOOR

AIR TEMP

CONNECTOR

AIR CONDITIONING (A/C) &

CONTINUOUS FAN (CF)

AIRFLOW SETUP SWITCHES

HUMIDIFIER

TERMINAL (24-VAC

0.5 AMP MAX.)

FLASH

UPGRADE

CONNECTOR

(FACTORY

ONLY)

ACRDJ – AIR

CONDITIONING

RELAY DISABLE

JUMPER

PL1 – LOW VOLTAGE MAIN

HARNESS CONNECTOR

3-AMP FUSE

TRANSFORMER 24-VAC

CONNECTIONS

115-VAC (L2) NEUTRAL

CONNECTIONS

115-VAC (L1) LINE

VOLTAGE CONNECTIONS

EAC-1 TERMINAL

115-VAC 1.0 AMP MAX.

PL2 – HOT SURFACE

IGNITER & INDUCER

MOTOR CONNECTOR

SOFTWARE

VERSION

L14F003

8 440 04 4801 00

Specifications subject to change without notice.

SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE

Table 2 Gas Rate (CU ft./hr)

SECONDS G

FOR 1 REVOLUTION

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 11 6 232 581 82 44 88 220 32 11 3 225 563 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 36 100 200 500 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

SIZE OF TEST DIAL

1 Cu Ft. 2 Cu Ft. 5 Cu Ft. 1 Cu Ft. 2 Cu Ft. 5 Cu Ft.

SECONDS

FOR 1 REVOLUTION

SIZE OF TEST DIAL

440 04 4801 00 9

Specifications subject to change without notice.

SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE

Table 3 Orifice Size and Manifold Pressure (in. w.c.) for Gas Input Rate − Two−Stage

TWO-STAGE FURNACE

(TABULATED DATA BASED ON 20,000 BTUH HIGH-HEAT / 13,000 BTUH LOW-HEAT PER BURNER,

DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL)

ALTITUDE

RANGE

ft (m)

092543 3.6 / 1.5 43 3.7 / 1.6 43 3.8 / 1.6 42 3.2 / 1.4

(0) 950 43 3.4 / 1.4 43 3.5 / 1.5 43 3.6 / 1.5 43 3.7 / 1.6

to 1000 44 3.5 / 1.5 44 3.6 / 1.5 44 3.8 / 1.6 43 3.4 / 1.4

U.S.A. and CanadaU.S.A. On

y U.S.A. Only U.S.A. and Canada

U.S.A. On

2000 1050 44 3.2 / 1.3 44 3.3 / 1.4 44 3.4 / 1.4 44 3.5 / 1.5

(610) 1075 45 3.7 / 1.6 45 3.8 / 1.6 44 3.3 / 1.4 44 3.4 / 1.4

U.S.A. 800 42 3.4 / 1.4 42 3.5 / 1.5 42 3.6 / 1.5 42 3.7 / 1.6

2001 (611) 825 43 3.8 / 1.6 42 3.3 / 1.4 42 3.4 / 1.4 42 3.5 / 1.5

to 850 43 3.6 / 1.5 43 3.7 / 1.6 42 3.2 / 1.3 42 3.3 / 1.4

3000 (914) 875 43 3.4 / 1.4 43 3.5 / 1.5 43 3.7 / 1.5 43 3.8 / 1.6

Canada 925 44 3.5 / 1.5 44 3.6 / 1.5 44 3.8 / 1.6 43 3.4 / 1.4

2001 (611) 950 44 3.3 / 1.4 44 3.4 / 1.5 44 3.6 / 1.5 44 3.7 / 1.6

to 975 44 3.2 / 1.3 44 3.3 / 1.4 44 3.4 / 1.4 44 3.5 / 1.5

4500 (1372) 1000 46 3.8 / 1.6 45 3.8 / 1.6 44 3.2 / 1.4 44 3.3 / 1.4

3001 800 43 3.8 / 1.6 42 3.2 / 1.4 42 3.3 / 1.4 42 3.4 / 1.4

(915) 825 43 3.6 / 1.5 43 3.7 / 1.6 43 3.8 / 1.6 42 3.2 / 1.4

4000 900 44 3.4 / 1.4 44 3.5 / 1.5 44 3.7 / 1.5 44 3.8 / 1.6

(1219) 925 44 3.2 / 1.4 44 3.4 / 1.4 44 3.5 / 1.5 44 3.6 / 1.5

4001 775 43 3.7 / 1.6 43 3.8 / 1.6 42 3.3 / 1.4 42 3.4 / 1.4

(1220) 800 43 3.5 / 1.5 43 3.6 / 1.5 43 3.7 / 1.6 43 3.8 / 1.6

5000 875 44 3.3 / 1.4 44 3.5 / 1.5 44 3.6 / 1.5 44 3.7 / 1.6

(1524) 900 44 3.2 / 1.3 44 3.3 / 1.4 44 3.4 / 1.4 44 3.5 / 1.5

5001 750 43 3.7 / 1.5 43 3.8 / 1.6 42 3.2 / 1.4 42 3.3 / 1.4

(1525) 775 43 3.4 / 1.4 43 3.5 / 1.5 43 3.7 / 1.5 43 3.8 / 1.6

6000 850 44 3.3 / 1.4 44 3.4 / 1.4 44 3.5 / 1.5 44 3.6 / 1.5

(1829) 875 45 3.7 / 1.6 44 3.2 / 1.3 44 3.3 / 1.4 44 3.4 / 1.4

6001 700 42 3.2 / 1.3 42 3.3 / 1.4 42 3.4 / 1.4 42 3.5 / 1.5

(1830) 725 43 3.6 / 1.5 43 3.7 / 1.6 43 3.8 / 1.6 42 3.3 / 1.4

7000 800 44 3.4 / 1.4 44 3.5 / 1.5 44 3.6 / 1.5 44 3.7 / 1.6

(2133) 825 44 3.2 / 1.3 44 3.3 / 1.4 44 3.4 / 1.4 44 3.5 / 1.5

HEATVALUE0.580.600.620.64

AT ALTITUDE Orifice Mnfld Press Orifice Mnfld Press Orifice Mnfld Press Orifice Mnfld Press

(Btu/cu ft) No. High/Low No. High/Low No. High/Low No. High/Low

900 43 3.8 / 1.6 42 3.2 / 1.4 42 3.3 / 1.4 42 3.4 / 1.4

975 44 3.7 / 1.6 44 3.8 / 1.6 43 3.4 / 1.5 43 3.6 / 1.5

1025 44 3.3 / 1.4 44 3.5 / 1.5 44 3.6 / 1.5 44 3.7 / 1.6

1100 46 3.7 / 1.6 46 3.8 / 1.6 45 3.8 / 1.6 44 3.2 / 1.4

900 44 3.7 / 1.6 44 3.8 / 1.6 43 3.5 / 1.5 43 3.6 / 1.5

775 42 3.3 / 1.4 42 3.4 / 1.4 42 3.5 / 1.5 42 3.6 / 1.5

850 44 3.8 / 1.6 43 3.5 / 1.5 43 3.6 / 1.5 43 3.7 / 1.6

875 44 3.6 / 1.5 44 3.7 / 1.6 43 3.4 / 1.4 43 3.5 / 1.5

950 45 3.7 / 1.6 44 3.2 / 1.3 44 3.3 / 1.4 44 3.4 / 1.4

750 42 3.3 / 1.4 42 3.4 / 1.4 42 3.5 / 1.5 42 3.6 / 1.5

825 44 3.8 / 1.6 43 3.4 / 1.4 43 3.5 / 1.5 43 3.6 / 1.5

850 44 3.5 / 1.5 44 3.7 / 1.5 44 3.8 / 1.6 43 3.4 / 1.4

925 46 3.8 / 1.6 45 3.7 / 1.6 44 3.2 / 1.4 44 3.3 / 1.4

725 42 3.2 / 1.4 42 3.3 / 1.4 42 3.4 / 1.5 42 3.5 / 1.5

800 44 3.7 / 1.6 44 3.8 / 1.6 43 3.4 / 1.5 43 3.5 / 1.5

825 44 3.5 / 1.5 44 3.6 / 1.5 44 3.7 / 1.6 44 3.8 / 1.6

900 46 3.7 / 1.6 46 3.8 / 1.6 45 3.8 / 1.6 44 3.2 / 1.4

675 42 3.4 / 1.4 42 3.5 / 1.5 42 3.6 / 1.5 42 3.8 / 1.6

750 43 3.4 / 1.4 43 3.5 / 1.5 43 3.6 / 1.5 43 3.7 / 1.6

775 44 3.6 / 1.5 44 3.7 / 1.6 43 3.4 / 1.4 43 3.5 / 1.5

850 46 3.8 / 1.6 45 3.8 / 1.6 44 3.2 / 1.4 44 3.3 / 1.4

SAGLARUTANFOYTIVARGCIFICEPSSAG.GVA

A11252A

10 440 04 4801 00

Specifications subject to change without notice.

SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE

Table 3 (cont.) Orifice Size and Manifold Pressure (in. w.c.) for Gas Input Rate − Two −Stage

TWO-STAGE FURNACE

(TABULATED DATA BASED ON 20,000 BTUH HIGH-HEAT / 13,000 BTUH LOW-HEAT PER BURNER,

DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL)

ALTITUDE

RANGE

ft (m)

7001 675 43 3.8 / 1.6 42 3.2 / 1.4 42 3.3 / 1.4 42 3.4 / 1.5

(2134) 700 43 3.5 / 1.5 43 3.7 / 1.5 43 3.8 / 1.6 42 3.2 / 1.4

8000 775 44 3.3 / 1.4 44 3.4 / 1.4 44 3.5 / 1.5 44 3.7 / 1.5

(2438) 800 45 3.8 / 1.6 44 3.2 / 1.4 44 3.3 / 1.4 44 3.4 / 1.4

8001 650 43 3.8 / 1.6 42 3.2 / 1.4 42 3.3 / 1.4 42 3.4 / 1.4

(2439) 675 43 3.5 / 1.5 43 3.6 / 1.5 43 3.7 / 1.6 42 3.2 / 1.3

U.S.A. OnlyU.S.A. Only U.S.A. Only

* Orifice numbers shown in BOLD are factory-installed.

9000 750 44 3.3 / 1.4 44 3.4 / 1.4 44 3.5 / 1.5 44 3.6 / 1.5

(2743) 775 45 3.7 / 1.6 44 3.2 / 1.3 44 3.3 / 1.4 44 3.4 / 1.4

9001 600 42 3.3 / 1.4 42 3.4 / 1.5 42 3.6 / 1.5 42 3.7 / 1.6

(2744) 625 43 3.7 / 1.6 42 3.2 / 1.3 42 3.3 / 1.4 42 3.4 / 1.4

10000 700 44 3.4 / 1.4 44 3.5 / 1.5 44 3.7 / 1.5 44 3.8 / 1.6

(3048) 725 44 3.2 / 1.3 44 3.3 / 1.4 44 3.4 / 1.4 44 3.5 / 1.5

HEATVALUE0.580.600.620.64

AT ALTITUDE Orifice Mnfld Press Orifice Mnfld Press Orifice Mnfld Press Orifice Mnfld Press

(Btu/cu ft) No. High/Low No. High/Low No. High/Low No. High/Low

650 42 3.4 / 1.4 42 3.5 / 1.5 42 3.6 / 1.5 42 3.7 / 1.6

725 44 3.8 / 1.6 43 3.4 / 1.4 43 3.5 / 1.5 43 3.6 / 1.5

750 44 3.5 / 1.5 44 3.7 / 1.5 44 3.8 / 1.6 43 3.4 / 1.4

825 46 3.7 / 1.6 46 3.8 / 1.6 45 3.8 / 1.6 44 3.2 / 1.4

625 42 3.4 / 1.4 42 3.5 / 1.5 42 3.6 / 1.5 42 3.7 / 1.6

700 44 3.7 / 1.6 43 3.4 / 1.4 43 3.5 / 1.5 43 3.6 / 1.5

725 44 3.5 / 1.5 44 3.6 / 1.5 44 3.7 / 1.6 44 3.8 / 1.6

650 43 3.5 / 1.5 43 3.6 / 1.5 43 3.7 / 1.6 43 3.8 / 1.6

675 44 3.7 / 1.6 44 3.8 / 1.6 43 3.4 / 1.4 43 3.5 / 1.5

SAGLARUTANFOYTIVARGCIFICEPSSAG.GVA

A11252B

Adjust Temperature Rise

NOTE: Blower door must be installed when taking temperature

rise reading. Leaving blower door off will result in incorrect temperature measurements, due to possible changes in duct static pressure and airflow.

CAUTION

FURNACE DAMAGE HAZARD

Failure to follow this caution may result in:

S Overheating the heat exchangers or condensing

flue gases in heat exchanger areas not designed for condensate.

S Shortened furnace life. S Component damage.

Temperature rise must be within limits specified on furnace rating plate. Recommended operation is at midpoint of rise range or slightly above.

Furnace must operate within ranges of temperature rise specified on the furnace rating plate.

When setup switch SW1−4 is ON, operation will be near the high end of the rise 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 to determine air temperature rise.

NOTE: Temperature rise can be determined for low−heat operation by locking the furnace in each mode of operation. The mode of operation is based on the position of set up switch SW1−2 on the furnace control board.

This 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 low− and high−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 Low Heat Rise Adjust switch SW1−3 on

furnace control is in ON position when a bypass humidifier is used. (See Figure 4 for switch location.)

e. Check Troubleshooting Guide for Variable−Speed

Condensing Furnaces.

To lock the furnace in Low Heat:

1. Turn SW1-2 ON at the furnace control. Set up switch

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 Low Heat:

440 04 4801 00 11

Specifications subject to change without notice.

SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE

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 Low Heat. Factory default position is OFF.

5. Turn 115 VAC power on.MN7A

6. Re--check Low Heat Temperature Rise

To lock the furnace in High Heat:

1. Connect a jumper across R and W/W1 and W2 at the thermostat terminals at the furnace control.

2. Allow the burners to ignite and the blower to turn on.

3. Allow the supply temperature to stabilize and verify the proper rise range.

If the temperature rise is too high or too low in High Heat:

1. Remove jumpers from R and W/W1 and W2.

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 OFF and SW1-3 is set to OFF, airflow is raised 7% for Low Heat and 10% for High Heat. Factory default position is ON. If SW1-3 is ON and SW1-4 is OFF, airflow is raised 18% for Low Heat and 10% for High Heat

5. Turn 115 VAC power on.

6. Re-check High 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 to the desired position.

4. Proceed to “Adjust Blower Off Delay” or install blower door if complete

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.

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.

WARNING

CAUTION

Adjust Blower Off Delay (Heat Mode)

a. Remove blower door if installed.

b. Turn Dip switch SW1−7 or SW1−8 ON or OFF for

desired blower off delay. (See Table 4 and Figure 4,

Figure 5)

Table 4 Blower Speed Taps

DESIRED HEATING MODE

BLOWER OFF DELAY

(SEC.)

90 OFF OFF

120 ON OFF

150 OFF ON

180 ON ON

SETUP SWITCH (SW1-7 and -8)

POSITION

Adjust Cooling Airflow − High−Speed and Low−Speed Cooling

The ECM blower can be adjusted for a range of airflows for low−speed or high−speed cooling. See Table 5−Air Delivery − CFM (with Filter) and Figure 5. Furnace Setup Switches and Descriptions. 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.

NOTE: 6 ton airflow will truncate at 2200 CFM on applicable models.

The high−speed or single−speed cooling airflow is adjusted by turning setup switches SW2−6, SW2−7 and SW2−8 either ON or OFF. Select the required airflow from Table 5. Table 5 is based on 350 CFM per ton. For other CFM per ton setup switch selections, see Figure 4, Figure 5 and Figure 16.

The Continuous Fan airflow selection via setup switches SW2−3, SW2−4 and SW2−5 is also the airflow for low−speed cooling when the furnace is used with a two−speed cooling or heat pump unit. Adjust the Continuous Fan CFM setup switches SW2−3, SW2−4 and SW2−5 to match the airflow required for low−speed cooling. Select the required airflow from

Table 5 and Figure 5. NOTE: The airflow selected via SW2−3, SW2−4 and SW2−5

(low−speed cooling airflow) cannot exceed the airflow selected via SW2−6, SW2−7 and SW2−8 (high−speed cooling airflow). For other CFM per ton setup switch selections, see Figure 4 and Figure 5.

For a complete explanation of cooling airflow, refer to the section titled “Sequence of Operation.”

Adjust Continuous Fan Airflow/Low Speed Cooling Airflow

NOTE: When the furnace is used with a two−speed cooling or

heat pump unit, the airflow selected for Continuous Fan via setup switch SW2−3, SW2−4 and SW2−5 will also be the airflow used for low−speed cooling, and vice versa.

NOTE: When the furnace is used with a two−speed cooling or heat pump unit, adjust the Continuous Fan CFM setup switches SW2−3, SW2−4 and SW2−5 to match the airflow required for low−speed cooling.

Select the required Continuous Fan airflow using setup switches SW2−3, SW2−4 and SW2−5 as shown in Figure 5 and Table 5.

12 440 04 4801 00

Specifications subject to change without notice.

SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE

Figure 5 Furnace Setup Switch Description

RCL

LHT

LHR

C/E

CFM

TST

OFF

DLY

TWN

CFM

CFAC

SW1

SW2

SETUP

SWITCH

SW11

SW12

SW13

SW14

SW15

SW16

SW17 &

SW18

SW21 Twining OFF

SW22

SW26, 7, 8

SW23, 4, 5

SWITCH

NAME

Status Code

Recovery

Low Heat

Only

(Adaptive

Heat Mode

when SW12

is OFF)

Low Heat

Rise

Adjustment

Comfort/

Efficiency

Adjustment

CFM per ton

adjust

Component

Self Test

Blower OFF

delay

CFM per ton

Adjust

(Cooling

Airflow)

(Continuous

Fan)

NORMAL

POSITION

DESCRIPTION OF USE

Turn ON to retrieve up to 7 stored status codes for troubleshooting assistance when R

OFF

thermostat lead is disconnected.

When SW12 is OFF allows two-stage operation with a single stage thermostat. Turn ON when using two-stage thermostat to allow Low Heat operation when R to W/W1

OFF

closes and High Heat operation when R to W/W1 and W2 close.

Turn ON to increase Low Heat airflow by 18 percent. This compensates for increased

OFF

return air temperature caused with bypass humidifier.

Turn ON to decrease Low Heat airflow by approximately 7 percent and High Heat air

flow by approximately 10 percent for maximum comfort.

OFF Turn ON for 400 CFM per ton, Turn OFF for 350 CFM per ton. See also SW2.

Turn ON to initiate Component Self Test for troubleshooting assistance when R

OFF

thermostat lead is disconnected. Turn OFF when Self Test is completed.

ON or OFF

Blower Off Delay time – adjustable 90 seconds to 180 seconds. See table in Adjustments section or refer to unit wiring diagram.

Allows for selection of furnace Main (OFF) or Secondary (ON) when Twinned furnace setup is required. See kit instructions for further directions on installation and setup.

Allows additional CFM per ton selections when used with SW15

325 CFM per ton (nominal) when SW22 ON and SW15 OFF

350 CFM per ton (nominal) when SW22 OFF and SW15 OFF

OFF

370 CFM per ton (nominal) when SW22 ON and SW15 ON

400 CFM per ton (nominal) when SW22 OFF and SW15 ON

See Air Delivery Tables for model specific CFM vs. static pressure

The AC setup switches select desired cooling or high stage cooling (two-stage units)

OFF

airflow. See Cooling Air Delivery Tables for specific switch settings.

The CF setup switches select desired Continuous Fan Airflow

The CF switch position is the low cooling airflow selection for two-stage cooling units.

OFF

The CFM values are shown in the Air Delivery Tables below for SW2 settings. SW23, 4, 5 cannot be set for airflow higher than SW 26, 7, 8. See Continuous Fan Air Flow Table for specific switch settings.

BASED ON 350 CFM/TON (Factory Default: SW1−5 = OFF, SW2−2 = OFF)

Model

Size

5 4 3 5 4 3 5 4 3 5 4 3 5 4 3 5 4 3 5 4 3 5 4 3

040-10 525 525 700 875 875 875 875 875 040-12 525 525 700 875 1050 1050 1050 1050 060-12 525 525 700 875 1050 1050 1050 1050 060-14 525 525 700 875 1050 1225 1225 1225 080-16 525 525 700 875 1050 1225 1400 1400 080-20 700 700 875 1050 1225 1400 1750 1750 100-20 700 700 875 1050 1225 1400 1750 1750 120-22 875 700 875 1050 1225 1400 1750 1925

ON ON ON

ON ON

440 04 4801 00 13

Specifications subject to change without notice.

SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE

Adjust Thermostat Heat Anticipator

a. Mechanical thermostat. Set thermostat heat

anticipator to match the amp. draw of the electrical components in the R−W/W1 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 6

across the R and W subbase terminals or R and W wires at wall.

(4.) Record amp. draw across terminals when

furnace is in low heat and after blower starts.

(5.) Set heat anticipator on thermostat per thermostat

instructions and install on subbase or wall. (6.) Turn SW1−2 switch OFF. (7.) Install blower door.

b. Electronic thermostat: Set cycle rate for 3 cycles per

hr.

Figure 6 Amp. Draw Check with Ammeter

THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED (ANITICIPATOR, CLOCK, ETC., MUST BE OUT OF CIRCUIT.)

HOOK-AROUND AMMETER

R Y W G

10 TURNS

FROM UNIT 24-V CONTROL TERMINALS

EXAMPLE:

5.0 AMPS ON AMMETER 10 TURNS AROUND JAWS

0.5 AMPS FOR THERMOSTAT

ANTICIPATOR SETTING

A96316

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 5 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 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 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 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. Put away tools and instruments. Clean up debris.

2. 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 4.

3. Verify that blower and control doors are properly installed.

4. Cycle test furnace with room thermostat.

5. Check operation of accessories per manufacturer’s instructions.

6. Review Home Owner’s Information with owner.

7. Attach literature packet to furnace.

14 440 04 4801 00

Specifications subject to change without notice.

SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE

Table 5 COOLING4 AND HEATING AIR DELIVERY - CFM (Bottom Return5 with filter)

(SW1-5 and SW2−2 set to OFF, except as indicated. See notes 1 and 2)

Unit Size Cooling Switch Settings External Static Pressure (ESP)

040-10

Clg Default: OFF OFF OFF 1125 1080 1020 970 905 855 805 755 700 635

Cooling (SW2)

Clg SW2: Maximum Clg Airflow

Heating

(SW1)

040-12

Clg Default: OFF OFF ON 575 540 490 435 385 See note 4

Cooling (SW2)

Clg SW2: Maximum Clg Airflow

Heating

(SW1)

060-12

Clg Default: OFF OFF OFF 1250 1210 1165 1115 1065 1015 955 895 815 745

Clg SW2: Maximum Clg Airflow

Heating

(SW1)

060-14

Clg Default: OFF OFF OFF 1330 1295 1260 1220 1190 1150 111 0 1075 1045 1005

Cooling (SW2)

Clg SW2: Maximum Clg Airflow

Heating

(SW1)

080-16

Clg Default: OFF OFF OFF 1805 1765 1720 1665 1610 1540 1475 1400 1315 1235

Cooling (SW2)

Clg SW2: Maximum Clg Airflow

Heating

(SW1)

SW2-8 SW2-7 SW2−6 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

OFF OFF ON 615 555 510 475 440 395 355 270 230 note 8 OFF ON OFF 785 740 695 665 630 590 565 520 485 450 OFF ON ON 990 950 910 875 850 815 770 720 670 615

ON OFF OFF 1125 1080 1020 970 905 855 805 755 700 635 ON OFF ON 1125 1080 1020 970 905 855 805 755 700 635 ON ON OFF 1125 1080 1020 970 905 855 805 755 700 635 ON ON ON 1125 1080 1020 970 905 855 805 755 700 635

High Heat Airflow

Low Heat Airflow

1125 1080 1020 970 905 855 805 755 700 635

815 770 725 695 660 625 595 550 510 475 660 605 560 530 495 450 415 340 300 note 7

OFF ON OFF 770 725 685 640 600 560 515 480 See note 4 OFF ON ON 945 910 875 835 800 770 735 695 665 635

ON OFF OFF 1140 1105 1075 1040 1005 970 930 885 835 790 ON OFF ON 1250 1210 1165 1115 1065 1015 965 915 860 810 ON ON OFF 1250 1210 1165 1115 1065 1015 965 915 860 810 ON ON ON 1250 1210 1165 1115 1065 1015 965 915 860 810

High Heat Airflow

Low Heat Airflow

1250 1210 1165 1115 1065 1015 965 915 860 810

860 825 785 745 705 670 630 595 565 525 650 595 545 500 460 415 365 320 275 note 7

OFF OFF ON 605 565 510 455 420 See note 4 OFF ON OFF 785 750 705 675 630 585 See note 4 OFF ON ON 955 920 895 860 825 785 755 720 685 650

ON OFF OFF 1135 1110 1080 1055 1020 990 935 880 825 745 ON OFF ON 1250 1210 1165 1115 1065 1015 955 895 815 745 ON ON OFF 1250 1210 1165 1115 1065 1015 955 895 815 745 ON ON ON 1250 1210 1165 1115 1065 1015 955 895 815 745

High Heat Airflow

Low Heat Airflow

1250 1210 1165 1115 1065 1015 955 895 815 745 1125 1100 1070 1045 1010 980 925 875 820 740

900 865 835 800 760 720 690 650 610 580

OFF OFF ON 725 660 600 520 435 See note 4 OFF ON OFF 780 725 660 615 540 See note 4 OFF ON ON 975 925 875 835 785 750 690 655 610 570

ON OFF OFF 1160 1120 1090 1045 1010 970 920 885 840 800 ON OFF ON 1330 1295 1260 1220 1190 1150 111 0 1075 1045 1005 ON ON OFF 1705 1650 1595 1545 1475 1415 1340 1275 1200 1105 ON ON ON 1705 1650 1595 1545 1475 1415 1340 1275 1200 1105

High Heat Airflow

Low Heat Airflow

1705 1650 1595 1545 1475 1415 1340 1275 1200 1105 1145 1105 1075 1030 995 955 905 870 825 785

870 820 760 720 655 620 560 525 470 435

OFF OFF ON 775 635 455 230 See note 8 OFF ON OFF 840 740 675 625 555 See note 4 OFF ON ON 995 955 910 860 815 770 720 660 620 585

ON OFF OFF 1175 1140 1090 1060 1025 980 940 905 855 815 ON OFF ON 1325 1280 1245 1210 1180 1140 1105 1070 1025 990 ON ON OFF 1545 1515 1480 1445 1410 1380 1350 1315 1245 1175 ON ON ON 1805 1765 1720 1665 1610 1540 1475 1400 1315 1235

High Heat Airflow

Low Heat Airflow

1805 1765 1720 1665 1610 1540 1475 1400 1315 1235 1520 1490 1455 1420 1385 1355 1320 1285 1220 1155 1180 1145 1095 1065 1030 985 945 910 860 820

440 04 4801 00 15

Specifications subject to change without notice.

SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE

COOLING4 AND HEATING AIR DELIVERY - CFM (Bottom Return5 with filter)

Unit Size Cooling Switch Settings External Static Pressure (ESP)

080-20

Clg Default: OFF OFF OFF 1905 1870 1825 1785 1750 1700 1665 1625 1560 1460

Cooling (SW2)

Clg SW2: Maximum Clg Airflow

Heating

(SW1)

100-20

Clg Default: OFF OFF OFF 1890 1845 1800 1755 1700 1655 1610 1560 1510 1460

Cooling (SW2)

Clg SW2: Maximum Clg Airflow

Heating

(SW1)

120-22

Clg Default: OFF OFF OFF 2010 1960 1910 1850 1800 1750 1690 1645 1565 1480

Cooling (SW2)

Clg SW2: Maximum Clg Airflow

Heating

(SW1)

SW2-8 SW2-7 SW2-6 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

OFF OFF ON 950 770 620 515 440 365 See note 4 OFF ON OFF 1015 935 880 825 765 690 625 580 See note 4 OFF ON ON 1155 1105 1040 990 920 875 815 755 710 645

ON OFF OFF 1335 1290 1245 1190 1145 1085 1040 990 930 890 ON OFF ON 1520 1485 1435 1390 1340 1300 1255 1200 1160 111 5 ON ON OFF 1905 1870 1825 1785 1750 1700 1665 1625 1560 1460 ON ON ON 2290 2230 2160 2085 2005 1915 1820 1730 1640 1525

High Heat Airflow

Low Heat Airflow

2290 2230 2160 2085 2005 1915 1820 1730 1640 1525 1575 1535 1485 1445 1400 1350 1310 1260 1215 1170 1230 1170 1125 1065 1015 955 900 855 795 755

OFF OFF ON 1015 825 630 485 405 325 See note 4 OFF ON OFF 1080 895 815 740 690 615 555 475 See note 4 OFF ON ON 1155 1080 1020 940 890 825 785 710 660 590

ON OFF OFF 1310 1260 1195 1140 1075 1025 970 925 875 810 ON OFF ON 1520 1475 1425 1365 1315 1255 1210 1155 111 0 1055 ON ON OFF 1890 1845 1800 1755 1700 1655 1610 1560 1510 1460 ON ON ON 2290 2230 2160 2085 2005 1915 1820 1730 1640 1525

High Heat Airflow

Low Heat Airflow

2290 2230 2160 2085 2005 1915 1820 1730 1640 1525 1905 1865 1825 1775 1730 1685 1640 1590 1545 1490 1480 1435 1375 1330 1265 1215 1160 1115 1060 1005

OFF OFF ON 1015 805 645 550 480 See note 4 OFF ON OFF 1075 975 915 835 765 See note 4 OFF ON ON 1205 1135 1055 1000 935 See note 4

ON OFF OFF 1400 1330 1260 1190 1145 1080 1035 970 905 845 ON OFF ON 1615 1550 1500 1435 1370 1325 1265 1215 1160 111 0 ON ON OFF 2010 1960 1910 1850 1800 1750 1690 1645 1565 1480 ON ON ON note 8 2375 2300 2205 2115 2010 1890 1750 1645 1550

High Heat Airflow

Low Heat Airflow

note 8 2375 2300 2205 2115 2010 1890 1750 1645 1550 note 8 2375 2300 2205 2115 2010 1890 1750 1645 1550

1735 1675 1625 1560 1500 1455 1395 1345 1285 1225

NOTE:

1. Nominal 350 CFM/ton cooling airflow is delivered with SW1−5 and SW2−2 set to OFF. Set both SW1−5 and SW2−2 to ON for +7% airflow (nominal 370 CFM/ton). Set SW1−5 to ON and SW2−2 to OFF for +15% airflow (nominal 400 CFM/ton). Set SW2−2 to ON and SW1−5 to OFF for −7% airflow (nominal 325 CFM/ton). The above adjustments in airflow are subject to motor horspower range/capacity.

2. Maximum cooling airflow is achieved when switches SW2−6, SW2−7, SW2−8 and SW1−5 are set to ON, and SW2−2 is set to OFF.

3. All heating CFM’s are when low heat rise adjustment switch (SW1−3) and comfort/efficiency adjustment switch (SW1−4) are both set to OFF.

4. Ductwork must be sized for high−heating CFM within the operational range of ESP. Operation within the blank areas of the chart is not recommended because high−heat operation will be above 1.0 ESP.

5. All airflows of 1880 CFM or less on 21” and 24.5” casing size furnaces are 5% less on side return only installations.

6. Airflows over 1800 CFM require bottom return, two−side return, or bottom and side return. A minimum filter size of 20” x 25” is required.

7. For upflow applications, air entering from one side into both the side of the furnace and a return air base counts as a side and bottom return.

8. Airflow not stable at this ESP.

16 440 04 4801 00

Specifications subject to change without notice.

SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE

SERVICE AND MAINTENANCE PROCEDURES

Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters. All other operations must be performed by trained service personnel. A qualified service person should inspect the furnace once a year.

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 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 Owner’s Manual.

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.

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 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.

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 4 positions shown in Figure 7, you must revise your orientation to component location accordingly.

WARNING

CAUTION

WARNING

CAUTION

Figure 7 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 tag switch with a suitable warning label.

The electrical ground and polarity for 115−v wiring must be properly maintained. Refer to Figure 8 for field wiring information and to Figure 16 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 4) 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 to be replaced.

Troubleshooting

Refer to the service label. (See Figure 15—Service Label) The Troubleshooting Guide − Flow Chart (See Figure 17) 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 − Flow Chart 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 indicator in blower door. The amber furnace control LED is either a heartbeat, off or a 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.

440 04 4801 00 17

Specifications subject to change without notice.

SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE

Figure 8 Heating and Cooling Application Wiring Diagram with Single−Stage Thermostat

FIELD 24-VOLT WIRING FIELD 115-, 208/230-, 460-VOLT WIRING FACTORY 24-VOLT WIRING FACTORY 115-VOLT WIRING

BLOWER

DOOR

SWITCH

BLK

WHT

GND

115-VOLT FIELD-

SUPPLIED

FUSED

DISCONNECT

BLK

WHT

JUNCTION BOX

FIVE

WIRE

THREE-WIRE

HEATING-

ONLY

FURNACE

COM

O N

W/W1

Y/Y2

R O

24-VOLT

TERMINAL

BLOCK

NOTE 2

WC Y RG

NOTE 1

NOTES: 1.

Connect Y/Y2-terminal as shown for proper operation. Some thermostats require a "C" terminal connection as shown.

2. If any of the original wire, as supplied, must be replaced, use

3. same type or equivalent wire.

1-STAGE THERMOSTAT TERMINALS

CONDENSING

UNIT

FIELD-SUPPLIED

FUSED DISCONNECT

GND

208/230- OR 460-VOLT THREE PHASE

208/230VOLT SINGLE PHASE

For an explanation of status codes, refer to service label located on control door or Figure 15, 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 indicator for current LED

status.

c. Remove blower door.

NOTE: The Status Codes cannot be retrieved by disconnecting the limit switch. To retrieve Status Codes, follow the procedure below.

2. Turn Setup Switch, SW1−1 “ON.”

3. Manually close blower door switch.

4. Control will flash up to 7 Status Codes.

5. The last 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 control door and refer to the SERVICE label on the control door 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.

A11401

3. Turn Setup Switch, SW−1−6 “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. Caution must be taken when manually closing this switch for service purposes.

WARNING

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.

5. Component Test sequence will function as follows: a. Inducer motor starts on high−speed and continues to

run until Step (d.) of component test sequence. b. Hot surface igniter is ON for 15 sec, then OFF. c. Blower operates for 15 sec, then turns off. d. Inducer motor goes to low−speed for 10 seconds,

then turns off. e. After component test is completed, one or more

status codes (heartbeat, 2+5) will flash. See

component test section of service label for

explanation of status codes.

NOTE: To repeat component test, turn setup switch SW1−6 OFF then back ON.

f. Turn setup switch SW1−6 OFF.

18 440 04 4801 00

Specifications subject to change without notice.

SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE

6. Release blower door switch, reattach wire to “R” terminal on furnace control board and replace blower door.

Care and Maintenance

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury, death and/or property damage.

Never store flammable or combustible materials on, near, or in contact with the furnace, such as:

1. Spray or aerosol cans, rags, brooms, dust mops, vacuum cleaners, or other cleaning tools.

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.

3. Paint thinners and other painting compounds, paper bags, or other paper products. Exposure to these materials could lead to corrosion of the heat exchangers.

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.

ELECTRICAL SHOCK AND FIRE HAZARD

Failure to follow this warning could result in personal injury, death, and/or property damage.

Turn off the gas and electrical supplies to the furnace and install lockout tag before performing any maintenance or service. Follow the operating instructions on the label attached to the furnace.

WARNING

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.

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

The air filter type may vary depending on the application or orientation. The filter is external to the furnace casing. There are no provisions for an internal filter with this furnace. See “Filter Arrangement” under the “Installation” section of this manual.

NOTE: If the filter has an airflow direction arrow, the arrow must point toward the blower. To clean or replace filters, proceed as follows:

WARNING

ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury or death, or property damage.

CARBON MONOXIDE POISONING AND FIRE HAZARD

Failure to follow this warning could result in personal injury, death and/or property damage.

Never operate furnace without a filter or filtration device installed. Never operate a furnace with filter or filtration device access doors removed.

CUT HAZARD

Failure to follow this caution may result in 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.

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.

WARNING

CAUTION

1. Turn off electrical supply to furnace.

2. Remove filter cabinet door.

3. Slide filter out of cabinet.

4. If equipped with permanent, washable filter, clean filter by spraying cold tap water through filter in opposite direction of airflow. Rinse filter and let dry. Oiling or coating of the filter is not recommended.

5. If equipped with factory specified disposable media filter, replace only with a factory specified media filter of the same size.

6. Slide filter into cabinet.

7. Replace filter cabinet door.

8. Turn on electrical supply to furnace.

Blower Motor and Wheel Maintenance

To ensure long life, economy, and high efficiency, clean accumulated dirt and grease from blower wheel and motor annually.

The inducer and blower motors are pre−lubricated and require no additional lubrication. These motors can be identified by the absence of oil ports on each end of the motor.

The following items should be performed by a qualified service technician. Clean blower motor and wheel as follows:

1. Turn off electrical supply to furnace.

2. Remove blower door.

440 04 4801 00 19

Specifications subject to change without notice.

SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE

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.

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 lb−in.

See Figure 9 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 balance 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 lb−in. when reassembling.

10. Torque blower wheel set screw to 160 +/− 20 lb−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.

Figure 9 Blower Assembly

MOTOR SHAFT FLAT

SET SCREW

GROMMET

SCREW LOCATION

BLO HSG ASSY

BRACKET

BRACKET ENGAGEMENT

DETAIL A

SEE DETAIL A

CUTOFF, BLOWER

WHEEL, BLOWER

BRACKET

POWER CHOKE

OR CAPACITOR

WHEN REQUIRED

SCREW

(GND)

MOTOR WHEEL HUB

A11584A

MOTOR ARM

SCREW

A11584B

A11584C

A11584D

BLOWER HSG ASSY

MOTOR, BLOWER

A11584E

20 440 04 4801 00

Specifications subject to change without notice.

SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE

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 2 screws securing blower assembly 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.

ELECTRICAL SHOCK AND FIRE HAZARD

Failure to follow this warning could result in personal injury, death, and/or property damage.

Turn off the gas and electrical supplies to the furnace and install lockout tag before performing any maintenance or service. Follow the operating instructions on the label attached to the furnace.

WARNING

ELECTRICAL OPERATION HAZARD

Failure to follow this warning could result in personal injury or death.

Blower door switch opens 115−v power to control. No component operation can occur unless switch is closed. Caution must be taken 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. Manually close blower door switch. Use a piece of tape 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. If outdoor temperature is below 70_F (21_C), turn off circuit breaker to outdoor unit before running furnace in the cooling cycle. Turn outdoor circuit breaker on after completing cooling cycle. (See Figure 4)

NOTE: If R−W/W1 thermostat terminals are jumpered at the time blower door switch is closed, blower will run for 90 sec before beginning a heating cycle.

a. Perform component self−test as shown at the bottom

of the SERVICE label, located on the control door.

b. Verify blower is rotating in the correct direction

18. If furnace is operating properly, RELEASE BLOWER DOOR SWITCH. Remove any jumpers or reconnect any disconnected thermostat leads. Replace blower door.

19. 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 the valve from rotating on the manifold or damaging the mounting to the burner assembly.

Refer to Figure 10.

1. Disconnect power at external disconnect, fuse or circuit breaker.

2. Turn off gas at external shut-off or gas meter.

3. Remove control door 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. Remove individual wires from terminals on gas valve (All other models).

7. Disconnect Hot Surface Igniter (HSI) wires from HSI.

8. Disconnect Flame Sensor wire from Flame Sensor.

9. Support the manifold and remove the 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 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 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 bracket 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 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.

440 04 4801 00 21

Specifications subject to change without notice.

SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE

3. Align the edges of the one-piece burner 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, 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 assembly before re-installing the manifold.

Figure 10 Burner Assembly

BURNER SUPT. ASSY

BURNER ASSY

FLAME ROLL−OUT SWITCH

FLAME SENSOR

(

BELOW BURNER)

Representative drawing only, some models may vary in appearance.

L11F064

6. Attach the green/yellow wire and ground terminal to one of the manifold mounting screws.

7. Install the remaining manifold mounting screws.

8. Check the igniter alignment. See Figure 10, Figure 11 and Figure 12.

Figure 11 Igniter Position − Top View

1-1/4-in.

2-1/2-in.

A11271

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.

Figure 12 Igniter Position − Side View

2ïin. 50 mm

3/8ïin.

9.6 mm

3/16ïin.

4.6 mm

+ 1/32

1/10ïin.

ï 1/16ïin.

+0.8

2.5 mm ï1.5 mm

L12F041

WARNING

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury, death, and/or property damage.

14. Check for gas leaks with a commercially available soap solution made specifically for the detection of leaks.

15. Turn gas on at electric switch on gas valve and at external shut-off or meter

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 control door when complete.

Servicing Hot Surface Igniter

The igniter does NOT require annual inspection. Check igniter resistance before removal. Refer to Figure 10, Figure 11 and Figure 12.

1. Turn off gas and electrical supplies to furnace.

2. Remove control door.

3. Disconnect igniter wire connection.

4. Check igniter resistance. Igniter resistance is affected by 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.

22 440 04 4801 00

Specifications subject to change without notice.

SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE

5. 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 10)

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.

6. To replace igniter and bracket assembly, reverse items

5a through 5d.

7. Reconnect igniter harness to the igniter, dressing the

igniter wires to ensure there is no tension on the igniter itself. (See Figure 10)

8. Turn on gas and electrical supplies to furnace.

9. Verify igniter operation by initiating control board self−test

feature or by cycling thermostat.

10. Replace control door.

Flushing Collector Box and Drainage System

ELECTRICAL SHOCK AND FIRE HAZARD

Failure to follow this warning could result in personal injury, death, and/or property damage.

Turn off the gas and electrical supplies to the furnace and install lockout tag before performing any maintenance or service. Follow the operating instructions on the label attached to the furnace.

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 the collector box plug from the top 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

water from condensate trap is clean and runs freely.

7. Repeat steps 4 thru 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.

WARNING

Cleaning Condensate Drain and Trap

NOTE: If the condensate trap 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.

2. Turn off gas at external shut-off or gas meter.

3. Remove control door and set aside.

4. Turn electric switch on gas valve to OFF.

5. 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 trap with the screw

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 control door when complete.

Checking Heat Pad Operation (If Applicable)

In applications where the ambient temperature around the furnace is 32_F (0_C) 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 discolored insulation is evident, replace heat tape.

3. Check that heat tape power supply circuit is on.

440 04 4801 00 23

Specifications subject to change without notice.

SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE

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:

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), 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 plate and rotate upwards to gain access to screws attaching burner assembly to cell panel.

6. Remove screws attaching burner assembly to cell panel. (See Figure 10)

NOTE: Burner 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 13)

Figure 13 Cleaning Heat Exchanger Cell

Figure 14 Burner Flame

Burner Flame

Burner

Manifold

A11461

WARNING

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury, death, and/or property damage.

13. Replace main furnace door.

Secondary 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

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 two complete heat operating cycles. Look at burners. Burner flames should be clear blue, almost transparent. (See Figure 14)

12. Check for gas leaks.

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:

24 440 04 4801 00

Specifications subject to change without notice.

SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE

6. Insert a field supplied funnel into the tube.

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 may occur.

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 box 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

7. Pour 1 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 4801 00 25

Specifications subject to change without notice.

SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE

Figure 15 Service Label

340688−2 REV A

440 04 4801 00 26

Specifications subject to change without notice.

SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE

Figure 16 Wiring Diagram

340688−2 REV B

27 440 04 4801 00

Specifications subject to change without notice.

SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE

Figure 17 Troubleshooting Guide − Flow Chart

Guide

NONO

Close the door switch.

Is circuit breaker closed?

Check for continuity in wire from circuit

breaker to furnace.

Close circuit breaker and go back to

START.

Check room thermostat or

interconnecting cable.

Is 24V present at W/W1, W2, Y1, Y/Y2 or

YES

Is door switch closed?

Is there 115V going to switch?

Replace door switch.

Replace transformer.

- Gas valve relay stuck open.

The control is locked out and will auto-

- Software check error.

reset after 1 hour. Lockout could be due

to any of the following:

- Flame sense circuit failure.

Reset power to clear lockout. Replace

control if code repeats.

Does the control respond to W/W1, W2,

YES

G thermostat terminals on the furn ace

Y1, Y/Y2, and G (24V) thermostat

YES

control?

Disconnect all the thermostat wires from

the furnace control.

YES

signals?

Run system through a low-heat, high-

heat, or cooling cycle to check operation.

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

Does the problem repeat when using a

jumper wire?

The thermostat is not compatible with the

furnace control. Either install a ballast

resistor, connect the Com24V thermostat

terminal to the thermostat, or replace the

thermostat.

YES

simultaneously until the heartbeat

flashes.

Replace furnace control.

Troubleshootin

the R thermostat connection, reset

power, and put setup switch SW1-1 in

the ON position. The AMBER LED will

flash the status codes in the order of

occurrence. Record status codes until

heartbeat flashes. After heartbeat

flashes several times the status codes

will repeat. 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 simultaneously until the heartbeat

flashes. When done put setup switch

The laststatus code has cleared. To

model plug PL4 is installed. The wiring

schematic shows all valid model plugs.

Is the correct model plug installed?

Replace model plug PL4.

recall a previous status code disconnect

YES

SW1-1 in the OFF position.

Was there a previous status code other

than the heartbeat?

YES

Is there 115V at L1 and L2?

YES

YES YES YES

Is there 24V at SEC-1 and SEC-2?

YES

Is the 24V fuse open?

Replace fuse then disconnect thermostat

leads to isolate short circuit.

Replace furnace control.

Check to make sure that the correct

YES

START

like a heartbeat, or flashing ON and

Is AMBER LED status light ON solid,

alternately flashing bright-dim-bright-dim

OFF?

Is AMBER LED status light ON solid?

heartbeat?

Is AMBER LED status light alternately

flashing bright-dim-bright-dim like a

short flashes and the second number

after the plus (+) sign is the number of

is a single or two digitnumber with the

first number determined b y the numb er of

long flashes?

Go to section below for the status code

that was flashed.

Determine status code. The status code

440 04 4801 00 28

Specifications subject to change without notice.

SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE

Figure 17 (CONT.) Troubleshooting Guide − Flow Chart

or rough ignition.

- Proper firing rate.

NOTE:

NUMBER IN UPPER LEFT HAND

CORNER REPRESENTS FLASH CODE

- Low inlet gas pressure.

Check for:

- Inadequate flame carryover

YES

Allow blower to come on and

YES

Replace furnace control.

Check for continuity in the

harness and igniter. Replace

defective component.

YES

Check that all gas valves are

Check connections. If OK,

turned on. Replace valve.

replace control.

YES

Check connections and retry.

If current is near typical value

(4.0-6.0 nominal) and burn er s

will not stay on, repeat check

in high-heat. If burners will

still not stay on replace

control. If burners operate in

high-heat then switch to low-

heat, check manifold

pressure. If OK, check

burner carryover and flame

repeat test to check for

intermittent operation.

YES

sensor location.

YES

permanent memory. This will happen if you forget to install the model

and is defaulting to the model selection stored in memory. If status code 2 +

5 flashes continuously it could indicate any of the following:

occurs if the limit or flame rollout switch is

- Model plug PL4 is missing and there is no valid model stored in

open longer than 3 minutes or 10

successive limit trips occurred during high-

heat. Control will auto-reset after 3 hours.

plug PL4 on a service replacement control.

- Thermostat call with SW1-1 ON.

Refer to status code #4.

only flashes 4 times on power-up the control is missing its model plug PL4

2 + 5 INVALID MODEL SELECTION OR SETUP ERROR –If status code 2 + 5

7 LIMIT CIRCUIT LOCKOUT – Lockout

software version V24 or later.

- Thermostat call with SW1-6 ON.

- SW1-1 and SW1-6 both ON.

- Two different furnace mo del s t winne d.

- Service replacement control is incorrect. Need non-modulating board with

Check for 115V between pin 3 and

NEUTRAL-L2 on the control. Was 115V

Unplug igniter harness from control and

repeat component test by turning setup

switch SW1-6 OFF and then back ON.

present for the 15 second period?

Reconnect the R thermostat lead and set

thermostat to call for heat. Connect

voltmeter across gas valve connections.

Does gas valve receive 24V?

Does gas valve open and allow gas to

flow?

Do the main burners ignite?

(115V OR 24V) – Normal operation.

Blower runs for 90 seconds, if unit is

powered up during a call for heat (R-

W/W1 closed) or when (R-W/W1 opens)

- Refer to status code #3.

- Control relay may be defecti v e.

- Stuck closed gas valve relay on control.

NOT auto reset. Turn off power and wait

5 minutes to retry. Che ck for:

- Miswire or short to gas valve wire.

8 GAS HEATING LOCKOUT – Control will

- Gas valve is miswired.

RELAY DID NOT CLOSE OR

REOPENED - Check for:

9 HIGH-HEAT PRESSURE SWITCH OR

transformer phasing.

voltage polarity. If units are twinne d,

check for proper low-voltage (24V)

10 POLARITY – Check for correct line

1 + 2 BLOWER ON AFTER POWER UP –

during the blower on-delay period.

6 + 1 IGNITION LOCKOUT –System failed to

Do the main burners stay on?

Repeat call for heat and check flame

sensor current during trial for ignition

period. Is the DC microamps below 0.5?

hours. Refer to status code #6.

ignite gas and prove flame in 4

attempts. Control will auto-reset after 3

Clean flame sensor with fine steel wool

and recheck current. Nominal current is

4.0 to 6.0 microamps.

Is current near typical value? Repla ce el ect ro de.

Will main burners ignite and stay on? Replace furnace control.

Fixed.

YES

component test. Does the igniter glow

orange/white by the end of the 15 second warm-

the control, reset power, and put setup switch

up period?

SW1-6 in the ON position to start the

To determine whether the problem is in the gas

valve, igniter, or flame sensor the system can be

operated in component test mode. To check the

igniter remove the R thermostat connection from

tubing.

compartment.

- Disconnected or obstructed pressure

- Air leak between vestibule and blower

- Low inlet gas pressure (if LGPS used).

Check for:

2 PRESSURE SWITCH DID NOT OPEN –

- Obstructed pressure tube.

NOT CLOSE OR REOPENED – If opens

during blower on-dela y period, blower will

come on for the selected blower off-delay.

If open longer than 5 minutes inducer

shuts off for 15 minutes before retry.

- Pressure switch stuck closed. 3 LOW-HEAT PRESSURE SWITCH DID

Check for:

29 440 04 4801 00

- Restricted vent.

- Proper vent sizing.

Specifications subject to change without notice.

pipe.

- Low inducer voltage (115 VAC)

- Defective Inducer mot or .

- Water in vent piping, possible sagging

- Defective or miswired pressure switches

- Excessive wind.

- Plugged condensate drain.

limit or a flame rollout switch is open or the

4 LIMIT CIRCUIT FAULT – Indicates the

trips. Blower will run for 4 min. or until

open switch remakes whichever is longer.

furnace is operating in high-heat only

mode due to 2 successive low-heat limit

blower shuts off. Flame rollout switch

If open longer than 3 min., code changes

to lockout #7. If open less than 3 min.

status code #4 continues to flash until

adjustment.

requires manual reset. Check for:

- Defective switch or connections.

- Improper low- or high-heat gas input

- Loose blower whe el.

Flame is proved while gas valve is de-

energized. Inducer will run until fault is

cleared. Check for:

- Improper limit switch or no limit gasket.

- Dirty filter or restricted duct system.

- Stuck open or leaky gas valve.

not sensed during the trial for ignition

period, the control will repeat the ignition

5 ABNORMAL FLAME-PROVING SIGNAL

6 IGNITION PROVING FAILURE – If flame is

the following before going to the next step.

sequence 3 more times before lockout #6 +

1 occurs. If flame signal is lost during the

blower on-delay period, blower will come on

- GREEN/YELLOW wire MUST be

for the selected blower off-delay. Check

- Gas valve turned off.

- Manual shut-off valve.

connected to furnace sheet metal.

- Flame sensor must not be grounded.

SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE

Sequence of Operation

NOTE: Furnace control must be grounded for proper operation

or else control will lock out. Control is grounded through green/yellow wire routed to gas valve and burner box screw. Using the schematic diagram in Figure 16, 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 W/W1−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 flash a heartbeat (bright−dim), 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.

1. Two−Stage Heating (Adaptive Mode) with Single−Stage Thermostat

NOTE: The low−heat only switch SW1−2 selects either the

low−heat only operation mode when ON, (see item 2. below) or the adaptive heating mode when OFF in response to a call for heat. (See Figure 5) When the W2 thermostat terminal is energized it will always cause high−heat operation when the R−to−W circuit is closed, regardless of the setting of the low−heat only switch. This furnace can operate as a two−stage furnace with a single−stage thermostat because the furnace control CPU includes a programmed adaptive sequence of controlled operation, which selects low−heat or high−heat operation. This selection is based upon the stored history of the length of previous gas−heating periods of the single−stage thermostat.

The furnace will start up in either low− or high−heat. If the furnace starts up in low−heat, the control CPU determines the low−heat on−time (from 0 to 16 minutes) which is permitted before switching to high−heat.

If the power is interrupted, the stored history is erased and the control CPU will select low− switch to high−heat, as long as the thermostat continues to call for heat. Subsequent selection is based on stored history of the thermostat cycle times.

The wall thermostat “calls for heat”, closing the R−to−W circuit. The furnace control performs a self−check, verifies the low−heat and high−heat pressure switch contacts LPS and HPS are open, and starts the inducer motor IDM in high−speed.

a. Inducer Prepurge Period

(1.) If the furnace control CPU selects low−heat

operation the inducer motor IDM comes up to speed, the low−heat pressure switch LPS closes, and the furnace control CPU begins a 15−second prepurge period. If the low−heat pressure switch LPS fails to remain closed the inducer motor IDM will remain running at high−speed. After the low−heat pressure switch re−closes the furnace control CPU will begin a 15−second prepurge period, and continue to run the inducer motor IDM at high−speed.

(2.) If the furnace control CPU selects high−heat

operation, the inducer motor IDM remains running at high−speed, and the high−heat pressure switch relay HPSR is de−energized to close the NC contact. When sufficient pressure is available the high−heat pressure switch HPS closes, and the high−heat gas valve solenoid

440 04 4801 00 30

heat for up to 16 minutes and then

Specifications subject to change without notice.

GV−HI is energized. The furnace control CPU begins a 15−second prepurge period after the low−heat pressure switch LPS closes. If the high−heat pressure switch HPS fails to close and the low−heat pressure switch LPS closes, the furnace will operate at low−heat gas flow rate until the high−heat pressure switch closes for a maximum of 2 minutes after ignition.

b. Igniter Warm−Up −At the end of the prepurge period,

the Hot−Surface Igniter HSI is energized for a

second igniter warm−up period.

17−

c. 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−M. The gas valve solenoid GV−M permits gas flow to the burners where it is ignited by the HSI. Five seconds after the GVR closes, a 2−second flame proving period begins. The HSI igniter will remain energized until the flame is sensed or until the 2−second flame proving period begins. If the furnace control CPU selects high−heat operation, the high−heat gas valve solenoid GV−HI is also energized.

d. Flame−Proving − When the burner flame is proved

at the flame−proving sensor electrode FSE, the inducer motor IDM switches to low−speed unless the furnace is operating in high−heat, and the furnace control CPU begins the blower−ON delay period and continues to hold the gas valve GV−M open. If the burner flame is not proved within two seconds, the control CPU will close the gas valve GV−M, and the control CPU will repeat the ignition sequence for up to three more 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 on high speed until flame is no longer proved.

e. Blower−On delay − If the burner flame is proven the

blower−ON delays for low−heat and high−heat are as follows: Low−heat − 45 seconds after the gas valve GV−M is opened the blower motor BLWM is turned ON at low−heat airflow.

High−heat

opened the BLWM is turned ON at high−heat airflow. Simultaneously, the humidifier terminal HUM and electronic air cleaner terminal EAC−1 are energized and remain energized throughout the heating cycle.

f. Switching from Low− to High−Heat − If the furnace

control CPU switches from low−heat to high−heat, the furnace control CPU will switch the inducer motor IDM speed from low to high. The high−heat pressure switch relay HPSR is de−energized to close the NC contact. When sufficient pressure is available the high−heat pressure switch HPS closes, and the high−heat gas valve solenoid GV−HI is energized. The blower motor BLWM will transition to high−heat airflow five seconds after the furnace control CPU switches from low−heat to high−heat.

g. Switching from High− to Low−Heat −The furnace

control CPU will not switch from high−heat to low−heat while the thermostat R−to−W circuit is closed when using a single−stage thermostat.

h. Blower−Off Delay −When the thermostat is satisfied,

the R to W circuit is opened, de−energizing the gas

− 25 seconds after the gas valve GV−M is

SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE

valve GV−M, stopping gas flow to the burners, and de−energizing the 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 low−heat airflow or transition to low−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.

2. Two−Stage Thermostat and Two−Stage Heating See Figure 18−Figure 21 for thermostat connections.

NOTE: In this mode the low−heat only switch SW1−2 must be ON to select the low−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 high−heat operation, regardless of the setting of the low−heat only switch. The wall thermostat “calls for heat”, closing the R−to−W1 circuit for low−heat or closing the R−to−W1−and−W2 circuits for high−heat. The furnace control performs a self−check, verifies the low−heat and high−heat pressure switch contacts LPS and HPS are open, and starts the inducer motor IDM in high−speed.

The start up and shut down functions and delays described in item 1. above apply to the 2−stage heating mode as well, except for switching from low− to high−Heat and vice versa.

a. Switching from Low− to High−Heat − If the

thermostat R−to−W1 circuit is closed and the R−to−W2 circuit closes, the furnace control CPU will switch the inducer motor IDM speed from low to high. The high−heat pressure switch relay HPSR is de−energized to close the NC contact. When sufficient pressure is available the high−heat pressure switch HPS closes, and the high−heat gas valve solenoid GV−HI is energized. The blower motor BLWM will transition to high−heat airflow five seconds after the R−to−W2 circuit closes.

b. Switching from High− to Low−Heat −If the

thermostat R−to− W2 circuit opens, and the R−to−W1 circuit remains closed, the furnace control CPU will switch the inducer motor IDM speed from high to low. The high−heat pressure switch relay HPSR is energized to open the NC contact and de−energize the high−heat gas valve solenoid GV−HI. When the inducer motor IDM reduces pressure sufficiently, the high−heat pressure switch HPS will open. The gas valve solenoid GV−M will remain energized as long as the low−heat pressure switch LPS remains closed. The blower motor BLWM will transition to low−heat airflow five seconds after the R−to−W2 circuit opens.

3. Cooling mode The thermostat “calls for cooling”.

Single−Speed Cooling−

See Figure 18 and Figure 20 for thermostat connections 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 Table 5. 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 4)

b. Two−Stage Thermostat and Two−Speed Cooling

See Figure 19 and Figure 21 for thermostat

connections 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−and−Y1 circuit starts the

furnace blower motor BLWM at low−cooling airflow which is the CF (continuous fan) selection as shown in Figure 5. 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 (air conditioning) selection shown in Figure 5. 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 16)

4. Dehumidfy Mode See Figure 18−Figure 24 for thermostat connections. The H output on the humidify sensing 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.

Activation/Deactivation

Once 24 vac is detected by the furnace control on the DHUM input, the furnace control operates in dehumidify mode. If the DHUM input is low for more than 48 hours, the furnace control reverts back to non−dehumidify mode. The cooling operation described in Item 3, Cooling mode. above also applies to operation with a humidity sensing thermostat. The exceptions are listed below:

a. Low Cooling−When the R−to−G−and−Y1 circuit is

closed and there is a demand for dehumidification, the low cooling airflow demand is reduced by 10 percent.

b. High

−Cooling−When the R−to−G−and−Y/Y2 circuit is

closed and there is a demand for dehumidification, the high cooling airflow demand is reduced by 10 percent.

c. 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.

5. 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 (continuous fan) selection shown in Figure 5. Factory default is shown in Figure 5. Terminal EAC−1 is energized as long as the blower motor BLWM is energized. During the call for heat, the furnace control CPU will keep the blower motor BLWM to continuous blower airflow. The blower motor BLWM will remain ON until the main burners ignite then shut OFF and remain OFF for the blower−ON delay (45 seconds in low−heat, and 25 seconds in high−heat), allowing the furnace heat exchangers to heat up more quickly, then restarts at the end of the blower−ON delay period at low−heat or high−heat airflow, respectively.

31 440 04 4801 00

Specifications subject to change without notice.

SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE

The blower motor BLWM will revert to continuous−blower airflow after the heating cycle is completed. In high−heat, the furnace control CPU will drop the blower motor BLWM to low−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 switch to 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. 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.

6. Heat pump See Figure 20 and Figure 21 for thermostat connections. 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, low−heat airflow, or 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 heating 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 low−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 18 for instructions.

Figure 18

NOTE 9

Figure 19

NOTE 9

Variable Speed Furnace with Single Stage Air Conditioner

Variable Speed Furnace with Two−Stage Air Conditioner

L09F027

440 04 4801 00 32

Specifications subject to change without notice.

SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE

Figure 20

NOTE 9

Variable Speed Furnace with Single Stage Heat Pump (Dual Fuel)

Figure 22

Figure 23

Variable Speed Furnace and Humidifier Only

L09F029

AC with Variable Speed Furnace, Humidifier, and Dehumidification

Figure 21

NOTE 9

L09F026

Variable Speed Furnace with Two−Stage Heat Pump (Dual Fuel)

L09F029

L09F028

33 440 04 4801 00

Specifications subject to change without notice.

SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE

Figure 24

HP with Variable Speed Furnace, Humidifier, and Dehumidification

L09F030

NOTES FOR FIGURES Figure 18 − Figure 24

1. Refer to outdoor equipment Installation Instructions for additional information and setup procedure.

2. Outdoor Air Temperature Sensor must be attached in all dual fuel applications.

3. Refer to ICP thermostat Installation Instructions for additional information and setup procedure.

4. When using a Humidity Sensing Thermostat, set DEHUMIDIFY OPTIONS to H DE−ENRGZD FOR DEHUM.

5. Optional connection. If wire is connected SW1−2 on VS furnace control should be set in ON position to allow ICP Thermostat to control the furnace staging.

6. HUM connection is 24 VAC and is energized when the blower turns on during a call for heat.

7. When connecting 115 VAC to humidifier use a separate 115 VAC supply.

8. When using a humidifier on a HP installation connect humidifier to hot water.

9. Thermostat signals may vary. Consult thermostat installation instructions for more information.

440 04 4801 00 34

Specifications subject to change without notice.

SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE

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

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 qualified 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.

International Comfort Products

Consumer Relations Department

P.O. Box 128

Lewisburg, TN 37091, USA

931−270−4100

35 440 04 4801 00

Specifications subject to change without notice.

SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE

PRODUCT NOMENCLATURE

DIGIT POSITION

G = Mainline Look 1 F = Mainline Look 2 N = Entry 9 = 90% − 100% EFFICIENCY M = Multiposition H = Horizontal U = Upflow D = Downflow A = Modulating Variable Speed ECM V = Variable Speed X = ECM S = Single−stage T = Two−stage 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 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 14 = 14−3/16” 17 = 17−1/2” 21 = 21” 24 = 24−1/2” 10 = 1000 CFM (max) 14 = 1400 CFM (max) 16 = 1600 CFM (max) 20 = 2000 CFM (max) 22 = 2200 CFM (max) SALES (MAJOR) REVISION DIGIT ENGINEERING (MINOR) REVISION DIGIT

1 2 3 4 5 6, 7, 8 9, 10 11, 12 13 14

9 M V E 060 17 14 A 2

FEATURE

INPUT HEAT

CABINET WIDTH

COOLING AIRFLOW

440 04 4801 00 36

Specifications subject to change without notice.

AHRI 9MVE0401410A2, 9MVE0401712A2, 9MVE0601412A2, 9MVE0601714A2, 9MVE0801716A2 Technical

Specifications and Main Features

Frequently Asked Questions

User Manual