Page 1
MULTI POSITION
SINGLE STAGE
GAS FURNACES
N9MP1, N9MP2 & *9MPD
This manual supports condensing gas furnaces manufactured in 2001
Manufactured by:
ã 2001 International Comfort Products Corporation (USA)
“A1 & A2”
Part Number
440 08 2001 02
4/2002
Page 2
N9MP1 -- Indoor combustion air (1 pipe only)
N9MP2 -- Direct Vent ONLY (2 pipe only)
*9MPD -- Dual Certified Venting (1 or 2 pipes)
* Denotes Brand (T, C or H)
Page 3
Single Stage Multi Position Furnace
Service Manual
TABLE OF CONTENTS
1. INTRODUCTION 2............................................................
2. UNIT IDENTIFICATION 2.....................................................
3. FURNACE THEORY OF OPERATION 3........................................
4. ELECTRICAL SUPPLY 4......................................................
5. INTERLOCK SWITCH 5......................................................
6. GAS SUPPLY 5..............................................................
7. BURNERS 7................................................................
8. L.P. PRESSURE SWITCH 7...................................................
9. HIGH ALTITUDE OPERATION 7...............................................
10. CHECKING TEMPERATURE RISE 8..........................................
11. ROOM THERMOSTATS 8....................................................
12. CONTROL WIRING 9.......................................................
13. TWINNING KITS 10..........................................................
14. LIMIT SWITCHES 10.........................................................
15. PRESSURE SWITCHES 12...................................................
16. VENT/COMBUSTION AIR PIPING 14..........................................
17. STANDARD VENT TERMINATION 14..........................................
18. CONCENTRIC VENT TERMINATION 16........................................
19. EXHAUST BLOWER 17......................................................
20. CONDENSATE DRAIN TRAP 17...............................................
21. HONEYWELL ST9160B FAN TIMER/FURNACE CONTROL 18....................
22. ST9160B TESTING SEQUENCE 19............................................
23. ST9160B -- UNIQUE CONTROL FUNCTIONS/RESPONSES 19...................
24. HONEYWELL SV9541M GAS VALVE/IGNITION SYSTEM 20.....................
25. HONEYWELL SV9541M SYSTEM OPERATION 20..............................
26. CHECKING FLAME CURRENT 21.............................................
27. CAPACITORS 22............................................................
28. BLOWER ASSEMBLY 22.....................................................
29. BLOWER ROTATION 23......................................................
30. HEAT EXCHANGER REMOVAL/REPLACEMENT 44.............................
SV9541M “SMART VALVE” -- Sequence of Operation 45.............................
SV9541M “SMART VALVE” -- Trouble shooting 47...................................
SV9541M “SMART VALVE” -- Electrical Variation 49.................................
WIRING DIAGRAM 50...........................................................
TECHNICAL SERVICE DATA (N9MP1 or 2) 52......................................
TECHNICAL SERVICE DATA (*9MPD/A1) 54......................................
TECHNICAL SERVICE DATA (*9MPD/A2) 55......................................
BLOWER PERFORMANCE DATA (N9MP1 or 2 & *9MPD) 56.........................
APPENDIX OF HELPFUL INFORMATION 57.......................................
Page 4
Service
Manual
1. INTRODUCTION
This service manual is designed to be used in conjunction
with the installation manual and/or technical support manual
provided with each furnace.
These furnaces represent the very latest in high efficiency
gas furnace technology. Consequently, they incorporate the
use of certain controls that contain highly sophisticated electronic components which are not user serviceable. there-
fore, it is essential that only competent, qualified, service
personnel attempt to install, service, or maintain this product.
This Service manual was written to assist the professional
HVAC service technician to quickly and accurately diagnose
and repair any malfunction of this product.
This service manual covers our new multi--position furnaces,
both Direct Vent (2 pipe Only), Indoor combustion (1 pipe
Only) and Dual Certified (1 or 2 pipe) models. The overall operation of all of these models is essentially the same.
This manual, therefore, will deal with all subjects in a general
nature (I.E. all text will pertain to all models) unless that subject is unique to a particular model or family, in which case
it will be so indicated.
Single Stage Multi Position Furnace
!
The information contained in this manual is
intended for use by a qualified service technician
who is familiar with the safety procedures required
in installation and repair and who is equipped with
the proper tools and test instruments.
Installation or repairs made by the unqualified
persons can result in hazards subjecting the
unqualified person making suchrepairs to the risk of
injury or electrical shock which can be serious, or
even fatal not only to them, but also to persons being
served by the equipment.
If you install or perform service on equipment, you
must assume responsibility for any bodily injury or
property damage which may result to you or others.
We will not be responsible for any injury or property
damage arising from improper installation, service
and/or service procedures.
2. UNIT IDENTIFICATION
The unit’s rating plate contains important information for the
service technician. It also lists the complete Model Manufacturing and Serial Numbers.
These complete numbers are required to obtain correct re-
MODEL NUMBER IDENTIFICATION GUIDE
placement parts (example, in certain model families a unit
having a MARKET REVISION of “C” is likely to be equipped
with one or more different components.
* 9 MP D 075 B 12 A 1
Brand Identifier Engineering Rev.
T=Tempstar Denotes minor changes
C = Comfortmaker Marketing Digit
H=Heil Denotes minor change
A = Arcoaire
X = Evaluation Cooling Airflow
Brand Identifier 08 = 800 CFM
8 = Non--Condensing, 80+% Gas Furnace 12 = 1200 CFM
9 = Condensing, 90+% Gas Furnace 14 = 1400 CFM
Installation Configuration 16 = 1600 CFM
UP = Upflow DN = Downflow UH = Upflow/Horizontal 20 = 2000 CFM
HZ = Horizontal DH = Downflow/Horizontal
MP = Multiposition, Upflow/Downflow/Horizontal Cabinet Width
Major Design Feature B = 15.5² Wide
1 = One (Single) Pipe N = Single Stage F = 19.1² Wide
2=TwoPipe P=PVCVent J = 22.8² Wide
D = 1 or 2 Pipe T = Two Stage L = 24.5² Wide
L = Low NOx V = Variable Speed Input (Nominal MBTUH)
440 08 2001 02
2
Page 5
Single Stage Multi Position Furnace
Service
Manual
Figure 1
Gas Valve/Ignition Module
Component Locations for Four Position Furnaces
Furnace Vent Pipe
Manual Gas Valve
Vent Drain Fitting
Diagnostic Light
Combustion Air
5
Blower
/8² OD Vent Pipe
Drain Hose
3
/4² OD Transition Box
Drain Hose
Door Interlock Switch
Fan/Delay Control
Vent Pipe
Grommet
Rating Plate
Air Intake Pipe
(Dual Certified or Direct
Vent Model)
Primary Heat Exchanger
Secondary Heat Exchanger
Pressure Switch
Plastic Transition Box
Circulating Air Blower
dwg 25--23--29a
3. FURNACE THEORY OF OPERATION
The high efficiencies and lower profile (compared to previous
series) of this furnace have been obtained using design techniques not typical of traditional furnace designs. A brief description of these new design techniques and the purpose
they serve follows.
1. Reducing the height of the furnace while maintaining
the high efficiency of pervious models required maintaining the surface area of the heat exchanger and yet
minimizing the overall size.
The design required to achieve these results is the “SERPENTINE” design, wherein the flue gasses must follow a
serpent shaped passage through the heat exchanger via
convection.
This “Serpentine” path is resistive to normal convective flow,
and requires that a partial vacuum be created at the outlet
of the heat exchanger to maintain the flow of flue products
through the heat exchanger.
2. The serpentine heat exchanger design does not lend
itself well to the ribbon type, or slotted port type burner
found in more traditional design furnaces for the following reasons:
A. The secondary combustion airflows at right angles
to the burner flame, making it likely to “pull” the flame
off a ribbon or slotted port type burner.
B. The flame “height” of a ribbon or slotted port type
burner would make it difficult (if not impossible) to
prevent impingement of the flame on the heat exchanger surfaces whole maintaining the low profile
heat exchanger.
For these reasons, an “INSHOT” type burner is used in this
series. The inshot burner (also called a “jet” burner) fires a
flame straight out its end. This burner is designed to fire into
a tube style heat exchanger, making it an ideal application in
the tube--like passages of the serpentine heat exchanger.
3. In order to extract the maximum amount of heat possible from the flue gasses, a secondary heat exchanger (condenser) is connected to the outlet of the primary
heat exchanger. This condenser removes additional
heat from the flue gasses, causing their temperature to
drop below dew point. This results in the forming of
condensation (water) which then must be routed to a
drain.
4. The placement of the secondary heat exchanger at the
outlet of the primary heat exchanger creates additional
resistance to the flow of gasses.
5. To overcome the resistance to convective flow of the
Primary and Secondary heat exchangers requires the
use of an Induced Draft Combustion Blower Assembly.
3
440 08 2001 02
Page 6
Service
Manual
Single Stage Multi Position Furnace
6. The Combustion Blower Assembly is mounted on the
outlet side of the Secondary heat exchanger, This
blower creates a partial vacuum (negative pressure)
within the heat exchangers drawing the flue products
out of the furnace.
4. ELECTRICAL SUPPLY
!
Electrical shock hazard.
Turn OFF electric power at fuse box or service panel
before making any electrical connections and ensure a proper ground connection is made before
connecting line voltage.
Failure to do so can result in death, personal injury
and/or property damage.
SUPPLY CIRCUIT
The furnace cannot be expected to operate correctly unless
it is properly connected (wired) to an adequately sized (15
amp.) single branch circuit.
SUPPLY VOLTAGE
Supply voltage to the furnace should be a nominal 115 volts.
It MUST be between 97 volts and 132 volts. Supply voltage
to the furnace should be checked WITH THE FURNACE IN
OPERATION. Voltage readings outside the specified range
can be expected to cause operating problems. Their cause
MUST be investigated and corrected.
ELECTRICAL GROUND
Grounding of the electrical supply to ALL FURNACES IS
REQUIRED for safety reasons.
CHECKING GROUNDING AND POLARITY
7. A pressure switch (Air Proving Switch) is used as a
safety device that prevents the ignition system from firing the furnace until it senses that a proper draft has
been established through the furnace.
Polarity may be verified as follows:
1. Turn the power supply “ON”.
2. Using a Vo lt m e t e r check for voltage between the Hot
(Black) and Neutral (White) wire of supply circuit.
POLARITY
CORRECT POLARITY of the line voltage supply to all furnaces is also required for safety reasons.
3. Reading should be Line (Supply) Voltage.
4. Check for Voltage between the Neutral (White) wire
and Ground wire of the supply circuit.
5. Reading should be zero Volts. (if line voltage is read,
polarity is reversed)
6. A zero Volt reading indicates there is no voltage potential on Neutral wire.
7. Double check by checking for voltage between the Hot
(Black) wire and Ground wire of the supply circuit.
8. Reading should be Line (supply) Vo lt a g e.(ifzero
volts is read, there is no ground, or polarity is reversed.)
Figure 2
NOTE: Junction Box can
be mounted to either the
left or right side.
Electrical Connections
Grounding may be verified as follows:
1. Turn the power supply “OFF”.
2. Using an Ohmmeter check for continuity between the
Neutral (white) wire and Ground wire (green) of the
supply circuit.
3. With the Ohmmeter set on the R x 1 scale, the reading
should be zero Ohms.
4. A zero Ohm reading indicates that the neutral is
grounded back to the main panel.
5. An alternate check would be to check for continuity
from the Neutral to a cold water pipe, (Pipe must be
metal, and must have a continuous, uninterrupted connection to ground) or to a continuous, uninterrupted
connection to ground) or to a driven ground rod.
6. Any readings other than zero Ohms would indicate a
poor ground, or no ground.
440 08 2001 02
25--23--42
4
Page 7
Single Stage Multi Position Furnace
5. INTERLOCK SWITCH
The blower compartment door of all models is equipped with
an interlock switch. This switch is “Normally Open” (closes
when the door is on the furnace) and interrupts furnace operation when the door is open. This interlock switch is a safety device, and SHOULD NEVER BE BY--PASSED.
Since this is a single pole switch, (breaking only one side of
the line) proper line voltage is essential to insure that furnace
components are not “HOT” when switch is open. (See
Checking Grounding and Polarity)
6. GAS SUPPLY
Typ ical Gas Valve HoneywellFigure 4
Pilot Pressure
Adjustment (Hid-
den)
On\Off
Switch
Diagnostic Light
An adequately sized gas supply to the furnace is required for
proper operation. Gas piping which is undersized will not
provide sufficient capacity for proper operation. Piping
should be sized in accordance with accepted industry standards.
NATURAL GAS
OUTLET
Manifold Pressure
Adjustment
dwg 25--23--31a
INLET
Manual
10--12--96
Figure 3
Service
Typical Interlock Switch
the inlet pressure MUST be a minimum of 11² W.C. If this
cannot be obtained, problems are indicated in either the regulator or pipe sizing.
Table 1 Gas Pressures Below 2000¢¢¢¢
Gas
Type
Natural 7² 14² 4.5² 3.5²
· With Propane gas, the rated input is obtained when the
· If Propane gas has a different BTU content, orifices
· Measured input can NOT exceed rated input.
· Any majorchange in gas flow requires changing burner
Recommended Max. Min.
LP 11² 14² 11² 10²
BTU content is 2,500 BTU per cubic foot and manifold
pressure set at 10²²²² W.C.
MUST be changed by licensed Propane installer.
orifice size.
Supply Pressure
Important Note:
Manifold
Pressure
CHECKING INPUT (FIRING) RATE
Once it has been determined that the gas supply is correct
to the furnace, it is necessary to check the input (firing) rate,
This can be done in two (2) ways. First by checking and adjusting (as necessary) the manifold (Outlet) pressure. The
second way is to “Clock” the gas meter.
Inlet (Supply) pressure to the furnace should be checked (at
the gas valve) with ALL OTHER GAS FIRED APPLIANCES
OPERATING. Inlet (Supply) pressure to the furnace under
these conditions MUST be a minimum of 4.5² W.C. (Water
Column). If the inlet pressure is less, it may be an indication
of undersized piping or regulator problems.
L.P. GAS
Inlet (Supply) pressure to the furnace should be checked in
the same manner as for Natural Gas, however with L.P. Gas,
!
Fire or explosion hazard.
Turn OFF gas at shut off before connecting
manometer.
Failure to turn OFF gas at shut off before
connecting manometer can result in death,
personal injury and/or property damage.
5
440 08 2001 02
Page 8
Service
H
Manual
Single Stage Multi Position Furnace
Figure 5
Pressure Connections
Typical "U" Tube
Manometer
MANIFOLD PRESSURE AND ORIFICE SIZE FOR HIGH ALTITUDE APPLICATIONS
Gas Pressure Testing Devices
3
2
1
0
1
2
3
0
INCHES OF WATER
510
MAGNEHELIC
MAX. PRESSURE 15 PSIG
15
1. Connect a manometer or Magnehelic gauge (0-- 12²
W.C. range) to the pressure tap on the “OUTLET” side
of the gas valve.
2. Turn gas “ON”, fire the furnace, and remove adjustment cover (screw--cap).
3. Turn adjustment screw clockwise (IN) to INCREASE
pressure, and counterclockwise (OUT) to DECREASE
pressure.
4. At altitudes BELOW 2,000¢¢¢¢ set manifold pressure to
3.5² W.C. for Natural Gas, and 10² W.C. for L.P. Gas.
5. For Natural Gas units ABOVE 2,000¢¢¢¢, set manifold
pressure according to TABLE 2.
6. For L.P. Gas units ABOVE 2,000¢¢¢¢, insure that orifice
size has been changed (per “National Fuel Gas Code”
-- Appendix “F”) if gas supply has not already been de-rated for altitude by the gas supplier .
7. For ALL UNITS ABOVE 8,000¢, contact the factory for
SPECIFIC de--rating information.
CHECKING MANIFOLD PRESSURE
Table 2 NATURAL GAS
eatValue
Btu/Cu.Ft.
800 3.5 3.5 3.5 3.5 3.5 3.5 3.5
850 3.5 3.5 3.5 3.5 3.5 3.5 3.5
900 3.5 3.5 3.5 3.5 3.5 3.5 3.4
950 3.5 3.5 3.5 3.5 3.3 3.2 3.1
1000 3.5 3.4 3.3 3.2 3.0 2.9 2.8
1050 3.2 3.1 3.0 2.9 2.7 2.6 2.5
1100 2.9 2.8 2.7 2.6 2.5 2.4 2.3
Orifice Size #42 #42 #42 #42 #42 #42 #42
0--1999
(²²²²××××wc)
2000--2999
(²²²²××××wc)
3000--3999
(²²²²××××wc)
“CLOCKING” GAS METER (NATURAL GAS)
1. Check with gas supplier to obtain ACTUAL BTU content of gas.
2. Turn “OFF” gas supply to ALL other gas appliances.
3. Time how many seconds it takes the smallest (normally 1 cfh) dial on the gas meter to make one complete
revolution.
Elevation Above Sea Level
4000--4999
(²²²²××××wc)
5000--5999
(²²²²××××wc)
6000--6999
(²²²²××××wc)
4. Calculate input rate by using ACTUAL BTU content of
gas in formula shown in example.
Example
Natural Gas
BTU Content
1,000 3,600 48 75,000
No. of Seconds
Per Hour
1,000 x 3,600 ¸ 48 = 75,000 BTUH
Time Per Cubic
Foot in Seconds
7000--7999
(²²²²××××wc)
BTU Per
Hour
440 08 2001 02
6
Page 9
Single Stage Multi Position Furnace
7. BURNERS
Burners used in this series of furnace are of the “INSHOT”
type. Their operation can be compared to that of a torch in
that they produce a hard, sharp, somewhat noisy flame.
Noise should not be an issue, however, because of the
closed compartment design. In order to insure that the burners are operating properly, and at their design noise level,
proper adjustment of the gas (manifold) pressure is essential. See page 6 for further information on manifold pressure
adjustments.
The burners used in this series ARE NOT EQUIPPED WITH
AIR SHUTTERS, as none are required. Proper operation
(flame characteristics) is obtained by insuring that the orifice
size, and manifold pressure are correct for the fuel being
used and the altitude of the installation.
8. L.P. PRESSURE SWITCH
Models converted to operate on L.P. Gas will be installed
with an L.P. Pressure Switch. If so equipped, the switch will
be located in the gas supply line (in a “Tee” fitting), just ahead
of the gas valve.
Figure 6
Figure 7
Service
Main Burner
Burner Face
Typical L.P . Pressure Switch
Manual
10--10--78
The purpose of this switch is to prevent furnace operating under low line (Supply) pressure conditions. Operating under
low line pressure conditions, can create problems such as incomplete combustion, flashback, sooting, etc.
The switch is a “Normally Open” pressure operated switch
that is wired in series with the furnace (vent) pressure switch.
The L.P. Pressure Switch closes when line (Supply) pressure is 8.0² W.C. or higher. the L.P. Pressure Switch Opens
if line pressure falls below 6.0²
power to the gas valve.
On some models, it is located (electrically) between the Furnace (vent) pressure switch and the gas Valve.
+
0.6² W.C. interrupting
9. HIGH ALTITUDE OPERATION
These furnaces are designed to operate in the majority of the
country without modifications. At altitudes over 2,000¢ above
sea level, however, certain measures need to be taken to insure continued, safe reliable operation. For example, units
must be de--rated for altitude (by adjusting manifold pressure and/or changing orifice size) based upon the type of fuel
(I.E. Natural Gas or L.P. gas), Btu content of the gas, and
installed altitude.
ALL UNITS must have a high altitude pressure switch
installed at altitudes above 4,000¢ above sea level.
When servicing a unit installed at altitudes above 2,000¢ insure that it has been properly modified to operate at that altitude. See the sections on Gas pressure (Page *), and pressure switches (Page **) to obtain specific information for you
particular installation altitude.
7
440 08 2001 02
Page 10
Service
Manual
10. CHECKING TEMPERATURE RISE
Single Stage Multi Position Furnace
Figure 8
Thermometer:
Return Air Temp.
Return
Air Flow
Checking Temperature Rise
Supply
Air Flow
Thermometer;
Supply Air Temp.
The furnace is designed to operate within a certain specified
range of temperature rise.
Operating the furnace outside the specified range may result
in lower efficiency and/or comfort levels, as well as premature combustion component failures.
Simply stated, the temperature rise through the furnace is
the difference in temperature between the return air, and the
supply air.
NOTE: BEFORE CHECKING TEMPERATURE RISE BE
CERTAIN THAT MANIFOLD PRESSURE IS PROPERLY
ADJUSTED.
ALLOWABLE TEMPERATURE RISE ALL
MODELS
Model
50 Mbtu 35°F--65°F
75, 100 & 125 Mbtu 40°F--70°F
Operate the furnace for 15 minutes before taking temperature readings. Subtract the return air temperature from the
supply air temperature. The result is the temperature rise.
Compare with the allowable rise listed for the model (size)
you are checking.
Temperature Rise can be checked by placing a thermometer
in the return air duct within 6¢ of furnace. Place a second thermometer in the supply duct at lease two (2) ft. away from the
furnace. (This will prevent any false readings caused by radiation from the furnace heat exchanger) Make sure that the
FILTER IS CLEAN and that ALL REGISTERS AND/OR
DAMPERS ARE OPEN.
If the rise is not within the specified range, it will be necessary
to change the heating blower speed. If the rise is too high,
it will be necessary to increase the blower speed. If the
rise is too low, it will be necessary to reduce the blower
speed.
Example:
Supply T emp. 170
Return Temp. 70°
Temperature Rise 100° =
Too High
Solution: Increase Blower Speed
Range
°
11. ROOM THERMOSTATS
Room thermostats are available from several different
manufactures in a wide variety of styles. They range from the
very simple and inexpensive Bi--metallic type to the complex.
They are simply a switch (or series of switches) designed to
turn equipment (or components) “ON” or “OFF” at the desired conditions.
An improperly operating, or poorly located room thermostat
can be the source of perceived equipment problems. A careful check of the thermostat and wiring must be made then to
insure that it is not the source of problems.
440 08 2001 02
8
Figure 9
THERMOSTAT
5 ft.
Thermostat Location
DRAFTS
SUN
SHIELD
LIGHT
Page 11
Single Stage Multi Position Furnace
Service
Manual
LOCATION
The thermostat should not be mounted where it may be affected by drafts, discharge air from registers (hot or cold), or
heat radiated from the sun of appliances. Never install in alcoves, bathrooms or bedrooms.
The thermostat should be located about 5 ft. above the floor
in an area of average temperature, with good air circulation.
Normally, an area in close proximity to the return air grille is
the best choice.
Mercury bulb type thermostats MUST be level to control temperature accurately to the desired set--point. Electronic digital type thermostats SHOULD be level for aesthetics.
HEAT ANTICIPATORS
Heat anticipators are small resistance heaters built into most
electric--mechanical thermostats. Their purpose is to prevent wide swings in room temperature during furnace operation.
In order to accomplish this, the heat output from the anticipator must be the same regardless of the current flowing
through it. Consequently, most thermostats have an adjustment to compensate for varying current draw in the thermostat circuit.
The proper setting of heat anticipators then is important to
insure proper temperature control and customer satisfaction.
Figure 10
Measuring Current Draw
The best method to obtain the required setting for the heat
anticipator, is to measure the actual current draw in the control circuit (“W”) using a low range (0--2.0 Amps) Ammeter.
(See Figure 10) After measuring the current draw, simply
set the heat anticipator to match that value.
If a low range ammeter is not available, a “Clamp--on” type
meter may be used as follows:
1. Wrap EXACTLY ten (10) turns of wire around the jaws
of a clamp--on type ammeter.
2. Connect one end of the wire to the “W” terminal of the
thermostat sub--base, and the other to the “R” terminal.
3. Turn power on, and wait approximately 1 minute, then
read meter.
4. Divide meter reading by 10 to obtain correct anticipator
setting.
If an ammeter is not available, a setting of 0.30 amps may
be used for models equipped with the HONEYWELL
SV9541M Gas Valve/Ignition Control. They should, however, provide satisfactory operation in most cases.
Electronic thermostats do not use a resistance type anticipator. These thermostats use a microprocessor (computer)
that determines a cycle rate based on a program loaded into
it at the factory.
These cycle rates are normally field adjustable for different
types to equipment. The method of adjustment, however,
varies from one thermostat manufacturer to another. Check
with the thermostat manufacturer to find out the proper way
of adjusting the cycle rate.
W
Amps
R
Subbase
Ammeter
12. CONTROL WIRING
Control wiring is an important part of the total equipment
installation, since it provides the vital communications link
between the thermostat, and the equipment malfunctions.
Control wiring that is either too long, undersized, or improperly connected (be it simply loose, or on the wrong terminal)
can in fact be the source of many equipment problems.
ALWAYS check to make sure that the control wiring is connected to the proper terminal(s) of the equipment and thermostat you are using. Remember, also, that the thermostat
terminals are not always identified alike by different thermostat manufacturers. Connections MUST be clean and tight
to insure trouble--free operation.
For years, installers have run a wire from the “Y” terminal of
the room thermostat and connected it directly to the contact
on coil of a condensing unit. (not making any connection to
the furnace with this wiring. Then, run the low voltage “Common” wire from the condensing unit back to the “C” terminal
of the furnace.
With the HONEYWELL ST9160B electronic Fan Timer/Furnace Control, the “Y” terminal of the furnace does in fact
serve a particular purpose. Failure to connect it will result in
certain improper operation as follows:
9
440 08 2001 02
Page 12
Service
Manual
Single Stage Multi Position Furnace
The COOLING fan speed is energized via the “Y” terminal.
Failure to connect the thermostat “Y” terminal to the “Y” terminal on the control will result in the failure to energize the
13. TWINNING KITS
Some installations may require a Heating capacity or Airflow
capabilities greater than a single furnace of this series can
provide.. When this is necessary, furnaces may be installed
in a “Twinned” configuration.
The T winning Kit allows the two (2) furnaces to be controlled
by the same room thermostat. When Twinned, the circulating (conditioned air) blowers of BOTH furnaces will operate
14. LIMIT SWITCHES
Two (2) different kinds of limit switches are used on this series of furnaces. They are the main limit and roll out limit
switches. The main limit, and roll limit switches are used on
all models.
NOTE: All limit switch es are safety devices and other
than for testing purposes, should never be jumped out!
Limit switches are “normally closed” electrical switches, designed to open when their predetermined “limit setting” has
been reached.
It should also be remembered, that when a limit switch
opens, it more than likely is not due to a bad switch! The
cause of the opening limit must be found and corrected, before the furnace can resume proper operation.
COOLING speed on a call for cooling from the thermostat.
(The HEATING speed will be energized instead via the “G”
terminal)
simultaneously.
Models equipped with a HONEYWELL ST9160B series Fan
Timer/Furnace Control may be twinned using a model
NAHA003WK01 twinning kit.
To assist troubleshooting efforts of “Twinned” installations,
“TYPICAL” control wiring diagrams are provided on pages **
through **.
Maximum allowable outlet air temperature. While the main
limit is open, combustion blower, and/or the circulating blower will be energized continuously. This control is an “Automatic” reset control, which will reset itself when the temperature sensed drops to a safe level.
If furnace (burner) cycles on this limit switch, (I.E. switch
opens and closes during furnace operation) it is more than
likely due to a high temperature rise through the furnace.
(See checking temperature on page 8 of this manual)
High temperature rise can be caused by either OVER
FIRING (high manifold pressure. incorrect orifices, etc.) or
LOW AIR FLOW (dirty filter, blower speed too low, excessive
static in duct system, etc.)
!
Fire hazard.
Limit controls are factory preset and MUST NOT be
adjusted. Use ONLY manufacturer’s authorized
replacement parts.
Failure to do so can result in death, personal injury
and/or property damage.
The specific functions of the two (2) limit switches used in
this series of furnaces are as follows:
MAIN LIMIT SWITCH
A “Normally Closed” switch located on the front partition of
the furnace. It monitors supply air temperature, and interrupts furnace (burner) operation when a supply air temperature is sensed which would result in the furnace exceeding
Figure 11
Typical Limit Switch
440 08 2001 02
10
Page 13
Single Stage Multi Position Furnace
Service
Manual
To verify this, the cut--out (opening) point of the switch should
be checked (using a thermocouple type thermometer connected to the face of the switch) as follows:
1. Operate furnace for several minutes.
2. Block return air grille(s) to furnace.
3. Observe temperature at which switch opens (burner
operation ceases).
4. Remove blockage from return grille(s).
5. Observe temperature at which switch closes (burner
operation resumes).
6. Compare readings with the limit setting listed in the
appropriate chart for the model you are servicing.
If switch is opening within the specified range, then it is simply doing its job, and the cause of the over--temperature must
be determined and corrected.
If, however , the switch is found to be opening prematurely,
then it should be replaced. When replacing ANY limit switch,
use ONLY a switch of EXACTLY the same temperature setting. Use of a different temperature limit switch can create a
dangerous situation. Some of the main limit switches used
in this series are SIMILAR IN APPEARANCE. DIFFERENT
TEMPERATURE SETTINGS, HOWEVER, ARE USED for
different models. Be certain you have the correct control for
the model you are servicing.
ROLL OUT LIMIT
A “Normally Closed” switch (wired in series with the Main
Limit switch) mounted on the burner box.
This switch may be of the manual type, depending upon the
particular model and/or family. Different temperature
(OPENING) settings are also used on different models.
When replacing this switch, be absolutely certain the correct
one is used.
The roll out switch monitors the temperature inside the burner box, and interrupts furnace (burner) operation when its
temperature indicates flame roll out has occurred.
If the roll out switch has opened, the cause must be determined. Some possible reasons for flame roll out include a restricted primary or secondary heat exchanger or over fired
furnace.
MANUAL RESET SWITCH MODELS
Furnace models which are equipped with a Honeywell
ST9160 Fan timer/furnace control use a manual reset roll out
switch. Once the roll out switch has opened, burner operation will be prevented until the roll out switch is “Manually Reset” by pressing the red button located on the switch. While
the roll out switch is open, (Depending upon the particular
model) the combustion blower and/or circulating blower will
be energized continuously.
AUXILIARY LIMIT SWITCHES
All models are equipped with one (1) additional (AUXILIARY)
limit switch mounted on the blower deck. Its purpose is to
monitor return air temperature, and interrupt burner operation when a temperature is sensed which could result in the
filter surface(s) exceeding allowable temperatures. Depending upon the particular model, the combustion blower, and/or
circulating blower may be energized continuously while the
auxiliary limit switch remains open.
This control is an “Automatic” reset control which will reset
itself when the temperature drops to a safe level. See the
Tech. Service Data Sheet for the model you are servicing, to
obtain its specific auxiliary limit switch setting.
Figure 12
Typical Roll Out Limit Switch
CAUTION
NEVER use an automatic reset roll out switch to replace
a manual reset type roll out switch.
Doing so may cause potentially unsafe and/or intermittent operation.
11
440 08 2001 02
Page 14
Service
²
W.C
1
8+0.1
0
W.C
Manual
15. PRESSURE SWITCHES
Single Stage Multi Position Furnace
Transition Pressure Switch
This switch is designed to monitor a blockage of the condensate drain line. It uses a single tap (port) “Normally Open”
pressure switch (wired in series with the furnace air proving
(pressure) switch. The switch “Closes” at a (negative) pressure setting for the switch associated with that particular
model furnace (See unit specitications).
Under normal operating conditions, sufficient pressure is developed by the exhaust (combustion) blower to close the
switch, and permit the burner to operate. As the condensate
drain begins to back--up, however, the pressure begins to reduce. When the pressure drops sufficiently, burner operation
will be prevented until the condition is corrected.
Blower Pressure Switch
An air proving switch (pressure switch) is used on all models
to insure that a draft has been established through the heat
exchanger before allowing burner operation.
To insure continued SAFE, RELIABLE, operation, NEVER
SUBSTITUTE a pressure switch with one that is similar in
appearance. ONLY FACTORY PROVIDED or
AUTHORIZED SUBSTITUTES ARE ACCEPTABLE.
All models installed at altitudes of 4,000¢ above sea level or
higher require replacing the standard pressure switch with a
high altitude pressure switch. The different pressure switch
settings allow continued SAFE, RELIABLE, high altitude
operation.
Figure 13
Pressure Switches
Blower
Transition
HIGH ALTITUDE PRESSURE SWITCHES - ALL
MODELS
--1.40
Max.
Close
²
Open Part #
--
--1.
.
²
--
.
Model
Upflow
Downflow
CHECK CURRENT TECHNICAL SUPPORT MANUAL
FOR PART NOS.
Under normal operating conditions, sufficient negative pressure will be created to close the pressure switch, and keep
it closed to keep furnace operating. Under abnormal conditions, however, such as a restricted vent pipe, or a leak in one
of the heat exchangers, sufficient negative pressure will not
be created. This will result in the switch failing to close or failing to remain closed during furnace operation.
When servicing a unit whose pressure switch will not close,
or remain closed during operation, the operating pressure of
that furnace should be checked and compared to
approximate operating pressures listed in Tab le 3 and the
switch setting(s) listed above for the model family you are
servicing.
It is important to remember, that greater negative pressures
are created by the furnace when “HOT” (I.E. upon initial
start--up) than when “COLD” (I.E. after furnaces has been in
operation for a few minutes). Because of this, furnace pressure should ONLY be checked when “HOT” to insure accurate readings.
Tab l e 3 lists approximate operating pressures for Direct
Vent (I.E. Two Pipe) installations of models in this series.
They were obtained in a test lab, under controlled conditions
using two (2) specific vent lengths. They are included in this
manual to provide you with a “Barometer” to gauge our pressures against. The pressures you obtain in the field will differ
slightly from these figures based upon vent length, gas pressure, operating temperature, etc.
Major discrepancies in pressures, will normally cause
problems with pressure switch operation. These Major discrepancies should be investigated as follows:
25--23--72
440 08 2001 02
12
Page 15
Single Stage Multi Position Furnace
0Mb
M
b
100Mb
1
25M
b
Tab l e 3 APPROXIMATE OPERATING PRESSURES (²²²² OF W.C.)
Model Vent Length @Blower @ Transition
5
75
tu
tu
tu
tu
Short -- (5¢ No. Elbows) --1.80 --2.60
Long -- (40¢ +590° Elbows) --1.30 --2.30
Short -- (5¢ No. Elbows) --1.80 --2.60
Long -- (40¢ +590° Elbows) --1.30 --2.30
Short -- (5¢ No. Elbows) --1.80 --2.60
Long -- (40¢ +590° Elbows) --1.70 --2.50
Short -- (5¢ No. Elbows) --1.80 --2.60
Long -- (40¢ +590° Elbows) --1.70 --2.50
Service
Manual
Lower (Lesser) Negative Pressures
Lower than normal negative pressures measured at the
Combustion Blower may be caused by:
1. Restriction on the Outlet side of the combustion blower. (I.E. Blocked Flue, Vent too long, Heat Exchanger
leak, etc.)
2. Leak (lack of restriction) on the Inlet side of the combustion blower.
Figure 14
UPFLOW
*8²²²² Min.
20¢¢¢¢ Max.
in same
atmospheric zone
Vent Pipes MUST be
supported Horizontal-
ly and Vertically
Typical Vent/Combustion Air Piping Installation
Aluminum or non--rusting shield recommended.
(See Vent Termination Shielding for dimensions).
Inlet Pipe
(not used
on
Single Pipe
models)
DISCHARGE AIR
Coupling on ends of exhaust pipe. Total pipe &
coupling outside structure = 8²²²²
*8²²²² Min.
20¢¢¢¢ Max.
in same atmospheric zone
Higher (Greater) Negative Pressures
Higher than normal negative pressures measured at the
Combustion Blower may be caused by:
1. Restriction on the Inlet side of the combustion blower.
(I.E. Plugged Heat Exchanger, air inlet orifice too
small)
DOWNFLOW
Inlet Pipe
(not used on
Single Pipe
models)
Vent Pipes MUST
be supported
Horizontally and
Vertically
See Vent Termination Shielding
in Vent Section.
*8²²²² Min.
20¢¢¢¢ Max.
in same
atmospheric
zone
Coupling on inside
and outside of wall to
restrain vent pipe
8² Min.
*8²²²² Min.
20¢¢¢¢ Max.
in same
atmospheric zone
* Increase minimum from 8²
0 °°°° F).
² to 18²²²² for cold climates (sustained temperatures below
²²
25--23--33
13
* Increase minimum from 8²²²² to 18²²²² for cold climates (sustained temperatures
below 0°°°°F).
25--23--33a
440 08 2001 02
Page 16
Service
Manual
16. VENT/COMBUSTION AIR PIPING
Single Stage Multi Position Furnace
Vent and combustion air piping are an extremely important
part of the total furnace installation. Improperly installed or
inadequately sized vent and/or combustion air piping can be
the source of many perceived furnace problems.
For example, most problems associated with pressure
switch operation can normally be traced to short comings in
the vent and/or combustion air piping. Anytime these type
problems arise, a thorough inspection of the vent and/or
combustion air piping should be conducted.
ALL MODELS require a vent (exhaust) pipe to carry flue
17. STANDARD VENT TERMINATION
Vent/Combustion Air Piping Charts
Dual Certified Models ONLY - Non- Direct Vent
Installation
Single Piping Chart
Tab l e 4
50,000 & 75,000 Btuh Furnaces
40¢ & (5) 90° elbows with 2² PVC pipe or
70¢ & (5) 90° elbows with 3² PVC pipe or
70¢ & (5) 90° elbows with 3² PVC pipe
40¢ & (5) 90° elbows with 3² PVC pipe
Elbows are DWVLong Radius Type for 2² and
3² vents.
If more than five elbows are required,reduce the length of both
the inlet and exhaust pipes 5¢ for each additional elbow used.
NOTE: It is allowable to use larger diameter pipe and fitting than
shown in the tables but not smaller diameters than shown.
All Series (Models) - Direct Vent Installation
Tab l e 5
50,000 & 75,000 Btuh Furnaces
40¢ & (5) 90° elbows with 2² PVC pipe or
70¢ & (5) 90° elbows with 3² PVC pipe or
70¢ & (5) 90° elbows with 3² PVC pipe
40¢ & (5) 90° elbows with 3² PVC pipe
Elbows are DWVLong Radius Type for 2² and
3
² ven ts.
Pipe Diameter Table
Single Piping ONLY
100,000 Btuh Furnace
125,000 Btuh Furnace
Dual Piping Chart
Pipe Diameter Table
Dual Piping ONLY
100,000 Btuh Furnace
125,000 Btuh Furnace
products to the outside of the structure.
Direct VENT (ONLY) models require a combustion air inlet
to bring in all air for combustion from outside the structure.
DUAL CERTIFIED models require a combustion air inlet
pipe to bring in all air for combustion from outside the structure only when installed as a Direct Vent Furnace (I.E. Two
Pipe Installation)
Consult the appropriate Venting tables and/or piping chart
for the model (series) you are servicing.
If more than five elbows are required,reduce the length of both
the inlet and exhaust pipes 5¢ (1.5m) for each additional elbow
used.
* Feet of pipe is whichever pipe run is the longest, eitherinlet or
outlet side.
Figure 15
Inlet is optional on
Dual Certified models
A=12² Above roof or snow accumulation level
B=8² Min., 20¢ Maximum, except in areas with extreme cold
temperatures (sustained below 0°F), the 18² Min.
Figure 16
Inlet is optional on
Dual Certified models
Standard Termination
Rooftop Termination
B
A
A
25--00--06
Sidewall Termination12² or More
Above Snow Level or Grade Level
8²²²² *
MIN.
20’
MAX
*18² Minimum for cold climates
(substained below 0° F)
25--00--05F
440 08 2001 02
14
Page 17
Single Stage Multi Position Furnace
Service
Manual
Figure 17
12²²²² Min.
Grade or
Snow Level
Dimension “A” is touching or 2² maximum separation.
Figure 18
Combustion
Concentric Vent and Combustion-
Air Roof Termination
Exhaust
Combustion
Air
Concentric Vent and Combustion-Air Sidewall Termination
Air
“A”
1²²²² Maximum
(TYP.)
Ven t
Figure 20
18²²²² Min. for Cold Climates
(Sustained Below 0°°°° F)
Exhaust
Figure 21
18²²²² Min. for Cold Climates
(Sustained Below 0°°°° F)
Sidewall Inlet Vent and Exhaust--Air
Termination with Exterior Risers
8²²²²
Inlet
Min.
12²²²² Min.
Grade or
Snow Level
8²²²² Min.
20¢¢¢¢ Max.
“A”
“A”
Dimension “A” is touching or 2² maximum separation.
Rooftop Inlet Vent and Exhaust--Air
Termination
Inlet
8²²²² Min.
20¢¢¢¢ Max.
Dimension “A” is touching or 2² maximum separation.
Figure 19
Inlet
12²²²² Min. Grade
or Snow Level
“A”
Ven t
Exhaust
25-- 22- -02d
Sidewall Inlet Vent and Exhaust--Air
Termination
“A”
Ex-
haust
“A”
8²²²² Min.
20¢¢¢¢ Max.
18²²²² Min. for
Cold Climates
(Sustained Below 0°°°° F)
Dimension “A” is touching or 2² maximum separation.
8²²²²
Min.
12²²²² Min.
Grade or
Snow Level
Exhaust
25-- 22- -43
15
440 08 2001 02
Page 18
Service
Manual
Single Stage Multi Position Furnace
Figure 22
FRONT VIEW
Recommended Alternate Installation for Sustained Cold Weather
(--0°°°° F & below)
OVERHANG
12²²²² MIN.
EXHAUST
90°°°°
INLET
12² MIN. Ground
Level
OR Snow Level
SIDE VIEW
12²
25--23--73
Same Joist
Space
18. CONCENTRIC VENT TERMINATION
Vent/Combustion Air Piping Charts
Concentric Termination Kit NAHA001CV
Tab l e 6
NAHA002CV -- 35¢ & (4) 90° elbows with 2² PVC pipe
NAHA001CV -- 65¢ & (4) 90° elbows with 3² PVC pipe
NAHA001CV -- 65¢ & (4) 90° elbows with 3² PVC pipe
NAHA001CV -- 35¢ & (4) 90° elbows with 3² PVC pipe
1. Do not include the field supplied 45° elbow in the total
elbow count.
2. If more than four elbows are required, reduce the length of
both the inlet and the exhaust pipes five feet for each
additional elbow used.
3. Elbows are DWV long radius type for 2² and 3² vents.
& NAHA002VC Venting Table Dual Piping
ONLY
50,000 & 75,000 Btuh Furnaces
100,000 Btuh Furnace
125,000 Btuh Furnace
Figure 23
Roof Boot/
Flashing
(Field Supplied)
Concentric Vent Roof Installation
Vent
Combustion
Air
Vent
Maintain 12² min. clearance
above highest anticipated
snow level. Max. of 24² above
roof.
Support
(Field Supplied)
45° Elbow
(Field Supplied)
440 08 2001 02
Note:
Support must be field installed to secure termination kit to structure.
16
Combustion Air
25--22--02
Page 19
Single Stage Multi Position Furnace
Service
Manual
Figure 24
3² x2² Bushings or
1
3² x2
/2² Bushings
If 3² vent not used
(Field supplied)
Vent
Combustion
Air
Note:
Securing strap must be field installed to prevent movement of termination kit
in side wall.
Concentric Vent Sidewall
Attachment
Strap
(Field Supplied)
45° Elbow
(Field Supplied)
Combustion
Air
Vent
Flush to
1² max.
25--22--02
19. EXHAUST BLOWER
Figure 25
Rubber Coupling
&Clamps
Exhaust Blower
Vent Pipe
(Top Panel Exit)
11²²²² Section PVC pipe
Vent Fitting
90°°°° Street
Elbow
Vent Pipe
(Side Panel EXit)
DRAIN SIDE VIEW
Rotate downward
20°°°° to 30°°°°
&Clamps
Combustion
Blower
25--23--35
20. CONDENSATE DRAIN TRAP
The removal of additional heat from the flue products which
takes place in the secondary heat exchanger (condenser)
causes them to drop below their dew point resulting in condensation. This condensation (water) then must be drained
from the furnace, and routed to a remote drain, or condensate pump.
The combustion blower creates a negative pressure in excess of 2² W.C. while operating. Without a condensate drain
trap of sufficient depth, condensate would be held in the furnace, (because of this negative pressure), and not be able
to drain. Figure 26 shows the transition assembly, which is
mounted between the combustion blower and the front partition.
The condensate drain trap supplied with the furnace MUST
be used. The drain line between the condensate drain trap
and the drain location must be constructed of
3
/4² PVC or
CPVC pipe.
In standard Upflow, Counterflow and/or horizontal
installations, the external drain trap provides sufficient
depth (4²) to insure proper drainage of condensate from the
furnace. Additional traps are NOT required, and should NOT
be used. The use of additional traps will PREVENT proper
drainage of condensate from the furnace. Care should be
taken with the routing of the condensate drain hose, to eliminate all dips or sagging tubing which can create another trap,
and cause drainage problems.
17
440 08 2001 02
Page 20
Service
Manual
Single Stage Multi Position Furnace
Figure 26 (Transition Assembly)
25--23--62
NOTE: The vent fitting MUST be installed with the airflow marking
arrow pointed toward the vent pipe, with the drain stub at a 20°
downward slope.(See Figure 27)
Floats and/or condensate sensors are NOT used in the drain
trap. If the drain line becomes clogged, the condensate level
will rise higher in the external trap. When the level rises sufficiently, the furnace will begin to “Cycle” (On and Off) on the
pressure switch. If the condensate level rises high enough
in the trap, the pressure switch may not close at all, and water may be heard “Paddling” inside the combustion blower.
Figure 27
Vent Drain
Connection
Condensate Drain Trap
Vent Pipe
(Side panel exit)
Drain Line
NEW
Vent Drain
(hidden)
Transition
Box Drain
OLD
25--23--63
21. HONEYWELL ST9160B Series FAN TIMER/FURNACE CONTROL
The Honeywell ST9160B Electronic Fan Timer/Furnace
Control contains NO USER SERVICEABLE COMPONENTS. It is, as its name implies, a fan timer and a furnace control of sorts. In addition to controlling the fan operation for heating, it also takes the place of the blower relay, the
combustion air relay and/or the system relay.
The ST9160B is used in models equipped with the SV9541M
GAS VALVE/IGNITION CONT ROL. It provides the power
source to begin the ignition sequence through a monitored
safety circuit. It also serves as a low voltage terminal strip.
Accessory terminals for connecting a Humidifier and/or
Electronic Air cleaner are also provided, as well as a Continuous fan terminal which allows for continuous fan operation
at a speed other than either the heating or cooling speed.
The control provides a fixed (non--adjustable) 60 second
“ON” and 60 second “OFF” delay for the circulating blower
in COOLING and a 30 second “ON” delay for the circulating
blower in HEATING.
The ST9160B control also provides an adjustable HEATING
“OFF” delay for the circulating blower which can be field adjusted to 60, 100, 140, or 180 seconds.
Figure 28
FUSE
Honeywell ST9160B
Dip
Switch
25--23--63
440 08 2001 02
18
Page 21
Single Stage Multi Position Furnace
Service
Manual
Figure 29
Heating “OFF” Delay DIP switch
Setting
COOL ON DELAY: 6 SEC.
COOL OFF DELAY: 60 SEC.
HEAT ON DELAY: 30 SEC.
25--23--47
22. ST9160B TESTING SEQUENCE
If furnace successfully passes this testing sequence, it can
be assumed that there are no problems with the ST9160B
FAN TIMER/FURNACE CONTROL. If it does not, however,
it does not necessarily mean that there are problems with the
control. Any malfunctions should be thoroughly investigated
before replacing and components.
CHECKING COOLING FUNCTIONS
1. JUMPER “Y” & “G” TO “R”
2. CHECK COOLING FAN DELAY “ON”
3. CHECK COOLING SPEED FAN OPERATION
4. REMOVE JUMPER
5. CHECK COOLING FAN “OFF” DELAY
Setting “OFF” and “ON”
Setting the ST9160B Heating Fan “OFF” Delay is accomplished by the positioning of “DIP” switches. The label on the
back of the furnace door indicates how to position these
switches to obtain the desired setting. (See Figure 29)
The ST9160B Heating “OFF” delay can be set to (60. 100,
140, or 180). The control was shipped out in the 140 position.
This may be satisfactory for some installations, but not for
others.
The Heating “ON” delay is fixed at 30 seconds is not ad -
justable.
The “OFF” delay should be set as long as possible without
creating “COLD AIR” complaints at the end of the cycle.
Troubleshooting
The operation of the HONEYWELL ST9160B series FAN
TIMER/FURNACE CONTROL (as well as the operation of
the furnace in general) can be verified in a few minutes by
using two (2) jumper wires (to jumper terminals of the low
voltage terminal strip) and the “TEST SEQUENCE” below.
CHECKING HEA TING FUNCTIONS
1. JUMPER “W” TO “R”
2. CHECK COMBUSTION BLOWER START--UP
3. CHECK IGNITION SYSTEM ACTIVATION
4. WHEN MAIN BURNER LIGHTS, CHECK HEATING
FAN “ON” DELAY
5. CHECK HEATING SPEED FAN OPERATION
6. REMOVE JUMPER
7. CHECK POST PURGE DELAY
8. CHECK HEATING FAN “OFF” DELAY
23. ST9160B - UNIQUE CONTROL FUNCTIONS/RESPONSES
There are some unique responses from these controls that
differ from what one would normally expect, and may be
somewhat confusing. (See Figure 28) Specifically, these
are as follows:
Energizing the “G” terminal of this control will cause the blower to run on the HEA TING speed. (With most other furnaces,
the blower relay is energized via the “G” terminal normally
causing the blower to run on the cooling speed.)
Energizing the “G” & “Y” terminals (together) will cause the
blower to run on the COOLING speed. It is important that you
take note of this, since control wiring improperly connected
can cause perceived as well as real equipment problems.
For example, in the past, the “Y” terminal in nearly all furnaces was simply a binding post. There was no electrical
connection between this terminal and the rest of the furnace.
Consequently, many installers would not use this terminal to
connect the “Y” signal from the thermostat, but would run it
directly from the thermostat to the condensing unit, the run
the “Common” signal back to the furnace “C” terminal.
This method of wiring will result in improper operation from
this control. The control MUST receive a “Y” signal in order
for it to energize the “COOL” terminal, bringing on the blower
in the cooling speed. If it is wired as above, the condensing
unit will come on, but the blower will run on the HEATING
speed.
“NO TERMINALS” ENERGIZED (on low voltage terminal
strip) -- If a speed tap wire has been connected to the
“CONT.” (continuous) terminal, (operational terminal provided on the ST9160B series controls) the blower will run on
this speed. Maximum allowable connected load for this terminal is 8.0 FLA.
19
440 08 2001 02
Page 22
Service
Manual
Single Stage Multi Position Furnace
The “CONTINUOUS” terminal of the ST9160B control is energized ONLY when there is NO OTHER CALL FOR OP-
ERATION of any kind. If there is a call for HEAT, COOL, or
thermostat sub--base to “FAN ON”, (energizing the “G”terminal) which causes the blower to run on the “HEATING”
speed.
“FAN ON”, this terminal is DE--ENERGIZED. The purpose
of this terminal is to provide a means of air circulation during
“OFF CYCLES” at a different speed than either heating or
cooling. The use of this terminal is operational, and there
will be no speed tap wires connected to this terminal
when the furnace is shipped.
“CONTINUOUS” fan should not be confused with “FAN ON”
which is obtained by switching the fan selector switch on the
The ST9160B Electronic Air Cleaner terminal (EAC)IS
ONLY energized in conjunction with the HEATING and
COOLING speed terminals. The maximum allowable con -
nected load to the HUM terminal is 0.8 (eight tenths)
Amp.*
*The combined connected loads of the EAC and HUM terminals cannot exceed a total of 0.8 (eight tenths) amp.
24. HONEYWELL SV9541M GAS VALVE/IGNITION CONTROL
The system consists basically of only two (2) components.
The Ignition System Control and the Pilot Hardware. The operate on Two (2) 24 volt power circuits received from the
ST9160B Fan Timer/Furnace Control. One is the power supply to the ignitor, the second is to activate the ignition sequence.
The Ignition System Control manages the ignition sequence,
and the flow of gas to the pilot and main burners. It is in essence a combination Gas Valve and Ignition control.
It contains sophisticated electronic components (internally)
and has NO USER SERVICEABLE COMPONENTS.
Should a problem be verified internally within the device, IT
IS NOT REPAIRABLE, and must be replaced.
The Pilot Hardware includes the pilot burner, the hot surface
element that lights the pilot burner, the flame rod that senses
pilot flame, and the cable that attaches to the system control.
The hot surface element is made of tough break resistant ceramic composite material. It operates on 24 Volts A.C. The
Igniter/Flame Rod assembly can be replaced independently
from the pilot burner assembly.
The system operation is quite simple, and forgiving (I.E. nuisance lockouts are eliminated)
Figure 30
Pilot Burner/Sensor
Honeywell ST9541M Ignition System
Ignition/Sensor
Gas Valve/Ignition Control
dwg 25-- 23--31a
25. HONEYWELL SV9541M SYSTEM OPERATION
Connecting the furnace to the line voltage supply with the
blower door interlock switch closed provides 24 volts to power the system. (This is accomplished by the connections
from terminals [pins] #4 & #2 from the ST9160B fan timer to
terminals #1 & #3 of the SV9541M gas valve.)
When the thermostat calls for heat, (the combustion blower
starts, causing the pressure switch to close completing the
circuit to the ignition system control) there will be approximately a two (2) second delay, while the ignition system control runs a self check.
Part of the self check is to see if a flame signal is detected.
If a flame signal is detected upon a call for heat (and naturally
there shouldn’t be), the ignition system control will energize
the electronic fan timer output (causing the conditioned air
blower to start after the fixed 60 second “ON” delay) and will
keep the valve and ignitor to circuit off.
Assuming that no flame signal is detected upon the call for
heat, (Normal operation), the ignition system control will
power the ignitor circuit (24 volts) causing the ignitor to heat
up.
440 08 2001 02
If the ignitor circuit is not proven (I.E. the ignitor is missing,
broken, or the connections are loose) their will be no response from the ignition system control. (Lockout)
Once the ignitor circuit has been proven, and the ignitor begins to heat up, the pilot valve will be energized allowing gas
to flow to the pilot burner.
With the ignitor now hot, and gas flowing to the pilot , the pilot
should light, and the sensor should sense flame.
If no flame is sensed, (I.E. no gas, pilot not lit, flame not enveloping sensor, etc.) the ignitor will stay on, and the pilot
valve will remain open until it does sense flame, or until the
call for heat is satisfied. THE SYSTEM WILL NOT LOCK
OUT under this condition.
Assuming that the pilot does light, and flame is sensed, (normal operation) the ignition system control will turn the ignitor
off, while energizing the main valve. This will allow the pilot
to light the main burner. It will also energize the electronic fan
timer output (causing the conditioned air blower to start after
the fixed 60 second “ON” delay).
20
Page 23
Single Stage Multi Position Furnace
Service
Manual
If a flame outage (I.E. loss of gas supply, blown out, etc.)
should occur during a run cycle (Main burner operation), the
ignition system immediately de--energize the main valve and
re--power the ignitor circuit placing the system back in to the
“Trial For Ignition” mode.
As previously, it will remain in this “Trial For Ignition” mode
(Ignitor powered and pilot valve open) either until the pilot
lights and flame is sensed, or until the call for heat ends.
The SV9541M system is not sensitive to furnace grounding
or line voltage polarity. Accordingly, you cannot experience
a lockout due to those reasons.
Assuming that the main burner did not experience any problems during the run cycle (normal operation) it would continue to operate as long as the call for heat remained.
Once the call for heat ended, the ignition system control
26. CHECKING FLAME CURRENT
The Honeywell SV9541Q Ignition system used in this furnace
series proves (verifies) flame via the Flame Rectification
method.
Flame Rectification is a process of converting Alternating
Current (A.C.) into Direct Current (D.C.) During the ignition
sequence, an alternating current (A.C.) Voltage is applied to
the Flame probe.
When the burner lights the flame conducts an electrical current between the flame probe and the burner ground. Due to
would immediately close the main and pilot valves, and de-energize the electronic fan timer output.
De--energizing the electronic fan timer output causes the
“OFF” delay timing to begin, and when the pre--selected time
(90, 100, 140, or 180 seconds) expires, the blower will turn
off.
TROUBLESHOOTING
Malfunctions of the HONEYWELL SV9541M “Smart Pilot”
system may be easily diagnosed using a voltmeter and a
spare igniter/flame rod assembly.
The igniter itself can also be checked using an Ohmmeter.
Resistance of a “Good” igniter should be 10 Ohms or less.
See trouble shooting flow chart and the sequence of operation flow chart on pages 36 and 37 of this manual for additional information on the operation and troubleshooting of this
system.
the difference in size between the flame probe and the burner ground area this current flows mostly in one direction. This
creates a pulsating Direct Current that flows back to the ignition control proving flame.
This flame current (D.C. Microamps) may be checked (while
flame is present) using a D.C. Flame Sensor kit is available
from outside vendors.
27. CAPACITORS
Figure 31
Checking Capacitor
Microfarads
5 mp
100 m¦
10 m¦
+
1000
m¦
10000 m¦
Capacitors are used for both the circulating (conditioned air)
blower motor and the exhaust (combustion) blower. Before
replacing one of these motors (assumed to be bad) the condition of its capacitor should be verified, since it, and not the
motor, may be the source of the problem.
Before checking any capacitor, the supply power to the unit
should be turned “OFF”. The capacitor should then be discharged (through a resistor) before testing. A 20,000 Ohm
2 Watt resistor can be used for this purpose.
The condition of the capacitor should then be verified with a
capacitor analyzer (one that indicated the capacitor’s value
in microfarads) rather than with an Ohmmeter. The reason
for this, is that an Ohmmeter test can only indicate if a capacitor is “OPEN’, or “SHORTED”, it cannot verify if its value (microfarads) is within an acceptable range.
Capacitor should test to within 10% of its rated value. Capacitors testing outside this range should be replaced. A weak
capacitor can be the cause of a motor failing to start.
21
440 08 2001 02
Page 24
Service
s
PofW
a
c
e
Manual
28. BLOWER ASSEMBLY
Single Stage Multi Position Furnace
All models use a multi--speed, permanent split capacitor motor, direct--drive, blower assembly. Different size (HP) motors and/or different diameter blower wheels are used in
each model to obtain the required air flow. The entire blower
assembly slides out on rails for servicing after removing the
two screws at the front.
SELECTING BLOWER SPEEDS
The wide variety of applications and installations of furnaces
throughout the country makes it impossible to “Factory Select” blower speeds that will provide proper operation for all
installations. This means then, that the blower speeds for
both heating and cooling must be “Field Selected” for each
particular installation to insure proper operation. is to prevent
wide swings in room temperature during furnace operation.
The criteria for selecting the proper blower speeds IS NOT
“High for Cooling, Low for Heating”. Although that may be
how it works out SOMETIMES, it can (in many cases) be exactly the opposite. (I.E. a Lower speed for Cooling, and a
Higher speed for Heating)
The PROPER CRITERIA FOR SELECTING BLOWER
SPEEDS is as follows:
HEATING
A blower speed must be selected that will provide proper
temperature rise through the furnace. (See “checking temperature rise” found elsewhere in this manual), The required
CFM for a particular temperature rise can also be calculated
using the following formula:
Output BTU
Temp. Rise X 1.08 = CFM
EXAMPLE: using a 75 Mbtu furnace of this series with an
output of 67,500 Btuh and a desired temperature rise of 50°
F (range of 40--70° F allowable) and a measured external
static pressure of 0.2² W.C. with a dry coil.
67,500
50 X 1.08 54 = 1250 CFM
Checking the blower performance data for this model, (see
Figure 36) indicates that @ 0.2² W.C. E.S.P. medium--high
speed will deliver 1249 CFM. Accordingly, medium speed
should be used in this example for the HEATING speed.
or 67,500
ample. The external static pressure is measured and found
to be 0.4² W.C.
400 CFM (nominal) per TON required
400x2=800CFMrequired
Checking the blower performance data (see Figure 36) for
this model indicates that @ 0.4² W.C. ESP low speed will deliver 788 CFM. Accordingly, low speed should be used in this
example for the COOLING speed.
Tab l e 7
Blower Performance Data
75,0000 BTUH
Air Delivery in Cubic Feet per Minute (CFM)
sure
Pres
atic
lSt
erna
Ext
(Furnace Rated @ 0.5² W.C. ESP)
TAP LOW MEDLMED H HIGH
.10 778 984 1263 1576
.20 786 1003 1249 1532
.C.
.30 790 1003 1244 1489
.40 788 1001 1215 1432
hes
In
.50 781 982 1186 1371
.60 765 962 1146 1308
.70 743 923 1094 1229
SAMPLE ONLY
CHANGING BLOWER SPEED
The procedure for changing blower speeds (if needed) is
shoun in Table 8.
!
Electrical shock hazard.
Turn OFF power to furnace before changing speed
taps.
Failure to do so can result in death and/or personal
injury.
COOLING
A blower speed must be selected that will provide proper air
flow (Nominal 400 CFM per ton) for the size (capacity) air
conditioning coil being used at the external static pressure
of the Duct system (installation). This requires CHECKING
THE EXTERNAL STATIC PRESSURE, then consulting the
BLOWER PERFORMANCE DATA to determine the required speed tap.
EXAMPLE: A 24,000 BTU (2 TON) air conditioning system,
using the same 75,000 BTU furnace as in the previous ex-
440 08 2001 02
Tab l e 8 Blower Speed Chart
Wire Color Motor Speed
Black High
Orange* Med--High
Blue Medium
Red Low
*Med--High speed may not be provided on all models.
22
Page 25
Single Stage Multi Position Furnace
Service
Manual
Figure 32
FUSE
Honeywell ST9160B
29. BLOWER ROTATION
Cool
Dip
Switch
Heat
M2
M1
25--23--63
HONEYWELL ST9160B
HEATING SPEED
Should it be necessary to change blower speeds to obtain
proper temperature rise, simply take the appropriate speed
tap wire, and plug it on to the terminal marked “HEAT”.
COOLING SPEED
When the proper speed has been determined, simply plug
it on to the terminal of the control marked “COOL”.
“UNUSED” TERMINALS
There are two (2) terminals (marked “UNUSED MOTOR
LEADS” on the Honeywell ST9160B which has no internal
connection to the control. Their purpose is to provide a place
to connect. “UNUSED” speed tap wires to keep them out of
the way and prevent them from shorting out against the furnace casing, or each other.
· The startup of a furnace will involve a cycle or two of the furnace to properly prime the condensate trap with water. Until
the trap is fully primed, some condensate will be pulled into
the combustion blower. The furnace may cycle on the pressure switch connected to the plastic transition box due to condensate buildup. After the trap is primed, the condensate will
start draining from the furnace. The combustion blower will
clear out any remaining condensate in the blower housing
through the vent fitting downstream of the blower. Note that
the condensate trap can also be primed by pouring water into
the vent drain side of the trap. Remove the small plastic cap
and clamps from the unused drain stub on the vent drain side
of the condensate trap. Connect a section of the
with a funnel to the drain stub and pour eight (8) ounces of water into the trap. Remove the hose and replace the plasticcap
and clamp. This will prime both the vent and the transition
sides of the trap.
· The startup of a furnace will have “milky or oily”. looking condensate coming from the furnace. This is residual drawing
lube in the secondary heat exchanger that is being washed
out by the condensate. The condensate will clear up as the
5
/8² OD hose
furnace operates. Poisonous carbon monoxide gas hazard.
· The use of a vent tee at the outlet of the condensate trap is not
required if the condensate drain line from the trap to the open
drain is properly sloped (
not trap the drain line in any otherlocation than at the condensate trap.
· The combustion blowers and blower gaskets are different on
some of the furnace models. There are two part numbers of
the combustion blower for the 2--stage furnace models. (See
the Tech. Manual for the correct part number for the furnace.)
Besides the part number difference, the 50M, 75M and 100M
BTUH models use the shaded pole motor version with the
7
1
/8² diameter back plate with a raised lip. The blower gasket
is approximately 2
the recessed opening in the transition. The 125M BTUH models use the PSC motor version with the 2² diameter back plate
with no lip. The blower gasket is approximately 3
diameter and is positioned on the flat surface of the transition.
A mismatch of blower backplated and/or gaskets can cause
the furnace to cycle on the pressure switch or to not operate.
This could be misread as a condensate drainage problem.
3
1
/4² per foot downward slope). Do
/4² outside diameterand is positioned into
1
/4² outside
23
440 08 2001 02
Page 26
Service
Manual
Single Stage Multi Position Furnace
Figure 33
Supply Air
Vent Pipe Grommet
Vent Fitting & Clamps
GasPipeGrommet
Rubber Coupling
&Clamps
Plastic Caps
Condensate Tr ap
& Gasket
(Left or Right Side)
Drain Line
Upflow Installation s (Dual Certified *9MPD(A1) Models)
LEFT Side Venting
Combustion Air
Vent Pipe
90°°°° Elbow
5
/8²²²² Hose &
Clamps
Combustion
Blower
Exhaust
Rubber
Plug
3
/4²²²² Hose
&Clamps
Inlet
Combustion
Blower
Mounting
Screws (4)
25- 23- 53
Pipe (optional)
Air Intake
Coupling
Plastic Caps
Pressure Switch
Hose, Blower
Pressure Switch
Hose, Transition
Pressure Switch,
Blower
Transition
Box
Return
Air
Pressure Switch,
Transition
DRAIN SIDE VIEW
Ven t D rai n
Rotate
downward
20° to 30°
RIGHT Side Venting
Supply Air
Inlet
Rigid Plastic
Rubber
Hose
Rubber
Hose
Drain Tube
clamp
clamp
Rigid
Plastic
Drain
Tube
Exhaust
Return
Air
Upflow Installations - (Dual Certified *9MPD) (See Figure 33)
Mount the condensate drain trap in a vertical position to either the
left or right side of the furnace using the two screws and gasket that
are provided. If needed, remove the hole plugs from the furnace
side panel and relocate to the open set ofholes in the opposite side
panel. Drill two
7
/64² diameter holes in the casing using the conden-
sate trap as the template.
Ensure that the vent fittingand the 90° elbow is securely attached to
the combustion blower using the rubber coupling and clamps.
Plug the rightdrain stub of the vent fitting with the rubber plug. Use a
blunt pointed screwdriver to push the plug into the stub.
For left side venting, remove vent fitting assembly from combustion
blower. Remove 90° elbow and rubber tubingfrom the vent fitting by
loosening the clamp on the vent fitting. Securely attachvent fittingto
combustion blower.
NOTE: The vent fitting MUST be installed with the airflow marking
arrowpointed towardthe vent pipe, with the drain stub at a 20° to 30°
downward slope.
This configuration allows left side venting from the furnace. If right
side venting is required, the combustion blower must be relocated
on the plastic transition box. Remove the four(4)screws that secure
the blower to the transition. Rotate the blower180° and securewith
the four(4) screws. Use caution to not over tighten the screws to prevent stripping out of the plastic mounting holes.
Plug the upper drain stub on the vent fittingwith the rubber plug.Use
a blunt pointed screwdriver to push the plug into the stub.
Route the hose to the large drain stub on the condensate trap. Cut
off excess hose and discard. Connect the hose with the 90° bend to
the drain stub on the trap and secure with a
For left side mounted condensate trap, connect the
hose to the drain stub on the bottom of the plastic transition box and
secure with a
For right side mounted condensate trap, the rigid plastic drain
tube MUST be used. Cut two 2² long sections from the
ber hose. Connect the plasticdrain tube to the drain stub on the bottom of the plastic transition box and to the stub on the condensate
trap using the two hose sections and
NOTE: The support leg on the plastic drain tube MUST be positioned on the blower partition.
Connect the
stub on the vent fitting and secure with a
Route the hose to the small drain stub on the condensate trap. Cut
off excess hose and discard. Connect the hose to the drain stub on
the trap and secure with a
NOTE: Ensure hoses maintain a downward slope to the condensate trap with no kinking or binding for proper condensate drainage.
3
/4² clamp.
3
/4² OD rubber
3
/4² clamp.
3
/4² OD rub-
3
/4² clamps.
5
/8² OD rubber hose with the 90° bend to the left drain
5
/8² clamp.
5
/8² clamp.
440 08 2001 02
24
Page 27
Single Stage Multi Position Furnace
Service
Manual
Figure 34
Air Intake Coupling
Ven t Pipe
Supply
Air
Ven t Pipe
Grommet
DRAIN SIDE VIEW
Horizontal Left Installations (Dual Certified *9MPD(A1) Models)
Pressure Switch Hose,
Blower
Exhaust
Vent Fitting
&Clamps
Combustion Air Pipe, (optional)
Plastic Caps
Inlet
Rubber
Plug
Gas Pipe
Grommet
5
/8²²²² Hose & Clamps
Transition Box
90°°°° Elbow
Condensate
Trap & Gasket
Pressure Switch,
Blower
Combustion
Blower
Combustion Blower
Mounting Screws
(4)
Pressure Switch Hose,
Transition
3
/4²²²² Hose & Clamps
Plastic Caps
Pressure Switch,
Transition
Return
Air
Rotate downward
20° to 30°
Rubber Coupling
&Clamps
Drain Line
Horizontal Left Installations - (Dual Certified *9MPD) (See Figure 34)
Relocate the plastic caps and clamps on the condensate drain trap
from the vertical drain stub to the horizontal drain stubs. Secure the
clamps tightly to prevent condensate leakage.
Mount the condensate drain trap in a vertical position to the left side
of the furnace using the two screws and gasket that are provided.
Note: The condensate trapwill be located under the furnace in a verticalposition when the furnace is placed horizontally on the left side.
If needed, remove the hole plugs from the furnace side panel and
relocate to the open set of holes in the opposite side panel. Drill two
7
/64² diameter holes in the casing using the condensate trap as the
template.
Connect the vent fitting and the 90° elbow to the combustion blower
using the rubber coupling and clamps.
NOTE: The vent fitting MUST be installed with the airflow marking
arrow pointed toward the vent pipe, with the drain stub at a 20 to 30°
downward slope.
Plug the upper drain stub on the vent fittingwith the rubber plug.Use
a blunt pointed screwdriver to push the plug into the stub.
3
Connect the
/4² OD rubber hose with the 90° bend to the drain stub
on the bottom of the plastic transition box and secure with a
clamp.
Route the hose to the large drain stub on the condensate trap. Cut
off excess hose and discard. Connect the hose to the drain stub on
the trap and secure with a
Connect the
5
/8² OD rubber hose with the90° bend tothe small drain
stub on the trap and secure with a
Route the hose to the lower drain stub on the vent fitting. Cut off excess hose and discard. Connect the hose to the drain stub on the
vent fitting and secure with a
NOTE: Ensure hoses maintain a downward slope to the condensate trap with no kinking or binding for proper condensate drainage.
3
/4² clamp.
5
/8² clamp.
5
/8² clamp.
dwg 25--23--54
3
/4²
25
440 08 2001 02
Page 28
Service
Manual
Single Stage Multi Position Furnace
Figure 35
Return
Air
Horizontal Right Installations (Dual Certified *9MPD(A1) Models)
Vent Pipe
Transition Box
Pressure Switch
Hose, Blower
Rubber Coupling & Clamps
5
/8²²²² Hose & Clamps
Combustion
Blower
Combustion Blower
Mounting
Screws (4)
Pressure Switch
Hose, Transition
Pressure Switch, Transition
Plastic Caps
Condensate Tr ap
& Gasket
Plastic Caps
Drain Line
90°°°° Elbow
Pressure Switch,
Blower
Vent Fitting
&Clamps
Rubber Plug
3
/4²²²² Hose & Clamps
Gas Pipe
Grommet
Vent Pipe
Grommet
DRAIN SIDE VIEW
Exhaust
Inlet
Air Intake
Coupling
Rotate downward
20° to 30°
Combustion
Air Pipe
(Optional)
Supply
Air
Horizontal Right Installations - (Dual Certified *9MPD) (See Figure 35)
Relocate the plastic caps and clamps on the condensate drain trap
from the vertical drain stub to the horizontal drain stubs. Secure the
clamps tightly to prevent condensate leakage.
Mount the condensate drain trap in a vertical position to the right
side of the furnace using the two screws and gasket that are provided. Note: The condensate trap will be located under the furnace
in a vertical position when the furnace is placed horizontally on the
right side. If needed, remove the hole plugs from the furnace side
panel and relocated to the open set of holes in the opposite side
panel. Drill two
7
/64² diameter holes in the casing using the conden-
sate trap as the template.
Connect the vent fitting and the 90° elbow to the combustion blower
using the rubber coupling and clamps.
NOTE: The vent fitting MUST be installed with the airflow marking
arrowpointed towardthe vent pipe, with the drain stubat a20° to 30°
downward slope.
Plug the upper drain stub on the vent fittingwith the rubber plug.Use
a blunt pointed screwdriver to push the plug into the stub.
Remove thepressure switchhose from the upper stub on the plastic
transition box.
Relocate the plastic caps on the stubs of the plastic transition box
from the lower stubs to the upper stubs and secure tightly with the
clamps.
Route the pressure switch hose to the lower stub on the plastic transition box. Cut off excess hose and discard. Connect the pressure
switch hose to the lower stub on the plastic transition box. NOTE:
Failure to correctly install the pressure switch hose to the transition
can adversely affect the safety control operation.
3
Connect the
/4² OD rubber hose with the 90° bend to the drain stub
on the bottom of the plastic transition box and secure with a
clamp.
Route the hose to the large drain stub on the condensate trap. Cut
off excess hose and discard. Connect the hose to the drain stub on
the trap and secure with a
Connect the
5
/8² OD rubber hose with the 90° bend to the lower
drain stub on the vent fitting and secure with a
Route the hose to thesmaller drain stub on the condensate trap. Cut
off excess hose and discard. Connect the hose to the drain stub on
the trap and secure with a
NOTE: Ensure hoses maintain a downward slope to the condensate trap with no kinking or binding for proper condensate drainage.
3
/4² clamp.
5
/8² clamp.
dwg 25--23--55
5
/8² clamp.
3
/4²
440 08 2001 02
26
Page 29
Single Stage Multi Position Furnace
Service
Manual
Figure 36
Inlet
DRAIN SIDE VIEW
Rotate downward
20° to 30°
Downflow Installations (Dual Certified *9MPD(A1) Models)
LEFT Side Venting
Return Air
Combustion Blower
Mounting Screws (4)
Exhaust
Supply Air
Pressure Switch,
Transition
Pressure Switch
Hose, Transition
Pressure Switch,
Blower
Pressure Switch
Hose, Blower
3
/4²²²² Hose
&Clamps
5
/8²²²² Hose &
Clamps
RIGHT Side Venting
Return Air
Combustion Blower
(Rotate 180°°°° for Left Side)
Transition
Box
Supply Air
Rubber
Plug
Plastic
Caps
Air Intake
Coupling
Combustion
Air Pipe, (Optional)
Inlet
Drain Line
Vent Pipe
Vent Fitting
Exhaust
&Clamps
Ven t Pipe
Grommet
Plastic
Caps
Condensate
Trap & Gasket
Gas Pipe
Grommet
Downflow Installations - (Dual Certified *9MPD Models) (See Figure 36)
Mount the condensate drain trap in a vertical position to either the
right or left side of the furnace using the two screws and gasket that
are provided. If needed, remove the hole plugs from the furnace
side panel and relocatedto the open set ofholes inthe oppositeside
panel. Drill two
7
/64² diameter holes in the casing using the conden-
sate trap as the template.
Ensure that the vent fittingand the 90° elbow is securely attached to
the combustion blower using the rubber coupling and clamps.
This configuration allows right side venting from the furnace. If the
left side venting is required, the combustion blower must be relocated on the plastic transition box. Remove the four(4) screws that
secure the blower to the transition. Rotate the blower 180° and secure with the four(4) screws. Use caution to not over tighten the
screws to prevent stripping out of the plastic mounting holes.
For right side venting, remove vent fitting assembly from combustion blower. Remove 90° elbow and rubber tubing from the vent fitting by loosening the clamp on the vent fitting. Securely attach vent
fitting to combustion blower.
NOTE: The vent fitting MUST be installed with the airflow marking
arrowpointed towardthe vent pipe, with the drain stub at a 20° to 30°
downward slope.
Plug the upper drain stub of the vent fittingwith the rubber plug. Use
a blunt pointed screwdriver to push the plug into the stub.
Remove thepressure switchhose from the upper stub on the plastic
transition box.
Relocate the plastic caps on the stubs of the plastic transition box
from the lower stubs to the upper stubs and secure tightly with the
clamps.
Route the pressure switch hose to the lower stub on the plastic transition box. Cut off excess hose and discard. Connect the pressure
switch hose to the lower stub on the plastic transition box. NOTE:
Failure to correctly install the pressure switch hose to the transition
box can adversely affect the safety control operation.
3
Connect the
/4² OD rubber hose with the 90° bend to the drain stub
on the bottom of the plastic transition box and secure with a
clamp.
Route the hose to the large drain stub on the condensate trap. Cut
off excess hose and discard. Connect the hose to the drain stub on
the trap and secure with a
Connect the
5
/8² OD rubber hose with the 90° bend to the left drain
stub on the vent fitting and secure with a
Route the hose to the smaller stub on the condensate trap. Cut off
excess hose and discard. Connect the hose to the drain stub on the
trap and secure with a
NOTE: Ensure hoses maintain a downward slope to the condensate trap with no kinking or binding for proper condensate drainage.
27
3
/4² clamp.
5
/8² clamp.
dwg 25--23--56
5
/8² clamp.
3
440 08 2001 02
/4²
Page 30
Service
Manual
Single Stage Multi Position Furnace
Figure 37
Ven t Pipe
Vent Pipe
Grommet
Vent Fitting
&Clamps
5
/8²²²² Hose & Clamps
Plastic
Caps
Condensate
Trap & Gasket
Drain Line
Upflow Installations (Single Pipe & Direct Vent N9MP1 & N9MP2(A1) Models)
RIGHT Side Venting
Supply Air
clamp
Rubber
Hose
Rigid
Plastic
Drain
Rubber
Tube
Hose
Inlet
Rigid Plastic
Drain Tube
clamp
dwg 25--23--57
Supply Air
Exhaust
LEFT Side Venting
Inlet
Rubber
Plug
Transition Box
3
/4²²²² Hose & Clamps
Combustion
Air Pipe,
N9MP2 ONLY
Plastic
Caps
Combustion Blower
(Rotate 180°°°° for
Left Side)
Pressure Hose,
Blower
Pressure Switch,
Blower
Return
Air
Pressure Switch
Hose, Transition
Pressure Switch,
Transition
DRAIN SIDE VIEW
Rotate
downward
20° to 30°
Combustion
Air Pipe,
N9MP2 ONLY
Combustion
Blower
Mounting
Screws (4)
Exhaust
Return
Air
Upflow Installations - (Single Pipe & Direct Vent N9MP1 & N9MP2 Models) (See Figure 37)
Mount the condensate drain trap in a vertical position to either the
left or right side of the furnace using the two screws and gasket that
are provided. If needed, remove the hole plugs from the furnace
side panel and relocate to the open set ofholes in the opposite side
panel. Drill two
7
/64² diameter holes in the casing using the conden-
sate trap as the template.
Ensure that the vent fittingand the 90° elbow is securely attached to
the combustion blower using the rubber coupling and clamps.
NOTE: The vent fitting MUST be installed with the airflow marking
arrowpointed towardthe vent pipe, with the drain stubat a20° to 30°
downward slope.
This configuration allows left side venting from the furnace. If right
side venting is required, the combustion blower must be relocated
on the plastic transition box. Remove the four(4)screws that secure
the blower to the transition. Rotate the blower180° and securewith
the four(4) screws. Use caution to not over tighten the screws to prevent stripping out of the plastic mounting holes.
Plug the upper drain stub of the vent fittingwith the rubber plug. Use
a blunt pointed screwdriver to push the plug into the stub.
For left side mounted condensate trap, connect the
hose with the 90° bend to the drain stub on the bottom of the plastic
transition box and secure with a
3
/4² clamp.
Route the hose to the large drain stub on the condensate trap. Cut
off excess hose and discard. Connect the hose to the drain stub on
the trap and secure with a
3
/4² clamp.
For right side mounted condensate trap, the rigid plastic drain
tube MUST be used. Cut two 2² long sections from the
ber hose. Connect the plasticdrain tube to the drain stub on the bottom of the plastic transition box and to the stub on the condensate
trap using the two hose sections and
3
/4² clamps.
NOTE: The support leg on the plastic drain tube MUST be positioned on the blower partition.
5
Connect the
/8² OD rubber hose with the 90° bend to the lower
drain stub on the vent fitting and secure with a
Route the hose to thesmaller drain stub on the condensate trap. Cut
off excess hose and discard. Connect the hose to the drain stub on
the trap and secure with a
5
/8² clamp.
NOTE: Ensure hoses maintain a downward slope to the condensate trap with no kinking or binding for proper condensate drainage.
3
/4² OD rubber
3
5
/8² clamp.
/4² OD rub-
440 08 2001 02
28
Page 31
Single Stage Multi Position Furnace
Service
Manual
Figure 38
Combustion
Air Pipe,
N9MP2 ONLY
Horizontal Left Installations (Single Pipe & Direct Vent N9MP1 & N9MP2(A1) Models)
Plastic
Caps
Supply
Air
Inlet
Combustion Blower
(Rotate 180°°°° for Right Side)
Transition
Box
Pressure Switch,
Blower
3
/4²²²² Hose
&Clamps
Condensate
Trap & Gasket
Rubber
Plug
Vent Pipe
Vent Pipe
Grommet
Exhaust
Vent Fitting
&Clamps
Plastic
Caps
Pressure Switch
Hose, Transition
Pressure Switch,
Transition
Pressure Switch
Hose, Blower
Combustion Blower
Mounting Screws (4)
5
/8²²²² Hose &
Clamps
Return
Air
Drain Line
dwg 25-- 23--58
Horizontal Left Installations - (Single Pipe & Direct Vent N9MP1 & N9MP2 Models) (See Figure 38)
Relocate the plastic caps and clamps on the condensate drain trap
fromthe verticaldrain stubs to the horizontal drain stubs. Secure the
clamps tightly to prevent condensate leakage.
Mount the condensate drain trap in a vertical position to the left side
of the furnace using the two screws and gasket that are provided.
Note: The condensate trapwill be located under the furnace in a verticalposition when the furnace is placed horizontally on the left side.
If needed, remove the hole plugs from the furnace side panel and
relocatedto the open set of holes in theopposite sidepanel. Drill two
7
/64² diameter holes in the casing using the condensate trap as the
template.
Relocate the combustion blower on the plastic transition box. Remove thefour(4) screws that secure the blower to the transition box.
Rotate the blower 180° so the blower snout is pointing up and secure with the four(4) screws. Use caution to not over tighten the
screws to prevent stripping out of the plastic mounting holes.
Ensure that the vent fittingand the 90° elbow is securely attached to
the combustion blower using the rubber coupling and clamps.
NOTE: The vent fitting MUST be installed with the airflow marking
arrowpointed towardthe vent pipe, with the drain stubat a20° to 30°
downward slope.
Plug the left drain stub on the vent fitting with the rubber plug. Use a
blunt pointed screwdriver to push the plug into the stub.
3
Connect the
/4² OD rubber hose with the 90° bend to the drain stub
on the bottom of the plastic transition box and secure with a
clamp.
Route the hose to the large drain stub on the condensate trap. Cut
off excess hose and discard. Connect the hose to the drain stub on
the trap and secure with a
Connect the
5
/8² OD rubber hose with the 90° bend to the rightdrain
stub on the vent fitting and secure with a
3
/4² clamp.
5
/8² clamp.
Route the hose to thesmaller drain stub on the condensate trap. Cut
off excess hose and discard. Connect the hose to the drain stub on
the vent fitting and secure with a
5
/8² clamp.
NOTE: Ensure hoses maintain a downward slope to the condensate trap with no kinking or binding for proper condensate drainage.
3
/4²
29
440 08 2001 02
Page 32
Service
Manual
Single Stage Multi Position Furnace
Figure 39
Return
Air
Horizontal Right Installations (Single Pipe & Direct Vent N9MP1 & N9MP2(A1) Models)
Vent Pipe
Grommet
Vent Fitting
&Clamps
Pressure Switch
Hose, Transition
Pressure
Switch, Blower
Inlet
Supply
Air
3
/4²²²² Hose
&Clamps
Combustion
Air Pipe,
N9MP2 ONLY
dwg 25--23--59
Combustion Blower
Combustion Blower
Mounting Screws (4)
Pressure Switch
Hose, Blower
Condensate
Trap & Gasket
Transition Box
Plastic
Caps
5
/8²²²² Hose &
Clamps
Plastic
Caps
Vent Pipe
Rubber
Plug
Pressure
Switch, Transition
Drain Line
Exhaust
Horizontal Right Installations - (Single Pipe & Direct Vent N9MP1 & N9MP2 Models) (See Figure 39)
Relocate the plastic caps and clamps on the condensate drain trap
from the vertical drain stub to the horizontal drain stubs. Secure the
clamps tightly to prevent condensate leakage.
Mount the condensate drain trap in a vertical position to the right
side of the furnace using the two screws and gasket that are provided. Note: The condensate trap will be located under the furnace
in a vertical position when the furnace is placed horizontally on the
right side. If needed, remove the hole plugs from the furnace side
panel and relocate to the open set of holes in the opposite side panel. Drill two
7
/64² diameter holes in the casing using the condensate
trap as the template.
Ensure that the vent fittingand the 90° elbow is securely attached to
the combustion blower using the rubber coupling and clamps.
NOTE: The vent fitting MUST be installed with the airflow marking
arrow pointed toward the vent pipe.
Plug the left drain stub on the vent fitting with the rubber plug. Use a
blunt pointed screwdriver to push the plug into the stub.
Remove thepressure switchhose from the upper stub on the plastic
transition box.
Relocate the plastic caps on the stubs of the plastic transition from
the lower stubs to the upper stubs and secure tightly with the
clamps.
Route the hose to the large drain stub on the condensate trap. Cut
off excess hose and discard. Connect the pressure switch hose to
the lower stub on the plastic transitionbox. NOTE: Failure tocorrectly installthe pressure switch hose to the transition can adversely affect the safety control operation.
3
Connect the
/4² OD rubber hose with the 90° bend to the drain stub
on the bottom of the plastic transition box and secure with a
clamp.
Route the hose to the large drain stub on the condensate trap. Cut
off excess hose and discard. Connect the hose to the drain stub on
the trap and secure with a
Connect the
5
/8² OD rubber hose with the 90° bend to the right stub
on the vent fitting and secure with a
3
/4² clamp.
5
/8² clamp.
Route the hose to thesmaller drain stub on the condensate trap. Cut
off excess hose and discard. Connect the hose to the drain stub on
the trap and secure with a
5
/8² clamp.
NOTE: Ensure hoses maintain a downward slope to the condensate trap with no kinking or binding for proper condensate drainage.
3
/4²
440 08 2001 02
30
Page 33
Single Stage Multi Position Furnace
Service
Manual
Figure 40
Vent Fitting
&Clamps
5
/8²²²² Hose &
Clamps
Inlet
Plastic Caps
Condensate
Trap & Gasket
Downflow Installations (Single Pipe & Direct Vent N9MP1 & N9MP2(A1) Models)
LEFT Side Venting
Return Air
Combustion Blower
Mounting Screws (4)
Rubber
Plug
Exhaust
3
/4²²²² Hose & Clamps
Pressure Switch
Hose, Transition
Plastic
Caps
Transition Box
Pressure
Switch, Blower
Pressure Switch
Hose, Blower
RIGHT Side Venting
Return Air
Combustion Blower
(Rotate 180°°°° for Left Side)
Pressure
Switch,
Transition
Vent Pipe
Grommet
Inlet
Combustion
Air Pipe,
N9MP2 ONLY
Ven t Pipe
Exhaust
DRAIN SIDE VIEW
Drain Line
Supply Air
Supply Air
dwg 25--23--60
Downflow Installations - (Single Pipe & Direct Vent N9MP1 & N9MP2 Models) (See Figure 40)
Mount the condensate drain trap in a vertical position to either the
right or left side of the furnace using the two screws and gasket that
are provided. If needed, remove the hole plugs from the furnace
side panel and relocatedto the open set ofholes inthe oppositeside
panel. Drill two
7
/64² diameter holes in the casing using the conden-
sate trap as the template.
Ensure that the vent fittingand the 90° elbow is securely attached to
the combustion blower using the rubber coupling and clamps.
NOTE: The vent fitting MUST be installed with the airflow marking
arrowpointed towardthe vent pipe, with the drain stubat a20° to 30°
downward slope.
This configuration allows right side venting from the furnace. If the
left side venting is required, the combustion blower must be relocated on the plastic transition box. Remove the four(4) screws that
secure the blower transition box. Rotate the blower 180° and secure
with the four(4)screws. Use caution to not over tightenthe screws to
prevent stripping out of the plastic mounting holes.
Plug the upper drain stub on the vent fittingwith the rubber plug.Use
a blunt pointed screwdriver to push the plug into the stub.
Relocate the plastic caps on the stubs of the plastic transition box
from the lower stubs to the upper stubs and secure tightly with the
clamps.
Route the pressure switch hose to the lower drainstub on the plastic
transition box. Cut off excess hose and discard. Connect the pressure switch hose to the lower stub on the plastic transition box.
NOTE: Failure to correctly install the pressure switch hose to the
transition c an adversely affect the safety control operation.
3
Connect the
/4² OD rubber hose with the 90° bend to the drain stub
on the bottom of the plastic transition box and secure with a
clamp.
Route the hose to the large drain stub on the condensate trap. Cut
off excess hose and discard. Connect the hose to the drain stub on
the trap and secure with a
Connect the
5
/8² OD rubber hose with the 90° bend to the lowerstub
on the vent fitting and secure with a
3
/4² clamp.
3
/4² clamp.
Route the hose to the smaller stub on the condensate trap. Cut off
excess hose and discard. Connect the hose to the drain stub on the
trap and secure with a
5
/8² clamp.
Rotate
downward
20° to 30°
3
/4²
Remove thepressure switchhose from the upper stub on the plastic
transition.
NOTE: Ensure hoses maintain a downward slope to the condensate trap with no kinking or binding for proper condensate drainage.
31
440 08 2001 02
Page 34
Service
Manual
Single Stage Multi Position Furnace
Figure 41
Yellow Plastic Cap
Vent Fitting
&Clamps
AIR FLOW
Condensate Trap & Gasket
(Left or Right Side)
Upflow Installations (Dual Certified *9MPD--A2 Models)
NOTE: TRAP MUST BE PRIMED BEFORE OPERATION
TOP Venting
Vent Pipe
Supply
Air
Inlet
Rubber Coupling &
Clamps
Combustion Blower
Mounting Screws (4)
Combustion Blower
Trap Connection
Vent Pipe Grommet
11²²²² Section PVC Pipe
Gas Pipe
Grommet
90°°°° Street
Elbow
5
/8²²²² Hose &
Clamps
Plastic Cap
“Clamp ears”
Pointed O UT
Exhaust
3
/4²²²² Hose
&Clamps
FLOW
AIR
Transition
Box
Pressure Switch,
Transition
Combustion Air
Pipe (optional)
Air Intake
Coupling
Plastic Cap
Some Models have
one pressure switch
Pressure Switch
Hose, Blower
Pressure Switch, Blower
Pressure Switch
Hose, Transition
Return Air
Drain Line
Preassemble &
insert into furnace
Upflow Installations - (Dual Certified *9MPD)(See Figure 41)
Note: For easier installation of the drain hoses and clamps to the
condensate trap, follow the directions outlined below except do not
make any clamp connections to any of the drain stubs and hoses
until the hose routing and lengths have been determined. Remove
the condensate trap and drain hoses from the furnace and secure
the drain hoses to the drain stubs on the trap with the hose clamps
(position the clamps as shown in Figure 41). Install the condensate
trap/hose assembly to the furnace casing. Hook one side of the
“clamp ears” on the drain stub through the hole in the casing and
push the condensate trap into position. Secure with the two screws.
Reconnect the drain hoses to the stubs on the vent fitting and the
plastic transition and secure with the clamps.
Mount the condensate drain trap in a vertical position to either the
left or right side of the furnace using the two screws and gasket that
are provided. If needed, remove the hole plugs from the furnace
side panel and relocate to the open set ofholes in the opposite side
panel.
NOTE: All gaskets and seals must be in place for sealed combustion applications.
440 08 2001 02
Ensure that the vent fitting and the 90° street elbow are securely attached to the combustion blower using the clamps.
Plug the upper drain stub on the vent fitting with the yellow plastic
cap.
Glue the 11² sectionof PVC pipe to the 90° street elbow after checking the fit up. (Follow the procedures outlined in the Joining Pipe and
Fittings section of this manual, page 30.) The PVC pipe will extend
through the top panel about 1
the end of the 11² section of PVC pipe using the clamp.
Note: There will be some misaligmentof thePVC pipeinside thefurnace. The rubber coupling will straighten out the misalignment at
the vent pipe connection at the top of the furnace.
For left side venting, remove 90° street elbow from the vent fitting by
loosening the clamp on the vent fitting. Securely attachvent fittingto
combustion blower.
NOTE: For left s ide venting, the vent fitting MUST be installed with
the airflow marking arrow pointed toward the vent pipe, with the
drain stub at a 20° to 30° downward slope.
32
25-- 24- -00a
1
². Connect the rubber coupling to
/2
Page 35
Single Stage Multi Position Furnace
Service
Manual
This configuration allows left side venting from the furnace. If right
side venting is required, the combustion blower must be relocated
on the plastic transition box. Remove the four(4)screws that secure
the blower to the transition. Rotate the blower180° and securewith
the four(4) screws. Use caution to not over tighten the screws to prevent stripping out of the plastic mounting holes.
NOTE: For rightside venting, the v ent fitting MUST be installed with
the airflow marking arrow pointed toward the vent pipe, with the
drain stub at a 5° to 10° downward slope. (See Figure 41)
Plug the upper drain stub on the vent fitting with the yellow plastic
cap.
Figure 42
Upflow Installation s (Dual Certified *9MPD--A2 Models)
RIGHT Side Venting
Supply Air
Inlet
NOTE: TRAP MUST BE PRIMED BEFORE OPERATION
Some Models
have one
pressure switch
Vent
Drain
For left side mounted condensate trap, connect the
hose with the 90° bend to the large drain stub on the condensate
trap and secure with a
3
/4² clamp.
3
/4² OD rubber
Route the hose to the drain stub on the bottom of the plastic transition box. Cut off excess hose and discard. Connect the hose to the
drain stub on the transition and secure with a
For right side mounted condensate trap, connect the
hose withthe 90° bend to the bottomof the plastic transition box and
secure with a
3
/4² clamp.
3
/4² clamp.
3
/4² OD rubber
Route the hose to the largedrain stub on the condensate pump. Cut
off excess hose and discard. Connect the hose to the drain stub on
the condensate trap and secure with a
3
/4² clamp.
Exhaust
DRAIN SIDE VIEW
Rotate downward
5°°°° to 10°°°°
oo
For left or right side mounted condensate trap, the pressure tap
on the condensate trap MUST be connected to the unused pressure tap located on the upper right hand corner of the plastic transition box. Remove the plastic caps from the pressure taps on the
condensate trap and the plastic transition and connect with the
5
/16²
OD rubber hose. (See Figure 41 and Figure 42)
Connect the
5
/8² OD rubber hose with the 90° bend to the lower
Trap Connection
“Clamp ears”
Pointed O UT
Return
Air
Preassemble
25-- 24- -00
drain stub on the vent fitting and secure with a
and insert
into furnace
5
/8² clamp.
Route the hose to the small drain stub on the condensate trap. Cut
off excess hose and discard. Connect the hose to the drain stub on
the trap and secure with a
5
/8² clamp.
NOTE: Ensure hoses maintain a downward slope to the condensate trap with no kinking or binding for proper condensate drainage.
33
440 08 2001 02
Page 36
Service
Manual
Single Stage Multi Position Furnace
Figure 43
Ven t Pipe
Supply
Air
Vent Fitting
&Clamps
Horizontal Left Installations (Dual Certified *9MPD--A2 Models)
Combustion Air
Pipe, (optional)
Exhaust
Vent Pipe
Grommet
Air Intake
Coupling
Inlet
Yellow
Plastic
Cap
AIR FLOW
Condensate
Trap & Gasket
5
/8²²²² Hose
&Clamps
Pressure Switch
Hose, Blower
Some Models
have one
pressure switch
Plastic
Cap
Plastic Cap
11²²²² Section
PVC Pipe
Drain
Line
NOTE: TRAP MUST BE PRIMED BEFORE OPERATION
Pressure Switch,
Blower
Gas Pipe
Grommet
Transition Box
Rubber Coupling & Clamps
90°°°° Street
Elbow
Pressure Switch,
Transition
Combustion
Blower
Combustion Blower
Mounting Screws
(4)
Pressure Switch Hose,
Transition
3
/4²²²²
Hose & Clamps
Horizontal Trap Connection
Return
Air
dwg 25--24--00b
“Clamp ears”
Pointed O UT
Preassemble and
insert into furnace
Horizontal Left Installations - (Dual Certified *9MPD) (See Figure 43)
Note: For easier installation of the drain hoses and clamps to the
condensate trap, follow the directions outlined below except do not
make any clamp connections to any of the drain stubs and hoses
until the hose routing and lengths have been determined. Remove
the condensate trap and drain hoses from the furnace and secure
the drain hoses to the drain stubs on the trap with the hose clamps
(position the clamps as shown in Figure 43). Install the condensate
trap/hose assembly to the furnace casing. Hook one side of the
“clamp ears” on the drain stub through the hole in the casing and
push the condensate trap into position. Secure with the two screws.
Reconnect the drain hoses to the stubs on the vent fitting and the
plastic transition and secure with the clamps.
Relocate the plastic cap and clamp on the condensate drain trap
from the vertical transition drain stub to the horizontal transition
drain stub. Secure the clamps tightly to prevent condensate leakage. Do not change the cap and clamp on the vent drain stub.
Mount the condensate drain trap in a vertical position to the left side
of the furnace using the two screws and gasket that are provided.
Note: The condensate trapwill be located under the furnace in a verticalposition when the furnace is placed horizontally on the left side.
If needed, remove the hole plugs from the furnace side panel and
relocate to the open set of holes in the opposite side panel.
NOTE: All gaskets and seals must be in place for sealed combustion applications.
Remove the 90° street elbow and vent fitting from the combustion
blower by loosening the clamps on the vent fitting. Connect the 90°
street elbow to the combustion blower using the rubber coupling
and clamps.Glue the 11²section of PVC pipe to the 90° street elbow
af ter checking thefit up. (Follow the procedures outlinedin the Join-
ing Pipe and Fittingssection of this manual,page 30.) The PVC pipe
will extend through the top panel about 1
ting to the end of the 11² section of PVC pipe using the clamp.
NOTE: The vent fitting MUST be installed with the airflow marking
arrow pointed toward the vent pipe, with the drain stub at a 20 to 30°
downward slope.
Plug the upper drain stub on the vent fitting with the yellow plastic
cap.
Connect the
5
/8² OD rubber hose with the 90° bend to the lower
drain stub on the vent fitting and secure with a
Route the hose to the horizontal drain stub on the condensate trap.
Cut off excess hoses and discard. Connect the hose to the drain
stub on the condensate trap and secure with a
Connect the
3
/4² OD rubber hose with the 90° bend to the large drain
stub on the condensate trap and secure with a
Route the hose to the drain stub on the bottom of the plastic transition box. Cut off excess hose and discard. Connect the hose to the
drain stub on the transition and secure with a
The pressure tap on the condensate trap MUST be connected to
the unused pressure tap located on the top of the plastic transition
box. Remove the plastic caps from the pressure taps on the condensate trap and the plastic transition and connect with the
rubber hose.
NOTE: This willrequire drilling a
next to the condensate trap.
NOTE: Ensure hoses maintain a downward slope to the condensate trap with no kinking or binding for proper condensate drainage.
1
². Connect the vent fit-
/2
5
/8² clamp.
5
/8² clamp.
3
/4² clamp.
3
/4² clamp.
5
² OD hole inthe furnace c asing
/16
5
² OD
/16
440 08 2001 02
34
Page 37
Single Stage Multi Position Furnace
Service
Manual
Figure 44
Horizontal Right Installations (Dual Certified *9MPD--A2 Models)
NOTE: TRAP MUST BE PRIMED
BEFORE OPERATION
Rubber Coupling
&Clamps
Plastic Caps
Combustion
Blower
Combustion Blower
Mounting Screws
(4)
Pressure Switch,
Transition
Plastic Cap
Condensate Trap
& Gasket
Return
Air
dwg 25--23--55b
5
/8²²²² Hose
&Clamps
Some Models
have one
pressure switch
2²²²² Section
PVC Pipe
90°°°° Street Elbow
3
/4²²²² Hose & Clamps
Pressure Switch,
Blower
Drain
Line
Yellow
Plastic
Cap
Gas Pipe
Grommet
Pressure Switch
Hose, Transition
Vent Pipe
Vent Fitting
&Clamps
Pressure Switch
Hose, Blower
Transition Box
Exhaust
Vent Pipe
Grommet
Air Intake
Coupling
Horizontal Trap Connection
Combustion
Air Pipe
(Optional)
Inlet
Supply
Air
“Clamp ears”
Pointed O UT
Preassemble
and insert
into furnace
Horizontal Right Installations - (Dual Certified *9MPD) (See Figure 44)
Note: For easier installation of the drain hoses and clamps to the
condensate trap, follow the directions outlined below except do not
make any clamp connections to any of the drain stubs and hoses
until the hose routing and lengths have been determined. Remove
the condensate trap and drain hoses from the furnace and secure
the drain hoses to the drain stubs on the trap with the hose clamps
(position the clamps as shown in Figure 44). Install the condensate
trap/hose assembly to the furnace casing. Hook one side of the
“clamp ears” on the drain stub through the hole in the casing and
push the condensate trap into position. Secure with the two screws.
Reconnect the drain hoses to the stubs on the vent fitting and the
plastic transition and secure with the clamps.
Relocate the plastic caps and clamps on the condensate drain trap
from the vertical drain stub to the horizontal drain stubs. Secure the
clamps tightly to prevent condensate leakage.
Mount the condensate drain trap in a vertical position to the right
side of the furnace using the two screws and gasket that are provided. Note: The condensate trap will be located under the furnace
in a vertical position when the furnace is placed horizontally on the
right side. If needed, remove the hole plugs from the furnace side
panel and relocated to the open set of holes in the opposite side
panel.
NOTE: All gaskets and seals must be in place for sealed combustion applications.
Remove the 90° street elbow and vent fitting from the combustion
blower by loosening the clamps on the vent fitting. Connect the 90°
street elbow to the combustion blower using the rubber coupling
and clamps. Cut a 2² section of PVC pipe from the PVC pipe provided with the furnace. Glue the 2² section of PVC pipe to the 90°
street elbow after checking the fit up. (Follow the procedures outlined in the Joining Pipe and Fittings section of this manual, page
30.) Connect the vent fitting to the end of the 2² section of PVC pipe
using the clamp.
NOTE: The vent fitting MUST be installed with the airflow marking
arrowpointed towardthe vent pipe, with the drain stubat a20° to 30°
downward slope.
Plug the upper drain stub on the vent fitting with the yellow plastic
cap.
Remove thepressure switchhose from the upper stub on the plastic
transition box.
Relocate the plastic caps on the stubs of the plastic transition box
from the lower stubs to the upper stubs and secure tightly with the
clamps.
Route the pressure switch hose to the lower stub on the plastic transition box. Cut off excess hose and discard. Connect the pressure
switch hose to the lower stub on the plastic transition box. Ensure
that the hose is routed above the stub on the transition box so that
condensate does not collect in the hose. NOTE: Failure to correctly
install the pressure switchhose to the transition can adversely affect
the safety control operation.
Connect the
3
/4² OD rubber hose with the 90° bend to the large drain
stub on the condensate trap and secure with a
Route the hose to the drain stub on the bottom of the plastic transi-
tion box. Cut off excess hose and discard. Connect the hose to the
drain stub on the transition and secure with a
5
Connect the
/8² OD rubber hose with the 90° bend to the lower
drain stub on the vent fitting and secure with a
35
3
/4² clamp.
3
/4² clamp.
5
/8² clamp.
440 08 2001 02
Page 38
Service
Manual
Single Stage Multi Position Furnace
Route the hose to thesmaller drain stub on the condensate trap. Cut
off excess hose and discard. Connect the hose to the drain stub on
the trap and secure with a
Figure 45
DRAIN SIDE VIEW
Rotate downward
20°°°° to 30°°°°
Exhaust
5
/8² clamp.
Downflow Installations (Dual Certified *9MPD--A2 Models)
NOTE: TRAP MUST BE PRIMED BEFORE OPERATION
LEFT Side Venting
Return Air
Pressure Switch
Hose, Transition
Some Models
have one
pressure switch
Combustion Blower
Mounting Screws (4)
NOTE: Ensure hoses maintain a downward slope to the condensate trap with no kinking or binding for proper condensate drainage.
AIRFLOW
RIGHT Side Venting
Return Air
Combustion Blower
(Rotate 180°°°° for Left Side)
Pressure Switch,
Transition
Transition
Box
Yellow
Plastic Cap
Plastic
Cap
Air Intake
Coupling
Combustion
Air Pipe, (Optional)
Inlet
V ent Pipe
Inlet
Supply Air
Pressure
Switch,
Blower
Pressure
Switch
Hose,
Blower
3
/4²²²² Hose
&Clamps
Supply Air
dwg 25--23--56
Downflow Installations - (Dual Certified *9MPD Models) (See Figure 45)
Note: For easier installation of the drain hoses and clamps to the
condensate trap, follow the directions outlined below except do not
make any clamp connections to any of the drain stubs and hoses
until the hose routing and lengths have been determined. Remove
the condensate trap and drain hoses from the furnace and secure
the drain hoses to the drain stubs on the trap with the hose clamps
(position the clamps as shown in Figure 45). Install the condensate
trap/hose assembly to the furnace casing. Hook one side of the
440 08 2001 02
“clamp ears” on the drain stub through the hole in the casing and
push the condensate trap into position. Secure with the two screws.
Reconnect the drain hoses to the stubs on the vent fitting and the
plastic transition and secure with the clamps.
Mount the condensate drain trap in a vertical position to either the
right or left side of the furnace using the two screws and gasket that
are provided. If needed, remove the hole plugs from the furnace
36
5
/8²²²² Hose &
Clamps
Preassemble
and insert
into furnace
Exhaust
Plastic Caps
Condensate
Trap & Gasket
GasPipeGrommet
Drain Line
Trap Connection
Vent Pipe
Grommet
Vent Fitting
&Clamps
“Clamp ears”
Pointed O UT
Page 39
Single Stage Multi Position Furnace
Service
Manual
side panel and relocatedto the open set ofholes inthe oppositeside
panel.
NOTE: All gaskets and seals must be in place for sealed combustion applications.
For both right and left side vent,remove the 90° street elbow from
the vent fitting by loosening the clamp on the vent fitting.
Ensure that the vent fitting is securely attached to the combustion
blower using the rubber coupling and clamps.
This configuration allows right side venting from the furnace. If the
left side venting is required, the combustion blower must be relocated on the plastic transition box. Remove the four(4) screws that
secure the blower to the transition. Rotate the blower 180° and secure with the four(4) screws. Use caution to not over tighten the
screws to prevent stripping out of the plastic mounting holes.
NOTE: The vent fitting MUST be installed with the airflow marking
arrowpointed towardthe vent pipe, with the drain stub at a 20° to 30°
downward slope.
Plug the upper drain stub on the vent fitting with the yellow plastic
cap.
Remove thepressure switchhose from the upper stub on the plastic
transition box.
Relocate the plastic caps on the stubs of the plastic transition box
from the lower stubs to the upper stubs and secure tightly with the
clamps.
Route the pressure switch hose to the lower stub on the plastic transition box. Cut off excess hose and discard. Connect the pressure
switch hose to the lower stub on the plastic transition box. NOTE:
Failure to correctly install the pressure switch hose to the transition
box can adversely affect the safety control operation.
Connect the
on the bottom of the plastic transition box and secure with a
3
/4² OD rubber hose with the 90° bend to the drain stub
3
/4²
clamp.
Route the hose to the large drain stub on the condensate trap. Cut
off excess hose and discard. Connect the hose to the drain stub on
the transition and secure with a
Connect the
5
/8² OD rubber hose with the 90° bend to the lower
drain stub on the vent fitting and secure with a
3
/4² clamp.
5
/8² clamp.
Route the hose to the smaller stub on the condensate trap. Cut off
excess hose and discard. Connect the hose to the drain stub on the
trap and secure with a
5
/8² clamp.
For left side or right side mounted condensate trap, the pressure tap on the condensate trap MUST be connected to the unused
pressure tap located on the top of the plastictransition box. Remove
the plastic caps from the pressure tap on the condensate trap and
the plastic transition and connect the
5
/16² OD rubber hose. (See
Figure 45)
NOTE: Ensure hoses maintain a downward slope to the conden-
sate trap with no kinking or binding for proper condensate drainage.
37
440 08 2001 02
Page 40
Service
Manual
Single Stage Multi Position Furnace
Figure 46
DRAIN SIDE VIEW
Rotate
downward
20°°°° to 30°°°°
Upflow Installations (Single Pipe & Direct Vent N9MP1 & N9MP2--A2 Models)
NOTE: TRAP MUST BE PRIMED BEFORE OPERATION
LEFT Side Venting
Supply Air
Inlet
V ent Pipe
Combustion Blower
Mounting Screws (4)
Exhaust
AIR FLOW
Vent Pipe
Grommet
90°°°° Elbow
Vent Fitting & Clamps
5
/8²²²² Hose & Clamps
Plastic Caps
Gas Pipe
Grommet
Yellow Plastic
Cap
AIR FLOW
Combustion
Air Pipe,
N9MP2 ONLY
Combustion Blower
(Rotate 180°°°° for
Right Side)
Plastic
Cap
Pressure Hose,
Blower
Pressure Switch, Blower
Pressure Switch Hose,
Transition
Pressure Switch,
Transition
Some Models have one
pressure switch
Transition
Box
Trap Connection
Condensate
Trap & Gasket
“Clamp ears”
Pointed O UT
Preassemble &
insert into furnace
Drain Line
3
/4²²²² Hose
&Clamps
Upflow Installations - (Single Pipe & Direct Vent N9MP1 & N9MP2 Models) (See Figure 46)
Note: For easier installation of the drain hoses and clamps to the
condensate trap, follow the directions outlined below except do not
make any clamp connections to any of the drain stubs and hoses
until the hose routing and lengths have been determined. Remove
the condensate trap and drain hoses from the furnace and secure
the drain hoses to the drain stubs on the trap with the hose clamps
(position the clamps as shown in Figure 46). Install the condensate
trap/hose assembly to the furnace casing. Hook one side of the
“clamp ears” on the drain stub through the hole in the casing and
push the condensate trap into position. Secure with the two screws.
Reconnect the drain hoses to the stubs on the vent fitting and the
440 08 2001 02
plastic transition and secure with the clamps.
Mount the condensate drain trap in a vertical position to either the
left or right side of the furnace using the two screws and gasket that
are provided. If needed, remove the hole plugs from the furnace
side panel and relocate to the open set ofholes in the opposite side
panel.
NOTE: All gaskets and seals must be in place for sealed combustion applications.
Ensure that the vent fitting is securely attached to the combustion
blower using the rubber coupling and clamps.
38
dwg 25--23--57
Return
Air
Page 41
Single Stage Multi Position Furnace
Service
Manual
NOTE: For left s ide venting, the vent fitting MUST be installed with
the airflow marking arrow pointed toward the vent pipe, with the
drain stub at a 20° to 30° downward slope.
This configuration allows left side venting from the furnace. If right
side venting is required, the combustion blower must be relocated
on the plastic transition box. Remove the four(4)screws that secure
the blower to the transition. Rotate the blower180° and securewith
the four(4) screws. Use caution to not over tighten the screws to prevent stripping out of the plastic mounting holes.
NOTE: For rightside venting, the v ent fitting MUST be installed with
the airflow marking arrow pointed toward the vent pipe, with the
drain stub at a 5° to 10° downward slope. (See Figure 46)
Plug the upper drain stub on the vent fitting with the yellow plastic
Figure 47
Upflow Installations (Single Pipe & Direct Vent N9MP1 & N9MP2--A2 Models)
RIGHT Side Venting
Supply Air
Inlet
NOTE: TRAP MUST BE PRIMED BEFORE OPERATION
Some Models
have one
pressure switch
cap.
For left side mounted condensate trap, connect the
hose with the 90° bend to the large drain stub on the condensate
trap and secure with a
3
/4² clamp.
3
/4² OD rubber
Route the hose to the drain stub on the bottom of the plastic transition box. Cut off excess hose and discard. Connect the hose to the
drain stub on the transition and secure with a
For right side mounted condensate trap, connect the
hose withthe 90° bend to the bottomof the plastic transition box and
secure with a
3
/4² clamp.
3
/4² clamp.
3
/4² OD rubber
Route the hose to the largedrain stub on the condensate pump. Cut
off excess hose and discard. Connect the hose to the drain stub on
the condensate trap and secure with a
3
/4² clamp.
Vent
Drain
Exhaust
DRAIN SIDE VIEW
Rotate downward
5°°°° to 10°°°°
oo
For left side or right side mounted condensate trap, the pressure tap on the condensate trap MUST be connected to the unused
pressure tap located on the upper right hand corner of the plastic
transition box. Remove the plastic caps from the pressure taps on
the condensate trap and the plastic transition and connect with the
5
/16² OD rubber hose. (See Figure 46 and Figure 47)
Connect the
5
/8² OD rubber hose with the 90° bend to the lower
Trap Connection
“Clamp ears”
Pointed O UT
Return
Air
Preassemble
25-- 24- -00
drain stub on the vent fitting and secure with a
and insert
into furnace
5
/8² clamp.
Route the hose to thesmaller drain stub on the condensate trap. Cut
off excess hose and discard. Connect the hose to the drain stub on
the trap and secure with a
5
/8² clamp.
NOTE: Ensure hoses maintain a downward slope to the condensate trap with no kinking or binding for proper condensate drainage.
39
440 08 2001 02
Page 42
Service
Manual
Single Stage Multi Position Furnace
Figure 48
Horizontal Left Installations (Single Pipe & Direct Vent N9MP1 & N9MP2--A2 Models)
NOTE: TRAP MUST BE PRIMED BEFORE OPERATION
Plastic Caps
Supply
Air
Inlet
Combustion
Air Pipe,
N9MP2 ONLY
Vent Pipe Grommet
Yellow Plastic Cap
AIR FLOW
Vent Pipe
Exhaust
Vent Fitting & Clamps
Pressure Switch Hose, Transition
Pressure Switch, Transition
Some Models have
one pressure switch
Pressure Switch, Blower
Pressure Switch Hose, Blower
Transition Box
5
/8²²²² Hose & Clamps
3
/4²²²² Hose & Clamps
Return
Air
Horizontal Trap Connection
Preassemble
and insert
into furnace
“Clamp ears”
Pointed O UT
Combustion Blower
(Rotate 180°°°° for Right Side)
Combustion Blower
Mounting Screws (4)
Drain Line
Plastic Cap
Condensate
Trap & Gasket
dwg 25--23--58
Horizontal Left Installations - (Single Pipe & Direct Vent N9MP1 & N9MP2 Models) (See Figure 48)
Note: For easier installation of the drain hoses and clamps to the
condensate trap, follow the directions outlined below except do not
make any clamp connections to any of the drain stubs and hoses
until the hose routing and lengths have been determined. Remove
the condensate trap and drain hoses from the furnace and secure
the drain hoses to the drain stubs on the trap with the hose clamps
(position the clamps as shown in Figure 48). Install the condensate
trap/hose assembly to the furnace casing. Hook one side of the
“clamp ears” on the drain stub through the hole in the casing and
push the condensate trap into position. Secure with the two screws.
Reconnect the drain hoses to the stubs on the vent fitting and the
plastic transition and secure with the clamps.
Relocate the plastic caps and clamps on the condensate drain trap
fromthe verticaldrain stubs to the horizontal drain stubs. Secure the
clamps tightly to prevent condensate leakage.
Mount the condensate drain trap in a vertical position to the left side
of the furnace using the two screws and gasket that are provided.
Note: The condensate trapwill be located under the furnace in a verticalposition when the furnace is placed horizontally on the left side.
If needed, remove the hole plugs from the furnace side panel and
relocated to the open set of holes in the opposite side panel.
NOTE: All gaskets and seals must be in place for sealed combustion applications.
440 08 2001 02
Relocate the combustion blower on the plastic transition box. Remove thefour(4) screws that secure the blower to the transition box.
Rotate the blower 180° so the blower snout is pointing up and secure with the four(4) screws. Use caution to not over tighten the
screws to prevent stripping out of the plastic mounting holes.
Ensure that the vent fitting is securely attached to the combustion
blower using the rubber coupling and clamps.
NOTE: The vent fitting MUST be installed with the airflow marking
arrow pointed toward the vent pipe.
Plug the left drain stub on the vent fitting with the yellow plastic cap.
Connect the
stub on the condensate trap and secure with a
3
/4² OD rubber hose with the 90° bend to the large drain
3
/4² clamp.
Route the hose to the drain stub on the bottom of the plastic transition box. Cut off excess hose and discard. Connect the hose to the
drain stub on the transition and secure with a
Connect the
5
/8² OD rubber hose with the 90° bend to the rightdrain
stub on the vent fitting and secure with a
3
/4² clamp.
5
/8² clamp.
Route the hose to thesmaller drain stub on the condensate trap. Cut
off excess hose and discard. Connect the hose to the drain stub on
the vent fitting and secure with a
5
/8² clamp.
NOTE: Ensure hoses maintain a downward slope to the condensate trap with no kinking or binding for proper condensate drainage.
40
Page 43
Single Stage Multi Position Furnace
Service
Manual
Figure 49
Horizontal Right Installations (Single Pipe & Direct Vent N9MP1 & N9MP2--A2 Models)
NOTE: TRAP MUST BE PRIMED BEFORE OPERATION
Ven t Pipe
Pressure
Switch, Transition
Return
Air
Horizontal Trap Connection
Combustion Blower
Combustion Blower
Mounting Screws (4)
“Clamp ears”
Pointed O UT
Preassemble
and insert
into furnace
Transition Box
5
/8²²²² Hose &
Clamps
Pressure Switch
Hose, Blower
Some Models
have one
pressure switch
Plastic
Caps
Condensate
Trap & Gasket
Plastic
Caps
Yellow
Plastic
Cap
Drain Line
Vent Pipe
Grommet
Vent Fitting
&Clamps
Exhaust
Pressure Switch
Hose, Transition
Pressure
Switch, Blower
Inlet
Supply
Air
3
/4²²²² Hose
&Clamps
Combustion
Air Pipe,
N9MP2 ONLY
dwg 25--23--59a
Horizontal Right Installations - (Single Pipe & Direct Vent N9MP1 & N9MP2 Models) (See Figure 49)
Note: For easier installation of the drain hoses and clamps to the
condensate trap, follow the directions outlined below except do not
make any clamp connections to any of the drain stubs and hoses
until the hose routing and lengths have been determined. Remove
the condensate trap and drain hoses from the furnace and secure
the drain hoses to the drain stubs on the trap with the hose clamps
(position the clamps as shown in Figure 49). Install the condensate
trap/hose assembly to the furnace casing. Hook one side of the
“clamp ears” on the drain stub through the hole in the casing and
push the condensate trap into position. Secure with the two screws.
Reconnect the drain hoses to the stubs on the vent fitting and the
plastic transition and secure with the clamps.
Relocate the plastic caps and clamps on the condensate drain trap
from the vertical drain stub to the horizontal drain stubs. Secure the
clamps tightly to prevent condensate leakage.
Mount the condensate drain trap in a vertical position to the right
side of the furnace using the two screws and gasket that are provided. Note: The condensate trap will be located under the furnace
in a vertical position when the furnace is placed horizontally on the
right side. If needed, remove the hole plugs from the furnace side
panel and relocate to the open set of holes in the opposite side panel.
NOTE: All gaskets and seals must be in place for sealed combustion applications.
Ensure that the vent fitting is securely attached to the combustion
blower using the clamps.
NOTE: The vent fitting MUST be installed with the airflow marking
arrow pointed toward the vent pipe.
Plug the left drain stub on the vent fitting with the yellow plastic cap.
Remove thepressure switchhose from the upper stub on the plastic
transition box.
Relocate the plastic caps on the stubs of the plastic transition from
the lower stubs to the upper stubs and secure tightly with the
clamps.
Route the pressure switch hose to the lower stub on the plastic transition box. Cut off excess hose and discard. Connect the pressure
switch hose to the lower stub on the plastic transition box. Ensure
that the hose is routed above the stub on the transition box so that
condensate does not collect in the hose. NOTE: Failure to correctly
install the pressure switchhose to the transition can adversely affect
the safety control operation.
Connect the
stub on the condensate trap and secure with a
3
/4² OD rubber hose with the 90° bend to the large drain
3
/4² clamp.
Route the hose to the drain stub on the bottom of the plastic transition box. Cut off excess hose and discard. Connect the hose to the
drain stub on the transition and secure with a
Connect the
on the vent fitting and secure with a
5
/8² OD rubber hose with the 90° bend to the right stub
5
/8² clamp.
3
/4² clamp.
Route the hose to thesmaller drain stub on the condensate trap. Cut
off excess hose and discard. Connect the hose to the drain stub on
the trap and secure with a
5
/8² clamp.
NOTE: Ensure hoses maintain a downward slope to the condensate trap with no kinking or binding for proper condensate drainage.
41
440 08 2001 02
Page 44
Service
Manual
Single Stage Multi Position Furnace
Figure 50
Vent Fitting
&Clamps
5
/8²²²² Hose &
Clamps
Inlet
Plastic Caps
Condensate
Trap & Gasket
Downflow Installations (Single Pipe & Direct Vent N9MP1 & N9MP2--A2 Models)
LEFT Side Venting
Return Air
Combustion Blower
Mounting Screws (4)
Yellow
Plastic
Cap
Exhaust
3
/4²²²² Hose & Clamps
Pressure Switch
Hose, Transition
Plastic
Caps
Transition Box
Pressure
Switch, Blower
Pressure Switch
Hose, Blower
Trap Connection
“Clamp ears”
Pointed
OUT
RIGHT Side Venting
Return Air
Combustion Blower
(Rotate 180°°°° for Left Side)
Pressure
Switch,
Transition
Some Models
have one
pressure switch
Vent Pipe
Grommet
Inlet
Exhaust
Combustion
Air Pipe,
N9MP2 ONLY
Ven t Pipe
DRAIN SIDE VIEW
Drain Line
Supply Air
Preassemble &
insert into furnace
AIRFLOW
Supply Air
dwg 25--23--60
NOTE: TRAP MUST BE PRIMED BEFORE OPERATION
Downflow Installations - (Single Pipe & Direct Vent N9MP1 & N9MP2 Models) (See Figure 50)
Note: For easier installation of the drain hoses and clamps to the
condensate trap, follow the directions outlined below except do not
make any clamp connections to any of the drain stubs and hoses
until the hose routing and lengths have been determined. Remove
the condensate trap and drain hoses from the furnace and secure
the drain hoses to the drain stubs on the trap with the hose clamps
(position the clamps as shown in Figure 50). Install the condensate
trap/hose assembly to the furnace casing. Hook one side of the
“clamp ears” on the drain stub through the hole in the casing and
push the condensate trap into position. Secure with the two screws.
Reconnect the drain hoses to the stubs on the vent fitting and the
plastic transition and secure with the clamps.
Mount the condensate drain trap in a vertical position to either the
right or left side of the furnace using the two screws and gasket that
are provided. If needed, remove the hole plugs from the furnace
side panel and relocatedto the open set ofholes inthe oppositeside
panel.
NOTE: All gaskets and seals must be in place for sealed combustion applications.
Ensure that the vent fitting is securely attached to the combustion
blower using the rubber coupling and clamps.
440 08 2001 02
This configuration allows right side venting from the furnace. If the
left side venting is required, the combustion blower must be relocated on the plastic transition box. Remove the four(4) screws that
secure the blower to the transition. Rotate the blower 180° and secure with the four(4) screws. Use caution to not over tighten the
screws to prevent stripping out of the plastic mounting holes.
NOTE: The vent fitting MUST be installed with the airflow marking
arrowpointed towardthe vent pipe, with the drain stub at a 20° to 30°
downward slope.
Plug the upper drain stub on the vent fitting with the yellow plastic
cap.
Remove thepressure switchhose from the upper stub on the plastic
transition box.
Relocate the plastic caps on the stubs of the plastic transition box
from the lower stubs to the upper stubs and secure tightly with the
clamps.
Route the pressure switch hose to the lower stub on the plastic transition box. Cut off excess hose and discard. Connect the pressure
switch hose to the lower stub on the plastic transition box. NOTE:
Failure to correctly install the pressure switch hose to the transition
box can adversely affect the safety control operation.
42
Rotate
downward
20°°°° to 30°°°°
Page 45
Single Stage Multi Position Furnace
Service
Manual
Connect the3/4² OD rubber hose with the 90° bend to the drain stub
on the bottom of the plastic transition box and secure with a
3
/4²
clamp.
Route the hose to the large drain stub on the condensate trap. Cut
off excess hose and discard. Connect the hose to the drain stub on
the transition and secure with a
5
Connect the
/8² OD rubber hose with the 90° bend to the left drain
stub on the vent fitting and secure with a
3
/4² clamp.
5
/8² clamp.
Route the hose to the smaller stub on the condensate trap. Cut off
excess hose and discard. Connect the hose to the drain stub on the
trap and secure with a
5
/8² clamp.
For left side or right side mounted condensate trap, the pressure tap on the condensate trap MUST be connected to the unused
pressure tap located on the top of the plastictransition box. Remove
the plastic caps from the pressure tap on the condensate trap and
the plastic transition and connect the
5
/16² OD rubber hose. (See
Figure 50)
NOTE: Ensure hoses maintain a downward slope to the conden-
sate trap with no kinking or binding for proper condensate drainage.
43
440 08 2001 02
Page 46
Service
Manual
30. HEAT EXCHANGER REMOVAL/REPLACEMENT
Single Stage Multi Position Furnace
Figure 51
“Exploded” Parts View -- Typical Four Position Furnaces
25--23--43a
Secondary Heat Exchanger
1. Turn ”OFF” electrical power and gas supply to furnace.
2. Disconnect vent pipe to furnace at flexible coupling.
3. Remove combustion blower.
4. Remove machine screws securing transition assembly
to furnace front partition.
5. Remove the collector box.
6. Loosen the four(4) screws on the manifold or as an alternative the four(4) screws on the manifold bracket.
7. Move the manifold bracket and valve up enough so the
secondary heat exchanger will clear the flange on the
baffle.
8. Remove machine screws securing secondary heat exchanger inlet flange to lower partition.
9. Remove screws around perimeter of lower partition.
10. Removed screws securing secondary heat exchanger
to the supports.
1 1. Coil can now be removed from furnace.
12. Reverse procedure to reinstall, making sure that any
gaskets that have been torn during disassembly are
replaced with new ones.
Primary Heat Exchanger
1. Turn ”OFF” electrical power and gas supply to furnace.
2. Disconnect vent pipe to furnace at flexible coupling.
440 08 2001 02
3. Disconnect combustion air inlet pipe at top panel (if
needed).
4. Remove furnace top panel.
5. Disconnect gas piping to furnace at gas valve. Note: Before performing next step, insure that the wiring diagram is available and readable, or tag all wires first.
6. Disconnect tubing and wiring to pressure switch, limit
switches, and gas valve.
7. Remove screws securing burner box to front partition.
8. Remove combustion blower.
9. Remove machine screws securing transition assembly
to furnace partition.
10. Remove the collector box.
1 1. Remove machine screws securing secondary heat ex-
changer inlet flange to lower partition.
12. Remove screws around perimeter of both the upper
and lower partitions (leaving the screws across the
center of the two panels in place).
13. Primary Heat Exchanger can now be removed with
both upper and lower partitions attached.
14. Reverse procedure to reinstall, making sure that any
gaskets that have been torn during disassembly are
replaced with new ones.
15. After reassembly, turn the gas supply on, and check for
leaks. All leaks must be repaired immediately .
16. Perform an operational check of the furnace.
44
Page 47
Single Stage Multi Position Furnace
Service
Manual
HONEYWELL SV9541M “SMART VALVE” Sequence of Operation
The following is the normal operating sequence for the control system.
Cooling (Y) Request:
24 VAC signals applied to Y & G terminals of EFT (electronic fan timer) control.
· Cool motor speed energized after 6 second Cool Fan On Delay time.
Y & G signals removed from EFT.
· Cool motor speed de--energized after 60 second Cool Fan Off Delay time.
Circulating Fan (G) Request:
24 VAC signals applied to G terminals of EFT control.
· Heat motor speed energized without delay.
G signal removed from EFT.
· Heat motor speed de--energized without delay.
Heating (W) Request:
24 VAC signals applied to W terminal of EFT control.
· Inducer motor turns on.
· The gas valve solenoid energizes.
· Followinga3secondprepurge delay, the pilot valve opens and the ignitor begins to warm up.
· After the pilot lights, the main burners energize and light.
· Timed from the opening of the main gas valve, the control will delay 30 seconds before switching the fan to Heat speed.
W signal removed from EFT.
· The gas valve de--energizes and the main burners go out.
· The inducer runs at its present speed for a 30 second postpurge period.
· Timed from the gas valve de--energizing, the Heat fan speed de--energizes after the selected Heat Fan Delay time
expires.
Heating Request with Gas Supply Line Shut Off:
24 VAC signals applied to W terminal of EFT control.
· Inducer motor turns on.
· The gas valve solenoid energizes.
· Followinga3secondprepurge delay, the pilot valve opens and the ignitor begins to warm up.
· The ignitor glows red--hot for 30 seconds, then turns off.
· The igniter stays off for 25 seconds, then begins to warm--up again.
· The igniter glows red--hot for 30 seconds, then turns off.
· The pilot valve closes 3 seconds after the igniter de--energizes.
· The inducer de--energizes 5 seconds after the pilot valve closes.
· The SmartValve proceeds to soft lockout and flashes error code 6.
· The control exits soft lockout after 5 minutes and begins
another ignition sequence.
45
440 08 2001 02
Page 48
Service
Manual
Single Stage Multi Position Furnace
HONEYWELL SV9541M “SMART VALVE” Sequence of Operation
POWER APPLIED TO APPLIANCE
THERMOSTAT CALLS FOR HEAT
PRESSURE SWITCHES PROVED OPEN?
COMBUSTION BLOWER ENERGIZED
PRESSURE SWITCHES CLOSED WITHIN
30 SECONDS?
3 SECOND PRE--PURGE
PILOT VALVE OPENS:
IGNITOR POWERED (1)
PILOT LIGHTS AND FLAME IS SENSED
DURING 90 SECOND TRAIL FOR
IGNITION?
YES
MAIN VALVE OPENS,
HEATING FAN “ON” DELAY BEGINS
NO
WAIT FOR PRESSURE SWITCHES TO OPEN
NO
COMBUSTION BLOWER DE--ENERGIZED
THREE SECOND FLAME
FAILURE RECYCLE DELAY
NO
PILOT VALVE CLOSES;
PILOT IGNITOR OFF
FIVE MINUTE WAIT PERIOD
AFTER DELAY: CIRCULATING BLOWER
STARTS
FLAME SENSE LOST?
THERMOSTAT CALL FOR HEAT ENDS
PILOT AND MAIN VALVE CLOSE
COMBUSTION BLOWER DE--ENERGIZED
AFTER 30 SECOND POST PURGE
CIRCULATING BLOWER O FF AFTER
DELAY
WAIT FOR NEXT CALL FOR HEAT
440 08 2001 02
NO
YES
PILOT AND MAIN VALVE CLOSE
FLAME SENSE LOST MORE THAN FIVE
TIMESINTHISCALLFORHEAT?
YES
(1) Ignitor “ON” for first 30 seconds of trial for ignition, then “OFF” for next 30 seconds.
If the pilot has not lit, it turns back “ON” for the final 30 seconds. The pilot valve remains
NOTE: If main limit string opens and takes longer than 2 minutes to close, system goes
46
CIRCULATING BLOWER O FF AFTER
DELAY
COMBUSTION AIR BLOWER OFF AFTER
NO
energized during the entire 90 second trial for ignition.
into 1 hour wait period (indicating circulating blower).
POST PURGE
Page 49
Single Stage Multi Position Furnace
HONEYWELL SV9541 “SMART VALVE” Trouble shooting
The 6 + X designation indicates a combination of flash codes: 6
flashes shows the control is in s oft lockout, followed by X flashes to
indicate the reason the control went into soft lockout. Last status
code indicates repair to address first
Service
Manual
LED
STATUS
Off No power to system control.
Heartbeat
Bright –
Dim
2 Flashes
3 Flashes
4 Flashes
5 Flashes
INDICATES CHECK/REPAIR
Normal indication whenever the system is powered,
unless s ome abnormal event has occurred.
Pressure switches closed when it should be open
(i.e. when call for heat begins).
(Combustion blower is not energized until pressure
switches opens)
Pressure switches , open when theyshould be closed
(i.e. longer than 30 seconds after combustion blower/
inducer is energized).
System goes into 5-- minute delay period, with combustion blower/inducer off. At end of the 5--minute
delay, another cycle will begin.
Main Limit or Roll Out Switch is open.
Combustion blower is energized, Circulating blower is
energized heat speed.
Flame signal sensed out of proper sequence.
Combustion blower is energized, Circulating blower is
energized heat speed after the “ON” delay.
Line voltage input at L1 and Neutralconnectors on ST9160B
Fan Timer.
Low voltage (24V) power at 24 VAC and COM terminals on
ST9160B
System wiring harness is in good condition and securely
connected.
Not Applicable -- Normal Operation (standby or call forheat)
Pressure switches stuck closed (system will wait for pressure switch to open).
Pressure switches miswired or jumpered.
Ignition system control switch must be in the ON position.
Pressure switches operation, tubing, and wiring.
Restrictions in furnace air intake or vent piping.
Main limit switch.
Manual reset burner rollout switch.
Limit and rollout switch wiring is in good condition and securely connected.
Duct restriction/overfire.
Flame at pilot burner.
6 Flashes
+
1Flash
6 Flashes
+
2 Flashes
Soft Lockout.
Failed to light pilot during 90 sec. trial for ignition
Combustion air blower is de--energized, Circulating
blower is de--energized after the “OFF” delay.
After 5--minute delay time, control system will reset
and initiate a new ignition sequence,
Soft Lockout.
Last failure was Flame Sense lost during run.
Maximum recycle count exceeded
Combustion air blower is de--energized, Circulating
blower is de--energized after the “OFF” delay.
After 5--minute delay time, control system will reset
and initiate a new ignition sequence,
Gas supply off or pressure too low or high for appliance to
operate.
Damaged or broken HIS element
Flame sense rod contaminated or in incorrect position.
Pilot burner located in incorrect position.
Pilotburner lead wires are in good condition and popery connected.
Pressure switches operation, tubing, and wiring.
Gas supply off or pressure too low or high for appliance to
operate.
Flame sense rod contaminated or in incorrect position.
Pilot burner located in incorrect position.
Pilot burner lead wires are in good condition and properly
connected.
Cycling, pressure switch
Condensate drain blocked
Pressure switches operation, tubing, and wiring.
47
440 08 2001 02
Page 50
Service
Manual
Single Stage Multi Position Furnace
HONEYWELL SV9541 “SMART VALVE” Trouble shooting continued
LED
STATUS
6 Flashes
+
3 Flashes
6 Flashes
+
4 Flashes
INDICATES CHECK/REPAIR
Soft Lockout.
Last failure was pressure switch
Maximum recycle count exceeded
Combustion air blower is de--energized, Circulating
blower is de--energized after the “OFF” delay.
After 5--minute delay time, control system will reset
and initiate a new ignition sequence,
Soft Lockout.
Last failure was limit circuit opened during run.
Combustion air blower is de--energized, Circulating
blower is de--energized after the “OFF” delay.
After 5--minute delay time, control system will reset
and initiate a new ignition sequence,
Soft Lockout.
Ignition system control switch must be in the ON position.
Pressure switches operation, tubing, and wiring.
Restrictions in furnace air intake or vent piping.
High winds blowing against vent.
Main limit switch.
Limit and rollout switch wiring is in good condition and securely
connected.
Restriction in duct work.
Dirty filter
Overfire
7 Flashes
Blower failure (typical)
Limit trip took longer than 2 minutes to reset.
System will start a new ignition sequence after 1 hour,
if call for heat still present.
Dead blower.
Blocked duct work.
440 08 2001 02
48
Page 51
Single Stage Multi Position Furnace
Service
Manual
SV9541M ELECTRICAL VARIATION
SINGLE STAGE
Connector (Pin #) Description Voltage Signal When Signal is Present
Neutrals
1
(5--
/4² QC’s )
L1
1
(2--
/4² QC’s )
HEAT
1
(
/4² QC’s )
COOL
1
(
/4² QC’s )
EAC
1
(
/4² QC’s )
CONSTANT FAN
1
(
/4² QC’s )
HUM
1
(
/4² QC’s )
P1 (pin 1) Line Voltage 115 VAC Present when the door interlock switch is closed.
P1 (pin 2) Data Line Non--periodic
P1 (pin 3) C (xfmr common) 0VAC Always present
P1 (pin 4) Neutral 0VAC Always present
P1 (pin 5) 24 VAC 24 VAC Present when the door interlock switch is closed.
P1 (pin 6) R 24 VAC Present when the door interlock switch is closed.
C1 (pin 1) Limit return
C1 (pin 2) Pressure Switch supply
C1 (pin 3) Pressure Switch return
C1 (pin 4) Data Line Non--periodic
C1 (pin 5) Limit Supply
C1 (pin 6) C (xfmr common) 0VAC Always present
C1 (pin 7) R 24 VAC Present when the door interlock switch is closed.
C1 (pin 8) 24 VAC 24 VAC Present when the door interlock switch is closed.
C2 (pin 1) HSI return 24 VAC (with igniter present) Present when HSI is not turned on. When HSI is on, this
C2 (pin 2) HSI supply 24 VAC Present when the door interlock switch is closed.
C2 (pin 3) Not connected 0VAC Not connected
C2 (pin 4) Flame sense >80 VAC Present when the door interlock switch is closed.
C3 (pin 1) Inducer supply 115 VA C Present when the inducer draft blower motor is on (Heat
C3 (pin 2) L1 115 VA C Present when the door interlock switch is closed.
C3 (pin 3) Inducer return 0VAC Always present (neutral connection).
C3 (pin 4) L2 (neutral) 0VAC Always present
* With a motor tap connected, voltage appears at “unpowered” fan terminals whenever the motor is running due to feedback through the motor windings.
** Voltage appears on the “unpowered” inducer terminal whenever the inducer motor is running due to feedback through the motor windings.
NOTE1: Using a Fluke 79 digital Multi--Meter (DMM),
meter.
Neutral 0VAC
Always present
(Neutral and earth ground should
be at the same potential)
Line Voltage 115 VA C Present when blower door interlock switch is closed.
Fan power *115 VAC Present when Heat fan speed is on (Open Limit mode)
Fan power *115 VAC Present when Cool fan speed is on (Cool (Y) mode).
Electronic Air--
115 VA C Present when High Heat or Cool fan speed is on.
Cleaner power
Continuous Fan
*115 VAC Present when other fan speeds is off.
power
Humidifier power 115 VA C Present when the Heat speeds is on.
1
wave rectified AC
(measures as an unstable AC volt-
/2
Present when the door interlock switch is closed.
age bouncing between 12 VAC and
16 VAC
1
wave rectified AC Present when the door interlock switch is closed. This
/2
1
wave rectified AC Present when the door interlock switch is closed. This
/2
1
wave rectified AC Present when the door interlock switch is closed. This
/2
voltage decreases when a limit switch is open.
signal is the same as the C1 (pin 1)
AC voltage decreases when the Low Pressure Switch
closes.
1
wave
rectified AC
1
wave rectified AC Present when the 24 VAC transformer is powered.
/2
/2
Present when the door interlock switch is closed. Same
signal as P1 (pin 5).
signal is 0 VAC to 10 VAC depending on input line voltage potential.
modes, Open Limit mode).
1
wave rectified AC voltage typically measures about 14 VAC. The Fluke 79 is not a “true” RMS
/2
49
440 08 2001 02
Page 52
Service
Manual
Single Stage Multi Position Furnace
Wiring Diagram (90+ Single Stage Furnaces)(A1)
COOL ON DELAY: 5 SEC
COOL OFF DELAY: 60 SEC
HEAT ON DELAY: 30 SEC.
12
ON
FACTORY
SETTING
N
GND.
LADDER DIAGRAM
HEAT MHI (O)
COOL HI (BK)
L1
L1
HOT 115V-60HZ NEUTRAL
INTERLOCK
SWITCH
L1
FAN CONTROL MODULE
S1
HEAT OFF DELAY
12
60 SEC.
N
BLOWER
MOTOR
LO (R)
M1 MLO (BL)
M2
L1
1
EAC
CAPACITOR
(SOME MODELS)
GAS
VALVE
4
1
2
3
5
6
87
3
4
N
1
2
3
4
12
4
INDUCER
MOTOR
EAC
L1
12
100 SEC.
N
NGN
ROLLOUT SWITCH
1 TO 3 IN SERIES
DEPENDING ON MODEL
PRESSURE SWITCH
HUM
HUM
L1
115V
L1
MAIN LIMIT
TRANSFORMER
24V
24VAC
5 A
FUSE
COM
12
140 SEC. 180 SEC.
1 TO 2 IN SERIES
DEPENDING ON MODEL
1
3
2
7
6
FURNACE
548
CONTROL
GAS
VALVE
1
23
4
1
3
2
4
3
2
1
6
4
5
12
LP PRESSURE
SWITCH
(LP MODELS ONLY)
IGNITER
SENSOR
Y
W
C
R
THERMOSTAT
W
Y
G
R
IF ANY OF T HE ORIGINAL W IRE AS SUPPLIED W ITH THE APPLIANCE
1012910-C
MUST BE REPLACED, IT MUST BE REPLACED WITH TYPE
AWM - 105° C WIRE OR ITS EQUIVA LENT.
ROLLOUT S WITCH
1 TO 3 IN SERIES
DEPENDING ON
MODEL
R
R
GAS VALVE
1
5
DISCONNECT BEFORE SERVICING
DANGER: ELECTRICAL SHOCK HAZARD
C1
MAIN LIMIT
R
INTERLOCK
SWITCH
CONNECTION DIAGRAM
FIELD
CONNECTION
BOX
BR
BR
PRESSURE SWITCH
1 TO 2 IN SERIES
DEPENDING ON
MODEL
LP PRESSURE
SWITCH
(LP MODELS ONLY)
BL
BL
BL
BK
INDUCER
MOTOR
W
W
BK
BK
1
3
2
4
7
6
8
P
IGNITOR
BK
C2
2
3
4
SENSOR
BL
Y
BL
O
C3
1
3
2
4
BK
W
W
24
NEUTRAL
4
56
COM
VAC
L1
L1
1
23
ON
DATA
5A FUSE
R
CONT
1 2
EAC
COOL
HEAT
HUM
M2
M1
FURNACE CONTROL
W
C
Y
W
Y
W
GND
HOT
115V
NEUTRAL
60HZ
COPPER
CONDUCTORS
ONLY
115V PRIMARY
TRANSFORMER
BL
24V SECONDARY
R
CAPACITOR
(SOME MODELS)
BK
COLOR CODE
W
BLACK BK
BLUE BL
BROWN BR
GREEN G
ORANGE O
RED R
WHITE W
YELLOW Y
PURPLE P
SPEED TAP CO DE
BLACK-HI BLUE-MLO
ORANGE-MHI RED-LO
LINE VOLTAGE FACTORY
LINE VOLTAGE FIELD
LOW VOLTAGE FACTORY
LOW VOLTAGE FIELD
INTERNAL CIRCUIT BOARD WIRING
RECTIFIED AC VOLTAGE
O
R
BLOWER
BL
MOTOR
BR
BR
G
CAPACITOR
G
Y
W
Y
G
R
THERMOSTAT
NOTE:
MOST VOLT METERS WILL READ 13-16 VOLTS TO
CHASSIS ON BOTH SIDES OF AN OPEN LIMIT OR
PRESSURE SWITCH IN THE RECTIFIED AC
VOLTAGE CIRCUIT
SEE MANUALS FOR ADJUSTING SPEED TAPS FOR PROPER HEATING, COOLING & CIRCULATING SPEEDS.
*
440 08 2001 02
50
Page 53
Single Stage Multi Position Furnace
Y
G
TH
ER
M
O
STAT
2
3
4
M
A
IN
L
IM
IT
GAS
VALVE
N
N
G
N
Y
1
5
IN
D
U
C
E
R
M
O
T
O
R
EAC
115V
ROLLOUT SWITCH
1 TO 3 IN SERIES
DEPENDING ON MODEL
3
6
4
2
TRANSFORMER
L1
HUM
L1
12
FAN CONTROL MODULE
W
Y
G
G
W
Y
W
TRANSFORMER
BLOW
ER
M
OTO
R
L1
L1
L1
C1
NEUTRAL
BL
BK
INDUCER
MOTOR
R
FURNACE
CONTROL
BK
W
ROLLOUT S WITCH
1 TO 3 IN SERIES
DEPENDING ON
MODEL
W
BL
W
B
K
O
R
4
L1
CONT
COOL
1
2
E
A
C
3
H
E
A
T
4
C2
4
56
24
V
S
E
C
O
N
D
A
R
Y
23
DATA
5A FUSE
24V
24VAC
O
BK
R
ON
115V
60HZ
HEAT ON DELAY: 30 SEC.
1012910-E
DISCONNECT BEFORE SERVICING
DANGER: ELECTRICAL SHOCK HAZARD
CONNECTION DIAGRAM
COOL ON DELAY: 5 SEC
COOL OFF DELAY: 60 SEC
S1
HEAT OFF DELAY
BL
GAS VALVE
R
W
BL
P
W
BK
G
N
D
COPPER
CONDUCTORS
ONLY
6
N
E
U
T
R
A
L
H
O
T
W
5
4
3
2
8
1
7
3
C3
C
O
M
W
2
4
V
A
C
C
Y
R
C
BL
R
W
Y
FU
R
N
A
C
E C
O
N
TR
O
L
G
BR
B
R
CA
PA
C
ITO
R
Y
R
R
1
2
3
4
3
7
2
1
6
5
4
8
1
EAC
HUM
N
2
4
87
12
3
4
4
SEE MANUALS FOR ADJUSTING SPEED TAPS FOR PROPER HEATING, COOLING & CIRCULATING SPEEDS.
COLOR CODE
6
3
5
BLACK BK
BLUE BL
BROWN BR
GREEN G
ORANGE O
RED R
WHITE W
YELLOW Y
PURPLE P
1
SPEED TAP CO DE
BLACK-HI BLUE-MLO
ORANGE-MHI RED-LO
*
LINE VOLTAGE FACTORY
LINE VOLTAGE FIELD
LOW VOLTAGE FACTORY
LOW VOLTAGE FIELD
INTERNAL CIRCUIT BOARD WIRING
5
A
F
U
S
E
FACTORY
SETTING
1
2
N
N
B
L
O
W
E
R
M
O
T
O
R
LO (R)
M2
M1 MLO (BL)
G
N
D
.
HEAT MHI (O)
COOL HI (BK)
LADDER DIAGRAM
IN
TE
R
LO
C
K
S
W
ITC
H
H
O
T 115V
-60H
Z N
E
U
TR
AL
IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE
MUST BE REPLACED, IT MUST BE REPLACED WITH TYPE
AWM - 105° C WIRE OR ITS EQUIVALEN T.
GAS
VALVE
LP PRESSURE
SWITCH
(LP MODELS ONLY)
ON
INTERLOCK
SWITCH
1
M
A
IN
L
IM
IT
FIELD
CONNECTION
BOX
LP
PR
ESS
UR
E
S
W
ITC
H
(LP M
O
D
ELS O
N
LY)
1 2
H
U
M
M
2
M
1
1
1
5V
P
R
IM
A
R
Y
R
1
2
3
THERMOSTAT
4
12
12
60 SEC.
140 SEC. 180 SEC.
12
100 SEC.
12
1
L1
L1
CO
M
BL
L1
SENSOR
IGNITOR
BL
PRESSURE SWITCH
1 TO 2 IN SERIES
DEPENDING ON
MODEL
PRESSURE SWITCH
1 TO 2 IN SERIES
DEPENDING ON MODEL
BR
BR
C
A
P
A
C
ITO
R
(S
O
M
E
M
O
D
E
LS)
CAPACITOR
(SOME MODELS)
IGNITER
SENSOR
RECTIFIED AC VOLTAGE FACTORY
NOTE:
MOST VOLT METERS WILL READ 13-16 VOLTS TO
CHASSIS ON BOTH SIDES OF AN OPEN LIMIT OR
PRESSURE SWITCH IN THE RECTIFIED AC
VOLTAGE CIRCUIT
BK
CAPACITOR
Wiring Diagram (90+ Single Stage Furnaces)(A2)
Service
Manual
51
440 08 2001 02
Page 54
Service
Manual
Manufacturers Number (Mfr No --SeeRatingPlate)
ALL Models
Specifications
General
Gas Type
Transformer Size (VA)
T’stat Heat Anticipator
Gas & Ignition
Gas Valve
Regulation Type
Manifold Press. (Inch’s WC)
Pilot Orifice Size .018 .011
Ignition Type/Series HW HSP HW HSP
Fan Controls
Fan Control (T ype)
Fan Control On
(Timed-- secs) Off
Gas Conversion Kits All Models
Nat to LP NAHF002LP *1009509
LP to Nat NAHF002NG *1009510
*Order from Service Parts
Nat LP
40
.10
HW SV9541M
SNAP
3.5
HW ST9160
30
60,100,140,180
40
.10
HW SV9541M
SNAP
10.0
HW ST9160
30
60,100,140,180
Single Stage Multi Position Furnace
Specifications
*9MP1050B12A1
*9MP2050B12A1
General
Input (Btuh)
Output (Btuh)
Tem p . R i s e (
°
F)
50,000
45,500
35--65
Electrical (V olts/Hz/FLA) 115/60/9.8 115/60/8.9 115/60/9.0 115/60/10.5 115/60/11.2
Gas & Ignition
Gas Type
Std. Main Orifices (No/Size)
Nat.
2/42
L.P.
2/54
Combustion
Flue Outlet Size (Inches)
Std. Outlet Temp (° F)
2
<140
@Blower/ @ Transition Box
Std. Pressures (² of WC)
5¢ No Elbows
40¢ +5-- 90° DWV Elbows
Limits & Controls
Rollout Switch (
Limit Control Setting (
°
F)
°
F)
Std. Transition Pressure Sw. (Part No)
Blower Switch Pressure (Close)
Blower Switch Pressure (Open)
Transition Switch Pressure (Close)
Transition Switch Pressure (Open)
High Altitude Pressure Sw. (Part No)
Blower Switch Pressure (Close)
Blower Switch Pressure (Open)
Transition Switch Pressure (Close)
Transition Switch Pressure (Open)
--1.80 / -- 2.60
--1.30 / -- 2.30
300
240
1013518
0.95
0.80
2.00
1.80
1013165
0.70
0.55
1.40
1.20
Blower Data
Type & Size
Motor Amps/Rpm
Motor Type/H.p.
Cap. Mfd/Volts
Filter Type
Cool Cap. (Tons) @ .5² W.C. L, ML, MHi & Hi
11- -8
10/850
PSC/
7.5/370
16x25x1
1
1
/2,2,21/2,3
1
/
2
*9MP1075B12A1
*9MP2075B12A1
75,000
68,000
40--70
Nat.
3/42
L.P.
3/54
2
<140
--1.80 / -- 2.60
--1.30 / -- 2.30
300
210
1013518
0.95
0.80
2.00
1.80
1013165
0.70
0.55
1.40
1.20
11- -8
8.0/1050
1
PSC/
/
2
7.5/370
16x25x1
1
1
/2,2,21/2,3
*9MP1100F14A1
*9MP2100F14A1
100,000
91,000
40--70
Nat.
4/42
3
<140
--1.80 / -- 2.60
--1.70 / -- 2.50
300
230
1013518
0.95
0.80
2.00
1.80
1013165
0.70
0.55
1.40
1.20
11- -1 0
10/1050
1
PSC/
/
2
10/370
16x25x1
1
1
/2,2,3,31/
L.P.
4/54
2
*9MP1100J20A1
*9MP2100J20A1
100,000
96,500
40--70
Nat.
4/42
L.P.
4/54
3
<140
--1.80 / -- 2.60
--1.70 / -- 2.50
300
220
1013518
0.95
0.80
2.00
1.80
1013165
0.70
0.55
1.40
1.20
11- -1 0
13/900
3
PSC/
/
4
40/370
16x25x1
1
3
/2,4,41/2,5
*9MP1125J20A1
*9MP2125J20A1
125,000
113,750
40--70
Nat.
5/42
3
<140
--1.80 / -- 2.60
--1.70 / -- 2.50
300
190
1013166
1.30
1.10
1.80
1.60
1013157
0.85
0.70
1.70
1.50
11- -1 0
13/900
3
PSC/
/
40/370
16x25x1
1
3
/2,4,41/2,5
L.P.
5/54
4
440 08 2001 02
52
Page 55
Single Stage Multi Position Furnace
Service
Manual
Manufacturers Number (Mfr No --SeeRatingPlate) ALL Models
Specifications (N9MP1)(A2)
N9MP1050B12 N9MP1075B12 N9MP1080F16 N9MP1100F14 N9MP1100J20 N9MP1125J20
General
Gas Type
Input (Btuh)
Output (Btuh)
Transformer Size (VA)
T’stat Heat Anticipator
Tem p . R i s e (
°
F)
Electrical (V olts/Hz/FLA) 115/60/9.8 115/60/8.9 115/60/9.0 115/60/9.0 115/60/10.5 115/60/11.2
Gas & Ignition
Gas Type
Gas Valve
Regulation Type
IgnitionType/Series
Manifold Press. (Inch’s WC)
Std. Main Orifices (No/Size)
Pilot Orifice Size
Fan Controls
Fan Control (Type)
Fan Control On
(Timed--secs) Off
Combustion
Flue Outlet Size (Inches)
Std. Outlet Temp (°5¢ No Elbows
Blower Pressure 5¢ No Elbows (² WC)
Blower Pressure 40¢ +5--90° DWV Elbows (² WC)
Transition Bx Pressure 5¢ No Elbows (² WC)
Transition Bx Pressure 40¢ +5--90° DWV Elbows (² WC)
Limits & Controls
Rollout Switch (
Limit Control Setting (
°
F)
°
F)
Standard Pressure Sw. (Part No)
Blower Switch Pressure (Close) (² WC)
Blower Switch Pressure (Open) (² WC)
Transition Switch Pressure (Close) (² WC)
Transition Switch Pressure (Open) (² WC)
High Altitude Pressure Sw. (Part No)
Blower Switch Pressure (Close) (² WC)
Blower Switch Pressure (Open) (² WC)
Transition Switch Pressure (Close) (² WC)
Transition Switch Pressure (Open) (² WC)
Long Vent Kit (Part No)
Pressure Switch (Part No)
Blower Switch Pressure (Close) (² WC)
Blower Switch Pressure (Open) (² WC)
Transition Switch Pressure (Close) (² WC)
Transition Switch Pressure (Open) (² WC)
High Altitude Long Vent Kit (Part No)
Pressure Switch (Part No)
Blower Switch Pressure (Close) (² WC)
Blower Switch Pressure (Open) (² WC)
Transition Switch Pressure (Close) (² WC)
Transition Switch Pressure (Open) (² WC)
Blower Data
Type & Size
Motor Amps/Rpm
Motor Type/H.p.
Cap. Mfd/Volts
Filter Type
Cool Cap. (Tons) @ .5² W.C. L, ML, MHi & Hi
Gas Conversion Kits
Nat to LP
LP to Nat
*Order from Service Parts
Nat./ LP
50,000
45,500
40
.10
35--65
Nat./ LP
75,000
68,000
40
.10
40--70
Nat./ LP
80,000
72,000
40
.10
35--65
Nat./ LP
100,000
91,000
40
.10
40--70
Nat./ LP
100,000
96,500
40
.10
40--70
Nat./ LP
125,000
113,750
40
.10
40--70
Nat. L.P. Nat. L.P. Nat. L.P. Nat. L.P. Nat. L.P. Nat. L.P.
HW SV9541M
SNAP
HW HSP
3.5
10.0
2/42
2/54
.018
.011
HW ST9160
30
60,100,140,180
2
<140
-- --
-- --
-- 2 . 6
-- 2 . 3
300
240
1013802
-- --
-- --
-- 2 . 2
-- 2 . 0
1013803
-- --
-- --
-- 2 . 0
-- 1 . 8
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
11- -8
10/850
1
PSC/
/
7.5/370
16x25x1
1
1
/2,2,21/2,3
NAHF002LP (*1009509)
NAHF002NG (*1009510)
2
HW SV9541M
SNAP
HW HSP
3.5
10.0
3/42
3/54
.018
.011
HW ST9160
30
60,100,140,180
2
<140
-- --
-- --
-- 2 . 6
-- 2 . 3
300
210
1013802
-- --
-- --
-- 2 . 2
-- 2 . 0
1013803
-- --
-- --
-- 2 . 0
-- 1 . 8
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
11- -8
8.0/1050
1
PSC/
/
2
7.5/370
16x25x1
1
1
/2,2,21/2,3
HW SV9541M
SNAP
HW HSP
3.5
10.0
4/44
4/55
.018
.011
HW ST9160
30
60,100,140,180
2
<140
-- --
-- --
-- 2 . 6
-- 2 . 5
300
230
1013811
-- --
-- --
-- 1 . 8
-- 1 . 6
1013812
-- --
-- --
-- 1 . 5
-- 1 . 3
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
11- -1 0
10/1050
1
PSC/
/
2
10/370
16x25x1
1
2
/2,3,31/2,4
NAHF003LP
(*1013815)
HW SV9541M
SNAP
HW HSP
3.5
10.0
4/46
4/54
.018
.011
HW ST9160
30
60,100,140,180
3
<140
-- 1 . 8
-- 1 . 7
-- 2 . 6
-- 2 . 5
300
230
1013801
-- --
-- --
-- 2 . 3
-- 2 . 1
1013803
-- --
-- --
-- 2 . 0
-- 1 . 8
NAHA001LV
1013518
-- 1 . 0
-- 0 . 8
-- 2 . 0
-- 1 . 8
NAHA003LV
11- -1 0
10/1050
1
PSC/
/
2
10/370
16x25x1
1
1
/2,2,3,31/2,
HW SV9541M
SNAP
HW HSP
3.5
10.0
4/42
4/54
.018
.011
HW ST9160
30
60,100,140,180
3
<140
-- 1 . 8
-- 1 . 7
-- 2 . 6
-- 2 . 5
300
220
1013802
-- --
-- --
-- 2 . 2
-- 2 . 0
1013803
-- --
-- --
-- 2 . 0
-- 1 . 8
NAHA002LV
1013515
-- 1 . 0
-- 0 . 8
-- 1 . 7
-- 1 . 5
1013165
-- 0 . 7
-- 0 . 6
-- 1 . 4
-- 1 . 2
11- -1 0
13/900
3
PSC/
/
4
40/370
16x25x1
1
3
/2,4,41/2,5
NAHF002LP (*1009509)
NAHF002NG (*1009510)
HW SV9541M
SNAP
HW HSP
3.5
10.0
5/42
5/54
.018
.011
HW ST9160
30
60,100,140,180
3
<140
-- 1 . 8
-- 1 . 7
-- 2 . 6
-- 2 . 5
300
190
1013166
-- 1 . 3
-- 1 . 1
-- 1 . 8
-- 1 . 6
1013157
-- 0 . 9
-- 0 . 7
-- 1 . 7
-- 1 . 5
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
11- -1 0
13/900
3
PSC/
/
40/370
16x25x1
1
3
/2,4,41/2,5
NAHF003NG
(*1013816)
4
53
440 08 2001 02
Page 56
Service
Manual
Single Stage Multi Position Furnace
Manufacturers Number (Mfr No --SeeRatingPlate)
ALL Models
Specifications
General
Gas Type
Transformer Size (VA)
T’stat Heat Anticipator
Nat LP
40
.10
40
.10
Gas & Ignition
Gas Valve
Regulation Type
Manifold Press. (Inch’s WC)
HW SV9541M
SNAP
3.5
HW SV9541M
SNAP
10.0
Pilot Orifice Size .018 .011
Ignition Type/Series HW HSP HW HSP
Fan Controls
Fan Control (T ype)
Fan Control On
(Timed-- secs) Off
HW ST9160
30
60,100,140,180
HW ST9160
30
60,100,140,180
Gas Conversion Kits All Models
Nat to LP NAHF002LP *1009509
LP to Nat NAHF002NG *1009510
*Order from Service Parts
Specifications
*9MPD050F12A1 *9MPD075F12A1 *9MPD100J14A1 *9MPD100J20A1 *9MPD125L20A1
General
Input (Btuh)
Output (Btuh)
Tem p . R i s e (
°
F)
Electrical (V olts/Hz/FLA) 115/60/9.8 115/60/8.9 115/60/9.0 115/60/10.5 115/60/11.2
Gas & Ignition
Gas Type
Std. Main Orifices (No/Size)
Combustion
Flue Outlet Size (Inches)
Std. Outlet Temp (° F)
@Blower/ @ Transition Box
Std. Pressures (² of WC)
5¢ No Elbows
40¢ +5-- 90° DWV Elbows
Limits & Controls
Rollout Switch (
Limit Control Setting (
°
F)
°
F)
Std. Transition Pressure Sw. (Part No)
Blower Switch Pressure (Close)
Blower Switch Pressure (Open)
Transition Switch Pressure (Close)
Transition Switch Pressure (Open)
High Altitude Pressure Sw. (Part No)
Blower Switch Pressure (Close)
Blower Switch Pressure (Open)
Transition Switch Pressure (Close)
Transition Switch Pressure (Open)
Blower Data
Type & Size
Motor Amps/Rpm
Motor Type/H.p.
Cap. Mfd/Volts
Filter Type
Cool Cap. (Tons) @ .5² W.C. L, ML, MHi & Hi
50,000
46,000
35--65
Nat.
2/42
2
<140
--1.80 / -- 2.60
--1.30 / -- 2.30
300
260
1013515
0.95
0.80
1.70
1.50
1013165
0.70
0.55
1.40
1.20
11- -8
10/850
1
PSC/
7.5/370
16x25x1
1
1
/2,2,21/2,3
75,000
69,000
40--70
L.P.
2/54
Nat.
3/42
L.P.
3/54
2
<140
--1.80 / -- 2.60
--1.30 / -- 2.30
300
240
1013515
0.95
0.80
1.70
1.50
1013165
0.70
0.55
1.40
1.20
11- -1 0
8.0/1050
1
/
2
PSC/
7.5/370
16x25x1
1
1
/2,2,21/2,3
/
2
100,000
92,000
40--70
Nat.
4/42
3
<140
--1.80 / -- 2.60
--1.70 / -- 2.50
300
220
1013515
0.95
0.80
1.70
1.50
1013165
0.70
0.55
1.40
1.20
11- -1 0
10/1050
1
PSC/
10/370
16x25x1
1
1
/2,2,3,31/
100,000
92,000
40--70
L.P.
4/54
Nat.
4/42
L.P.
4/54
3
<140
--1.80 / -- 2.60
--1.70 / -- 2.50
300
220
1013515
0.95
0.80
1.70
1.50
1013165
0.70
0.55
1.40
1.20
11- -1 0
13/900
3
/
2
2
PSC/
40/370
16x25x1
1
3
/2,4,41/2,5
/
4
125,000
115,000
40--70
Nat.
5/42
3
<140
--1.80 / -- 2.60
--1.70 / -- 2.50
300
190
1013166
1.30
1.10
1.80
1.60
1013157
0.85
0.70
1.70
1.50
11- -1 0
13/900
3
PSC/
40/370
16x25x1
1
3
/2,4,41/2,5
/
L.P.
5/54
4
440 08 2001 02
54
Page 57
Single Stage Multi Position Furnace
Service
Manual
Manufacturers Number (Mfr No --SeeRatingPlate) ALL Models
Specifications (*9MPD)(A2)
*9MPD050F12A *9MPD075F12A *9MPD080J16A *9MPD100J14A *9MPD100J20A *9MPD125L20A
General
Gas Type
Input (Btuh)
Output (Btuh)
Transformer Size (VA)
T’stat Heat Anticipator
Tem p . R i s e (
°
F)
Electrical (V olts/Hz/FLA) 115/60/9.8 115/60/8.9 115/60/9.0 115/60/9.0 115/60/10.5 115/60/11.2
Gas & Ignition
Gas Type
Gas Valve
Regulation Type
IgnitionType/Series
Manifold Press. (Inch’s WC)
Std. Main Orifices (No/Size)
Pilot Orifice Size
Fan Controls
Fan Control (Type)
Fan Control On
(Timed--secs) Off
Combustion
Flue Outlet Size (Inches)
Std. Outlet Temp (°5¢ No Elbows
Blower Pressure 5¢ No Elbows (² WC)
Blower Pressure 40¢ +5--90° DWV Elbows (² WC)
Transition Bx Pressure 5¢ No Elbows (² WC)
Transition Bx Pressure 40¢ +5--90° DWV Elbows (² WC)
Limits & Controls
Rollout Switch (
Limit Control Setting (
°
F)
°
F)
Standard Pressure Sw. (Part No)
Blower Switch Pressure (Close) (² WC)
Blower Switch Pressure (Open) (² WC)
Transition Switch Pressure (Close) (² WC)
Transition Switch Pressure (Open) (² WC)
High Altitude Pressure Sw. (Part No)
Blower Switch Pressure (Close) (² WC)
Blower Switch Pressure (Open) (² WC)
Transition Switch Pressure (Close) (² WC)
Transition Switch Pressure (Open) (² WC)
Long Vent Kit (Part No)
Pressure Switch (Part No)
Blower Switch Pressure (Close) (² WC)
Blower Switch Pressure (Open) (² WC)
Transition Switch Pressure (Close) (² WC)
Transition Switch Pressure (Open) (² WC)
High Altitude Long Vent Kit (Part No)
Pressure Switch (Part No)
Blower Switch Pressure (Close) (² WC)
Blower Switch Pressure (Open) (² WC)
Transition Switch Pressure (Close) (² WC)
Transition Switch Pressure (Open) (² WC)
Blower Data
Type & Size
Motor Amps/Rpm
Motor Type/H.p.
Cap. Mfd/Volts
Filter Type
Cool Cap. (Tons) @ .5² W.C. L, ML, MHi & Hi
Gas Conversion Kits
Nat to LP
LP to Nat
*Order from Service Parts
Nat./ LP
50,000
46,000
40
.10
35--65
Nat./ LP
75,000
69,000
40
.10
40--70
Nat./ LP
80,000
73,600
40
.10
35--65
Nat./ LP
100,000
92,000
40
.10
40--70
Nat./ LP
100,000
92,000
40
.10
40--70
Nat./ LP
125,000
115,000
40
.10
40--70
Nat. L.P. Nat. L.P. Nat. L.P. Nat. L.P. Nat. L.P. Nat. L.P.
HW SV9541M
SNAP
HW HSP
3.5
10.0
2/42
2/54
.018
.011
HW ST9160
30
60,100,140,180
2
<140
-- --
-- --
-- 2 . 6
-- 2 . 3
300
260
1013802
-- --
-- --
-- 2 . 2
-- 2 . 0
1013803
-- --
-- --
-- 2 . 0
-- 1 . 8
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
11- -8
10/850
1
PSC/
/
7.5/370
16x25x1
1
1
/2,2,21/2,3
NAHF002LP (*1009509)
NAHF002NG (*1009510)
2
HW SV9541M
SNAP
HW HSP
3.5
10.0
3/42
3/54
.018
.011
HW ST9160
30
60,100,140,180
2
<140
-- --
-- --
-- 2 . 6
-- 2 . 3
300
240
1013802
-- --
-- --
-- 2 . 2
-- 2 . 0
1013803
-- --
-- --
-- 2 . 0
-- 1 . 8
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
11- -1 0
8.0/1050
1
PSC/
/
2
7.5/370
16x25x1
1
1
/2,2,21/2,3
HW SV9541M
SNAP
HW HSP
3.5
10.0
4/44
4/55
.018
.011
HW ST9160
30
60,100,140,180
2
<140
-- --
-- --
-- 2 . 6
-- 2 . 5
300
220
1013812
-- --
-- --
-- 1 . 5
-- 1 . 3
1013813
-- --
-- --
-- 1 . 2
-- 1 . 0
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
11- -1 0
10/1050
1
PSC/
/
2
10/370
16x25x1
1
2
/2,3,31/2,4
NAHF003LP
(*1013815)
HW SV9541M
SNAP
HW HSP
3.5
10.0
4/42
4/54
.018
.011
HW ST9160
30
60,100,140,180
3
<140
-- 1 . 8
-- 1 . 7
-- 2 . 6
-- 2 . 5
300
220
1013802
-- --
-- --
-- 2 . 2
-- 2 . 0
1013803
-- --
-- --
-- 2 . 0
-- 1 . 8
NAHA002LV
NAHA003LV
11- -1 0
10/1050
1
PSC/
/
2
10/370
16x25x1
1
1
/2,2,3,31/
HW SV9541M
SNAP
HW HSP
3.5
10.0
4/42
4/54
.018
.011
HW ST9160
30
60,100,140,180
3
<140
-- 1 . 8
-- 1 . 7
-- 2 . 6
-- 2 . 5
300
220
1013802
-- --
-- --
-- 2 . 2
-- 2 . 0
1013803
-- --
-- --
-- 2 . 0
-- 1 . 8
1013518
-- 1 . 0
-- 0 . 8
-- 2 . 0
-- 1 . 8
1013165
-- 0 . 7
-- 0 . 6
-- 1 . 4
-- 1 . 2
11- -1 0
13/900
3
PSC/
/
4
40/370
16x25x1
1
3
2
/2,4,41/2,5
NAHF002LP (*1009509)
NAHF002NG (*1009510)
HW SV9541M
SNAP
HW HSP
3.5
10.0
5/42
5/54
.018
.011
HW ST9160
30
60,100,140,180
3
<140
-- 1 . 8
-- 1 . 7
-- 2 . 6
-- 2 . 5
300
190
1013166
-- 1 . 3
-- 1 . 1
-- 1 . 8
-- 1 . 6
1013157
-- 0 . 9
-- 0 . 7
-- 1 . 7
-- 1 . 5
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
11- -1 0
13/900
3
PSC/
/
40/370
16x25x1
1
3
/2,4,41/2,5
NAHF003NG
(*1013816)
4
55
440 08 2001 02
Page 58
Service
Speed
s
W
a
a
E
Speed
s
W
a
a
E
Speed
s
W
S
e
r
E
e
s
PofW
t
o
h
x
Speed
r
C
teso
h
E
Speed
s
t
o
h
r
E
Manual
CIRCULATION AIR BLOWER DAT A
For 050 Models 3 Ton Units
CFM
re
ssur
Pre
atic
lSt
rrn
Exte
Speed
Tap
0.1 826 1083 1301 1408
0.2 804 1050 1242 1347
.
.C.
0.3 770 1028 1195 1295
0.4 735 985 1153 1237
of
0.5 698 952 1093 1183
hes
Inc
0.6 657 909 1040 111 8
0.7 -- -- -- 863 935 1053
0.8 -- -- -- -- 812 865 976
0.9 -- -- -- -- -- -- 802 887
1.0 -- -- -- -- -- -- 720 787
Low Med L Med H Hi
Single Stage Multi Position Furnace
For 080 Models 4 Ton 19²²²² &223/4²²²² Units
Speed
Tap
0.1 823 1109 1527 1850
e
sur
.C.
Pres
tic
lSta
hes
Inc
rrnal
xter
E
0.2 795 1087 1482 1791
0.3 747 1056 1426 1720
0.4 677 1016 1382 1648
0.5 617 970 1317 1575
0.6 544 854 1245 1485
0.7 -- -- -- 763 1154 1401
0.8 -- -- -- 652 1043 1284
0.9 -- -- -- -- -- -- 905 1161
1.0 -- -- -- -- -- -- 737 1028
Low Med L Med H Hi
For 075 Models 3 Ton Units
CFM
re
ssur
Pre
atic
lSt
rrn
Exte
.
.C.
of
hes
Inc
Speed
Tap
0.1 706 917 1163 1368
0.2 677 875 1120 1319
0.3 636 840 1076 1263
0.4 595 812 1031 1202
0.5 546 766 987 1148
0.6 490 702 889 1077
0.7 -- -- -- 630 821 989
0.8 -- -- -- 550 750 914
0.9 -- -- -- 462 676 833
1.0 -- -- -- -- -- -- 601 747
Low Med L Med H Hi
For 100 Models 3.5 Ton 19²²²² &223/4²²²² Units
Speed
Tap
0.1 700 912 1209 1550
0.2 660 884 1171 1492
0.3 616 843 1139 1434
0.4 575 790 1088 1378
sure
Pre
W.C .
tatic
sof
Inch
I
rnal
xter
0.5 528 735 1040 1317
0.6 472 677 979 1247
0.7 -- -- -- 608 909 1161
0.8 -- -- -- 528 827 1058
0.9 -- -- -- -- -- -- 733 932
1.0 -- -- -- -- -- -- 624 778
Low Med L Med H Hi
CFM
For 100 Models 5 Ton 223/4²²²² Units
Speed
ure
ress
tic P
lSta
rrnal
xter
.C.
fW.
Inc
Tap
0.1 1682 1870 2081 2263
0.2 1654 1826 2031 2193
0.3 1597 1775 1963 2165
0.4 1547 1719 1899 2056
0.5 1498 1653 1825 1978
0.6 1428 1583 1737 1854
0.7 1355 1503 1650 1757
0.8 1267 1392 1548 1644
0.9 -- -- -- -- 1266 1428 1515
1.0 -- -- -- -- -- -- -- -- -- -- -- -- 1351
Low Med L Med H Hi
For 125 Models 5 Ton Units
Speed
Tap
0.1 1720 1910 2127 2315
ure
res
.C.
tic P
of W.
lSta
hes
Inc
rrnal
Exte
0.2 1686 1881 2087 2268
0.3 1644 1833 2024 2201
0.4 1600 1777 1961 2131
0.5 1533 1720 1891 2029
0.6 1494 1647 1804 1948
0.7 1413 1571 1708 1820
0.8 1306 1470 1604 1730
0.9 -- -- -- -- 1349 1484 1614
1.0 -- -- -- -- -- -- -- -- 1328 1430
Low Med L Med H Hi
CFM
CFM
440 08 2001 02
56
Page 59
INDEX
A
Adjusting Heat Anticipator, 9
Adjusting Manifold Pressure, 6
Air Proving Switch, See Pressure Switch
Auxiliary Limit Switch, 11
B
Blower Assembly, Conditioned Air, 22
Blower Rotation, 23
Blower Speeds, Changing, 23
Blower Speeds, Selecting, 22
Blower, Exhaust, 17
Burners, 7
C
Capacitors, 22
Checking Capacitors, 22
Checking Flame Current, 21
Checking Grounding and Polarity, 4
Checking Input (Firing) Rate, 5
E
Electrical Supply, 4
Electrical Variation (SV9541M), 49
Electronic Fan Timer, 18
Exhaust Blower, 17
F
Fan Timer, Electronic, 18
Flame Current, Checking, 21
G
Gas Valve/Ignition Control, Honeywell SV9541M, 20
Ground, Electrical, 4
H
Heat Anticipators, 9
Heat Exchanger Removal/Replacement, 44
High Altitude Operation, 7
Honeywell ST9160B Fan Timer, 19
Honeywell SV9540 Gas Valve/Ignition Control, 20
Checking Manifold Pressure, 6
Checking T emperature Rise, 8
Circulating Air Blower Data, 56
Combustion Air/Vent Piping, 14--17
Combustion Blower. See Exhaust Blower
Condensate Drain Trap, 17--18
Control Wiring, 10
D
“DIP” Switch Settings, ST9160, 19
Drain Trap, Condensate, 18
I
Inlet Air Restrictor, 13
Interlock Switch, 5
Introduction, 1
K
Kits, Twinning, 10
L
Limit Switches, 10
Page 60
INDEX
P
Piping, Vent/Combustion Air, 14--16
Polarity, Line Voltage, 4
Pressure Switches, 12--14
Pressures, Approximate Operating, 14
R
Roll Out Limit Switch, 11
Room Thermostat, 8
S
Sequence of Operation Chart, SV9541M, 46
ST9160 Testing Sequence, 19
Supply, Electrical, 4
Supply, Gas, 5
SV9541M System Operation, 20
Switch, Blower Door Interlock, 5
Switch, “DIP”-- ST9140, 19
Switch, Auxiliary Limit, 11
Switch, Transition Pressure, 12
Switch,L.P.GasPressure,7
Switch, Main Limit, 10
Switch, Pressure, 12--13
Switch, Roll Out Limit, 11
Switches, Limit, 10
T
Technical Service Data , 52 -- 60
Temperature Rise, 8
Testing Sequence, ST9160, 20
Thermostat, Room, 8
Transition Pressure Switch, 12
Troubleshooting Chart, Honeywell SV9541M, 47
Twinning Kits, 10
U
Unit Identification, 2
V
Vent Termination, Concentric, 16
Vent Termination, Standard, 14--15
Vent/Combustion Air Piping, 14
W
Wiring Diagram, 50 -- 51
Wiring, Control, 9
Loading...