The signal words DANGER, WARNING,
CAUTION, and NOTE are used to identify levels of
hazard seriousness. The signal word DANGER is
only used on product labels to signify an immediate
hazard. The signal words WARNING, CAUTION,
and NOTE will be used on product labels and
throughout this manual and other manual that may
apply to the product.
DANGER− Immediate hazards which will result in
severe personal injury or death.
WARNING− Hazards or unsafe practices which
could result in severe personal injury or death.
CAUTION − Hazards or unsafe practices which
may result in minor personal injury or product or
property damage.
NOTE − Used to highlight suggestions which will
result in enhanced installation, reliability, or
operation.
Signal Words in Manuals
The signal word WARNING is used throughout
this manual in the following manner:
!
WARNING
The signal word CAUTION is used throughout
this manual in the following manner:
!
CAUTION
Signal Words on Product Labeling
Signal words are used in combination with
colors and/or pictures or product labels.
Safety−alert symbol
When you see this symbol on the unit and in
instructions or manuals, be alert to the
potential for personal injury.
TABLE OF CONTENTS
START−UP, ADJUSTMENT, AND SAFETY CHECK4...........
Use of the AHRI Certified TM Mark indicates a
manufacturer’s participation in the program.
For verification of certification for individual
products, go to www.ahridirectory.org .
Printed in U.S.A.440 04 4201 03 July 2012
SAFETY CONSIDERATIONS
Improper installation, adjustment, alteration, service,
maintenance, or use can cause explosion, fire, electrical shock,
or other conditions which may cause death, personal injury, or
property damage. Consult a qualified installer, service agency,
or your distributor or branch for information or assistance. The
qualified installer or agency must use factory−authorized kits or
accessories when modifying this product. Refer to the individual
instructions packaged with the kits or accessories when
installing.
Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Use quenching cloth for brazing operations.
Have fire extinguisher available. Read these instructions
thoroughly and follow all warnings or cautions included in
literature and attached to the unit. Consult local building codes,
the current editions of the National Fuel Gas Code (NFCG)
NFPA 54/ANSI Z223.1, and the National Electrical Code (NEC)
NFPA 70.
In Canada refer to the current editions of the National standards
of Canada CAN/CSA−B149.1 and .2 Natural Gas and Propane
Installation Codes, and Canadian Electrical Code CSA C22.1.
Recognize safety information. This is the safety−alert symbol
. When you see this symbol on the unit and in instructions or
manuals, be alert to the potential for personal injury.
Understand these signal words; DANGER, WARNING, and
CAUTION. These words are used with the safety−alert symbol.
DANGER identifies the most serious hazards which will result in
severe personal injury or death. WARNING signifies hazards
which could result in personal injury or death. CAUTION is used
to identify unsafe practices which may result in minor personal
injury or product and property damage. NOTE is used to
highlight suggestions which will result in enhanced installation,
reliability, or operation.
!
WARNING
PERSONAL INJURY, AND/OR PROPERTY DAMAGE
HAZARD
Failure to carefully read and follow this warning could
result in equipment malfunction, property damage,
personal injury and/or death.
Installation or repairs made by unqualified persons could
result in equipment malfunction, property damage,
personal injury and/or death.
The information contained in this manual is intended for
use by a qualified service technician familiar with safety
procedures and equipped with proper tools and test
instruments.
Installation must conform with local building codes and
with the Natural Fuel Gas Code (NFCG) NFPA 54/ANSI
Z223.1, and National standards of Canada
CAN/CSA−B149.1 and .2 Natural Gas and Propane
Installation Codes.
!
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could cause personal
injury or death.
Before performing service or maintenance operations
on unit, always turn off main power switch to unit and
install lockout tag. Unit may have more than one power
switch.
!
WARNING
WARNING
CARBON MONOXIDE POISONING AND FIRE
HAZARD
Failure to follow safety warnings could result in personal
injury, death, and/or property damage.
This furnace is not designed for use in mobile homes,
trailers or recreational vehicles.
!
CAUTION
CUT HAZARD
Failure to follow this caution may result in damage
personal injury.
Sheet metal parts may have sharp edges or burrs. Use
care and wear appropriate protective clothing, safety
glasses and gloves when handling parts and servicing
furnaces.
2
Specifications are subject to change without notice.
440 04 4201 03
SERVICE AND TECHNICAL SUPPORT MANUALGas Furnace: (F/G)9MAC
START−UP CHECK SHEET
For Variable Speed Models (F/G)9MAC
(This sheet is optional. Keep for future reference.)
Date of Start−Up:
Dealer Name:
Address:
City, State(Province), Zip or Postal Code:
Phone:
Owner Name:
Address:
City, State(Province), Zip or Postal Code:
Model Number:
Serial Number:
Setup Checks
Check the box when task is complete.
All Electrical Connections Tight?
Have hoses been relocated for furnace U/D/H
application?
Condensate Drain Connected?
Condensate Drain Trapped?
Manual Gas Shut−off Upstream of Furnace/Drip Leg
Heating Check
Measured Line Pressure During High Heat:
Measured Manifold Pressure: Max Heat
Min Heat
Temperature of Supply Air: Max Heat
Min Heat
Temperature of Return Air:
Temperature Rise (Supply − Return): Max Heat
Min Heat
In Rise Range (see furnace rating plate)?
Static Pressure (Ducts) High Heat: Supply
Return
Optional Check: CO?
CO2?
Cooling Check
Temperature of Supply Air:
Temperature of Return Air:
Temperature Difference:
Static Pressure (Ducts) Cooling: Supply
Return
Gas Valve turned ON?
Dealer Comments:
Type of Gas: Natural: Propane:
Filter Type and Size:
Shade in Final Furnace Settings Below:
Calculated Input (BTU) Rate: (See Checks and
Adjustments Section).
440 04 4201 033
Specifications subject to change without notice.
SERVICE AND TECHNICAL SUPPORT MANUALGas Furnace: (F/G)9MAC
START−UP, ADJUSTMENT, AND SAFETY
CHECK
General
1. Furnace must have a 115-v power supply properly
connected and grounded.
NOTE: Proper polarity must be maintained for 115-v wiring.
Control status indicator light flashes code 10 and furnace does
not operate if polarity is incorrect or if the furnace is not
grounded.
2. Thermostat wire connections at terminals R, W/W1, G,
Y/Y2, etc. must be made at 24-v terminal block on
furnace control. See communicating wall control
instructions for proper wiring of communicating controls.
3. Natural gas service pressure must not exceed 0.5 psig
(14- in. w.c., 350 Pa), but must be no less than 0.16 psig
(4.5-in. w.c., 1125 Pa).
4. Blower door must be in place to complete 115-v
electrical circuit and supply power to furnace.
!
CAUTION
UNIT OPERATION HAZARD
Failure to follow this caution may result in intermittent unit
operation or performance dissatisfaction.
These furnaces are equipped with a manual reset limit
switch in burner assembly. This switch opens and shuts off
power to the gas valve if an overheat condition (flame
rollout) occurs in the burner assembly/enclosure. Correct
inadequate combustion-air supply, improper gas pressure
setting, improper burner or gas orifice positioning, or
improper venting condition before resetting switch. DO
NOT jumper this switch.
Before operating furnace, check flame rollout manual reset
switch for continuity. If necessary, press button to reset switch.
EAC-1 terminal is energized whenever blower operates. HUM
terminal is only energized when blower is energized in heating.
Select Setup Switch Positions
There are four sets of setup switches on the furnace control
board. These switches configure the furnace for correct
application requirement. They also select the airflow settings for
Air Conditioning and Continuous Fan airflows.
The Setup Switch locations are shown and described on
Figure 3, Figure 4, Table 3 and Table 6. The set up switches
are also shown on the unit wiring label.
Setup Switches (SW1)
The furnace control has eight setup switches that may be set to
meet the application requirements. Refer to Figure 4 and
Adjustments section for set up switch configurations.
To set these setup switches for the appropriate requirement:
1. Remove blower door.
2. Locate setup switches on furnace control.
3. Configure the set-up switches as necessary for the
application.
4. Replace blower door.
NOTE: If a bypass humidifier is used, setup switch SW1-3
(Min/Int Rise Adjust) should be in ON position. This
compensates for the increased temperature in return air
resulting from bypass.
NOTE: If modulating dampers are used, blower motor
automatically compensates for modulating dampers.
Air Conditioning (A/C) Setup Switches (SW2)
The air conditioning setup switches are used to match furnace
airflow to required cooling airflow or high stage cooling airflow
4440 04 4201 03
Specifications subject to change without notice.
when a two−stage outdoor unit is used. Refer to Figure 4 and
the Adjustments section for set up switch configurations.
To set the desired cooling airflow:
1. Remove blower door.
2. Locate A/C setup switches on furnace control.
3. Determine air conditioning tonnage used.
4. Configure the switches for the required cooling airflow.
NOTE: Incorrect airflow caused by improper A/C switch setup
may cause condensate blow−off or a frozen indoor coil in the
cooling mode.
5. Replace blower door.
Continuous Fan (CF) Setup Switches (SW3)
The CF setup switches are used to select desired airflow when
thermostat is in continuous fan mode or to select low-cooling
airflow for two-speed cooling units. Refer to Figure 4 and the
Adjustments section for set up switch configurations.
1. Remove blower door.
2. Locate CF setup switches on furnace control.
3. Determine desired continuous fan airflow or low-cooling
airflow.
4. Configure the switches for the required continuous fan or
low−cooling airflow.
5. Replace blower door.
Additional Setup Switches (SW4)
The furnace control has three additional setup switches labeled
SW4.
Setup switch SW4-2 can be used to lock the furnace into
intermediate heat. When setup switch SW4-2 is ON it will over
ride setup switch SW1-2 if it is ON. SW4−3 is used to adjust
airflow. Refer to Figure 4 and the Adjustments section for set
up switch configurations.
1. Remove blower door.
2. Locate setup switch SW4 on furnace control.
3. Configure the switches for the required heat stages air
flow if necessary.
4. Replace blower door.
Prime Condensate Trap with Water
!WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow these warnings could result in personal injury
or death.
Failure to use a properly configured trap or NOT
water-priming trap before operating furnace may allow
positive pressure vent gases to enter the structure through
drain tube. Vent gases contain carbon monoxide which is
tasteless and odorless.
!
CAUTION
UNIT OPERATION HAZARD
Failure to follow this caution may result in intermittent unit
operation or performance satisfaction.
Condensate trap must be PRIMED or proper draining may
not occur. The condensate trap has two internal
chambers which can ONLY be primed by pouring water
into the inducer drain side of condensate trap.
1. Remove upper and middle collector box drain plugs
opposite of the condensate trap. (See Figure 1)
2. Connect field-supplied 5/8-in. (16 mm) ID tube with
attached funnel (see Figure 1) to upper collector box
drain connection.
SERVICE AND TECHNICAL SUPPORT MANUALGas Furnace: (F/G)9MAC
3. Pour one quart (liter) of water into funnel/tube. Water
should run through collector box, overfill condensate
trap, and flow into open field drain.
5. Connect field-supplied 5/8-in. (16 mm) ID tube to middle
collector box drain port.
6. Pour one quart (liter) of water into funnel/tube. Water
should run through collector box, overfill condensate
trap, and flow into open field drain.
7. Remove funnel and tube from collector box and replace
collector box drain plug.
Figure 1Priming Condensate Drain
Figure 2Orifice Hole
BURNER
ORIFICE
A93059
For proper operation and long term reliability, the Furnace input
rate must be within +/− 2 percent of input rate on furnace rating
plate, or as adjusted for altitude.
The gas input rate on rating plate is for installations at altitudes
up to 2000 ft. (610 M).
NOTICE
Representative drawing only, some models may vary in appearance.
L11F065
Purge Gas Lines
If not previously done, purge the lines after all connections
have been made and check for leaks.
!
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death, and/or property damage.
Never purge a gas line into a combustion chamber. Never
test for gas leaks with an open flame. Use a commercially
available soap solution made specifically for the detection
of leaks to check all connections. A fire or explosion may
result causing property damage, personal injury or loss of
life.
WARNING
Adjustments
!
CAUTION
FURNACE DAMAGE HAZARD
Failure to follow this caution could result in reduced
furnace life.
DO NOT push or force gas valve adjusting screw. This
can result in damage to the adjustment screw resulting in
incorrect manifold pressure, which can result in a no heat
situation or shorten the life of the heat exchangers.
The NATURAL GAS manifold pressure adjustments in Table 4
and Table 5 compensate for BOTH altitude AND gas heating
value. DO NOT apply an additional de−rate factor to the
pressures shown in Table 4 or Table 5. The values in these
Tables are NOT referenced to sea level; they are
AS−MEASURED AT ALTITUDE.
The heating content of natural gas at altitude may already
provide for a reduction in capacity or the furnace. Be sure to
obtain the expected in−season gas heating value of the gas
from the gas supplier BEFORE making any adjustments for
capacity or altitude. Refer to Table 4 or Table 5. No
adjustments to the furnace may be necessary at altitude for
certain gas heating values.
Refer to the instructions provided in the factory-specified
LP/Propane conversion kit for instructions for setting gas
manifold pressures for LP/Propane applications.
In the USA, the input rating for altitudes above 2000 ft. (610 M)
must be reduced by 2 percent for each 1000 ft. (305 M) above
sea level. Refer to Table 1. The natural gas manifold pressures
in Table 4 and Table 5 adjust for BOTH altitude and natural gas
heating value.
In Canada, the input rating must be reduced by 5 percent for
altitudes of 2000 ft. (610 M) to 4500 ft. (1372 M) above sea
level. The natural gas manifold pressures in Table 4 and
Table 5 adjust for BOTH altitude and natural gas heating value.
NOTE: For Canadian altitudes of 200 to 4500 ft. (610 to 1372
M), use USA altitudes of 2001 to 3000 ft. (611 to 914 M) in
Table 4 and Table 5.
To adjust manifold pressure to obtain the proper input rate, first,
determine if the furnace has the correct orifice installed. At
higher altitudes or different gas heat contents, it may be
necessary to change the factory orifice to a different orifice.
Tables have been provided in the furnace Service and
Technical Manual to match the required orifice to the manifold
pressure to the heat content and specific gravity of the gas.
NOTE: There are two sets of manifold pressure tables. Use
Table 4 for all models EXCEPT *9MAC0602120 Btuh model.Use Table 5 for only the *9MAC0602120 model.
440 04 4201 035
Specifications subject to change without notice.
SERVICE AND TECHNICAL SUPPORT MANUALGas Furnace: (F/G)9MAC
To do this:
1. Obtain average heat value (at installed altitude) from
local gas supplier.
2. Obtain average specific gravity from local gas supplier.
3. Find installation altitude range for your installation in the
manifold pressure tables. See Table 4 for the 20,000
Btuh Max−Heat/8,000/Btuh Min−Heat per burner models
or Table 5 for model *9MAC0602120 only (20,200 Btuh
Max−Heat/8,000 Btuh Min−Heat per burner).
4. Find closest natural gas heat value and specific gravity in
Table 4 or Table 5 depending on furnace gas input rate.
5. Follow heat value and specific gravity lines to point of
intersection to find orifice size and maximum and
minimum manifold pressure settings for proper operation.
6. Check and verify burner orifice size in furnace. Never
assume orifice size. NEVER ASSUME ORIFICE SIZE.
ALWAYS CHECK AND VERIFY.
NOTICE
If orifice hole appears damaged or it is suspected to have been
redrilled, check orifice hole with a numbered drill bit of correct
size. Never redrill an orifice. A burr−free and squarely aligned
orifice hole is essential for proper flame characteristics.
7. Replace orifice with correct size, if required by Table 4
or Table 5 depending on furnace gas input rate. Use only
factory−supplied orifices. See EXAMPLE 1.
EXAMPLE 1:
(See Table 4)
0 - 2000 ft. (0 - 609.6M) altitude
Heating value = 1050 Btu/cu ft.
Specific gravity = 0.62
Therefore: Orifice No. 44
(Furnace is shipped with No. 44 orifices. In this example, all
main burner orifices are the correct size and do not need to be
changed to obtain proper input rate.)
Manifold pressure: 3.4-in. w.c. (847 Pa) for Maximum heat,
.55-in. w.c. (349 Pa) for Minimum heat
NOTE: To convert gas manifold Table pressures to Pascals,
multiply the in.w.c. value by 249.1 Pa/in. w.c. (1 in. wc. = 249.1
Pa).
Table 1Altitude Derate Multiplier for U.S.A.
ALTITUDE
FT. (M)
0–2000
(0−610)
2001–3000
(610−914)
3001–4000
(914−1219)
4001–5000
(1219−1524)
5001–6000
(1524−1829)
6001–7000
(1829−2134)
7001–8000
(2134−2438)
8001–9000
(2438−2743)
9001–10,000
(2743−3048)
* Derate multiplier factors are based on midpoint altitude for altitude range.
PERCENT
OF DERATE
01.00
4−60.95
6−80.93
8−100.91
10−120.89
12−140.87
14−160.85
16−180.83
18−200.81
DERATE MULTIPLIER
FACTOR*
NOTE: For Canadian altitudes of 2000 to 4500 ft. (610 to
1372 M), use USA altitudes of 2001 to 3000 ft. (610 to 914
M).
Check Inlet Gas Pressure
The inlet gas pressure must be checked with the furnace
operating in maximum heat. This is necessary to make sure the
inlet gas pressure does not fall below the minimum pressure of
4.5−in. w.c. for natural gas. The maximum inlet gas pressure is
13.6−in. w.c. If the inlet pressure is too low, you will not be able
to adjust the manifold pressure to obtain the proper input rate.
To check the inlet gas pressure:
1. Make sure the gas supply is turned off to the furnace and
at the electric switch on the gas valve.
2. Remove the 1/8 inch NPT plug from the inlet pressure
tap on the gas valve.
3. Connect a manometer to the inlet pressure tap on gas
valve.
4. Turn on furnace power supply.
5. Turn gas supply manual shutoff valve to ON position.
6. Turn furnace gas valve switch to ON position.
7. Jumper the R to W/W1 and W2 thermostat connections
at the furnace control board.
8. When main burners ignite, confirm inlet gas pressure is
Between 4.5−in. w.c. and 13.6−in. w.c.
9. Remove jumper across thermostat connections to
terminate call for heat. Wait until the blower off delay is
completed.
10. Turn furnace gas valve electric switch to OFF position.
11. Turn gas supply manual shutoff valve to OFF position.
12. Turn off furnace power supply.
13. Remove manometer from the inlet pressure tap of the
gas valve.
!
FIRE HAZARD
Failure to follow this warning could result in personal injury,
death, and/or property damage.
Re−install manifold pressure tap plug in gas valve to
prevent gas leak.
14. Apply pipe dope sparingly to end of inlet gas pipe plug
and re−install in the gas valve.
WARNING
Adjust Manifold Pressure−Maximum Heat
The modulating furnace manifold pressure is set at two points.
The first point is Maximum Heat.
The second point is Minimum Heat. Do not adjust Intermediate
Heat manifold pressure. Intermediate Heat manifold pressure is
checked as part of the temperature rise, but is not adjustable.
Always adjust Maximum Heat first, then Minimum Heat.
NOTICE
DO NOT set maximum heat manifold pressure less than 3.2−in.
w.c. (947 Pa) for natural gas. If required manifold pressure is
outside this range, change main burner orifices to obtain
manifold pressure in this range.
To adjust manifold pressure to obtain input rate for Maximum
Heat:
1. Make sure the gas supply is turned off to the furnace and
at the electric switch on the gas valve.
6440 04 4201 03
Specifications subject to change without notice.
SERVICE AND TECHNICAL SUPPORT MANUALGas Furnace: (F/G)9MAC
2. Remove the 1/8 inch NPT plug from the outlet pressure
tap on the gas valve.
3. Connect a manometer to the outlet pressure tap on gas
valve.
4. Turn on furnace power supply.
5. Turn gas supply manual shutoff valve to ON position.
6. Turn furnace gas valve switch to ON position.
7. Jumper the R to W/W1 and W2 thermostat connections
at the furnace control board.
8. After the main burners ignite and the blower starts,
confirm Maximum Heat manifold pressure is correct,
based on the manifold pressure tables in the installation
instructions.
9. To adjust the Maximum Heat manifold pressure, slowly
turn adjusting screw counterclockwise to decrease
manifold pressure or clockwise to increase manifold
pressure. Turn adjustment no more than one click per
second until you obtain the required manifold pressure.
10. Main burner flame should be clear blue, almost
transparent.
11. After adjusting the Maximum Heat manifold pressure,
remove jumpers across thermostat connections to
terminate the call for heat.
12. Wait for blower off-delay to finish then reset 115-v power
to furnace.
Adjust Manifold Pressure−Minimum Heat
To adjust manifold pressure to obtain input rate for Minimum
Heat:
1. Turn SW1−2 ON at the furnace control. Set up switch
SW4−2 must be OFF.
2. Jumper R and W/W1 thermostat connections on control
to start furnace.
3. After the main burners ignite and the blower starts,
confirm Minimum Heat manifold pressure is correct,
based on the manifold pressure tables in the installation
instructions.
4. To adjust the Minimum Heat manifold pressure, slowly
turn adjusting screw counterclockwise (out) to decrease
manifold pressure or clockwise (in) to increase manifold
pressure. Turn adjustment no more than one click per
second until you obtain the required manifold pressure.
5. After adjusting the manifold pressure, remove jumpers
across thermostat connections to terminate the call for
heat. Wait until the blower off delay is completed.
6. Move setup switch SW1-2 to the OFF position.
7. Turn gas supply manual shutoff valve to OFF position.
8. Turn off furnace power supply.
!
FIRE HAZARD
Failure to follow this warning could result in personal injury,
death, and/or property damage.
Re−install manifold pressure tap plug in gas valve to
prevent gas leak.
9. Remove manometer from the inlet pressure tap of the
gas valve.
10. Apply pipe dope sparingly to end of inlet gas pipe plug
and re-install in the gas valve.
WARNING
11. Re-install cap over adjustment screw on the top of the
gas valve.
Clocking the Meter
Verify natural gas input rate by clocking meter.
NOTE: Contact your HVAC distributor or gas supplier for metric
gas meter Tables, if required.
1. Turn off all other gas appliances and pilots served by the
meter.
2. Move setup switches SW1-2 to ON position and SW4-2
to OFF. This keeps furnace locked in Minimum Heat
operation when only W/W1 is energized or Maximum
Heat operation when R to W/W1 and W2 are jumpered.
3. Jumper R to W/W1 and W2. Run furnace for 3 minutes in
Maximum Heat operation.
4. Measure time (in sec) for gas meter to complete one
revolution and note reading. The 2 or 5 cubic feet dial
provides a more accurate measurement of gas flow.
5. Refer to Table 3 for cubic ft. of gas per hr. Multiply gas
rate cu ft./hr by heating value (Btuh/cu ft.) to obtain input
rate.
6. If clocked rate does not match required input from Step
5, increase manifold pressure to increase input or
decrease manifold pressure to decrease input. Repeat
steps 3 through 5 until correct maximum heat input is
achieved.
7. Remove jumpers across thermostat connections to
terminate the call for heat. Wait until the blower off delay
is completed then reset 115-v power to furnace.
8. Jumper R and W/W1 thermostat connections on control
to start furnace.
NOTE: Setup switches SW1-2 must be ON and SW4-2 must
be OFF. This keeps furnace locked in minimum heat operation
when R to W/W1 is energized. Repeat items 3 through 6 for
minimum heat operation until minimum heat input is achieved
9. Restore furnace to normal operating condition.
10. Remove jumpers across thermostat connections to
terminate the call for heat. Wait until the blower off delay
is completed.
11. Disconnect 115 VAC power to furnace.
12. Turn gas valve ON/OFF switch to OFF.
13. Remove water column manometer or similar device from
manifold pressure tap (if still connected).
!
FIRE HAZARD
Failure to follow this warning could result in personal injury,
death, and/or property damage.
Re−install manifold pressure tap plug in gas valve to
prevent gas leak.
14. Replace manifold pressure tap plug to gas valve.
15. Turn gas valve ON/OFF switch to ON.
16. Move setup SW1-2 on furnace control to position
required for attached thermostat (OFF for single-stage
thermostats, ON for two-stage thermostats).
17. Check for gas leaks and verify furnace operation.
WARNING
440 04 4201 037
Specifications subject to change without notice.
SERVICE AND TECHNICAL SUPPORT MANUALGas Furnace: (F/G)9MAC
Figure 3Variable Speed Furnace Control for ECM Blower Motor (Modulating)
MODEL PLUG
CONNECTOR
SW1 SETUP
SWITCHES AND
BLOWER OFFï
DELAY
AIR CONDITIONING
(A/C) AIRFLOW
SETUP SWITCHES
24ïV THERMOSTAT
TERMINALS
STATUS AND COMM
LED LIGHTS
3ïAMP FUSE
TRANSFORMER 24ïVAC
CONNECTIONS
COMMUNICATION
CONNECTOR
CONTINUOUS FAN
(CF) AIRFLOW
SETUP SWITCHES
OUTDOOR
IR TEMP
CONNECTOR
SW4 SETUP
SWITCHES
PL8 ï MODULATING
GAS VALVE
CONNECTOR
HUMIDIFIER
TERMINAL (24AVAC
0.5 AMP MAX.
UPGRADE
CONNECTOR
(FACTORY
PL3 ć ECM BLOWER
HARNESS
CONNECTOR
ï
FLASH
ONLY)
115ïVAC (L2) NEUTRAL
CONNECTIONS
PART NUMBER AND
PL1 ć LOW VOLTAGE MAIN
HARNESS CONNECTOR
SOFTWARE
VERSION
DATE CODE WWYY
(115ïVAC 1.0 AMP MAX.)
Adjust Temperature Rise
NOTE: Blower door must be installed when taking temperature
rise reading. Leaving blower door off will result in incorrect
temperature measurements.
EACï1 TERMINAL
115ïVAC (L1) LINE
VOLTAGE CONNECTIONS
NOTE: Temperature rise can be determined for Minimum Heat,
Intermediate Heat and Maximum Heat operation by locking the
furnace in each mode of operation. The mode of operation is
based on the position of Set-up switch SW1-2 and SW4-2 on
the furnace control board.
PL2 ć HOT SURFACE
IGNITER & INDUCER
MOTOR CONNECTOR
The furnace is capable of automatically providing proper airflow
!
CAUTION
FURNACE DAMAGE HAZARD
Failure to follow this caution may result in:
SOverheating the heat exchangers or condensing
flue gases in heat exchanger areas not designed
for condensate
SShortened furnace life
SComponent damage
Temperature rise must be within limits specified on furnace
rating plate. Recommended operation is at midpoint of rise
range or slightly above.
Furnace must operate within ranges of temperature rise
specified on the furnace rating plate. When setup switch SW1-4
is ON, operation will be near the high end of the rise range for
improved comfort.
Determine air temperature rise as follows:
1. Place thermometers in return and supply ducts as near
furnace as possible. Be sure thermometers do not see
heat exchanger so that radiant heat does not affect
readings. This practice is particularly important with
straight-run ducts.
2. When thermometer readings stabilize, subtract return-air
temperature from supply-air temperature to determine air
temperature rise.
8440 04 4201 03
Specifications subject to change without notice.
to maintain the temperature rise within the range specified on
furnace rating plate. If temperature rise is outside this range,
proceed as follows:
a. Check gas input for Minimum, Intermediate, and
Maximum heat operation.
b. Check derate for altitude if applicable.
c. Check all return and supply ducts for excessive
restrictions causing static pressure greater than 0.5-in.
w.c.
d. Ensure Min/Int Rise Adjust switch SW1−3 on furnace
control is in ON position when a bypass humidifier is
used. (See Figure 3 for switch location.)
e. Check Troubleshooting Guide for Variable−Speed Step
Modulating Condensing Furnaces.
f. Verify correct model plug is installed.
To lock the furnace in Minimum Heat:
1. Turn SW1−2 ON at the furnace control. Set up switch
SW4−2 must be OFF.
2. Connect a jumper across R and W/W1 at the thermostat
terminals at the furnace control.
3. Allow the burners to ignite and the blower to turn on.
4. Allow the supply temperature to stabilize and verify the
proper rise range.
If the temperature rise is too high or too low in Minimum
Heat:
1. Remove jumpers from R and W/W1.
L11F091
SERVICE AND TECHNICAL SUPPORT MANUALGas Furnace: (F/G)9MAC
2. Wait until the blower off delay is completed.
3. Turn 115 VAC power off.
4. Check the position of Set up switch SW1−3. When set to
ON, airflow is raised 18% for Minimum Heat and for
Intermediate Heat. Factory default position is OFF.
5. Turn 115 VAC power on.
6. Re−check Minimum Heat Temperature Rise.
To lock the furnace in Intermediate Heat:
1. Turn SW1−2 OFF and SW4−2 ON at the furnace control.
2. Connect a jumper across R and W/W1 at the thermostat
terminals at the furnace control.
3. Allow the burners to ignite and the blower to turn on.
4. Allow the supply temperature to stabilize and verify the
proper rise range.
If the temperature rise is too high or too low in Intermediate
Heat:
1. Remove jumpers from R and W/W1.
2. Wait until the blower off delay is completed.
3. Turn 115 VAC power off.
4. Check the position of Set up switch SW1−3. When set to
ON, airflow is raised 18% for Minimum Heat and for
Intermediate Heat. Factory default position is OFF.
5. Turn 115 VAC power on.
6. Re−check Intermediate Heat Temperature Rise .
To lock the furnace in Maximum Heat:
1. Connect a jumper across R and W/W1 and W2 at the
thermostat terminals at the furnace control.
2. Allow the burners to ignite and the blower to turn on.
3. Allow the supply temperature to stabilize and verify the
proper rise range.
If the temperature rise is too high or too low in Maximum
Heat:
1. Remove jumpers from R and W/W1 and W2.
2. Wait until the blower off delay is completed.
3. Turn 115 VAC power off.
4. Check the position of Set up switch SW1−4. When set to
OFF, and SW1−3 is set to OFF, airflow is raised 10% for
Minimum Heat, 7.5% for Intermediate Heat and 17.5%
for Maximum Heat. Factory default position is ON. If
SW1−3 is ON and SW1−4 is OFF, airflow is raised 18%
for Minimum and Intermediate heat and 10% for
Maximum Heat.
5. Turn 115 VAC power on.
6. Re−check Maximum Heat Temperature Rise.
After the temperature rise has been verified:
1. Remove jumpers from thermostat terminals.
2. Allow the blower off delay to complete.
3. Turn Set up switches SW1−2 and SW4−2 to the OFF
position unless two−stage thermostat operation is
desired. (See Figure 4)
4. Proceed to “Adjust Blower Off Delay” or install blower
door if complete.
!
FIRE HAZARD
Failure to follow this warning could result in personal injury,
death, and/or property damage.
Reinstall manifold pressure tap plug in gas valve to
prevent gas leak.
WARNING
Adjust Blower Off Delay (Heat Mode)
a. Remove blower door if installed.
b. Turn Dip switch SW−7 or SW−8 ON or OFF for
desired blower off delay. (See Table 2, Figure 3 and
Figure 4)
Table 2Blower Speed Taps
DESIRED HEATING MODE
BLOWER OFF DELAY
(SEC.)
90OFFOFF
120ONOFF
150OFFON
180ONON
SETUP SWITCH POSITION
SW1-7SW1-8
Adjust Cooling Airflow − High−Speed and
Low−Speed Cooling
The ECM blower can be adjusted for a range of airflows for
low−speed or high−speed cooling. See Table 3 − Airflow
Switch Table, Table 6 − Air Delivery − CFM (with Filter) andFigure 4. Furnace Setup Switches and Descriptions.
Depending on the model size, the cooling airflow can be
adjusted from 1.5 tons to 6 tons of nominal cooling based on
350 CFM ton.
NOTE: 6 ton airflow will truncate at 2200 CFM on applicable
models.
The high−speed or single−speed cooling airflow is adjusted by
turning setup switches SW2−1, SW2−2 and SW2−3 either ON
or OFF. Select the required airflow from Table 6. Table 6 is
based on 350 CFM per ton. For other CFM per ton setup switch
selections, see Table 3, Figure 4 and Figure 15.
The Continuous Fan airflow selection via setup switches SW3
is also the airflow for low−speed cooling when the furnace is
used with a two−speed cooling or heat pump unit. Adjust the
Continuous Fan CFM setup switches SW3 to match the airflow
required for low−speed cooling. Select the required airflow from
Table 6 and Figure 4.
NOTE: The airflow selected via SW3 (low−speed cooling
airflow) cannot exceed the airflow selected via SW2
(high−speed cooling airflow). For other CFM per ton setup
switch selections, see Table 3 and Figure 4.NOTE: The airflow settings for SW2 and SW3 selections are
the same, EXCEPT for the default values. (See Table 6)
For a complete explanation of cooling airflow, refer to the
section titled “Sequence of Operation.”
Adjust Continuous Fan Airflow/Low Speed
Cooling Airflow
NOTE: When the furnace is used with a two−speed cooling or
heat pump unit, the airflow selected for Continuous Fan via
setup switch SW3 will also be the airflow used for low−speed
cooling, and vice versa.
NOTE: When the furnace is used with a two−speed cooling or
heat pump unit, adjust the Continuous Fan CFM setup
switches SW3 to match the airflow required for low−speed
cooling.
Select the required Continuous Fan airflow using setup
switches SW3 as shown in Table 3, Figure 4 and Figure 15.
!
CAUTION
FURNACE OVERHEATING HAZARD
Failure to follow this caution may result in reduced furnace
life.
Recheck temperature rise. It must be within limits specified
on the rating plate. Recommended operation is at the
mid−point of rise range or slightly above.
440 04 4201 039
Specifications subject to change without notice.
SERVICE AND TECHNICAL SUPPORT MANUALGas Furnace: (F/G)9MAC
T
Bl
Off Del
Allows additional CFM per ton selections when used with SW
Turn ON to retrieve up to 7 stored status codes for
troubleshooting assistance when R thermostat lead is
disconnected.
When SW1-2 and SW4-2 are OFF allows Modulating operation
with a single stage thermostat. Turn ON SW1-2 when using
two-stage thermostat to allow Minimum Heat operation when
R to W/W1 closed and a Maximum heat operation when R to
W/W1 and R to W2 close.
urn ON to increase Minimum Heat and Intermediate Heat
airflow by 18 percent. This compensates for increased return
air temperature caused with bypass humidifier. This also
increases the Intermediate Heat inducer speed 15 percent.
Turn ON to decrease Minimum heat airflow by 10 percent,
Intermediate Heat airflow 7.5 percent and Maximum Heat
airflow 17.5 percent for maximum comfort.
Turn ON for 400 CFM per ton, Turn OFF for 350 CFM per ton.
See also SW4.
Turn ON to initiate Component Self Test for troubleshooting
assistance when R thermostat lead is disconnected. Turn
OFF when Self Test is completed.
ower
seconds. See table in Adjustments section or refer to unit
wiring diagram.
When SW1-2 and SW4-2 are OFF allows Modulating operation
with a single stage thermostat. Turn ON SW4-2 when using
two-stage thermostat to allow Intermediate Heat operation
when R to W/W1 closed and a Maximum heat operation when
R to W/W1 and R to W2 close.
ay time – adjustable 90 seconds to 180
1
SW2
1
SW3
AC
CF
1-5
325 CFM per ton (nominal) when SW 4-3 ON and SW 1-5 OFF
350 CFM per ton (nominal) when SW 4-3 OFF and SW 1-5 OFF
SW4-3
O
N
1
2
3
O
N
1
2
3
SW 2, AC (Cooling Airflow) SETUP SWITCHES
The AC setup switch selects desired cooling or high stage cooling (two stage units) airflow.
See Cooling Air Delivery Tables for specific switch settings
SW 3, CF (Continuous Fan) SETUP SWITCHES
The CF setup switch selects desired Continuous Fan Airflow
The CF switch position is the Low Cooling airflow selection for two stage cooling units.
SW 3 cannot be set for airflow higher than SW 2
See Continuous Fan Air Delivery Tables for specific switch settings
CFM per ton Adjust
AIR CONDITIONING (A/C) SETUP SWITCHES
CONTINUOUS FAN (CF) SETUP SWITCHES
OFF
370 CFM per ton (nominal) when SW4-3 ON and SW 1-5 ON
400 CFM per ton (nominal) when SW 1-5 ON and SW 4-3 OFF
See Air Delivery Tables for model specific CFM vs. static
ressure
10440 04 4201 03
A11575
Specifications subject to change without notice.
SERVICE AND TECHNICAL SUPPORT MANUALGas Furnace: (F/G)9MAC
321N321
N 321N 321N 321N 321N 321N 321N 321N
321N321
N 321N 321N 321N 321N 321N 321N 321N
321N321
N 321N 321N 321N 321N 321N 321N 321N
321N321
N 321N 321N 321N 321N 321N 321N 321N
060-14
080-14
060-20
080-20
100-22
120-22
1860
1860
1116
1116
976
976
1200
1200
1860
2100
1488
1860
2100
930
744
930
1116
1302
1488
744
744
930
1116
1302
1860
744
744
930
1116
1302
1488
1860
1860
1860
744
744
930
1116
1302
1488
1860
1860
1302
1302
1302
558
558
744
930
1116
1302
558
558
744
930
1116
1302
1302
1627
1953
NOMINAL AIRFLOW BASED ON 370 CFM/TON (SW1-5 = ON, SW4-3 = ON)
Model Size
SW2 Clg Defa ult
SW3 CF Default
COOLING (SW2) AND CONTINUOUS FAN (SW3) AIRFLOW: SET-UP SWITCH POSITIONS
1302
1627
1953
1627
814
651
814
976
1139
1302
1627
651
651
814
976
1139
1627
651
651
814
976
1139
1302
1627
1627
1627
651
651
814
976
1139
1302
1627
1627
1139
1139
1139
488
488
651
814
976
1139
488
488
651
814
976
1139
1139
2000
2100
NOMINAL AIRFLOW BASED ON 325 CFM/TON (SW1-5 = OFF, SW4-3 = ON)
Model Size
SW2 Clg Defa ult
SW3 CF Default
COOLING (SW2) AND CONTINUOUS FAN (SW3) AIRFLOW: SET-UP SWITCH POSITIONS
1600
2000
2100
2000
1000
800
1000
1200
1400
1600
2000
800
800
1000
1200
1400
2000
800
800
1000
1200
1400
1600
2000
2000
2000
800
800
1000
1200
1400
1600
2000
2000
1400
1400
1400
600
600
800
1000
1200
1400
600
600
800
1000
1200
1400
1400
1400
1750
2100
NOMINAL AIRFLOW BASED ON 400 CFM/TON (SW1-5 = ON, SW4-3 = OFF)
Model Size
SW2 Clg Defa ult
SW3 CF Default
COOLING (SW2) AND CONTINUOUS FAN (SW3) AIRFLOW: SET-UP SWITCH POSITIONS
1750
875
700
875
1050
1225
1750
700
700
875
1050
1225
1400
1750
2100
1750
700
700
875
1050
1225
1400
1750
1750
1750
700
700
875
1050
1225
1400
1750
1750
1050
525
525
700
875
1050
1225
1225
1225
NOMINAL AIRFLOW BASED ON 350 CFM/TON (Factory Default - SW1-5 = OFF, SW4-3 = OFF)
Model Size
SW2 Clg Defa ult
SW3 CF Default
COOLING (SW2) AND CONTINUOUS FAN (SW3) AIRFLOW: SET-UP SWITCH POSITIONS
1050
525
525
700
875
1050
1225
1225
1225
Table 3Airflow Switch Table
OOOOOOOOO
060-14
080-14
060-20
080-20
100-22
120-22
OOOOOOOOO
060-14
080-14
060-20
080-20
100-22
120-22
OOOOOOOOO
060-14
080-14
060-20
080-20
100-22
120-22
OOOOOOOOO
Adjust Thermostat Heat Anticipator
a. Mechanical thermostat. Set thermostat heat
anticipator to match the amp. draw of the electrical
components in the R−W/W1 circuit. Accurate amp.
draw readings can be obtained at the wires normally
connected to thermostat subbase terminals, R and W.
The thermostat anticipator should NOT be in the
circuit while measuring current.
(1.) Set SW1−2 switch on furnace control board to
ON.
(2.) Remove thermostat from subbase or from wall.
L11F092
(3.) Connect an amp. meter as shown in Figure 5
across the R and W subbase terminals or R and
W wires at wall.
(4.) Record amp. draw across terminals when
furnace is in minimum heat and after blower
starts.
(5.) Set heat anticipator on thermostat per thermostat
instructions and install on subbase or wall.
(6.) Turn SW1−2 switch OFF.
(7.) Install blower door.
b. Electronic thermostat: Set cycle rate for three cycles
per hr.
440 04 4201 0311
Specifications subject to change without notice.
SERVICE AND TECHNICAL SUPPORT MANUALGas Furnace: (F/G)9MAC
Figure 5Amp. Draw Check with Ammeter
THERMOSTAT SUBBASE
TERMINALS WITH
THERMOSTAT REMOVED
(ANITICIPATOR, CLOCK, ETC.,
MUST BE OUT OF CIRCUIT.)
HOOK-AROUND
AMMETER
R Y W G
10 TURNS
FROM UNIT 24-V
CONTROL TERMINALS
EXAMPLE:
5.0 AMPS ON AMMETER
10 TURNS AROUND JAWS
0.5 AMPS FOR THERMOSTAT
=
ANTICIPATOR SETTING
A96316
Check Safety Controls
The flame sensor, gas valve, and pressure switch were all
checked in the Start−up procedure section as part of normal
operation.
1. Check Main Limit Switch
This control shuts off combustion system and energizes
air−circulating blower motor, if furnace overheats. By
using this method to check limit control, it can be
established that limit is functioning properly and will
operate if there is a restricted return−air supply or motor
failure. If limit control does not function during this test,
cause must be determined and corrected.
a. Run furnace for at least five minutes.
b. Gradually block off return air with a piece of
cardboard or sheet metal until the limit trips.
c. Unblock return air to permit normal circulation.
d. Burners will re−light when furnace cools down.
2. Check Pressure Switch(es)
This control proves operation of the draft inducer blower.
a. Turn off 115−v power to furnace.
b. Disconnect inducer motor lead wires from wire
harness.
c. Turn on 115−v power to furnace.
d. Set thermostat to “call for heat” and wait 1 minute.
When pressure switch is functioning properly, hot
surface igniter should NOT glow and control
diagnostic light flashes a status code 3. If hot surface
igniter glows when inducer motor is disconnected,
shut down furnace immediately.
e. Determine reason pressure switch did not function
properly and correct condition.
f. Turn off 115−v power to furnace.
g. Reconnect inducer motor wires, replace blower door,
and turn on 115−v power.
h. Blower will run for 90 seconds before beginning the
call for heat again.
i. Furnace should ignite normally.
Checklist
1. Put away tools and instruments. Clean up debris.
2. Verify that switches SW1−1 and SW1−6 are OFF and
other setup switches are set as desired. Verify that
switches SW1−7 and SW1−8 for the blower OFF DELAY
are set as desired per Table 2.
3. Verify that blower and control doors are properly
installed.
4. Cycle test furnace with room thermostat.
5. Check operation of accessories per manufacturer’s
instructions.
6. Review Home Owner’s Information with owner.
7. Attach literature packet to furnace.
12440 04 4201 03
Specifications subject to change without notice.
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