International Comfort Products G9MAE0601714A, G9MAE0602120A, G9MAE0801714A, G9MAE0802120A, G9MAE1002122A TECHNICAL MANUAL

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SERVICE AND TECHNICAL

(

SUPPORT MANUAL

Modulating, Variable Speed Blower Motor

35” Tall, High Efficiency Condensing Gas Furnace

F/G)9MAE

Save this manual for future reference.

Safety Labeling and Signal Words

DANGER, WARNING, CAUTION, and NOTE

The signal words DANGER, WARNING, CAUTION, and NOTE are used to identify levels of

hazard seriousness. The signal word DANGER is only used on product labels to signify an immediate hazard. The signal words WARNING, CAUTION, and NOTE will be used on product labels and throughout this manual and other manual that may apply to the product.

DANGER − Immediate hazards which will result in severe personal injury or death.

WARNING − Hazards or unsafe practices which could result in severe personal injury or death.

CAUTION − Hazards or unsafe practices which may result in minor personal injury or product or property damage.

NOTE − Used to highlight suggestions which will result in enhanced installation, reliability, or operation.

Signal Words in Manuals

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

WARNING

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

CAUTION

Signal Words on Product Labeling

Signal words are used in combination with colors and/or pictures or product labels.

Safety−alert symbol

When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury.

TABLE OF CONTENTS

START−UP, ADJUSTMENT, AND SAFETY CHECK 4...........

SELECT SETUP SWITCH POSITIONS 4.....................

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

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

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

ADJUST TEMPERATURE RISE 8............................

ADJUST BLOWER OFF DELAY (HEAT MODE) 9..............

ADJUST COOLING AIRFLOW 9.............................

ADJUST CONTINUOUS FAN AIRFLOW 9....................

ADJUST THERMOSTAT HEAT ANTICIPATOR 11...............

CHECK SAFETY CONTROLS 12.............................

CHECKLIST 12.............................................

COOLING AND HEATING AIR DELIVERY - CFM 17.............

SERVICE AND MAINTENANCE PROCEDURES 21.............

ELECTRICAL CONTROLS AND WIRING 21...................

CLEANING AND/OR REPLACING AIR FILTER 23..............

CLEANING BURNERS AND FLAME SENSOR 25...............

SERVICING HOT SURFACE IGNITER 26......................

FLUSHING COLLECTOR BOX AND DRAINAGE SYSTEM 27....

CLEANING CONDENSATE DRAIN AND TRAP 27..............

WINTERIZATION 28........................................

SERVICE LABEL 29.........................................

TROUBLESHOOTING CHART − FLOW CHART 31.............

TROUBLESHOOTING GUIDE − FLOW CHART 32..............

SEQUENCE OF OPERATION 34.............................

PARTS REPLACEMENT INFORMATION GUIDE 38.............

PRODUCT NOMENCLATURE 39.............................

MODELS

(F/G)9MAE0601714A (F/G)9MAE0602120A (F/G)9MAE0801714A (F/G)9MAE0802120A (F/G)9MAE1002122A (F/G)9MAE1202422A

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 4700 00 Aug. 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

CARBON MONOXIDE POISONING AND FIRE HAZARD

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

This furnace is not designed for use in mobile homes, trailers or recreational vehicles.

CAUTION

CUT HAZARD

Failure to follow this caution may result in damage personal injury.

Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety glasses and gloves when handling parts and servicing furnaces.

Specifications are subject to change without notice.

440 04 4700 00

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

START−UP CHECK SHEET

For Variable Speed Models (F/G)9MAE

(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 4700 00 3

Specifications subject to change without notice.

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

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

4 440 04 4700 00

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 MANUAL Gas Furnace: (F/G)9MAE

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

4. Remove funnel; replace collector box drain plug.

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

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

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

Figure 1 Priming Condensate Drain

Figure 2 Orifice 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 *9MAE0602120 Btuh model. Use Table 5 for only the *9MAE0602120 model.

440 04 4700 00 5

Specifications subject to change without notice.

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

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 *9MAE0602120 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 1 Altitude Derate Multiplier for U.S.A.

ALTITUDE

FT. (M)

0–2000

(0−610)

2001–3000

(610−914)

3001–4000

(914−1219)

4001–5000

(1219−1524)

5001–6000

(1524−1829)

6001–7000

(1829−2134)

7001–8000

(2134−2438)

8001–9000

(2438−2743)

9001–10,000

(2743−3048)

* Derate multiplier factors are based on midpoint altitude for altitude range.

PERCENT

OF DERATE

0 1.00

4−6 0.95

6−8 0.93

8−10 0.91

10−12 0.89

12−14 0.87

14−16 0.85

16−18 0.83

18−20 0.81

DERATE MULTIPLIER

FACTOR*

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.

6 440 04 4700 00

Specifications subject to change without notice.

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

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 4700 00 7

Specifications subject to change without notice.

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

Figure 3 Variable 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

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:

S Overheating the heat exchangers or condensing

flue gases in heat exchanger areas not designed for condensate

S Shortened furnace life S Component damage

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

Furnace must operate within ranges of temperature rise specified on the furnace rating plate. When setup switch SW1-4 is ON, operation will be near the high end of the rise range for improved comfort.

Determine air temperature rise as follows:

1. Place thermometers in return and supply ducts as near furnace as possible. Be sure thermometers do not see heat exchanger so that radiant heat does not affect readings. This practice is particularly important with straight-run ducts.

2. When thermometer readings stabilize, subtract return-air temperature from supply-air temperature to determine air temperature rise.

8 440 04 4700 00

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 MANUAL Gas Furnace: (F/G)9MAE

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 2 Blower Speed Taps

DESIRED HEATING MODE

BLOWER OFF DELAY

(SEC.)

90 OFF OFF

120 ON OFF

150 OFF ON

180 ON ON

SETUP SWITCH POSITION

SW1-7 SW1-8

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) and Figure 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 4700 00 9

Specifications subject to change without notice.

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

Off Del

Allows additional CFM per ton selections when used with SW

Figure 4 Furnace Setup Switch Description

Furnace Setup Switch Description

ESU FO NOITPIRCSEDNOITISOP LAMRONEMAN HCTIWSHCTIWS PUTES

SW1-1 Status Code Recovery OFF

Minimum Heat Only

SW1-2

SW1-3

SW1-4

SW1-5 CFM per ton adjust OFF

SW1-6 Component Self Test OFF

SW1-7 & SW1-8 Blower OFF delay ON or OFF

SW4-2

(Adaptive Heat Mode

when SW1-2 and SW4-2

are OFF)

Min/Int Heat Rise

Adjustment

Comfort/Efficiency

Adjustment

Intermediate Heat

Only

(Adaptive Heat Mode

when both SW1-2 and

SW4-2 are OFF)

OFF

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

SW2

SW3

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

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

10 440 04 4700 00

A11575

Specifications subject to change without notice.

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

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

1116

976

1200

1860

2100

1488

1860

2100

930

744

930

1116

1302

1488

744

930

1116

1302

1860

744

930

1116

1302

1488

1860

744

930

1116

1302

1488

1860

1302

558

744

930

1116

1302

558

744

930

1116

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

814

976

1139

1627

651

814

976

1139

1302

1627

651

814

976

1139

1302

1627

1139

488

651

814

976

1139

488

651

814

976

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

1000

1200

1400

2000

800

1000

1200

1400

1600

2000

800

1000

1200

1400

1600

2000

1400

600

800

1000

1200

1400

600

800

1000

1200

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

875

1050

1225

1400

1750

2100

1750

700

875

1050

1225

1400

1750

700

875

1050

1225

1400

1750

1050

525

700

875

1050

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

700

875

1050

1225

Table 3 Airflow 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 4700 00 11

Specifications subject to change without notice.

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

Figure 5 Amp. Draw Check with Ammeter

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

HOOK-AROUND AMMETER

R Y W G

10 TURNS

FROM UNIT 24-V CONTROL TERMINALS

EXAMPLE:

5.0 AMPS ON AMMETER 10 TURNS AROUND JAWS

0.5 AMPS FOR THERMOSTAT

ANTICIPATOR SETTING

A96316

Check Safety Controls

The flame sensor, gas valve, and pressure switch were all checked in the Start−up procedure section as part of normal operation.

1. Check Main Limit Switch This control shuts off combustion system and energizes air−circulating blower motor, if furnace overheats. By using this method to check limit control, it can be established that limit is functioning properly and will operate if there is a restricted return−air supply or motor failure. If limit control does not function during this test, cause must be determined and corrected.

a. Run furnace for at least 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.

12 440 04 4700 00

Specifications subject to change without notice.

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

Table 4

Orifice Size and Manifold Pressure (in. w.c.) for Gas Input Rate TO BE USED WITH MODULATING FURNACES EXCEPT THE (F/G)9MAE0602120

MODULATING FURNACE

(TABULATED DATA BASED ON 20,000 BT UH M AX-HEAT / 8,000 BTUH MIN-HEAT PER BURNER,

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

ALTITUDE

RANGE

ft (m)

092543 3.6 /0.55 43 3.7 /0.60 43 3.8 /0.60 42 3.2 /0.50

(0) 950 43 3.4 /0.55 43 3.5 /0.55 43 3.6 /0.60 43 3.7 /0.60

to 1000 44 3.5 /0.55 44 3.6 /0.60 44 3.8 /0.60 43 3.4 /0.55

U.S.A. and CanadaU.S.A. and CanadaU.S.A. Only

U.S.A. On

2000 1050 44 3.2 /0.50 44 3.3 /0.55 44 3.4 /0.55 44 3.5 /0.55

(610) 1075 45 3.7 /0.60 45 3.8 /0.60 44 3.3 /0.50 44 3.4 /0.55

U.S.A. 800 42 3.4 /0.55 42 3.5 /0.55 42 3.6 /0.55 42 3.7 /0.60

2001 (611) 825 43 3.8 /0.60 42 3.3 /0.50 42 3.4 /0.55 42 3.5 /0.55

to 850 43 3.6 /0.60 43 3.7 /0.60 42 3.2 /0.50 42 3.3 /0.55

3000 (914) 875 43 3.4 /0.55 43 3.5 /0.55 43 3.7 /0.60 43 3.8 /0.60

Canada 925 44 3.5 /0.55 44 3.6 /0.60 44 3.8 /0.60 43 3.4 /0.55

2001 (611) 950 44 3.3 /0.55 44 3.4 /0.55 44 3.6 /0.55 44 3.7 /0.60

to 975 44 3.2 /0.50 44 3.3 /0.50 44 3.4 /0.55 44 3.5 /0.55

4500 (1372) 1000 46 3.8 /0.60 45 3.8 /0.60 44 3.2 /0.50 44 3.3 /0.55

3001 800 43 3.8 /0.60 42 3.2 /0.50 42 3.3 /0.55 42 3.4 /0.55

(915) 825 43 3.6 /0.55 43 3.7 /0.60 43 3.8 /0.60 42 3.2 /0.50

4000 900 44 3.4 /0.55 44 3.5 /0.55 44 3.7 /0.60 44 3.8 /0.60

(1219) 925 44 3.2 /0.50 44 3.4 /0.55 44 3.5 /0.55 44 3.6 /0.55

4001 775 43 3.7 /0.60 43 3.8 /0.60 42 3.3 /0.50 42 3.4 /0.55

(1220) 800 43 3.5 /0.55 43 3.6 /0.60 43 3.7 /0.60 43 3.8 /0.60

5000 875 44 3.3 /0.55 44 3.5 /0.55 44 3.6 /0.55 44 3.7 /0.60

(1524) 900 44 3.2 /0.50 44 3.3 /0.50 44 3.4 /0.55 44 3.5 /0.55

5001 750 43 3.7 /0.60 43 3.8 /0.60 42 3.2 /0.50 42 3.3 /0.55

(1525) 775 43 3.4 /0.55 43 3.5 /0.55 43 3.7 /0.60 43 3.8 /0.60

6000 850 44 3.3 /0.50 44 3.4 /0.55 44 3.5 /0.55 44 3.6 /0.60

(1829) 875 45 3.7 /0.60 44 3.2 /0.50 44 3.3 /0.55 44 3.4 /0.55

6001 700 42 3.2 /0.50 42 3.3 /0.50 42 3.4 /0.55 42 3.5 /0.55

(1830) 725 43 3.6 /0.60 43 3.7 /0.60 43 3.8 /0.60 42 3.3 /0.50

7000 800 44 3.4 /0.55 44 3.5 /0.55 44 3.6 /0.60 44 3.7 /0.60

(2133) 825 44 3.2 /0.50 44 3.3 /0.55 44 3.4 /0.55 44 3.5 /0.55

HEATVALUE0.580.600.620.64

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

(Btu/cu ft) No. Max/Min No. Max/Min No. Max/Min No. Max/Min

900 43 3.8 /0.60 42 3.2 /0.50 42 3.3 /0.55 42 3.4 /0.55

975 44 3.7 /0.60 44 3.8 /0.60 43 3.4 /0.55 43 3.6 /0.55

1025 44 3.3 /0.55 44 3.5 /0.55 44 3.6 /0.55 44 3.7 /0.60

1100 46 3.7 /0.60 46 3.8 /0.60 45 3.8 /0.60 44 3.2 /0.50

900 44 3.7 /0.60 44 3.8 /0.60 43 3.5 /0.55 43 3.6 /0.55

775 42 3.3 /0.55 42 3.4 /0.55 42 3.5 /0.55 42 3.6 /0.60

850 44 3.8 /0.60 43 3.5 /0.55 43 3.6 /0.55 43 3.7 /0.60

875 44 3.6 /0.60 44 3.7 /0.60

950 45 3.7 /0.60 44 3.2 /0.50 44 3.3 /0.55 44 3.4 /0.55

750 42 3.3 /0.50 42 3.4 /0.55 42 3.5 /0.55 42 3.6 /0.55

825 44 3.8 /0.60 43 3.4 /0.55 43 3.5 /0.55 43 3.6 /0.60

850 44 3.5 /0.55 44 3.7 /0.60 44 3.8 /0.60 43 3.4 /0.55

925 46 3.8 /0.60 45 3.7 /0.60 44 3.2 /0.50 44 3.3 /0.55

725 42 3.2 /0.50 42 3.3 /0.55 42 3.4 /0.55 42 3.5 /0.55

800 44 3.7 /0.60 44 3.8 /0.60 43 3.4 /0.55 43 3.5 /0.55

825 44 3.5 /0.55 44 3.6 /0.55 44 3.7 /0.60 44 3.8 /0.60

900 46 3.7 /0.60 46 3.8 /0.60 45 3.8 /0.60 44 3.2 /0.50

675 42 3.4 /0.55 42 3.5 /0.55 42 3.6 /0.60 42 3.8 /0.60

750 43 3.4 /0.55 43 3.5 /0.55 43 3.6 /0.55 43 3.7 /0.60

775 44 3.6 /0.60 44 3.7 /0.60 43 3.4 /0.55 43 3.5 /0.55

850 46 3.8 /0.60 45 3.8 /0.60 44 3.2 /0.50 44 3.3 /0.55

43 3.4 /0.55 43 3.5 /0.55

SAGLARUTANFOYTIVARGCIFICEPSSAG.GVA

A11251A

440 04 4700 00 13

Specifications subject to change without notice.

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

Table 4 (Cont.)

ALTITUDE

RANGE

U.S.A. Only

* Orifice numbers shown in BOLD are factory-ins talled.

Orifice Size and Manifold Pressure (in. w.c.) for Gas Input Rate TO BE USED WITH MODULATING FURNACES EXCEPT THE (F/G)9MAE0602120

(TABULATED DATA BASED ON 20,000 BT UH M AX-HEAT / 8,000 BTUH MIN-HEAT PER BURNER,

HEATVALUE0.580.600.620.64

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

ft (m)

7001 675 43 3.8 /0.60 42 3.2 /0.50 42 3.3 /0.55 42 3.4 /0.55

(2134) 700 43 3.5 /0.55 43 3.7 /0.60 43 3.8 /0.60 42 3.2 /0.50

8000 775 44 3.3 /0.55 44 3.4 /0.55 44 3.5 /0.55 44 3.7 /0.60

(2438) 800 45 3.8 /0.60 44 3.2 /0.50 44 3.3 /0.55 44 3.4 /0.55

8001 650 43 3.8 /0.60 42 3.2 /0.50 42 3.3 /0.55 42 3.4 /0.55

(2439) 675 43 3.5 /0.55 43 3.6 /0.60 43 3.7 /0.60 42 3.2 /0.50

9000 750 44 3.3 /0.50 44 3.4 /0.55 44 3.5 /0.55 44 3.6 /0.55

(2743) 775 45 3.7 /0.60 44 3.2 /0.50 44 3.3 /0.50 44 3.4 /0.55

9001 600 42 3.3 /0.55 42 3.4 /0.55 42 3.6 /0.55 42 3.7 /0.60

(2744) 625 43 3.7 /0.60 42 3.2 /0.50 42 3.3 /0.55 42 3.4 /0.55

10000 700 44 3.4 /0.55 44 3.5 /0.55 44 3.7 /0.60 44 3.8 /0.60

(3048) 725 44 3.2 /0.50 44 3.3 /0.55 44 3.4 /0.55 44 3.5 /0.55

(Btu/cu ft) No. Max/Min No. Max/Min No. Max/Min No. Max/Min

650 42 3.4 /0.55 42 3.5 /0.55 42 3.6 /0.60 42 3.7 /0.60

725 44 3.8 /0.60 43 3.4 /0.55 43 3.5 /0.55 43 3.6 /0.60

750 44 3.5 /0.55 44 3.7 /0.60 44 3.8 /0.60 43 3.4 /0.55

825 46 3.7 /0.60 46 3.8 /0.60 45 3.8 /0.60 44 3.2 /0.50

625 42 3.4 /0.55 42 3.5 /0.55 42 3.6 /0.55 42 3.7 /0.60

700 44 3.7 /0.60 43 3.4 /0.55 43 3.5 /0.55 43 3.6 /0.55

725 44 3.5 /0.55 44 3.6 /0.60 44 3.7 /0.60 44 3.8 /0.60

650 43 3.5 /0.55 43 3.6 /0.55 43 3.7 /0.60 43 3.8 /0.60

675 44 3.7 /0.60 44 3.8 /0.60 43 3.4 /0.55 43 3.5 /0.55

MODULATING FURNACE

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

SAGLARUTANFOYTIVARGCIFICEPSSAG.GVA

A11251B

14 440 04 4700 00

Specifications subject to change without notice.

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

Table 5

Orifice Size and Manifold Pressure (in. w.c.) for Gas Input Rate TO BE USED WITH MODULATING FURNACES (F/G)9MAE0602120 FURNACE ONLY

(TABULATED DATA BASED ON 20,200 BTUH MAX-HEAT / 8,000 BTUH MIN-HEAT PER BURNER,

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

ALTITUDE

RANGE

ft (m)

0 925 43 3.7 /0.55 43 3.8 /0.60 42 3.2 /0.50 42 3.3 /0.50

(0) 950 43 3.5 /0.55 43 3.6 /0.55 43 3.7 /0.60 43 3.8 /0.60

to 1000 44 3.6 /0.55 44 3.7 /0.60 44 3.8 /0.60 43 3.5 /0.55

U.S.A. and CanadaU.S.A. and CanadaU.S.A. Only

U.S.A. Only

2000 1050 44 3.3 /0.50 44 3.4 /0.55 44 3.5 /0.55 44 3.6 /0.55

(610) 1075 45 3.8 /0.60 44 3.2 /0.50 44 3.3 /0.50 44 3.4 /0.55

U.S.A. 800 42 3.4 /0.55 42 3.5 /0.55 42 3.7 /0.55 42 3.8 /0.60

2001 (611) 825 42 3.2 /0.50 42 3.3 /0.50 42 3.4 /0.55 42 3.6 /0.55

to 850 43 3.7 /0.60 43 3.8 /0.60 42 3.2 /0.50 42 3.3 /0.55

3000 (914) 875 43 3.5 /0.55 43 3.6 /0.55 43 3.7 /0.60 43 3.8 /0.60

Canada 925 44 3.6 /0.55 44 3.7 /0.60 44 3.8 /0.60 43 3.4 /0.55

2001 (611) 950 44 3.4 /0.55 44 3.5 /0.55 44 3.6 /0.55 44 3.7 /0.60

to 975 44 3.2 /0.50 44 3.3 /0.50 44 3.4 /0.55 44 3.6 /0.55

4500 (1372) 1000 45 3.7 /0.60 44 3.2 /0.50 44 3.3 /0.50 44 3.4 /0.55

3001 800 42 3.2 /0.50 42 3.3 /0.50 42 3.4 /0.55 42 3.5 /0.55

(915) 825 43 3.6 /0.55 43 3.7 /0.60 42 3.2 /0.50 42 3.3 /0.50

4000 900 44 3.5 /0.55 44 3.6 /0.55 44 3.7 /0.60 43 3.4 /0.55

(1219) 925 44 3.3 /0.50 44 3.4 /0.55 44 3.5 /0.55 44 3.6 /0.55

4001 775 43 3.8 /0.60 42 3.2 /0.50 42 3.3 /0.50 42 3.4 /0.55

(1220) 800 43 3.6 /0.55 43 3.7 /0.60 43 3.8 /0.60 42 3.2 /0.50

5000 875 44 3.4 /0.55 44 3.5 /0.55 44 3.6 /0.55 44 3.8 /0.60

(1524) 900 44 3.2 /0.50 44 3.3 /0.50 44 3.4 /0.55 44 3.6 /0.55

5001 750 43 3.7 /0.60 42 3.2 /0.50 42 3.3 /0.50 42 3.4 /0.55

(1525) 775 43 3.5 /0.55 43 3.6 /0.55 43 3.7 /0.60 42 3.2 /0.50

6000 850 44 3.3 /0.50 44 3.4 /0.55 44 3.6 /0.55 44 3.7 /0.60

(1829) 875 45 3.8 /0.60 44 3.3 /0.50 44 3.4 /0.55 44 3.5 /0.55

6001 700 42 3.2 /0.50 42 3.3 /0.50 42 3.5 /0.55 42 3.6 /0.55

(1830) 725 43 3.7 /0.60 43 3.8 /0.60 42 3.2 /0.50 42 3.3 /0.50

7000 800 44 3.5 /0.55 44 3.6 /0.55 44 3.7 /0.60 44 3.8 /0.60

(2133) 825 44 3.2 /0.50 44 3.4 /0.55 44 3.5 /0.55 44 3.6 /0.55

AVG. GAS SPECIFIC GRAVITY OF NATURAL GAS

HEAT VALUE 0.58 0.60 0.62 0.6 4

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

(Btu/cu ft) No. Max/Min No. Max/Min No. Max/Min No. Max/Min

900 42 3.2 /0.50 42 3.3 /0.50 42 3.4 /0.55 42 3.5 /0.55

975 44 3.8 /0.60 43 3.4 /0.55 43 3.5 /0.55 43 3.6 /0.55

1025 44 3.4 /0.55 44 3.5 /0.55 44 3.6 /0.55 44 3.8 /0.60

1100 46 3.8 /0.60 45 3.7 /0.60 44 3.2 /0.50 44 3.3 /0.50

900 44 3.8 /0.60 43 3.4 /0.55 43 3.5 /0.55 43 3.6 /0.55

775 42 3.4 /0.55 42 3.5 /0.55 42 3.6 /0.55 42 3.7 /0.60

850 43 3.4 /0.55 43 3.5 /0.55 43 3.6 /0.55 43 3.8 /0.60 875 44 3.7 /0.60 44 3.8 /0.60 43 3.4 /0.55 43 3.6 /0.55

950 45 3.8 /0.60 44 3.2 /0.50 44 3.4 /0.55 44 3.5 /0.55 750 42 3.3 /0.50 42 3.4 /0.55 42 3.6 /0.55 42 3.7 /0.55

825 44 3.8 /0.60 43 3.5 /0.55 43 3.6 /0.55 43 3.7 /0.60 850 44 3.6 /0.55 44 3.7 /0.60 43 3.4 /0.55 43 3.5 /0.55

925 45 3.7 /0.60 44 3.2 /0.50 44 3.3 /0.50 44 3.4 /0.55 725 42 3.3 /0.50 42 3.4 /0.55 42 3.5 /0.55 42 3.6 /0.55

800 44 3.8 /0.60 43 3.4 /0.55 43 3.5 /0.55 43 3.6 /0.55 825 44 3.5 /0.55 44 3.7 /0.55 44 3.8 /0.60 43 3.4 /0.55

900 46 3.8 /0.60 45 3.7 /0.60 44 3.2 /0.50 44 3.3 /0.50 675 42 3.5 /0.55 42 3.6 /0.55 42 3.7 /0.60 42 3.8 /0.60

750 43 3.4 /0.55 43 3.5 /0.55 43 3.7 /0.55 43 3.8 /0.60 775 44 3.7 /0.60 44 3.8 /0.60 43 3.4 /0.55 43 3.5 /0.55

850 45 3.7 /0.60 44 3.2 /0.50 44 3.3 /0.50 44 3.4 /0.55

L11F100A

440 04 4700 00 15

Specifications subject to change without notice.

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

Table 5 (Cont.)

ALTITUDE

U.S.A. Only

* Orifice numbers shown in BOLD are factory-installed.

Orifice Size and Manifold Pressure (in. w.c.) for Gas Input Rate TO BE USED WITH MODULATING FURNACES (F/G)9MAE0602120 FURNACE ONLY

(TABULATED DATA BASED ON 20,200 BTUH MAX-HEAT / 8,000 BTUH MIN-HEAT PER BURNER,

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

AVG. GAS SPECIFIC GRAVITY OF NATURAL GAS

RANGE

ft (m)

7001 675 42 3.2 /0.50 42 3.3 /0.50 42 3.4 /0.55 42 3.5 /0.55

(2134) 700 43 3.6 /0.55 43 3.7 /0.60 42 3.2 /0.50 42 3.3 /0.50

8000 775 44 3.4 /0.55 44 3.5 /0.55 44 3.6 /0.55 44 3.7 /0.60

(2438) 800 44 3.2 /0.50 44 3.3 /0.50 44 3.4 /0.55 44 3.5 /0.55

8001 650 42 3.2 /0.50 42 3.3 /0.50 42 3.4 /0.55 42 3.5 /0.55

(2439) 675 43 3.6 /0.55 43 3.7 /0.60 43 3.8 /0.60 42 3.2 /0.50

9000 750 44 3.3 /0.50 44 3.4 /0.55 44 3.5 /0.55 44 3.7 /0.55

(2743) 775 45 3.8 /0.60 44 3.2 /0.50 44 3.3 /0.50 44 3.4 /0.55

9001 600 42 3.4 /0.55 42 3.5 /0.55 42 3.6 /0.55 42 3.8 /0.60

(2744) 625 43 3.8 /0.60 42 3.2 /0.50 42 3.3 /0.55 42 3.5 /0.55

10000 700 44 3.5 /0.55 44 3.6 /0.55 44 3.7 /0.60 44 3.8 /0.60 (3048) 725 44 3.3 /0.50 44 3.4 /0.55 44 3.5 /0.55 44 3.6 /0.55

HEAT VALUE 0.58 0.60 0.62 0.64

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

(Btu/cu ft) No. Max/Min No. Max/Min No. Max/Min No. Max/Min

650 42 3.4 /0.55 42 3.6 /0.55 42 3.7 /0.60 42 3.8 /0.60

725 43 3.4 /0.55 43 3.5 /0.55 43 3.6 /0.55 43 3.7 /0.60 750 44 3.6 /0.55 44 3.7 /0.60 43 3.4 /0.55 43 3.5 /0.55

825 46 3.8 /0.60 45 3.7 /0.60 44 3.2 /0.50 44 3.3 /0.50 625 42 3.4 /0.55 42 3.5 /0.55 42 3.7 /0.55 42 3.8 /0.60

700 44 3.8 /0.60 43 3.4 /0.55 43 3.6 /0.55 43 3.7 /0.55 725 44 3.6 /0.55 44 3.7 /0.60 44 3.8 /0.60 43 3.4 /0.55

650 43 3.5 /0.55 43 3.6 /0.55 43 3.8 /0.60 42 3.2 /0.50 675 44 3.8 /0.60 43 3.4 /0.55 43 3.5 /0.55 43 3.6 /0.55

L11F100B

16 440 04 4700 00

Specifications subject to change without notice.

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

Table 6 COOLING4 AND HEATING AIR DELIVERY - CFM (Bottom Return5 with Filter)

(SW1-5 and SW4-3 set to OFF, except as indicated. See notes 1 and 2)

Unit Size

060-14

Clg Default: OFF OFF OFF 1060 1070 1080 1080 1075 1065 1050 1035 1025 1010

CF Default: OFF OFF OFF 545 530 520 525 510 See note 4

Cooling (SW2)

Cont Fan (SW3)

Clg/CF Switch Settings External Static Pressure (ESP)

SWx-3 SWx-2 SWx-1 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

OFF OFF ON 545 530 520 525 510 See note 4

OFF ON OFF 710 710 710 695 690 See note 4

OFF ON ON 875 880 890 895 895 890 885 880 870 855

ON OFF OFF 1060 1070 1080 1080 1075 1065 1050 1035 1025 1010

ON OFF ON 1235 1240 1250 1255 1255 1250 1230 1190 1155 111 5

ON ON OFF 1235 1240 1250 1255 1255 1250 1230 1190 1155 111 5

ON ON ON 1235 1240 1250 1255 1255 1250 1230 1190 1155 1115

Clg SW2: Maximum Clg Airflow

Maximum Heat Airflow

Heating

(SW1)

Intermediate Heat Airflow

Minimum Heat Airflow

Unit Size

Clg/CF Switch Settings External Static Pressure (ESP)

SWx-3 SWx-2 SWx-1 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

1425 1425 1405 1370 1335 1300 1260 1225 1190 1155

1075 1085 1095 1095 1090 1080 1065 1050 1035 1020

535 515 505 515 495 See note 4

420 410 415 400 380 See note 4

060−20

Clg Default: OFF OFF OFF 1735 1735 1725 1715 1700 1685 1665 1650 1625 1605

CF Default: OFF OFF OFF 545 530 520 525 510 See note 4

OFF OFF ON 540 525 525 520 540 See note 4

OFF ON OFF 680 725 725 720 720 See note 4

OFF ON ON 925 915 910 895 900 890 875 865 860 855

Cooling (SW2)

ON OFF OFF 1070 1075 1080 1070 1080 1075 1055 1045 1030 1020

Cont Fan (SW3)

ON OFF ON 1215 1245 1235 1220 1220 1210 1200 1195 1185 1175

ON ON OFF 1380 1385 1395 1390 1395 1390 1380 1365 1355 1340

ON ON ON 1735 1735 1725 1715 1700 1685 1665 1650 1625 1605

Clg SW2: Maximum Clg Airflow

Maximum Heat Airflow

Heating

(SW1)

Intermediate Heat Airflow

Minimum Heat Airflow

440 04 4700 00 17

1955 1950 1940 1925 1905 1885 1855 1815 1745 1685

1080 1085 1095 1090 1095 1085 1070 1055 1045 1030

685 725 730 725 730 See note 4

560 555 555 550 565 See note 4

Specifications subject to change without notice.

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

Table 6 (Cont.) COOLING4 AND HEATING AIR DELIVERY - CFM (Bottom Return5 with Filter)

Unit Size

080-14

Clg Default: OFF OFF OFF 1055 1065 1080 1075 1065 1050 1045 1035 1025 1005

CF Default: OFF OFF OFF 520 505 505 495 490 See note 4

Cooling (SW2)

Cont Fan (SW3)

Clg/CF Switch Settings External Static Pressure (ESP)

SWx-3 SWx-2 SWx-1 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

OFF OFF ON 520 505 505 495 490 See note 4

OFF ON OFF 665 685 680 660 665 See note 4

OFF ON ON 885 895 905 900 900 895 885 875 860 845

ON OFF OFF 1055 1065 1080 1075 1065 1050 1045 1035 1025 1005

ON OFF ON 1245 1245 1255 1255 1260 1255 1250 1235 1220 1185

ON ON OFF 1245 1245 1255 1255 1260 1255 1250 1235 1220 1185

ON ON ON 1245 1245 1255 1255 1260 1255 1250 1235 1220 1185

Clg SW2: Maximum Clg Airflow

Maximum Heat Airflow

Heating

(SW1)

Intermediate Heat Airflow

Minimum Heat Airflow

Unit Size

Clg/CF Switch Settings External Static Pressure (ESP)

SWx-3 SWx-2 SWx-1 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

1520 1485 1450 1415 1375 1335 1300 1265 1225 1190

755 745 755 755 765 See note 4

620 625 630 620 610 See note 4

080−20

Clg Default: OFF OFF OFF 1745 1755 1755 1760 1755 1750 1745 1725 1705 1685

CF Default: OFF OFF OFF 700 710 750 725 750 See note 4

OFF OFF ON 700 710 750 725 750 See note 4

OFF ON OFF 830 860 870 890 960 See note 4

OFF ON ON 1045 1045 1060 1070 1070 1070 1095 1090 1080 1070

Cooling (SW2)

ON OFF OFF 1215 1220 1245 1240 1235 1235 1225 1220 1235 1235

Cont Fan (SW3)

ON OFF ON 1370 1370 1390 1390 1400 1395 1400 1390 1390 1385

ON ON OFF 1745 1755 1755 1760 1755 1750 1745 1725 1705 1685

ON ON ON 1745 1755 1755 1760 1755 1750 1745 1725 1705 1685

Clg SW2: Maximum Clg Airflow

Maximum Heat Airflow

Heating

(SW1)

Intermediate Heat Airflow

Minimum Heat Airflow

18 440 04 4700 00

1920 1920 1945 1945 1945 1960 1950 1940 1915 1900

1340 1355 1370 1385 1380 1385 1400 1400 1385 1380

780 810 835 840 845 See note 4

595 595 600 595 605 See note 4

Specifications subject to change without notice.

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

Table 6 (Cont.) COOLING4 AND HEATING AIR DELIVERY - CFM (Bottom Return5 with Filter)

Unit Size

100-22

Clg Default: OFF OFF OFF 1820 1825 1840 1845 1840 1835 1825 1805 1780 1770

CF Default: OFF OFF OFF 750 740 745 730 715 See note 4

Clg/CF Switch Settings External Static Pressure (ESP)

SWx-3 SWx-2 SWx-1 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

OFF OFF ON 750 740 745 730 715 See note 4

OFF ON OFF 900 900 915 910 905 See note 4

Cooling (SW2)

Cont Fan (SW3)

OFF ON ON 1070 1075 1095 1095 1090 1085 1095 1080 1065 1070

ON OFF OFF 1280 1285 1305 1305 1310 1305 1295 1300 1290 1285

ON OFF ON 1440 1445 1465 1465 1470 1485 1480 1485 1475 1460

ON ON OFF 1820 1825 1840 1845 1840 1835 1825 1805 1780 1770

ON ON ON 2135 2140 2140 2135 2140 2130 2115 2100 2070 2015

Clg SW2: Maximum Clg Airflow

Maximum Heat Airflow

Heating

(SW1)

Intermediate Heat Airflow

Minimum Heat Airflow

Unit Size

Clg/CF Switch Settings External Static Pressure (ESP)

SWx-3 SWx-2 SWx-1 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

2160 2165 2175 2170 2160 2150 2135 2120 2065 2020

1570 1575 1595 1595 1600 1605 1600 1600 1590 1575

950 955 965 975 970 See note 4

755 745 750 735 720 See note 4

120-22

Clg Default: OFF OFF OFF 1850 1855 1860 1855 1850 1830 1805 1775 1750 1730

CF Default: OFF OFF OFF 930 925 915 900 885 See note 4

OFF OFF ON 765 745 740 705 680 See note 4

OFF ON OFF 930 925 915 900 885 See note 4

OFF ON ON 1095 1100 111 0 1105 1085 See note 4

Cooling (SW2)

ON OFF OFF 1265 1255 1265 1280 1275 1285 1270 1260 1250 1230

Cont Fan (SW3)

ON OFF ON 1465 1455 1470 1465 1465 1470 1455 1450 1435 1415

ON ON OFF 1850 1855 1860 1855 1850 1830 1805 1775 1750 1730

ON ON ON 2200 2200 2200 2190 2185 2170 2145 2085 1990 1890

Clg SW2: Maximum Clg Airflow

Maximum Heat Airflow

Heating

(SW1)

Intermediate Heat Airflow

Minimum Heat Airflow

2200 2200 2200 2190 2185 2170 2145 2085 1990 1890

1815 1820 1825 1820 1815 1795 1775 1745 1720 1700

1095 1100 111 0 1105 1085 See note 4

905 900 890 875 855 See note 4

1. Nominal 350 CFM/ton cooling airflow is delivered with SW1−5 and SW4−3 set to OFF. Set SW1−5 to ON for nominal 400 CFM/ton (+15% airflow). Set SW4−3 to ON for nominal 325 CFM/ton (−7% airflow). Set both SW1−5 and SW4−3 to ON for nominal 370 CFM/ton (+7% airflow). The above adjustments in airflow are subject to motor horspower range/capacity.

2. Maximum cooling airflow is achieved when switches SW2−1, SW2−2, SW2−3 and SW1−5 are set to ON, and SW4−3 is set to OFF.

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

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

5. All airflows on 21” casing size furnaces are 5% less on side return only installations.

6. Side returns for 24.5” casing sizes require two sides, or side and bottom, to allow sufficient airflow at the return of the furnace.

440 04 4700 00 19

Specifications subject to change without notice.

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

Table 7

SECONDS G

FOR 1 REVOLUTION

10 360 720 1800 50 72 144 360 11 327 655 1636 51 71 141 355 12 300 600 1500 52 69 138 346 13 277 555 1385 53 68 136 340 14 257 514 1286 54 67 133 333 15 240 480 1200 55 65 131 327 16 225 450 1125 56 64 129 321 17 212 424 1059 57 63 126 316 18 200 400 1000 58 62 124 310 19 189 379 947 59 61 122 305 20 180 360 900 60 60 120 300 21 171 343 857 62 58 116 290 22 164 327 818 64 56 112 281 23 157 313 783 66 54 109 273 24 150 300 750 68 53 106 265 25 144 288 720 70 51 103 257 26 138 277 692 72 50 100 250 27 133 267 667 74 48 97 243 28 129 257 643 76 47 95 237 29 124 248 621 78 46 92 231 30 120 240 600 80 45 90 225 31 116 232 581 82 44 88 220 32 113 225 563 84 43 86 214 33 109 218 545 86 42 84 209 34 106 212 529 88 41 82 205 35 103 206 514 90 40 80 200 36 100 200 500 92 39 78 196 37 97 195 486 94 38 76 192 38 95 189 474 96 38 75 188 39 92 185 462 98 37 74 184 40 90 180 450 100 36 72 180 41 88 176 439 102 35 71 178 42 86 172 429 104 35 69 173 43 84 167 419 106 34 68 170 44 82 164 409 108 33 67 167 45 80 160 400 110 33 65 164 46 78 157 391 112 32 64 161 47 76 153 383 116 31 62 155 48 75 150 375 120 30 60 150 49 73 147 367

Gas Rate (CU ft./hr)

SIZE OF TEST DIAL

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

SECONDS

FOR 1 REVOLUTION

SIZE OF TEST DIAL

20 440 04 4700 00

Specifications subject to change without notice.

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

SERVICE AND MAINTENANCE PROCEDURES

! WARNING

FIRE, INJURY OR DEATH HAZARD

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

The ability to properly perform service and maintenance on this equipment requires certain knowledge, mechanical skills, tools, and equipment. If you do not possess these, do not attempt to perform any service and maintenance on this equipment other than those procedures recommended in the User’s Manual.

! CAUTION

ENVIRONMENTAL HAZARD

Failure to follow this caution may result in environmental pollution.

Remove and recycle all components or materials (i.e. oil, refrigerant, control board, etc.) before unit final disposal.

! WARNING

ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

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

Before installing, modifying, or servicing system, main electrical disconnect switch must be in the OFF position and install a lockout tag. There may be more than one disconnect switch. Lock out and tag switch with a suitable warning label. Verify proper operation after servicing.

! CAUTION

ELECTRICAL OPERATION HAZARD

Failure to follow this caution may result in improper furnace operation or failure of furnace.

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

General

These instructions are written as if the furnace is installed in an upflow application. An upflow furnace application is where the blower is located below the combustion and controls section of the furnace, and conditioned air is discharged upward. Since this furnace can be installed in any of the four positions shown in Figure 6, you must revise your orientation to component location accordingly.

Figure 6 Multipoise Orientations

A93041

Electrical Controls and Wiring

! WARNING

ELECTRICAL SHOCK HAZARD

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

There may be more than one electrical supply to the furnace. Check accessories and cooling unit for additional electrical supplies that must be shut off during furnace servicing. Lock out and tag switch with a suitable warning label.

The electrical ground and polarity for 115−v wiring must be properly maintained. Refer to Figure 7 for field wiring information and to Figure 15 for furnace wiring information.

NOTE: If the polarity is not correct, the STATUS LED on the control will flash code 10 and prevent the furnace from heating. The control system also requires an earth ground for proper operation of the control and flame−sensing electrode.

The 24−v circuit contains an automotive−type, 3−amp. fuse located on the control. (See Figure 3) Any shorts of the 24−v wiring during installation, service, or maintenance will cause this fuse to blow. If fuse replacement is required, use ONLY a 3−amp. fuse. The control LED display will be off when fuse needs replacing.

Troubleshooting

Refer to the service label. (See Figure 14—Service Label) The Troubleshooting Chart− Flow Chart (See Figure 16) can

be a useful tool in isolating furnace operation problems. Beginning with the word “Start,” answer each question and follow the appropriate arrow to the next item.

The Chart − Flow Chart will help to identify the problem or failed component. After replacing any component, verify correct operation sequence.

Proper instrumentation is required to service electrical controls. The control in this furnace is equipped with a Status Code LED (Light−Emitting Diode) to aid in installation, servicing, and troubleshooting. Status codes can be viewed at the sight glass in blower access door. The amber furnace control LED is either heartbeat, off or a code composed of 1 or 2 digits. The first digit is the number of short flashes, the second digit is the number of long flashes.

440 04 4700 00 21

Specifications subject to change without notice.

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

Figure 7 Heating and Cooling Application Wiring Diagram with Single−Stage Thermostat

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

FIELD-SUPPLIED

FUSED DISCONNECT

GND

CONDENSING

UNIT

208/230- OR 460-VOLT THREE PHASE

208/230VOLT SINGLE PHASE

BLOWER

DOOR

SWITCH

BLK

WHT

GND

115-VOLT FIELD-

SUPPLIED

FUSED

DISCONNECT

BLK

WHT

JUNCTION BOX

FIVE

WIRE

THREE-WIRE

HEATING-

ONLY

FURNACE

COM

O N

W/W1

Y/Y2

R O

24-VOLT

TERMINAL

BLOCK

NOTE 2

WC Y RG

NOTE 1

NOTES: 1.

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

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

3. same type or equivalent wire.

1-STAGE THERMOSTAT TERMINALS

For an explanation of status codes, refer to service label located on blower access door or Figure 14, and the

Caution must be taken when manually closing this switch for

service purposes. troubleshooting guide which can be obtained from your distributor.

Retrieving Stored Fault Codes

The stored status codes will NOT be erased from the control memory, when 115− or 24−v power is interrupted. The control will store up to the last 7 Status Codes in order of occurrence.

1. To retrieve status codes, proceed with the following:

NOTE: NO thermostat signal may be present at control, and all blower−OFF delays must be completed.

a. Leave 115−v power to furnace turned on. b. Look into blower door sight glass for current LED

status.

c. Remove blower door.

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

2. Turn Setup Switch, SW1−1 “ON.”

3. Manually close blower door switch.

4. Control will flash up to 7 Status Codes.

5. The last Status Code, or 8th Code, will be a heartbeat.

6. Turn SW1−1 “OFF.”

7. A heartbeat amber LED will appear and indicates proper operation.

8. Release blower door switch, install blower door and or refer to the SERVICE label for more information.

Component Self−Test

Component Test can ONLY be initiated by performing the following:

1. Remove blower door.

2. Remove the wire from the “R” terminal of the control board.

3. Turn Setup Switch, SW1−6 “ON.”

4. Manually close blower door switch.

ELECTRICAL SHOCK HAZARD

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

Blower door switch opens 115−v power to furnace control. No component operation can occur unless switch is closed. Exercise caution to avoid electrical shock from exposed electrical components when manually closing this switch for service purposes.

Component Test sequence will function as follows:

NOTE: The EAC terminals are energized when the blower is operating.

After the component test is completed, 1 or more status codes (heartbeat, 2+5, 3+5, 4+1, 4+2) will flash. See Service label on control door or Service/status Code instructions for explanation of status codes.

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

! WARNING

1. The furnace control CPU turns the inducer motor IDM ON at medium speed and keeps it ON through Step 4.

2. The furnace control CPU will test communication with the modulating gas valve GV.

3. After waiting 15 seconds the furnace control CPU turns the hot surface igniter ON for 15 seconds, then OFF.

4. The furnace control CPU then turns the blower motor BLWM ON at mid−range airflow for 15 seconds, then OFF.

5. After shutting the blower motor BLWM OFF the furnace control CPU shuts the inducer motor IDM OFF.

6. RELEASE BLOWER DOOR SWITCH, reattach wire to “R” terminal on furnace control board, replace blower door.

Blower door switch opens 115−v power to control. No component operation can occur unless switch is closed.

22 440 04 4700 00

Specifications subject to change without notice.

A11401

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

Care and Maintenance

! WARNING

FIRE OR EXPLOSION HAZARD

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

Never store anything on, near, or in contact with the furnace, such as:

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

2. Soap powders, bleaches, waxes or other cleaning compounds, plastic or plastic containers, gasoline, kerosene, cigarette lighter fluid, dry cleaning fluids, or other volatile fluids.

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

For continuing high performance and to minimize possible furnace failure, periodic maintenance must be performed on this furnace. Consult your local dealer about proper frequency of maintenance and the availability of a maintenance contract.

! WARNING

ELECTRICAL SHOCK AND FIRE HAZARD

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

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

! WARNING

CARBON MONOXIDE POISONING AND FIRE HAZARD

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

Never operate furnace without a filter or with filter access door removed.

! CAUTION

CUT HAZARD

Failure to follow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety glasses and gloves when handling parts, and servicing furnaces.

The minimum maintenance on this furnace is as follows:

1. Check and clean air filter each month or more frequently if required. Replace if torn.

2. Check blower motor and wheel for cleanliness each heating and cooling season. Clean as necessary.

3. Check electrical connections for tightness and controls for proper operation each heating season. Service as necessary.

4. Inspect burner compartment before each heating season for rust, corrosion, soot or excessive dust. If necessary, have furnace and burner serviced by a qualified service agency.

5. Inspect the vent pipe/vent system before each heating season for water leakage, sagging pipes or broken fittings. Have vent pipes/vent system serviced by a qualified service agency.

6. Inspect any accessories attached to the furnace such as a humidifier or electronic air cleaner. Perform any service or maintenance to the accessories as recommended in the accessory instructions.

Cleaning and/or Replacing Air Filter

The air filter arrangement will vary depending on the application.

NOTE: If the filter has an airflow direction arrow, the arrow must point towards the blower.

To clean or replace filters, proceed as follows:

! WARNING

ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

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

1. Turn off electrical supply to furnace.

2. Remove filter cabinet door.

3. Slide filter out of cabinet.

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

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

6. Slide filter into cabinet.

7. Replace filter cabinet door.

8. Turn on electrical supply to furnace.

Blower Motor and Wheel Maintenance

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

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

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

1. Turn off electrical supply to furnace.

2. Remove blower door.

3. All factory wires can be left connected, but field thermostat and accessory wiring may need to be disconnected depending on their length and routing.

4. If the vent and combustion air pipe passes through the blower compartment, it will be necessary to remove the pipes from the blower compartment.

Disconnect the vent and combustion air pipe by:

a. Loosen the clamps on the vent couplings and

combustion air pipe external to the furnace.

b. Separate the pipes from the couplings and move

them aside.

c. Loosen the clamps on the vent couplings and

combustion air pipe located on the blower shelf.

440 04 4700 00 23

Specifications subject to change without notice.

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

d. Separate the pipes from the blower compartment and

set aside.

e. Remove the couplings from the pipe adapters and set

aside.

f. After servicing the blower, reverse steps a through e.

g. Tighten all clamps 15 lb−in.

See Figure 8 for steps 5 through 14.

5. Remove screws securing blower assembly to blower shelf and slide blower assembly out of furnace. Detach ground wire and disconnect blower motor harness plugs from blower motor.

NOTE: Blower wheel is fragile. Use care.

6. Clean blower wheel and motor by using a vacuum with soft brush attachment. Be careful not to disturb balance weights (clips) on blower wheel vanes. Do not bend wheel or blades as balance will be affected.

7. If greasy residue is present on blower wheel, remove wheel from the blower housing and wash it with an appropriate degreaser. To remove wheel:

a. Mark blower wheel location on shaft before disassembly

to ensure proper reassembly.

b. Loosen setscrew holding blower wheel on motor shaft.

NOTE: Mark blower mounting arms and blower housing so each arm is positioned at the same hole location during reassembly.

c. Mark blower wheel orientation and cutoff plate location

to ensure proper reassembly.

d. Remove screws securing cutoff plate and remove cutoff

plate from housing.

e. Remove bolts holding motor mounts to blower housing

and slide motor and mounts out of housing.

f. Remove blower wheel from housing.

g. Clean wheel per instructions on degreaser cleaner. Do

not get degreaser in motor.

8. Reassemble motor and blower wheel by reversing items 7b through 7f. Ensure wheel is positioned for proper rotation.

9. Torque motor mounting bolts to 40 +/− 10 lb−in. when reassembling.

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

11. Verify that blower wheel is centered in blower housing and set screw contacts the flat portion of the motor shaft. Loosen set screw on blower wheel and reposition if necessary.

12. Spin the blower wheel by hand to verify that the wheel does not rub on the housing.

13. Reinstall blower assembly in furnace.

14. Reinstall two (2) screws securing blower assembly to blower deck.

15. Reconnect blower leads to furnace control. Refer to furnace wiring diagram, and connect thermostat leads if previously disconnected.

NOTE: Be sure to attach ground wire and reconnect blower harness plugs to blower motor.

Figure 8 Blower Assembly

MOTOR SHAFT FLAT

SET SCREW

GROMMET

MOTOR ARM

SCREW LOCATION

BLO HSG ASSY

BRACKET

BRACKET ENGAGEMENT

DETAIL A

SEE DETAIL A

CUTOFF, BLOWER

WHEEL, BLOWER

BRACKET

MOTOR WHEEL HUB

A11584A

SCREW

A11584B

A11584C

A11584D

BLOWER HSG ASSY

POWER CHOKE

OR CAPACITOR

WHEN REQUIRED

24 440 04 4700 00

Specifications subject to change without notice.

SCREW

(GND)

MOTOR, BLOWER

A11584E

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

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

! WARNING

ELECTRICAL SHOCK HAZARD

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

Blower access door switch opens 115−v power to furnace control. No component operation can occur unless switch is closed. Exercise caution to avoid electrical shock from exposed electrical components when manually closing this switch for service purposes.

16. Downflow or horizontal furnaces with vent pipe through furnace only:

a. Install and connect short piece of vent pipe inside

furnace to existing vent.

b. Connect vent connector to vent elbow.

17. Turn on electrical supply. If outdoor temperature is below 70_F (21_C), turn off circuit breaker to outdoor unit before running furnace in the cooling cycle. Manually close blower access panel door switch. Use a piece of tape to hold switch closed. Check for proper rotation and speed changes between heating and cooling by jumpering R to G and R to Y/Y2 on furnace control thermostat terminals. Turn outdoor circuit breaker on after completing cooling cycle. (See Figure 3)

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

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

the SERVICE label, located on the front of blower access door.

b. Verify blower is rotating in the correct direction

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

19. Downflow or horizontal furnaces with vent pipe through furnace only:

a. Install and connect short piece of vent pipe inside

furnace to existing vent.

b. Connect vent connector to vent elbow.

20. Reinstall outer door.

21. Turn on gas supply and cycle furnace through one complete heating cycle. Verify the furnace temperature rise as shown in Adjustments Section. Adjust temperature rise as shown in Adjustments Section.

Cleaning Burners and Flame Sensor

The following items must be performed by a qualified service technician. If the burners develop an accumulation of light dirt or dust, they may be cleaned by using the following procedure:

NOTE: Use a back-up wrench on the gas valve to prevent the valve from rotating on the manifold or damaging the mounting to the burner assembly.

Refer to Figure 9.

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

3. Remove outer doors and set aside.

4. Turn electric switch on gas valve to OFF.

5. Disconnect the gas pipe from gas valve and remove pipe from the furnace casing.

6. Disconnect the connector harness from gas valve.

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

8. Disconnect Flame Sensor wire from Flame Sensor.

9. Support the manifold and remove the four (4) screws that secure the manifold assembly to the burner assembly and set aside. Note the location of the green/yellow wire and ground terminal.

10. Inspect the orifices in the manifold assembly for blockages or obstructions. Remove orifice and clean or replace orifice.

11. Remove the four (4) screws that attach the top plate of the casing to the furnace.

12. Raise top plate up slightly and prop it up with a small piece of wood or folded cardboard.

13. Support the burner assembly and remove the screws that attach the burner assembly to the heat exchanger cell panel.

14. Remove wires from both rollout switches.

15. Slide one-piece burner assembly out of slots on sides of burner assembly.

16. Remove the flame sensor from the burner assembly.

17. (Optional) Remove the Hot Surface Igniter (HSI) and bracket from the burner assembly.

18. Check igniter resistance. Nominal resistance is 40 to 70 ohms at room temperature and is stable over the life of the igniter.

19. Clean burner assembly with a brush and a vacuum.

20. Clean the flame sensor with fine steel wool (0000 grade). Do not use sand paper or emery cloth.

To reinstall burner assembly:

1. Install the Hot Surface Igniter (HSI) and bracket in burner assembly.

2. Install flame sensor on burner assembly.

3. Align the edges of the one-piece burner assembly with the slots in the burner assembly and slide the burners forward until they are fully seated in the burner assembly.

4. Align the orifices in the manifold assembly with the support rings on the end of the burner.

5. Insert the orifices in the support rings of the burners.

NOTE: If manifold does not fit flush against the burner assembly, do not force the manifold on the burner assembly. The burners are not fully seated forward in the burner assembly. Remove the manifold and check burner positioning in the burner assembly before re-installing the manifold.

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

7. Install the remaining manifold mounting screws.

8. Check the igniter alignment. See Figure 9, Figure 10 and Figure 11.

440 04 4700 00 25

Specifications subject to change without notice.

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

Figure 9 Burner Assembly

BURNER SUPT. ASSY

BURNER ASSY

FLAME ROLL−OUT SWITCH

FLAME SENSOR

(

BELOW BURNER)

L11F064

Representative drawing only, some models may vary in appearance.

Figure 10 Igniter Position − Top View

1-1/4-in.

(31.8)

2-1/2-in.

(64.4)

A11405

9. Attach the wires to the roll-out switches.

10. Align the burner assembly with the openings in the primary cell inlet panel and attach the burner assembly to the cell panel.

11. Connect the wire for the flame sensor

12. Connect the wire for the Hot Surface Igniter.

NOTE: Use propane-resistant pipe dope to prevent leaks. Do not use Teflon tape.

13. Install the gas pipe to the gas valve.

! WARNING

FIRE OR EXPLOSION HAZARD

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

14. Check for gas leaks with a soap and water solution.

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

Figure 11 Igniter Position − Side View

2ïin.

50 mm

3/8ïin.

9.6 mm

3/16ïin.

4.6 mm

+ 1/32

1/10ïin.

ï 1/16ïin.

+0.8

2.5 mm ï1.5 mm

L12F041

16. Turn power on at external disconnect, fuse or circuit breaker.

17. Run the furnace through two complete heating cycles to check for proper operation

18. Install outer door when complete.

Servicing Hot Surface Igniter

The igniter does NOT require annual inspection. Check igniter resistance before removal. Refer to Figure 9, Figure 10 and Figure 11.

1. Turn off gas and electrical supplies to furnace.

2. Remove control door.

3. Disconnect igniter wire connection.

4. Check igniter resistance. Igniter resistance is affected by temperature. Only check resistance when the igniter is at room temperature.

a. Using an ohm meter, check resistance across both

igniter leads in connector.

b. Cold reading should be between 40 ohms and 70 ohms.

Resistance reading will increase as igniter temperature increases.

5. Remove igniter assembly. a. Using a 1/4−in. driver, remove the two screws securing

the igniter mounting bracket to the burner assembly. (See Figure 9)

b. Carefully withdraw the igniter and bracket assembly

through the front of the burner assembly without striking

the igniter on surrounding parts. c. Inspect igniter for signs of damage or failure. d. If replacement is required, remove the screw that

secures the igniter on igniter bracket and remove the

igniter.

6. To replace igniter and bracket assembly, reverse items 5a through 5e.

7. Reconnect igniter harness to the igniter, dressing the igniter wires to ensure there is no tension on the igniter itself. (See Figure 9)

26 440 04 4700 00

Specifications subject to change without notice.

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

8. Turn on gas and electrical supplies to furnace.

9. Verify igniter operation by initiating control board self−test feature or by cycling thermostat.

10. Replace control door.

Flushing Collector Box and Drainage System

1. Turn off gas and electrical supplies to furnace.

2. Remove control door.

3. Disconnect pressure switch tube from pressure switch port.

NOTE: Ensure the pressure switch tube disconnected from the pressure switch is higher than the collector box opening or water will flow out of tube.

4. Remove one of the collector box plugs from a port on the upper corner of the collector box. (See Figure 1)

5. Attach a funnel with a flexible tube to port on the collector box.

6. Flush inside of collector box with water until discharge from condensate trap is clean and runs freely.

7. Repeat steps 4 through 6 with middle plug on upper corner of collector box.

8. Remove the pressure switch tube from the collector box.

NOTE: Do Not blow into tube with tube connected to the pressure switch.

9. Clean pressure switch port on collect box with a small wire. Shake any water out of pressure switch tube.

10. Reconnect tube to pressure switch and pressure switch port.

11. Remove the relief tube from the port on the collector box and the trap.

12. Clean the relief port on collect box and the trap with a small wire. Shake any water out of the tube.

13. Reconnect relief tube to trap and collector box ports.

Cleaning Condensate Drain and Trap

NOTE: If the condensate trap is removed, a new gasket

between the trap and collector box is required. Verify a condensate trap gasket is included in the service kit or obtain one from your local distributor.

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

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

3. Remove outer doors and set aside.

4. Turn electric switch on gas valve to OFF.

5. Disconnect external drain from condensate drain elbow or drain extension pipe inside the furnace and set aside.

6. Disconnect the condensate trap relief hose from collector box port and condensate trap.

NOTE: If condensate has a heat pad attached to the trap, trace the wires for the pad back to the connection point and disconnect the wires for the heat pad.

7. Remove the screw that secures the condensate trap to the collector box, remove the trap and set aside.

8. Remove the trap gasket from the collector box if it did not come off when the trap was removed.

9. Discard the old trap gasket.

10. Rinse condensate trap in warm water until trap is clean.

11. Flush condensate drain lines with warm water. Remember to check and clean the relief port on the collector box.

12. Shake trap dry.

13. Clean port on collector box with a small wire.

To re-install Condensate Drain and Trap:

1. Remove adhesive backing from condensate trap gasket

2. Install gasket on collector box

3. Align the condensate trap with the drain opening on the collector box and secure the trap with the screw

4. Attach the relief hose to the relief port on the condensate trap and collector box.

5. Secure tubing to prevent any sags or traps in the tubing.

6. Connect condensate drain elbow or drain extension elbow to the condensate trap

7. Connect the leads of the condensate heat pad (if used)

8. Connect external drain piping to the condensate drain elbow or drain extension pipe.

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

10. Turn power on at external disconnect, fuse or circuit breaker.

11. Run the furnace through two complete heating cycles to check for proper operation

12. Install outer door when complete.

Checking Heat Pad Operation (If Applicable)

In applications where the ambient temperature around the furnace is 32_F (0_C) or lower, freeze protection measures are required. If this application is where heat tape has been applied, check to ensure it will operate when low temperatures are present.

NOTE: The Heat Pad, when used, should be wrapped around the condensate drain trap. There is no need to use heat tape within the furnace casing. Most heat tapes are temperature activated, and it is not practical to verify the actual heating of the tape. Check the following:

1. Check for signs of physical damage to heat tape such as nicks, cuts, abrasions, gnawing by animals, etc.

2. Check for discolored heat tape insulation. If any damage or discolored insulation is evident, replace heat tape.

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

Cleaning Heat Exchangers

The following items must be performed by a qualified service technician.

Primary Heat Exchangers

If the heat exchangers get an accumulation of light dirt or dust on the inside, they may be cleaned by the following procedure:

Figure 12 Cleaning Heat Exchanger Cell

NOTE: If the heat exchangers get a heavy accumulation of

soot and carbon, both the primary and secondary heat exchangers should be replaced rather than trying to clean them thoroughly due to their intricate design. A build−up of soot and carbon indicates that a problem exists which needs to be

440 04 4700 00 27

Specifications subject to change without notice.

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

corrected, such as improper adjustment of manifold pressure, insufficient or poor quality combustion air, improper vent termination, incorrect size or damaged manifold orifice(s), improper gas, or a restricted heat exchanger (primary or secondary). Action must be taken to correct the problem.

1. Turn off gas and electrical supplies to furnace.

2. Remove control door.

3. Disconnect wires or connectors to flame rollout switch, gas valve, igniter, and flame sensor.

4. Using backup wrench, disconnect gas supply pipe from furnace gas control valve.

5. Remove two screws attaching top filler panel and rotate upwards to gain access to screws attaching burner assembly to cell panel.

6. Remove screws attaching burner assembly to cell panel. (See Figure 9)

NOTE: Burner assembly, cover, manifold, gas valve, and burner assembly should be removed as one assembly.

7. Clean heat exchanger openings with a vacuum and a soft brush. (See Figure 12)

NOTE: After cleaning, inspect the heat exchangers to ensure they are free of all foreign objects that may restrict flow of combustion products.

8. Reverse items 6 through 1 for reassembly.

9. Refer to furnace wiring diagram and reconnect wires to flame rollout switch, gas valve, igniter, and flame sensor.

10. Turn on gas and electrical supplies to furnace.

11. Check furnace operation through 2 complete heat operating cycles. Look through sight glass in burner enclosure to check burners. Burner flames should be clear blue, almost transparent. (See Figure 13)

Figure 13 Burner Flame

Burner Flame

Burner

Manifold

A11461

! WARNING

FIRE OR EXPLOSION HAZARD

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

12. Check for gas leaks.

13. Replace control door.

Secondary Heat Exchangers

The condensing side (inside) of the secondary heat exchanger CANNOT be serviced or inspected without complete removal of the heat exchanger assembly. Detailed information on heat exchanger removal can be obtained from your Distributor.

Winterization

UNIT AND PROPERTY DAMAGE HAZARD

Failure to follow this caution may result in unit component or property damage.

If the furnace is installed in an unconditioned space where the ambient temperatures may be 32_ F (0_ C) or lower, freeze protection measures must be taken to prevent property or product damage.

Since the furnace uses a condensing heat exchanger, some water will accumulate in the unit as a result of the heat transfer process. Therefore, once it has been operated, it cannot be turned off and left off for an extended period of time when temperatures will reach 32_F (0_C) or lower unless winterized. Follow these procedures to winterize your furnace:

UNIT COMPONENT DAMAGE HAZARD

Failure to follow this caution may result in damage to the furnace and other property damage.

Do not use ethylene glycol (automotive antifreeze coolant or equivalent). Failure of plastic components may occur.

1. Obtain propylene glycol (RV/swimming pool antifreeze or equivalent).

2. Turn off gas and electrical supplies to your furnace.

3. Remove furnace control door.

4. Remove the top unused rubber plug from the port on the collector box opposite the condensate trap. (See Figure 1)

5. Connect a field supplied 3/8−in. (9.5−mm) ID tube to the open port on the collector box

6. Insert a field supplied funnel into the tube.

7. Pour one quart of anti−freeze solution into the funnel/tube. Antifreeze should run through the collector box, overfill condensate trap and flow to an open drain.

8. Replace the rubber plug in the port on the collector box.

9. Remove the middle unused rubber plug from the port on the collector box opposite the condensate trap. See Figure 1.

10. Repeat Steps 5 through 8.

11. If a condensate pump is used, check with pump manufacturer to verify pump is safe for use with antifreeze used. Allow pump to start and pump anti−freeze to open drain.

12. Replace main door.

13. When furnace is re−started, flush condensate pump with clear water to check for proper operation before re−starting furnace.

14. Propylene glycol need not be removed before re−starting furnace.

CAUTION

28 440 04 4700 00

Specifications subject to change without notice.

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

Figure 14 Service Label

338316−2 Rev I

440 04 4700 00 29

Specifications subject to change without notice.

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

Figure 15 Wiring Diagram

338316−2 Rev I

30 440 04 4700 00

Specifications subject to change without notice.

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

Figure 16 Troubleshooting Chart − Flow Chart

Guide

NONO

Close the door switch.

Is circuit breaker closed?

Check for continuity in wire from circuit

breaker to furnace.

Close circuit breaker and go back to

START.

Check roomthermostat or

interconnecting cable.

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

YES

Is doorswitch closed?

Isthere115Vgoingtoswitch?

Replacedoor switch.

Replace transformer.

The control is locked out and will auto-

reset after 1 hour. Lockout could be due

to any ofthe following:

- Flame sense circuit failure.

- Gas valverelay stuck open.

-Softwarecheckerror.

Resetpower to clear lockout. Replace

controlif code repeats.

Does the control respond to W/W1, W2,

YES

G thermostat terminals on the furnace

control?

Disconnectall the thermostatwires from

the furnace control.

YES

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

signals?

Run system through a minimum-heat,

maximum-heat, or cooling cycleto check

operation. Status codes are erased after

72 hours or can be manually erased by

putting setup switch SW1-1 in the ON

position and jumpering R, W/W1, and

Does the problem repeat when using a

jumper wire?

The thermostat is not compatible with the

furnace control. Either install a ballast

resistor, connect the Com24Vthermostat

terminal to the thermostat, or replace the

thermostat.

YES

Y/Y2 simultaneously untilthe heartbeat

flashes.

Replace furnace control.

Troubleshootin

YES

Is there 115V at L1 and L2?

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

YES YES YES

YES

Is the 24V fuse open?

Replacefuse then disconnect thermostat

leads to isolate short circuit.

Replace furnace control.

Check to make sure that the correct

model plug PL4 is installed. The rating

YES

The last status code has cleared. To

recalla previous statuscode disconnect

the R thermostat connection, reset

power,andputsetupswitchSW1-1in

the ON position. The AMBER LED will

flash the status codes in the order of

occurrence. Record status codes until

heartbeat flashes. After heartbeat

flashes several times the status codes

will repeat. Status codes are erased

after 72 hours or can be manually erased

by putting setup switch SW1-1 in the ON

position and jumpering R, W/W1, and

Y/Y2 simultaneously until the heartbeat

flashes. When done put setup switch

SW1-1 in the OFF position.

Was there a previous status code other

plate shows the correct model plug for

this furnace. Is the correct model plug

installed?

Replace model plug PL4.

YES

than theheartbeat?

YES

START

Is AMBER LED status light ON solid,

alternately flashing bright-dim-bright-dim

like a heartbeat, or flashing ON and

OFF?

Is AMBER LED status light ON solid?

Is AMBER LED status light alternately

flashing bright-dim-bright-dim like a

heartbeat?

Determine status code. The status code

is a single or two digit number with the

first number determined by the number of

short flashes and the second number

after the plus (+) sign is the number of

long flashes?

Go to section below for the status code

that was flashed.

440 04 4700 00 31

Specifications subject to change without notice.

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

Figure 16 (CONT.) Troubleshooting Guide − Flow Chart

or rough ignition.

Replace furnace control.

Check for continuity in the

harness and igniter. Replace

defective component.

Check that all gas valves are

Check connections. If OK,

turned on. Replace valve.

replace control.

Check for:

- Inadequate flame carryover

bracket.

Allow unit to drop to min-heat,

- Low inletgas pressure.

- Proper firing rate.

- Air leakage around igniter

and check manifold pressure.

Check connections and retry.

If current is near typical value

(4.0-6.0 nominal) and burners

will not stay on, repeat check

in maximum-heat. If burners

will still not stay on replace

control. If burners operate in

maximum-heatthen switch to

intermediate-heat, check

manifoldpressure. If OK,

check burner carryover and

Repeat test to check for

intermittent operation.

flame sensor location.

YES

failed to ignite gas and prove

flame in 4 attempts. Control will

auto-reset after 3 hours. Refer to

status code #6.

6 + 1 IGNITION LOCKOUT – System

(115V OR 24V) – Normal operation.

Blower runs for 90 seconds, if unit is

powered up during a call for heat (R-

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

during the blower on-delay period.

Unplug igniter harness from control and

repeat component test by turning setup

switch SW1-6 OFF and then back ON.

Check for 115V between pin 3 and

NEUTRAL-L2 on the control. Was 115V

Indicates the blower failedto reach 250

RPM or the blower failed to

communicate within 30 seconds after

beingturnedONintwosuccessiveheat

cycles. Control will auto-reset after 3

hours. Refertostatuscode#4+1.

present for the 15 second period?

Reconnect the R thermostat lead and set

thermostatto call for heat. Connect

voltmeter across gas valve BLUE and

GREEN/YELLOW wires. Does gas valve

receive 24V?

SETUP ERROR – If status code 2 + 5

only flashes 4 times on power-up the

control is missing its model plug PL4

and is defaulting to the model selection

stored in memory. If status code 2 + 5

flashes continuously it could indicate

any of the following:

- Model plugPL4 is missing and there

YES

is no validmodel stored in permanent

memory. This will happenif you

YES

Does gas valve open and allow gas to

flow?

Dothemainburnersignite?

forget to install the model plug PL4 on

a servicereplacement control.

- Thermostat call with SW1-1 ON.

- Thermostat call with SW1-6 ON.

- SW1-1 and SW1-6 both ON.

- Two different furnace models

twinned.

YES

Dothemainburnersstayon?

incorrect. Need modulating board

with software version V17 or later.

- Service replacement control is

modulatinggas valve failedto respond

YES

Clean flame sensor with fine steel wool

Repeat call for heat and check flame

sensor current during trial for ignition

period. Is the DC microamps below 0.5?

ORANGE wire at gas valve or PL8

to a command from the furnace control

connections.

or power to the gas valve electronics

was interrupted. Check for:

- Intermittent RED, YELLOW, or

and recheck current. Nominal current is

YES

4.0to6.0microamps.

Is current near typical value? Replace electrode.

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

Fixed.

YES

1+2 BLOWERONAFTERPOWERUP–

Check for:

- Obstructed pressure tube.

- Pressure switch stuck closed.

2 PRESSURE SWITCH DID NOT OPEN –

32 440 04 4700 00

3 LOW PRESSURE SWITCH DID NOT

1 + 5 BLOWER MOTOR LOCKOUT –

CLOSE OR REOPENED – If opens during

blower on-delay period, blower will come

on for the selected blower off-delay. If

opens within 5 minutes after ignition the

next heating cycle will be restricted to

maximum-heat. Check for:

2 + 5 INVALID MODEL SELECTION OR

71% of maximum

compartment.

tubing.

setupswitchSW1-3ONtoboost

inducer speed

-Properventsizing.

- Air leak between vestibule and blower

- Low inletgas pressure (if LGPS used).

- Restricted vent.

- Disconnected or obstructed pressure

- Defectiveor miswired pressure switches

- Excessive wind. If problem persists turn

Specifications subject to change without notice.

pipe.

- Plugged condensate drain.

- Water in vent piping, possible sagging

limit or a flame rollout switch is open or the

furnace is operating in maximum-heat only

mode due to 2 successive limit trips while

operating at any rate <

rate. Blower will run for 4 min. or until

open switch remakes whichever is longer.

4 LIMIT CIRCUIT FAULT – Indicates the

3 + 5 GAS VALVE FAULT – Indicates the

If openlonger than 3 min.,code changes

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

status code #4 continues to flash until

blower shuts off. Flame rollout switch

gas input adjustment.

requires manual reset. Check for:

- Defective switch or connections.

- Improper minimum- or maximum-heat

- Improper limit switch or no limit gasket.

- Loose blower wheel.

Flame is proved while gas valve is de-

energized. Inducer will run until fault is

cleared. Check for:

- Dirty filter or restricted duct system.

- Stuck open or leaky gas valve.

5 ABNORMAL FLAME-PROVING SIGNAL

To determine whether the problem is in the gas

valve, igniter, or flame sensor the system can be

operated in component test mode. To check the

igniter remove the R thermostat connection from

the control, reset power, and put setup switch

SW1-6 in the ON position to start the

component test. Does the igniter glow

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

not sensedduring the trialfor ignition

period, the control will repeat the ignition

sequence 3 more times before lockout #6 +

1 occurs. If flame signal is lost during the

blower on-delay period, blower will come on

for the selected blower off-delay. Check

6 IGNITION PROVING FAILURE – If flame is

the following before going to the next step.

connected to furnace sheet metal.

- Gas valveturned off.

- GREEN/YELLOW wire MUST be

- Manual shut-off valve.

up period?

- Flame sensormust not be grounded.

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

Figure 16 (CONT.) Troubleshooting Chart − Flow Chart

YES

Youhaveanopenwireorbad

terminalon either theBLACK or

WHITE power leads between

the furnace control and the

blower motor. If you have a

power choke disconnect it and

check continuity.

Youhaveanopenwireorbad

terminal on either the RED or

GREEN wire between the

furnace control and the blower

motor.

YES

Turn power back on. Is there 115VAC at

PL14-5 and PL14-4?

Is there 12-VDC at PL13-1 RED (+) and

PL13-4 GREEN (-)?

Is there 12-VDC at PL3-1 RED (+) and

PL3-2 GREEN (-)?

Replace the furnace control.

YES

Is there 5-VDC at PL3-3

YES

YELLOW (+) and PL3-2

GREEN (-)?

Youhaveanopenwireorbad

terminal on the YELLOW wire

between the furnace control and

the blower motor.

YES

Is there 5-VDC at PL13-2 YELLOW (+)

and PL13-4 GREEN (-)?

The voltage just measured should be

very stable and should not fluctuate more

than .02-VDC. If the voltage fluctuates

more than this get a different voltmeter

before proceeding.

Turn poweroff, reconnect PL13 and

PL14 to the blower motor, then turn

power back on. Connect a DC voltmeter

Turn power off, disconnect PL13 and

PL14 from the blower motor, then turn

power back on. Connect a DC voltmeter

across PL13-3 BLUE (+) and PL13-4

GREEN(-). Thevoltageshouldbenear

0-VDC but it will fluctuate briefly several

times a second. If you havean analog

voltmeter the needle will briefly go high

several times a second. If you have a

digitalvoltmeter with a bar graph it will

show alarge change in magnitude on the

bar graphseveral timesa second. If you

have a standard digital voltmeter it will

show a brief fluctuationin voltage and the

magnitude may vary depending on the

across PL3-3 YELLOW (+) and PL3-2

GREEN (-). Does the voltage fluctuate

more than it did in the previous step?

voltmeter used.

YES

4 + 1 BLOWER MOTOR FAULT – Indicates

7 LIMIT CIRCUIT LOCKOUT – Lockout

theblowerfailedtoreach250RPMor

the blower failed to communicate within

the prescribed time limits. Thirty

seconds after being turned ON or ten

secondsduring steady-stateoperation.

Turn power off and check the following

items first before proceeding to the next

step.

motor.

- Rubbing blower wheel.

- Loose blower wheel.

- Wiring from furnace control to blower

Remove the R thermostat connection

from the furnace control, disconnect

both connectors from the blower motor

PL13 and PL14. Does the blower wheel

turn freely?

Replace the blower control module attached to

the blower motor. Follow theinstructionswith

the blower control module to make sure the

entire blower motor does not need to be

replaced.

You have an open wire or bad terminal on the

BLUE wirebetween the furnacecontrol and the

blowermotor.

Replace the furnace control.

Connect a DC voltmeter across PL3-4 BLUE

(+) and PL3-2 GREEN (-). Does the voltage

fluctuate as described two steps back?

YES

Does the voltage fluctuate as described in the

previous step?

Replace the blower control module attached to

the blower motor. Follow theinstructionswith

the blower control module to make sure the

entire blower motor does not need to be

replaced.

YES

tubing.

used).

the inducer motor has not started within

20 seconds after a callfor heat, the

inducer motor RPM is outside its valid

range ofoperation, or theinducer RPM

signal was lost for 5 seconds during

operation. Check for:

- Proper vent sizing.

- Failed inducer motor.

- Restricted combustion air supply.

- Impropermotor wiring.

SWITCH OPEN WHILE MEDIUM OR

HIGH PRESSURE SWITCH IS

CLOSED - Check for:

- Low or Med press. switch stuck open.

- Disconnected or obstructed pressure

PRESSURE SWITCH OR PSR RELAY

DID NOT CLOSE OR REOPENED -

Check for:

- PSR relay may be defective.

- Refer to status code #3.

voltage polarity. If units are twinned,

check for proper low-voltage(24V)

occurs if the limit or flame rollout switch is

open longer than 3 minutes or 10

successive limit trips occurred during

maximum-heat. Control willauto-reset

after 3 hours. Refer to status code #4.

NOT auto reset. Turn off powerand wait

5 minutes to retry. Check for:

- Stuck closed gas valve relay on control.

- Miswire or short to gas valve BLUE wire.

8 GAS HEATING LOCKOUT – Control will

9 MEDIUM PRESSURE SWITCH, HIGH

transformer phasing.

10 POLARITY – Check for correct line

4 + 2 INDUCER MOTOR FAULT – Indicates

4 + 3 LOW OR MEDIUM PRESSURE

- Improper pressure switch wiring.

pipe.

- Low inletgas pressure (ifLGPS

- Plugged condensate drain.

- Water in vent piping, possible sagging

440 04 4700 00 33

Specifications subject to change without notice.

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

SEQUENCE OF OPERATION

CAUTION

UNIT OPERATION HAZARD

Failure to follow this caution may result in intermittent unit operation.

Furnace control must be grounded for proper operation or control will lock out. Control is grounded through green/yellow wire routed to gas valve and manifold bracket screw.

Using the schematic diagram (See Figure 15), follow the sequence of operation through the different modes. Read and follow the wiring diagram very carefully!!

NOTE: If a power interruption occurs during a call for heat (W/W1 or W/W1-and-W2), the control will start a 90-second blower-only ON period two seconds after power is restored, if the thermostat is still calling for gas heating. The amber LED light will flash code 1+2 during the 90-second period, after which the LED flash a heartbeat (bright−dim), as long as no faults are detected. After the 90-second period, the furnace will respond to the thermostat normally.

The blower door must be installed for power to be conducted through the blower door interlock switch ILK to the furnace control CPU, transformer TRAN, inducer motor IDM, blower motor BLWM, hot surface igniter HSI, and gas valve GV.

Communicating Control and Modulating Heating (Adaptive Mode)

Best comfort will be attained when a communicating wall control is used with this product. Wiring and setup instructions are provided with the communicating control. See the furnace data sheet accessory section for help in selecting the appropriate communicating control for this furnace.

When a communicating control is used, the furnace will modulate through its full operation range, or can be limited via the minimum and maximum CFM capacity configurations.

Operation of the furnace at the beginning and end of each heating cycle will be the same as detailed below in the Single-Stage Thermostat section, EXCEPT that the communicating control will send modulating rate command signals through the communication bus rather than energizing the 24−V thermostat terminals. Note that the R to W/W1 circuit signal will be controlled by the COMMR relay on the furnace control. See the wiring diagram in Figure 15.

Single-Stage Thermostat and Modulating Heating (Adaptive Mode)

NOTE: Minimum-heat only switch SW1-2 selects the

minimum-heat only operation mode when ON. Intermediate-heat only switch SW4-2 selects intermediate-heat only operation mode when ON. If both switches are ON the furnace control will default to intermediate-heat. If either or both switches are ON, the furnace control will operate at two-stages only as referenced in Two Stage Thermostat section below. If both switches are OFF the furnace control will operate in the adaptive heating mode in response to a call for heat. (See Figure 15) When the W2 thermostat terminal is energized it will always cause maximum-heat operation as long as the R to W circuit is closed, regardless of the setting of the minimum-heat or intermediate-heat only switches.

This furnace can operate as a modulating furnace with a single-stage thermostat because the furnace control CPU includes a programmed adaptive sequence of controlled operation, which selects a modulated rate between minimumand maximum-heat. This selection is based upon the stored history of the length of previous gas-heating periods of the single-stage thermostat.

The furnace will start up in either intermediate-, or maximum-heat. The furnace will transition and operate at minimum-heat or the calculated modulating rate after starting and operating for 45 seconds at intermediate-heat. The furnace control CPU defaults to minimum-heat on the first thermostat cycle and calculates the modulating rate that the furnace should run at for 19 minutes on subsequent heat cycles.

If the power is interrupted, the stored modulating rate is erased and the furnace control will select intermediate-heat for 45 seconds, minimum-heat for 19 minutes and then switch to maximum-heat, as long as the thermostat continues to call for heat. The furnace control CPU then uses this information to calculate the modulating rate the furnace will operate at on the next heating cycle. If the calculated modulating rate is between 40% - 99% then the furnace control CPU will operate for 45 seconds at intermediate-heat, and then operate at the calculated modulating rate for up to 19 minutes and then switch to maximum-heat as long as the thermostat continues to call for heat. If the calculated modulating rate is 100% then the furnace control will only operate at maximum-heat until the thermostat is satisfied.

The wall thermostat ”calls for heat”, closing the R to W circuit. The furnace control CPU performs a self-check, verifies the low, medium, and high pressure switch contacts LPS,MPS, and HPS are open, then de-energizes the PSR relay to close the NC contact.

1. Inducer Prepurge Period  The furnace control CPU turns on inducer motor IDM and slowly increases the inducer motor speed. After the low pressure switch LPS closes the furnace control CPU continues to increase the inducer motor speed until the medium pressure switch MPS closes. When the medium pressure switch MPS closes, inducer motor RPM is noted by the furnace control CPU, and a 25-second prepurge period begins. The RPM is used to evaluate vent system resistance. This evaluation is then used to determine the required RPM necessary to operate the inducer motor during pre-purge, the first 45 seconds of intermediate-heat, or any modulating rate that the furnace will transition to after the blower on-delay is completed.

NOTE: The heat cycle can start in either intermediate- or maximum-heat. If a maximum-heat cycle is initiated, the furnace control CPU will continue to increase the inducer motor speed after the medium pressure switch MPS closes. When the medium pressure switch closes, inducer motor RPM is noted by the furnace control CPU, and a 25-second prepurge period begins. The RPM is used to evaluate vent system restriction. This evaluation is then used to determine the required RPM necessary to operate the inducer motor in maximum-heat pre-purge, or maximum-heat. The high pressure switch HPS should be closed before ignition but the furnace control ignores this input until after ignition occurs.

2. Igniter Warm-Up - At the end of the prepurge period, the Hot-Surface Igniter HSI is energized for a 17-second igniter warm-up period

3. Trial-For-Ignition Sequence  When the igniter warm-up period is completed the main gas valve relay contact GVR closes to energize the gas valve solenoid GV. The gas valve solenoid GV permits gas flow to the burners where it is ignited. Five seconds after the GVR closes, a 2-second Flame-Proving period begins. The HSI igniter will remain energized until flame is sensed or until the 2-second flame proving period begins.

4. Flame-Proving - When the burner flame is proved at the flame-proving sensor electrode FSE, the furnace control CPU begins the blower-ON delay period and continues to hold the gas valve GV open. If the burner flame is not proved within two seconds, the furnace control CPU will

34 440 04 4700 00

Specifications subject to change without notice.

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

close the gas valve GV, and the furnace control CPU will repeat the ignition sequence for up to three more Trials-For-Ignition before going to Ignition-Lockout. Lockout will be reset automatically after three hours, or by momentarily interrupting 115 vac power to the furnace, or by interrupting 24 vac power at SEC1 or SEC2 to the furnace control CPU (not at W/W1, G, R, etc.). If flame is proved when flame should not be present, the furnace control CPU will lock out of Gas-Heating mode and operate the inducer motor IDM at full speed until flame is no longer proved.

5. Inducer Speed Change - If the cycle starts in intermediate-heat, the furnace control CPU reduces the inducer speed slightly after flame sense. If cycle starts in maximum-heat, the furnace control CPU increases the inducer speed after flame sense.

6. Blower-On delay — If the burner flame is proven, the blower-ON delay for intermediate-heat and maximum-heat are as follows: Intermediate-heat - 45 seconds after the gas valve GV is opened the blower motor BLWM is turned ON at the modulating heat airflow. Maximum-heat - 25 seconds after the gas valve GV is opened the BLWM is turned ON at maximum-heat airflow. Simultaneously, the humidifier terminal HUM and electronic air cleaner terminal EAC-1 are energized and remain energized throughout the heating cycle.

7. Switching from Intermediate-Heat to a Low Range Input - If the furnace control CPU switches from intermediate-heat to a low range input (low range input is an input rate less than or equal to 51% of full rate), the furnace control CPU will turn the blower ON or switch to the modulating heat airflow, energize the PSR relay to open the NC contact, and slowly decrease the inducer motor speed to the desired inducer RPM.

Switching from a Intermediate-Heat to a Medium Range Input - If the furnace control CPU switches from

intermediate-heat to a different medium range input (medium range input is an input rate between 52% and 71% of full rate), the furnace control CPU will turn the blower ON or switch to the modulating heat airflow, and continue to maintain the inducer motor speed or change it further if required.

Switching from a Intermediate-Heat to a High Range Input - If the furnace control CPU switches from

intermediate-heat to a high range input (high range input is an input rate greater than or equal to 72% of full rate), the furnace control CPU will turn the blower ON or switch to the modulating heat airflow, and increase the inducer motor speed to the desired inducer motor RPM.

Switching from Low Range Input to Maximum-Heat -

If the furnace control CPU switches from a low range input to maximum-heat, the furnace control CPU will de-energize the PSR relay to close the NC contact and slowly increase the inducer motor speed until the medium pressure switch MPS closes. When the medium pressure switch MPS closes the inducer motor RPM is noted by the furnace control CPU. The RPM is used to evaluate vent system resistance. This evaluation is then used to determine the required RPM necessary to operate the inducer motor at maximum-heat. The blower motor BLWM will transition to maximum-heat airflow five seconds after the furnace control CPU switches from a low range input to maximum-heat. As the inducer RPM increases, the high pressure switch HPS should close.

Switching from Medium Range Input to Maximum-Heat - If the furnace control CPU switches

from medium range input to maximum-heat, the furnace control CPU will increase the inducer motor speed to the maximum-heat inducer motor RPM. The blower motor BLWM will transition to the maximum-heat airflow five seconds after the furnace control CPU switches from a medium range input to maximum-heat. As the inducer RPM increases, the high pressure switch HPS should close.

8. Blower-Off Delay — When the thermostat is satisfied, the R to W circuit is opened, de-energizing the gas valve GV, stopping gas flow to the burners, and humidifier terminal HUM. The inducer motor IDM will remain energized for a 15-second post-purge period. The blower motor BLWM and air cleaner terminal EAC-1 will remain energized at minimum-heat airflow or transition to minimum-heat airflow for 90, 120, 150, or 180 seconds (depending on selection at blower-OFF delay switches). The furnace control CPU is factory-set for a 120-second blower- OFF delay.

Two-Stage Thermostat and Modulating Heating (Adaptive Mode)

Operation of Modulating Heating (Adaptive Mode; SW1-2 and SW4-2 are both OFF) with a two-stage thermostat is the same as with a single-stage thermostat, EXCEPT for the following:

If the two-stage thermostat R to W2 circuit closes along with the R to W/W1 circuit, while the furnace is operating at any capacity less than maximum, the furnace will switch to the maximum heating capacity. At this point, the furnace control heating algorithm is overridden and the two-stage thermostat takes control of staging until BOTH R to W/W1 and R to W2 circuits are opened.

The furnace will transition back to the lower heating capacity if the two-stage thermostat opens the R to W2 circuit, but leaves R to W/W1 circuit closed. The furnace control will continue to follow the commands from the two-stage thermostat for W/W1 and W2, until the R to W/W1 circuit is opened.

After the two-stage thermostat opens both the R to W/W1 and R to W2 circuits, the adaptive algorithm will set the beginning capacity of the next heating cycle to the same value as the heating cycle that most recently completed.

Two-Stage Thermostat and Two-Stage Minimum/Maximum Heating

NOTE: In this mode, the minimum-heat only switch SW1-2

must be ON to select the minimum-heat only operation mode in response to closing the thermostat R to W1 circuit. Closing the thermostat R to W1-and-W2 circuits always causes maximum-heat operation, regardless of the setting of the minimum-heat only switch.

The furnace will start up in either intermediate-, or maximum-heat. The furnace will operate in minimum-heat after starting and operating for 1 minute at intermediate-heat before transitioning to minimum-heat.

The wall thermostat ”calls for heat”, closing the R to W1 circuit for minimum-heat or closing the R to W1-and-W2 circuits for maximum-heat. The furnace control performs a self-check, and verifies the low, medium and high pressure switch contacts LPS, MPS and HPS are open, then de-energizes the PSR relay to close the NC contact.

The start up and shut down functions and delays described above apply to the two-stage minimum/maximum heating mode as well, except for switching from maximum- to minimum-heat.

1. Switching from Maximum- to Minimum-Heat — If the thermostat R to W2 circuit opens, and the R to W1 circuit remains closed, the furnace control CPU will gradually decrease the inducer motor speed to the required intermediate-heat RPM. When the inducer motor IDM reduces pressure sufficiently, the high pressure switch

440 04 4700 00 35

Specifications subject to change without notice.

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

HPS will open and the gas rate will be changed to intermediate-heat. The gas valve solenoid GV will remain energized as long as the low pressure switch LPS remains closed. When the inducer motor speed gets within 15% of the required intermediate-heat RPM the furnace control CPU will start a 5 second blower airflow change delay. After the 5 second blower airflow change delay is completed the blower airflow will transition to minimum-heat airflow. At this point the furnace control CPU will energize the PSR relay to open the NC contact and slowly decrease the inducer motor speed to the required minimum-heat RPM. When the PSR relay is energized and the NC contact opens the furnace control CPU will reduce the gas rate to minimum-heat RPM.

Two-Stage Thermostat and Two-Stage Intermediate/ Maximum Heating

NOTE: In this mode the intermediate-heat only switch SW4-2

must be ON to select the intermediate-heat only operation mode in response to closing the thermostat R to W1 circuit. Closing the thermostat R to W1-and-W2 circuits always causes maximum-heat operation, regardless of the setting of the intermediate-heat only switch.

The wall thermostat ”calls for heat”, closing the R to W1 circuit for intermediate-heat or closing the R to W1-and-W2 circuits for maximum-heat. The furnace control performs a self-check, and verifies the low, medium and high pressure switch contacts LPS, MPS and HPS are open , then de-energizes the PSR relay to close the NC contact.

The start up and shut down functions and delays described above apply to the 2-stage intermediate/maximum heating mode as well, except for switching from maximum- to intermediate-heat.

1. Switching from Maximum- to Intermediate-Heat — If the thermostat R to W2 circuit opens, and the R to W1 circuit remains closed, the furnace control CPU will gradually decrease the inducer motor speed to the required intermediate-heat RPM. When the inducer motor IDM reduces pressure sufficiently, the high pressure switch HPS will open and the gas rate will be changed to intermediate-heat. When the inducer motor speed gets within 15% of the required intermediate-heat RPM the furnace control CPU will start a 5 second blower airflow change delay. After the 5 second blower airflow change delay is completed the blower airflow will transition to intermediate-heat airflow.

Cooling Mode

The thermostat “calls for cooling.”

1. Single-Speed Cooling

The thermostat closes the R to G-and-Y circuits. The R to Y circuit starts the outdoor unit, and the R to G-and-Y/Y2 circuits start the furnace blower motor BLWM on cooling airflow. Cooling airflow is based on the A/C selection shown in Figure 4, Table 3 and Table 6.

The electronic air cleaner terminal EAC-1 is energized with 115 vac when the blower motor BLWM is operating. When the thermostat is satisfied, the R to G-and-Y circuits are opened. The outdoor unit will stop, and the furnace blower motor BLWM will continue operating at cooling airflow for an additional 90 seconds. Jumper Y/Y2 to DHUM to reduce the cooling off-delay to 5 seconds. (See Figure 3).

Two−Stage Thermostat and Two-Speed Cooling

The thermostat closes the R to G-and-Y1 circuits for low cooling or closes the R to G-and-Y1-and-Y2 circuits for high cooling. The R to Y1 circuit starts the outdoor unit on low cooling speed, and the R to G-and-Y1 circuit starts the furnace blower motor BLWM at low-cooling airflow which is the true on-board CF selection as shown in Figure 4, Table 3 and

Table 6. The R to Y1-and-Y2 circuits start the outdoor unit on

36 440 04 4700 00

Specifications subject to change without notice.

high-cooling speed, and the R to G-and-Y/Y2 circuits start the furnace blower motor BLWM at high-cooling airflow. High-cooling airflow is based on the A/C selection shown in Figure 4, Table 3 and Table 6.

The electronic air cleaner terminal EAC-1 is energized with 115 vac whenever the blower motor BLWM is operating.

When the thermostat is satisfied, the R to G-and-Y1 or R to G-and-Y1-and-Y2 circuits are opened. The outdoor unit stops, and the furnace blower BLWM and electronic air cleaner terminal EAC-1 will remain energized for an additional 90 seconds. Jumper Y1 to DHUM to reduce the cooling off-delay to 5 seconds. (See Figure 3)

Dehumidification Mode

The dehumidification output, H on the Thermostat should be connected to the furnace control thermostat terminal DHUM. When there is a dehumidify demand, the DHUM input is activated, which means 24 vac signal is removed from the DHUM input terminal. In other words, the DHUM input logic is reversed. The DHUM input is turned ON when no dehumidify demand exists. Once 24 vac is detected by the furnace control on the DHUM input, the furnace control operates in Thermostat mode. If the DHUM input is low for more than 48 hours, the furnace control reverts back to non-Thermostat mode.

The cooling operation described above in the Cooling Mode section also applies to Dehumidification Mode. The exceptions are listed below:

1. Low cooling – When the R to G-and-Y1 circuit is closed and there is a demand for dehumidification, the furnace blower motor BLWM will drop the blower airflow to 86% of low cooling airflow which is the true on-board CF

selection as shown in Figure 4, Table 3 and Table 6.

2. High cooling – When the R to G-and Y/Y2 circuit is closed and there is a demand for dehumidification, the furnace blower motor BLWM will drop the blower airflow to 86% of high-cooling airflow. High-cooling airflow is based on the A/C selection shown in Figure 4, Table 3

and Table 6.

3. Cooling off-delay – When the “call for cooling” is satisfied and there is a demand for dehumidification, the cooling blower-off delay is decreased from 90 seconds

to 5 seconds.

Continuous Blower Mode

When the R to G circuit is closed by the thermostat, the blower motor BLWM will operate at continuous blower airflow. Continuous blower airflow selection is initially based on the CF selection shown in Figure 4, Table 3 and Table 6. Factory default is shown in Figure 4, Table 3 and Table 6. Terminal EAC-1 is energized as long as the blower motor BLWM is energized.

During a call for heat, the furnace control CPU will transition the blower motor BLWM to continuous blower airflow, minimum-heat airflow, or the mid-range airflow, whichever is lowest. The blower motor BLWM will remain ON until the main burners ignite then shut OFF and remain OFF for the blower-ON delay (45 seconds in intermediate heat, and 25 seconds in maximum-heat), allowing the furnace heat exchangers to heat up more quickly, then restarts at the end of the blower-ON delay period at modulating or maximum-heat airflow respectively.

The blower motor BLWM will revert to continuous-blower airflow after the heating cycle is completed. When the thermostat satisfies, the furnace control CPU will drop the blower motor BLWM to minimum-heat airflow during the selected blower-OFF delay period before transitioning to continuous-blower airflow.

When the thermostat “calls for low-cooling”, the blower motor BLWM will operate at low-cooling airflow. When the thermostat

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

is satisfied, the blower motor BLWM will operate an additional 90 seconds at low-cooling airflow before transitioning back to continuous-blower airflow.

When the thermostat “calls for high-cooling”, the blower motor BLWM will operate at high cooling airflow. When the thermostat is satisfied, the blower motor BLWM will operate an additional 90 seconds at high-cooling airflow before transitioning back to continuous-blower airflow.

When the R to G circuit is opened, the blower motor BLWM will continue operating for an additional 5 seconds, if no other function requires blower motor BLWM operation.

Heat Pump

See Thermostat Instructions for thermostat connections. When installed with a heat pump, the furnace control automatically changes the timing sequence to avoid long blower off times during demand defrost cycles. Whenever W/W1 is energized along with Y1 or Y/Y2, the furnace control CPU will transition to or bring on the blower motor BLWM at cooling airflow, minimum-heat airflow, or the mid-range airflow, whichever is

lowest. The blower motor BLWM will remain on until the main burners ignite then shut OFF and remain OFF for 25 seconds before coming back on at modulating heat airflow. When the W/W1 input signal disappears, the furnace control begins a normal inducer post-purge period while changing the blower airflow. If Y/Y2 input is still energized the furnace control CPU will transition the blower motor BLWM airflow to cooling airflow. If Y/Y2 input signal disappears and the Y1 input is still energized the furnace control CPU will transition the blower motor BLWM to low-cooling airflow. If both the Y1 and Y/Y2 signals disappear at the same time, the blower motor BLWM will remain on at minimum-heat airflow for the selected blower-OFF delay period. At the end of the blower-OFF delay, the blower motor BLWM will shut OFF unless G is still energized, in which case the blower motor BLWM will operate at continuous blower airflow.

Component Self Test

Refer to page 22 for instructions.

440 04 4700 00 37

Specifications subject to change without notice.

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

PARTS REPLACEMENT INFORMATION GUIDE

Casing Group

Control door Blower door Top filler plate Bottom filler plate Door Knob Assembly

Electrical Group

Control box Junction box Limit switch(es) Circuit board Door switch Transformer 3−Amp fuse Flame Rollout Switch Main Wiring Harness Blower Motor Harness (when used)

Filter Group

Filter(s)

Blower Group

Cut−off Plate Blower housing Blower motor Blower wheel Capacitor (when used) Capacitor strap (when used) Power choke (when used)

Gas Control Group

Manifold Burner Orifice Flame sensor Hot surface igniter Gas valve

Heat Exchanger Group

Primary Heat Exchanger assembly Primary Heat Exchanger cell panel Secondary Heat Exchanger assembly Coupling box Containment Plate Tubing Gaskets

Inducer Group

Pressure switch(es) Inducer assembly Inducer Inducer motor Motor Module (when used) Inducer motor capacitor (when used) Collector box Condensate trap Condensate trap elbow Gaskets

WARNING

FIRE, EXPLOSION, ELECTRICAL SHOCK AND CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in dangerous operation, personal injury, death or property damage. Improper installation, adjustment, alteration, service, maintenance, or use can cause carbon monoxide poisoning, explosion, fire,

electrical shock, or other conditions which may cause personal injury or property damage. Consult a qualified installer, service agency, local gas supplier, or your distributor or branch for information or assistance. The qualified installer or agency must use only factory-authorized and listed kits or accessories when modifying this product.

Have available the product/model number and the serial number located on the unit rating plate to ensure correct replacement parts.

TO OBTAIN INFORMATION ON PARTS: Consult your installing dealer or the classified section of your local telephone directory under the “Heating Equipment“ or “Air Conditioning Contractors and Systems” headings for dealer listing by brand name.

38 440 04 4700 00

Specifications subject to change without notice.

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

PRODUCT NOMENCLATURE

DIGIT POSITION

G = Mainline Look 1 F = Mainline Look 2 N = Entry 9 = 90% − 100% EFFICIENCY M = Multiposition H = Horizontal U = Upflow D = Downflow A = Modulating Variable Speed ECM V = Variable Speed X = ECM S = Single−stage T = Two−stage B = Base AFUE Efficiency E = Extra AFUE Efficiency C = Communicating D = Dual Certified 2−pipe or 1−pipe R = 2−pipe only S = Single−stage T = Two−stage N = Standard L = Low Nox 060 = 60,000 BTU/hr 080 = 80,000 BTU/hr 100 = 100,000 BTU/hr 120 = 120,000 BTU/hr 14 = 14−3/16” 17 = 17−1/2” 21 = 21” 24 = 24−1/2” 10 = 1000 CFM (max) 14 = 1400 CFM (max) 16 = 1600 CFM (max) 20 = 2000 CFM (max) 22 = 2200 CFM (max) SALES (MAJOR) REVISION DIGIT ENGINEERING (MINOR) REVISION DIGIT

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

9 M A E 060 17 14 A 1

FEATURE

INPUT HEAT

CABINET WIDTH

COOLING AIRFLOW

International Comfort Products, LLC

Consumer Relations Department

P.O. Box 128

Lewisburg, TN 37091, USA

931−270−4100

440 04 4700 00 39

Specifications subject to change without notice.

International Comfort Products G9MAE0601714A, G9MAE0602120A, G9MAE0801714A, G9MAE0802120A, G9MAE1002122A TECHNICAL MANUAL

Specifications and Main Features

Frequently Asked Questions

User Manual