ICP N9MP1 Service Manual
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ICP N9MP1 Service Manual

ICP N9MP1 Service Manual

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See also: User's Information Manual , Instruction and Installation Manual
MULTI POSITION
SINGLE STAGE
GAS FURNACES
N9MP1, N9MP2 & *9MPD
"A1 & A2"
This manual supports condensing gas furnaces manufactured in 2001
Manufactured by:
Part Number
440 08 2001 02
4/2002
ã 2001 International Comfort Products Corporation (USA)

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  • Page 1 MULTI POSITION SINGLE STAGE GAS FURNACES N9MP1, N9MP2 & *9MPD “A1 & A2” This manual supports condensing gas furnaces manufactured in 2001 Manufactured by: Part Number 440 08 2001 02 4/2002 ã 2001 International Comfort Products Corporation (USA)
  • Page 2 N9MP1 - - Indoor combustion air (1 pipe only) N9MP2 - - Direct Vent ONLY (2 pipe only) *9MPD - - Dual Certified Venting (1 or 2 pipes) * Denotes Brand (T, C or H)

  • Page 3: Table Of Contents

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

  • Page 4: Introduction

    Service Manual Single Stage Multi Position Furnace 1. INTRODUCTION This service manual is designed to be used in conjunction with the installation manual and/or technical support manual provided with each furnace. The information contained in this manual is intended for use by a qualified service technician These furnaces represent the very latest in high efficiency who is familiar with the safety procedures required gas furnace technology.

  • Page 5: Furnace Theory Of Operation

    Service Manual Single Stage Multi Position Furnace Figure 1 Component Locations for Four Position Furnaces Air Intake Pipe Rating Plate Furnace Vent Pipe (Dual Certified or Direct Vent Pipe Vent Model) Grommet Manual Gas Valve Primary Heat Exchanger Gas Valve/Ignition Module Vent Drain Fitting Secondary Heat Exchanger Diagnostic Light...

  • Page 6: Electrical Supply

    Service Manual Single Stage Multi Position Furnace 6. The Combustion Blower Assembly is mounted on the 7. A pressure switch (Air Proving Switch) is used as a outlet side of the Secondary heat exchanger, This safety device that prevents the ignition system from fir- blower creates a partial vacuum (negative pressure) ing the furnace until it senses that a proper draft has within the heat exchangers drawing the flue products...

  • Page 7: Interlock Switch

    Service Manual Single Stage Multi Position Furnace 5. INTERLOCK SWITCH The blower compartment door of all models is equipped with Figure 3 Typical Interlock Switch an interlock switch. This switch is “Normally Open” (closes when the door is on the furnace) and interrupts furnace op- eration when the door is open.
  • Page 8 Service Manual Single Stage Multi Position Furnace CHECKING MANIFOLD PRESSURE Figure 5 Gas Pressure Testing Devices 1. Connect a manometer or Magnehelic gauge (0--12² W.C. range) to the pressure tap on the “OUTLET” side of the gas valve. Pressure Connections 2.

  • Page 9: Burners

    Service Manual Single Stage Multi Position Furnace 7. BURNERS Burners used in this series of furnace are of the “INSHOT” Figure 6 type. Their operation can be compared to that of a torch in Main Burner that they produce a hard, sharp, somewhat noisy flame. Noise should not be an issue, however, because of the closed compartment design.

  • Page 10: Checking Temperature Rise

    Service Manual Single Stage Multi Position Furnace 10. CHECKING TEMPERATURE RISE ALLOWABLE TEMPERATURE RISE ALL Checking Temperature Rise Figure 8 MODELS Thermometer: Model Range Supply Return Air Temp. 50 Mbtu 35°F - - 65°F 75, 100 & 125 Mbtu 40°F - - 70°F Air Flow Thermometer;...

  • Page 11: Control Wiring

    Service Manual Single Stage Multi Position Furnace LOCATION The best method to obtain the required setting for the heat anticipator, is to measure the actual current draw in the con- The thermostat should not be mounted where it may be af- trol circuit (“W”) using a low range (0--2.0 Amps) Ammeter.

  • Page 12: Twinning Kits

    Service Manual Single Stage Multi Position Furnace The COOLING fan speed is energized via the “Y” terminal. COOLING speed on a call for cooling from the thermostat. Failure to connect the thermostat “Y” terminal to the “Y” ter- (The HEATING speed will be energized instead via the “G” minal on the control will result in the failure to energize the terminal) 13.
  • Page 13 Service Manual Single Stage Multi Position Furnace To verify this, the cut--out (opening) point of the switch should The roll out switch monitors the temperature inside the burn- be checked (using a thermocouple type thermometer con- er box, and interrupts furnace (burner) operation when its nected to the face of the switch) as follows: temperature indicates flame roll out has occurred.

  • Page 14: Pressure Switches

    Service Manual Single Stage Multi Position Furnace 15. PRESSURE SWITCHES Transition Pressure Switch HIGH ALTITUDE PRESSURE SWITCHES - MODELS This switch is designed to monitor a blockage of the conden- sate drain line. It uses a single tap (port) “Normally Open” Max.
  • Page 15 Service Manual Single Stage Multi Position Furnace Table 3 APPROXIMATE OPERATING PRESSURES (² ² ² ² OF W.C.) Model Vent Length @Blower @ Transition Short - - (5¢ No. Elbows) - -1.80 - -2.60 50 Mbtu 50 Mbtu Long - - (40¢ + 5 90° Elbows) - -1.30 - -2.30 Short - - (5¢...

  • Page 16: Vent/Combustion Air Piping

    Service Manual Single Stage Multi Position Furnace 16. VENT/COMBUSTION AIR PIPING Vent and combustion air piping are an extremely important products to the outside of the structure. part of the total furnace installation. Improperly installed or Direct VENT (ONLY) models require a combustion air inlet inadequately sized vent and/or combustion air piping can be to bring in all air for combustion from outside the struc- the source of many perceived furnace problems.
  • Page 17 Service Manual Single Stage Multi Position Furnace Concentric Vent and Combustion- Sidewall Inlet Vent and Exhaust- -Air Figure 17 Figure 20 Air Roof Termination Termination with Exterior Risers 18² ² ² ² Min. for Cold Climates “A” (Sustained Below 0° ° ° ° F) 8²...

  • Page 18: Concentric Vent Termination

    Service Manual Single Stage Multi Position Furnace Recommended Alternate Installa- Figure 22 tion for Sustained Cold Weather (- -0° ° ° ° F & below) OVERHANG 12² ² ² ² MIN. EXHAUST 90° ° ° ° INLET 12² MIN. Ground Level 25- -23- -73 OR Snow Level...

  • Page 19: Exhaust Blower

    Service Manual Single Stage Multi Position Furnace Concentric Vent Sidewall Figure 24 Attachment Strap 3² x 2² Bushings or (Field Supplied) Combustion 3² x 2 ² Bushings If 3² vent not used (Field supplied) Vent Vent Flush to Combustion 1² max. 45°...

  • Page 20: Honeywell St9160B Fan Timer/Furnace Control

    Service Manual Single Stage Multi Position Furnace Condensate Drain Trap (Transition Assembly) Figure 26 Figure 27 Vent Pipe Vent Drain (Side panel exit) Transition Box Drain Vent Drain Drain Line Connection (hidden) 25- -23- -62 25- - 23- - 63 NOTE: The vent fitting MUST be installed with the airflow marking arrow pointed toward the vent pipe, with the drain stub at a 20°...

  • Page 21: St9160B Testing Sequence

    Service Manual Single Stage Multi Position Furnace Setting “OFF” and “ON” Heating “OFF” Delay DIP switch Figure 29 Setting Setting the ST9160B Heating Fan “OFF” Delay is accom- plished by the positioning of “DIP” switches. The label on the back of the furnace door indicates how to position these COOL ON DELAY: 6 SEC.

  • Page 22: Honeywell Sv9541M Gas Valve/Ignition System

    Service Manual Single Stage Multi Position Furnace The “CONTINUOUS” terminal of the ST9160B control is en- thermostat sub--base to “FAN ON”, (energizing the “G” ter- ergized ONLY when there is NO OTHER CALL FOR OP- minal) which causes the blower to run on the “HEATING” ERATION of any kind.

  • Page 23: Checking Flame Current

    Service Manual Single Stage Multi Position Furnace If a flame outage (I.E. loss of gas supply, blown out, etc.) would immediately close the main and pilot valves, and de-- should occur during a run cycle (Main burner operation), the energize the electronic fan timer output. ignition system immediately de--energize the main valve and De--energizing the electronic fan timer output causes the re--power the ignitor circuit placing the system back in to the...

  • Page 24: Blower Assembly

    Service Manual Single Stage Multi Position Furnace 28. BLOWER ASSEMBLY All models use a multi--speed, permanent split capacitor mo- ample. The external static pressure is measured and found tor, direct--drive, blower assembly. Different size (HP) mo- to be 0.4² W.C. tors and/or different diameter blower wheels are used in 400 CFM (nominal) per TON required each model to obtain the required air flow.

  • Page 25: Blower Rotation

    Service Manual Single Stage Multi Position Furnace HONEYWELL ST9160B Honeywell ST9160B Figure 32 HEATING SPEED Should it be necessary to change blower speeds to obtain proper temperature rise, simply take the appropriate speed Cool tap wire, and plug it on to the terminal marked “HEAT”. Heat COOLING SPEED When the proper speed has been determined, simply plug...
  • Page 26 Service Manual Single Stage Multi Position Furnace Figure 33 Upflow Installations (Dual Certified *9MPD(A1) Models) LEFT Side Venting RIGHT Side Venting Combustion Air Pipe (optional) Supply Air Supply Air Vent Pipe Air Intake Vent Pipe Grommet Coupling Vent Fitting & Clamps Plastic Caps Gas Pipe Grommet 90°...
  • Page 27 Service Manual Single Stage Multi Position Furnace Figure 34 Horizontal Left Installations (Dual Certified *9MPD(A1) Models) Pressure Switch Hose, Transition Box Air Intake Coupling Combustion Air Pipe, (optional) Blower Pressure Switch, Vent Pipe Blower Pressure Switch, Plastic Caps Transition Combustion Blower Supply Return...
  • Page 28 Service Manual Single Stage Multi Position Furnace Figure 35 Horizontal Right Installations (Dual Certified *9MPD(A1) Models) Vent Pipe Vent Fitting Combustion & Clamps Air Pipe Rubber Coupling & Clamps 90° ° ° ° Elbow (Optional) Gas Pipe Rubber Plug Plastic Caps Grommet ²...
  • Page 29 Service Manual Single Stage Multi Position Furnace Figure 36 Downflow Installations (Dual Certified *9MPD(A1) Models) LEFT Side Venting RIGHT Side Venting Air Intake Return Air Return Air Coupling Combustion Air Pipe, (Optional) Combustion Blower Pressure Switch, (Rotate 180° ° ° ° for Left Side) Combustion Blower Transition Mounting Screws (4)
  • Page 30 20° to 30° dwg 25--23--57 Upflow Installations - (Single Pipe & Direct Vent N9MP1 & N9MP2 Models) (See Figure 37) Mount the condensate drain trap in a vertical position to either the For left side mounted condensate trap, connect the ²...
  • Page 31 (Rotate 180° ° ° ° for Right Side) Drain Line dwg 25- -23- -58 Horizontal Left Installations - (Single Pipe & Direct Vent N9MP1 & N9MP2 Models) (See Figure 38) Relocate the plastic caps and clamps on the condensate drain trap NOTE: The vent fitting MUST be installed with the airflow marking from the vertical drain stubs to the horizontal drain stubs.
  • Page 32 Switch, Blower Drain Line dwg 25--23--59 Horizontal Right Installations - (Single Pipe & Direct Vent N9MP1 & N9MP2 Models) (See Figure 39) Relocate the plastic caps and clamps on the condensate drain trap Relocate the plastic caps on the stubs of the plastic transition from from the vertical drain stub to the horizontal drain stubs.
  • Page 33 20° to 30° dwg 25--23--60 Downflow Installations - (Single Pipe & Direct Vent N9MP1 & N9MP2 Models) (See Figure 40) Mount the condensate drain trap in a vertical position to either the Relocate the plastic caps on the stubs of the plastic transition box...
  • Page 34 Service Manual Single Stage Multi Position Furnace Figure 41 Upflow Installations (Dual Certified *9MPD- - A2 Models) NOTE: TRAP MUST BE PRIMED BEFORE OPERATION Yellow Plastic Cap Combustion Air TOP Venting Pipe (optional) Vent Pipe Supply Air Intake Coupling Rubber Coupling & Clamps Vent Fitting Vent Pipe Grommet...
  • Page 35 Service Manual Single Stage Multi Position Furnace This configuration allows left side venting from the furnace. If right For left side mounted condensate trap, connect the ² OD rubber side venting is required, the combustion blower must be relocated hose with the 90° bend to the large drain stub on the condensate on the plastic transition box.
  • Page 36 Service Manual Single Stage Multi Position Furnace Figure 43 Horizontal Left Installations (Dual Certified *9MPD- -A2 Models) Combustion Air NOTE: TRAP MUST BE PRIMED BEFORE OPERATION Some Models Pipe, (optional) have one Air Intake pressure switch Pressure Switch, Pressure Switch Transition Box Pressure Switch, Vent Pipe...
  • Page 37 Service Manual Single Stage Multi Position Furnace Figure 44 Horizontal Right Installations (Dual Certified *9MPD- -A2 Models) NOTE: TRAP MUST BE PRIMED BEFORE OPERATION Vent Pipe Gas Pipe Grommet Yellow Combustion Plastic Air Pipe Rubber Coupling Vent Fitting (Optional) & Clamps &...
  • Page 38 Service Manual Single Stage Multi Position Furnace Route the hose to the smaller drain stub on the condensate trap. Cut NOTE: Ensure hoses maintain a downward slope to the conden- off excess hose and discard. Connect the hose to the drain stub on sate trap with no kinking or binding for proper condensate drainage.
  • Page 39 Service Manual Single Stage Multi Position Furnace side panel and relocated to the open set of holes in the opposite side Route the pressure switch hose to the lower stub on the plastic tran- panel. sition box. Cut off excess hose and discard. Connect the pressure NOTE: All gaskets and seals must be in place for sealed combus- switch hose to the lower stub on the plastic transition box.
  • Page 40 Service Manual Single Stage Multi Position Furnace Figure 46 Upflow Installations (Single Pipe & Direct Vent N9MP1 & N9MP2- -A2 Models) NOTE: TRAP MUST BE PRIMED BEFORE OPERATION DRAIN SIDE VIEW LEFT Side Venting Rotate downward 20° ° ° ° to 30° ° ° °...
  • Page 41 Plug the upper drain stub on the vent fitting with the yellow plastic the condensate trap and secure with a ² clamp. Figure 47 Upflow Installations (Single Pipe & Direct Vent N9MP1 & N9MP2- -A2 Models) NOTE: TRAP MUST BE PRIMED BEFORE OPERATION RIGHT Side Venting Supply Air...
  • Page 42 Service Manual Single Stage Multi Position Furnace Horizontal Left Installations (Single Pipe & Direct Vent N9MP1 & N9MP2- -A2 Models) Figure 48 Vent Pipe NOTE: TRAP MUST BE PRIMED BEFORE OPERATION Plastic Caps Vent Pipe Grommet Yellow Plastic Cap Vent Fitting & Clamps...
  • Page 43 Service Manual Single Stage Multi Position Furnace Horizontal Right Installations (Single Pipe & Direct Vent N9MP1 & N9MP2- -A2 Models) Figure 49 NOTE: TRAP MUST BE PRIMED BEFORE OPERATION Vent Pipe Grommet Vent Pipe Transition Box Vent Fitting & Clamps...
  • Page 44 Service Manual Single Stage Multi Position Furnace Figure 50 Downflow Installations (Single Pipe & Direct Vent N9MP1 & N9MP2- -A2 Models) RIGHT Side Venting LEFT Side Venting Return Air Vent Fitting Return Air Vent Pipe & Clamps Grommet Pressure Switch...
  • Page 45 Service Manual Single Stage Multi Position Furnace Connect the ² OD rubber hose with the 90° bend to the drain stub excess hose and discard. Connect the hose to the drain stub on the on the bottom of the plastic transition box and secure with a ²...

  • Page 46: Heat Exchanger Removal/Replacement

    Service Manual Single Stage Multi Position Furnace 30. HEAT EXCHANGER REMOVAL/REPLACEMENT Figure 51 “Exploded” Parts View - - Typical Four Position Furnaces 25--23--43a Secondary Heat Exchanger 3. Disconnect combustion air inlet pipe at top panel (if needed). 1. Turn ”OFF” electrical power and gas supply to furnace. 4.

  • Page 47: Sv9541M "Smart Valve" -- Sequence Of Operation

    Service Manual Single Stage Multi Position Furnace HONEYWELL SV9541M “SMART VALVE” Sequence of Operation The following is the normal operating sequence for the control system. Cooling (Y) Request: 24 VAC signals applied to Y & G terminals of EFT (electronic fan timer) control. ·...
  • Page 48 Service Manual Single Stage Multi Position Furnace HONEYWELL SV9541M “SMART VALVE” Sequence of Operation POWER APPLIED TO APPLIANCE THERMOSTAT CALLS FOR HEAT PRESSURE SWITCHES PROVED OPEN? WAIT FOR PRESSURE SWITCHES TO OPEN COMBUSTION BLOWER ENERGIZED COMBUSTION BLOWER DE- - ENERGIZED FIVE MINUTE WAIT PERIOD PRESSURE SWITCHES CLOSED WITHIN 30 SECONDS?

  • Page 49: Sv9541M "Smart Valve" -- Trouble Shooting

    Service Manual Single Stage Multi Position Furnace HONEYWELL SV9541 “SMART VALVE” Trouble shooting The 6 + X designation indicates a combination of flash codes: 6 indicate the reason the control went into soft lockout. Last status flashes shows the control is in soft lockout, followed by X flashes to code indicates repair to address first INDICATES CHECK/REPAIR...
  • Page 50 Service Manual Single Stage Multi Position Furnace HONEYWELL SV9541 “SMART VALVE” Trouble shooting continued INDICATES CHECK/REPAIR STATUS Soft Lockout. Last failure was pressure switch Ignition system control switch must be in the ON position. Flashes Maximum recycle count exceeded Pressure switches operation, tubing, and wiring. Restrictions in furnace air intake or vent piping.

  • Page 51: Sv9541M "Smart Valve" -- Electrical Variation

    Service Manual Single Stage Multi Position Furnace SV9541M ELECTRICAL VARIATION SINGLE STAGE Connector (Pin #) Description Voltage Signal When Signal is Present Neutrals Neutral 0 VAC Always present (5- - ² QC’s) (Neutral and earth ground should be at the same potential) Line Voltage 115 VAC Present when blower door interlock switch is closed.

  • Page 52: Wiring Diagram

    Service Manual Single Stage Multi Position Furnace Wiring Diagram (90+ Single Stage Furnaces)(A1) FAN CONTROL MODULE COOL ON DELAY: 5 SEC COOL OFF DELAY: 60 SEC HEAT OFF DELAY HEAT ON DELAY: 30 SEC. FACTORY 60 SEC. 100 SEC. 140 SEC. 180 SEC.
  • Page 53 Service Manual Single Stage Multi Position Furnace Wiring Diagram (90+ Single Stage Furnaces)(A2) 440 08 2001 02...

  • Page 54: Technical Service Data (N9Mp1 Or 2)

    Service Manual Single Stage Multi Position Furnace Manufacturers Number (Mfr No - - See Rating Plate) ALL Models Specifications General Gas Type Transformer Size (VA) T’stat Heat Anticipator Gas & Ignition Gas Valve HW SV9541M HW SV9541M Regulation Type SNAP SNAP Manifold Press.
  • Page 55 Service Manual Single Stage Multi Position Furnace Manufacturers Number (Mfr No - - See Rating Plate) ALL Models Specifications (N9MP1)(A2) N9MP1050B12 N9MP1075B12 N9MP1080F16 N9MP1100F14 N9MP1100J20 N9MP1125J20 General Gas Type Nat./ LP Nat./ LP Nat./ LP Nat./ LP Nat./ LP Nat./ LP...

  • Page 56: Technical Service Data (*9Mpd/A1)

    Service Manual Single Stage Multi Position Furnace Manufacturers Number (Mfr No - - See Rating Plate) ALL Models Specifications General Gas Type Transformer Size (VA) T’stat Heat Anticipator Gas & Ignition Gas Valve HW SV9541M HW SV9541M Regulation Type SNAP SNAP Manifold Press.

  • Page 57: Technical Service Data (*9Mpd/A2)

    Service Manual Single Stage Multi Position Furnace Manufacturers Number (Mfr No - - See Rating Plate) ALL Models Specifications (*9MPD)(A2) *9MPD050F12A *9MPD075F12A *9MPD080J16A *9MPD100J14A *9MPD100J20A *9MPD125L20A General Gas Type Nat./ LP Nat./ LP Nat./ LP Nat./ LP Nat./ LP Nat./ LP Input (Btuh) 50,000 75,000...

  • Page 58: Blower Performance Data (N9Mp1 Or 2 & *9Mpd)

    Service Manual Single Stage Multi Position Furnace CIRCULATION AIR BLOWER DATA For 050 Models 3 Ton Units For 080 Models 4 Ton 19² ² ² ² & 22 ² ² ² ² Units Speed Speed Speed Med L Med H Med L Med H 1109...

  • Page 59: Appendix Of Helpful Information

    INDEX Electrical Supply, 4 Adjusting Heat Anticipator, 9 Electrical Variation (SV9541M), 49 Adjusting Manifold Pressure, 6 Electronic Fan Timer, 18 Air Proving Switch, See Pressure Switch Exhaust Blower, 17 Auxiliary Limit Switch, 11 Fan Timer, Electronic, 18 Blower Assembly, Conditioned Air, 22 Flame Current, Checking, 21 Blower Rotation, 23 Blower Speeds, Changing, 23...
  • Page 60 INDEX Switch, Roll Out Limit, 11 Switches, Limit, 10 Piping, Vent/Combustion Air, 14--16 Polarity, Line Voltage, 4 Pressure Switches, 12--14 Technical Service Data , 52 -- 60 Pressures, Approximate Operating, 14 Temperature Rise, 8 Testing Sequence, ST9160, 20 Thermostat, Room, 8 Roll Out Limit Switch, 11 Transition Pressure Switch, 12 Room Thermostat, 8...

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