Table of Contents
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Two−Stage, Variable Speed ECM Blower Motor
35" Tall, High Efficiency Condensing Gas Furnace
DANGER, WARNING, CAUTION, and NOTE
The
signal
words
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.
TABLE OF CONTENTS
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Printed in U.S.A.
SERVICE AND TECHNICAL
SUPPORT MANUAL
(F/G)9MVE
Save this manual for future reference.
Safety Labeling and Signal Words
DANGER,
WARNING,
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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.
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(F/G)9MVE0401410A
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(F/G)9MVE0601714A
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(F/G)9MVE0801716A
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(F/G)9MVE0802120A
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(F/G)9MVE1002120A
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(F/G)9MVE1202422A
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440 04 4800 00
MODELS
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 .
Aug. 2012
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Summary of Contents for ICP F9MVE0401410A
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Page 1: Table Of Contents
SERVICE AND TECHNICAL SUPPORT MANUAL Two−Stage, Variable Speed ECM Blower Motor 35” Tall, High Efficiency Condensing Gas Furnace (F/G)9MVE Save this manual for future reference. Safety Labeling and Signal Words DANGER, WARNING, CAUTION, and NOTE Signal Words in Manuals signal words DANGER, WARNING,... - Page 2 SAFETY CONSIDERATIONS WARNING Improper ins t allation, adjus t ment, alteration, serv ic e, maintenance, or use can cause explosion, fire, electrical shock, PERSONAL INJURY, AND/OR PROPERTY or other conditions which may cause death, personal injury, or DAMAGE HAZARD property damage. Consult a qualified installer, service agency, Failure to carefully read and follow this warning could or your distributor or branch for information or assistance.
- Page 3 SERVICE AND TECHNICAL MANUAL Gas Furnace: (F/G)9MVE START−UP CHECK SHEET For Variable Speed Models (F/G)9MVE (This sheet is optional. Keep for future reference.) Date of Start−Up: Calculated Input (BTU) Rate: (See Checks and Adjustments Section). Dealer Name: Heating Check Address: Measured Line Pressure During High Heat: City, State(Province), Zip or Postal Code: Measured Manifold Pressure:...
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Page 4: Start−Up, Adjustment, And Safety Check
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE START−UP, ADJUSTMENT, AND SAFETY 3. Determine air conditioning tonnage used. 4. Configure the switches for the required cooling airflow. CHECK 5. Replace blower door. General NOTE: Incorrect airflow caused by improper A/C switch setup 1. -
Page 5: Purge Gas Lines
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE 4. Remove funnel; replace collector box drain plug. CAUTION 5. Connect field-supplied 5/8-in. (16 mm) ID tube to middle collector box drain port. FURNACE DAMAGE HAZARD 6. Pour one quart (liter) of water into funnel/tube. Water should run through collector box, overfill condensate Failure to follow this caution may result in reduced furnace trap, and flow into open field drain. - Page 6 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE level. The natural gas manifold pressures in Table 3 adjust for (Furnace is shipped with No. 44 orifices. In this example, all BOTH altitude and natural gas heating value. main burner orifices are the correct size and do not need to be changed to obtain proper input rate.) NOTE: For Canadian altitudes of 2000 to 4500 ft.
- Page 7 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE c. When correct input is obtained, replace caps that NOTICE conceal gas valve regulator adjustment screws. Main burner flame should be clear blue, almost transparent. (See Figure 14) DO NOT set low−heat manifold pressure less than 1.3−in. w.c. (324 Pa) or more than 1.7−in.
- Page 8 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE Figure 4 Example of Variable Speed Furnace Control for ECM Blower Motor COMMUNICATION CONTINUOUS FAN OUTDOOR SW4 SETUP CONNECTOR F) AIRFLOW IR TEMP SWITCHES SETUP SWITCHES CONNECTOR MODEL PLUG CONNECTOR SW1 SETUP SWITCHES AND BLOWER OFF DELAY...
- Page 9 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE Table 2 Gas Rate (CU ft./hr) SECONDS G SIZE OF TEST DIAL SECONDS SIZE OF TEST DIAL FOR 1 REVOLUTION FOR 1 REVOLUTION 1 Cu Ft. 2 Cu Ft. 5 Cu Ft. 1 Cu Ft.
- Page 10 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE Table 3 Orifice Size and Manifold Pressure (in. w.c.) for Gas Input Rate − Two−Stage TWO-STAGE FURNACE (TABULATED DATA BASED ON 20,000 BTUH HIGH-HEAT / 13,000 BTUH LOW-HEAT PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE RANGE HEAT VALUE...
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Page 11: Adjust Temperature Rise
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE Table 3 (cont.) Orifice Size and Manifold Pressure (in. w.c.) for Gas Input Rate − Two−Stage TWO-STAGE FURNACE (TABULATED DATA BASED ON 20,000 BTUH HIGH-HEAT / 13,000 BTUH LOW-HEAT PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE RANGE HEAT VALUE... -
Page 12: Adjust Blower Off Delay (Heat Mode)
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE 1. Remove jumpers from R and W/W1. Table 4 Blower Speed Taps 2. Wait until the blower off delay is completed. DESIRED HEATING MODE 3. Turn 115 VAC power off. SETUP SWITCH (SW1-7 and -8) BLOWER OFF DELAY 4. - Page 13 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE Figure 5 Furnace Setup Switch Description Furnace Setup Switch Description SETUP SWITCH SWITCH NAME NORMAL POSITION DESCRIPTION OF USE Turn ON to retrieve up to 7 stored status codes for SW1 1 Status Code Recovery troubleshooting assistance when R thermostat lead is disconnected.
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Page 14: Adjust Thermostat Heat Anticipator
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE Adjust Thermostat Heat Anticipator Check Safety Controls a. Mechanical thermostat. Set thermostat heat The flame sensor, gas valve, and pressure switch were all anticipator to match the amp. draw of the electrical checked in the Start−up procedure section as part of normal components in the R−W/W1 circuit. -
Page 15: Cooling And Heating Air Delivery - Cfm
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE Table 5 COOLING AND HEATING AIR DELIVERY - CFM (Bottom Return with filter) (SW1-5 and SW4-3 set to OFF, except as indicated. See notes Unit Size Cooling Switch Settings External Static Pressure (ESP) SW2-3 SW2-2 SW2-1... - Page 16 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE Table 5 (cont.) COOLING AND HEATING AIR DELIVERY - CFM (Bottom Return with filter) Unit Size Cooling Switch Settings External Static Pressure (ESP) SW2-3 SW2-2 SW2-1 080-20 Clg Default: 1905 1870 1825 1785 1750 1700...
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Page 17: Service And Maintenance Procedures
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE NOTE: 1. Nominal 350 CFM/ton cooling airflow is delivered with SW1−5 and SW4−3 set to OFF. Set both SW1−5 and SW4−3 to ON for +7% airflow (nominal 370 CFM/ton). Set SW1−5 to ON and SW4−3 to OFF for +15% airflow (nominal 400 CFM/ton). Set SW4−3 to ON and SW1−5 to OFF for −7% airflow (nominal 325 CFM/ton). - Page 18 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE Troubleshooting Proper instrumentation is required to service electrical controls. The control in this furnace is equipped with a Status Code LED Refer to the service label. (See Figure 15—Service Label) (Light−Emitting Diode) to aid in installation, servicing, and The Troubleshooting Guide −...
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Page 19: Cleaning And/Or Replacing Air Filter
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE b. Hot surface igniter is energized for 15 sec, then CAUTION deenergized. c. Blower operates for 10 sec, then turns off. CUT HAZARD d. Inducer motor goes to low−speed for 10 seconds, Failure to follow this caution may result in personal then turns off. -
Page 20: Blower Motor And Wheel Maintenance
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE 5. If equipped with factory specified disposable media filter, g. Clean wheel per instructions on degreaser cleaner. replace only with a factory specified media filter of the Do not get degreaser in motor. same size. -
Page 21: Cleaning Burners And Flame Sensor
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE 19. Turn on gas supply and cycle furnace through one Blower Assembly (cont.) complete heating cycle. Verify the furnace temperature CUTOFF, BLOWER rise shown Adjustments Section. Adjust temperature rise as shown in Adjustments Section. WHEEL, BLOWER Cleaning Burners and Flame Sensor The following items must be performed by a qualified service... -
Page 22: Servicing Hot Surface Igniter
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE Figure 10 Burner Assembly Figure 12 Igniter Position − Side View URNER UPT. 2 in. 50 mm URNER 3/8 in. 9.6 mm LAME OLL−OUT WITCH 3/16 in. 4.6 mm LAME ENSOR ELOW URNER) + 1/32 1/10 in. -
Page 23: Flushing Collector Box And Drainage System
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE b. Carefully withdraw the igniter and bracket assembly 3. Remove control door and set aside. through the front of the burner assembly without 4. Turn electric switch on gas valve to OFF. striking the igniter on surrounding parts. - Page 24 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE NOTE: If the heat exchangers get a heavy accumulation of Figure 14 Burner Flame soot and carbon, both the primary and secondary heat exchangers should be replaced rather than trying to clean them Burner Flame thoroughly due to their intricate design.
- Page 25 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE 6. Insert a field supplied funnel into the tube. CAUTION 7. Pour 1 quart of anti−freeze solution into the funnel/tube. Antifreeze should run through the collector box, overfill condensate trap and flow to an open drain. UNIT COMPONENT DAMAGE HAZARD 8.
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Page 26: Service Label
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE Figure 15 Service Label 338317−2 Rev H 440 04 4800 00 Specifications subject to change without notice. -
Page 27: Wiring Diagram
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE Figure 16 Wiring Diagram 338317−2 Rev H 440 04 4800 00 Specifications subject to change without notice. -
Page 28: Troubleshooting Guide − Flow Chart
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE Figure 17 Troubleshooting Guide − Flow Chart 440 04 4800 00 Specifications subject to change without notice. - Page 29 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE Figure 17 (CONT.) Troubleshooting Guide − Flow Chart 440 04 4800 00 Specifications subject to change without notice.
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Page 30: Sequence Of Operation
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE Sequence of Operation GV−HI is energized. The furnace control CPU begins a 15−second prepurge period after the NOTE: Furnace control must be grounded for proper operation low−heat pressure switch LPS closes. If the or else control will lock out. - Page 31 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE valve GV−M, stopping gas flow to the burners, and b. Two−Stage Thermostat and Two−Speed Cooling de−energizing the humidifier terminal HUM. The See Figure 19 and Figure 21 for thermostat inducer motor IDM will remain energized for a connections 15−second post−purge period.
- Page 32 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE low−heat or high−heat airflow, respectively. Variable Speed Furnace with Single Figure 18 The blower motor BLWM will revert to continuous−blower Stage Air Conditioner airflow after the heating cycle is completed. In high−heat, the furnace control CPU will drop the blower motor BLWM low−heat...
- Page 33 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE Variable Speed Furnace with Single Variable Speed Furnace and Figure 20 Figure 22 Stage Heat Pump (Dual Fuel) Humidifier Only NOTE 9 L09F029 AC with Variable Speed Furnace, Figure 23 Humidifier, and Dehumidification L09F026 Variable Speed Furnace with Figure 21...
- Page 34 4. When using a Humidity Sensing Thermostat, set DEHUMIDIFY OPTIONS to H DE−ENRGZD FOR DEHUM. 5. Optional connection. If wire is connected SW1−2 on VS furnace control should be set in ON position to allow ICP Thermostat to control the furnace staging.
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Page 35: Parts Replacement Information Guide
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE PARTS REPLACEMENT INFORMATION GUIDE Casing Group Gas Control Group Control door Manifold Blower door Burner Top filler plate Orifice Bottom filler plate Flame sensor Door Knob Assembly Hot surface igniter Gas valve Electrical Group Heat Exchanger group Control box... -
Page 36: Product Nomenclature
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MVE PRODUCT NOMENCLATURE DIGIT POSITION 6, 7, 8 9, 10 11, 12 G = Mainline Look 1 F = Mainline Look 2 N = Entry 9 = 90% − 100% EFFICIENCY M = Multiposition H = Horizontal U = Upflow D = Downflow...
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