Table of Contents
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PG9UAA
INDEX
SAFETY CONSIDERATIONS
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INSTRUCTIONS
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EXAMPLE
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GENERAL
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SEQUENCE OF OPERATION
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Single- -Stage Thermostat and Two- -Stage Heating (Adaptive Mode)
Two- -Stage Thermostat and Two- -Stage Heating
Cooling Mode
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Single- -Speed Cooling
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Single- -Stage Thermostat and Two- -Speed Cooling (Adaptive Mode)
Two- -Stage Thermostat and Two- -Speed Cooling
Dehumidify Mode
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Super- -Dehumidify Mode
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Continuous- -Blower Mode
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Heat Pump Defrost
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Component Test
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SERVICE/STATUS CODE INSTRUCTIONS
START HERE
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RAPID FLASHING AMBER LED
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IMPROPER COOLING AIR FLOW
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HIGH HEAT TEMPERATURE RISE TOO LOW
STATUS CODE 11 - - NO PREVIOUS CODE
STATUS CODE 12 - - BLOWER ON AFTER POWER UP
STATUS CODE 13 - - LIMIT CIRCUIT LOCKOUT
STATUS CODE 14 - - IGNITION LOCKOUT
STATUS CODE 15 – BLOWER MOTOR LOCKOUT
STATUS CODE 21 - - GAS HEATING LOCKOUT
STATUS CODE 22 - - ABNORMAL FLAME- -PROVING SIGNAL
STATUS CODE 23 - - PRESSURE SWITCH DID NOT OPEN
STATUS CODE 24 - - SECONDARY VOLTAGE FUSE IS OPEN
STATUS CODE 25 – MODEL SELECTION OR SETUP ERROR
STATUS CODE 31 – HIGH- -HEAT SWITCH OR RELAY DID NOT CLOSE OR REOPEN
STATUS CODE 32 - - LOW- -HEAT PRESSURE SWITCH DID NOT CLOSE OR
REOPENED
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STATUS CODE 33 - - LIMIT CIRCUIT FAULT
STATUS CODE 34 - - IGNITION- -PROVING FAULT
STATUS CODE 41 – BLOWER MOTOR FAULT
STATUS CODE 42 – INDUCER MOTOR FAULT
STATUS CODE 43 - - LOW- -HEAT PRESSURE SWITCH OPEN WHILE HIGH- -HEAT
PRESSURE SWITCH IS CLOSED
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STATUS CODE 45 – CONTROL CIRCUITRY LOCKOUT
CLEANUP AND START- -UP INSTRUCTIONS
APPENDIX A - - BOARD LAYOUT & WIRING SCHEMATIC
APPENDIX B - - ECM BLOWER MOTOR DESCRIPTION & OPERATION
APPENDIX C - - PRESSURE CHECK DIAGRAM
APPENDIX D - - STATIC PRESSURE READING LOCATION DIAGRAMS
APPENDIX E - - QUICK REFERENCE INFORMATION
APPENDIX F - - FURNACE STAGING ALGORITHM
Troubleshooting Guide
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VARIABLE SPEED, TWO---STAGE
ELECTRONIC CONDENSING
SAFETY CONSIDERATIONS
Installing and servicing heating equipment can be hazardous due to
gas and electrical components. Only trained and qualified
1
personnel should install, repair, or service heating equipment.
1
2
Untrained personnel can perform basic maintenance functions such
as cleaning coils, or cleaning and replacing filters. All other
2
operations should be performed by trained service personnel.
2
When working on heating equipment, observe precautions in
2
literature, on tags, and on labels attached to or shipped with the
3
unit, and other safety precautions that may apply.
4
4
Follow all safety codes. In the United States, follow all safety
4
codes including the National Fuel Gas Code (NFGC) NFPA
54- -2009/ANSI Z223.1- -2009. In Canada, refer to the National
4
Standard of Canada Natural Gas and Propane Installation Codes
4
(NSCNGPIC), CSA B149.1- -10.
5
5
Wear safety glasses and work gloves. Have a fire extinguisher
5
available during start- -up, adjustment procedures, and service calls.
5
6
Recognize safety information. This is the safety- -alert symbol
8
When you see this symbol on the furnace and in instructions or
9
manuals, be alert to the potential for personal injury.
10
Understand the signal words DANGER, WARNING, and
11
CAUTION, and NOTE. The words DANGER, WARNING, and
12
CAUTION are used with the safety- -alert symbol.
12
identifies the most serious hazards which will result in severe
13
personal injury or death.
14
could result in personal injury or death. CAUTION is used to
14
identify unsafe practices which may result in minor personal injury,
14
or product and property damage. NOTE is used to highlight
15
suggestions which will result in enhanced installation, reliability, or
15
operation.
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18
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This guide uses your expertise and observations to lead you to the
trouble spot as efficiently as possible. This is only intended as a
20
guide and should not be used blindly.
22
expertise are of high value when troubleshooting this unit. Do not
24
disregard all of your instincts.
25
The variable speed furnace control was designed with diagnostic
27
capabilities built in. An AMBER LED is used to flash a status
code which will lead you to one of the sections as listed in the
29
Index.
30
You should ALWAYS begin in the START HERE section (see
30
Index for page number) which will guide you to the appropriate
31
section where a minimal number of steps will be used to correct the
33
problem. Once in a section, read the ACTION. An ACTION may
34
have a number in the GO TO column. Do whatever the ACTION
35
says, then proceed to the step indicated in the GO TO column.
36
37
If the ACTION is a question (a question will have a number in the
YES or NO column), answer it YES or NO. If the answer is YES,
go to the step indicated in the YES column. If the answer is NO,
go to the step indicated in the NO column.
1
GAS FURNACE
WARNING signifies hazards which
INSTRUCTIONS
Your experience and
.
DANGER
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Table of Contents
Related Manuals for Carrier PG9UAA
Summary of Contents for Carrier PG9UAA
-
Page 1: Troubleshooting Guide
PG9UAA VARIABLE SPEED, TWO---STAGE ELECTRONIC CONDENSING GAS FURNACE Troubleshooting Guide INDEX SAFETY CONSIDERATIONS PAGE Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained and qualified SAFETY CONSIDERATIONS .......... -
Page 2: Example
Let’s try our guide out using the EXAMPLE section below, and see how it works. Suppose that the problem is a defective low heat pressure switch (for example the contacts will not open). This is an internal problem and cannot simply be seen. We go to the START HERE section to Step 1. -
Page 3: Two- -Stage Thermostat And Two- -Stage Heating
resistance. This evaluation is then used to determine the high-heat pressure switch HPS closes, the high-heat gas required RPM necessary to operate the inducer motor valve solenoid GV-HI is energized and the inducer during the low- -heat prepurge period and low- -heat motor RPM is noted by the furnace control CPU. -
Page 4: Cooling Mode
blower motor BLWM will transition to low-heat airflow furnace blower motor BLWM at low- -cooling airflow which is the five seconds after the R to W2 circuit opens. true on- -board CF selection as shown in Table 1. 3. COOLING MODE If the furnace control CPU switches from low- -cooling to high- -cooling, the furnace control CPU will energize the air The thermostat ”calls for cooling”. -
Page 5: Super- -Dehumidify Mode
high- -cooling airflow. High- -cooling airflow is based on on the room thermostat for 1- -3 seconds after the blower motor the A/C selection shown in Table 1. BLWM is operating. The furnace control CPU will shift the continuous- -blower airflow from the factory setting to the next c. -
Page 6: Service/Status Code Instructions
SERVICE/STATUS CODE INSTRUCTIONS If status code recall is needed disconnect the “R” thermostat lead, reset power, and put setup switch “SW1- -1” in the ON position. To clear the status code history put setup switch “SW1- -1” in the ON position and jumper thermostat terminals “R”, “W/W1”, and “Y/Y2” simultaneously until status code #11 is flashed. -
Page 7: Component Test
33 LIMIT CIRCUIT FAULT – Indicates the limit, or flame rollout is open or the furnace is operating in high- -heat only mode due to 2 success- ive low heat limit trips. Blower will run for 4 minutes or until open switch remakes whichever is longer. If open longer than 3 minutes, code changes to lockout #13. -
Page 8: Start Here
START HERE - - If a problem exists, the service technician should always begin troubleshooting here. Special Note: All voltmeters are not the same - - your voltage readings will vary. This applies to the entire content of this troubleshooting manual. They are not absolute values. Correct 115- - VAC VOLTAGE, CUR- RENT, and power MEASUREMENTS CANNOT BE TAKEN ON VARIABLE SPEED FURNACES UN- LESS USING A TRUE rms METER. -
Page 9: Rapid Flashing Amber Led
ACTION GO TO STEP Is 115- -vac across the transformer leads? Replace the transformer. Is 24- -vac across W/W1 and C V on the variable speed furnace control? OM- - 24 You will not be able to check for voltage across W/W1 and C V if the furnace is con- OM- - 24 nected to a User Interface at the ABCD connector. -
Page 10: Improper Cooling Air Flow
IMPROPER COOLING AIR FLOW - - Generally, this indicates the Y/Y2 thermostat lead is not properly connected. STEP ACTION GO TO Remove blower access panel and depress door switch. Use a piece of tape to hold switch closed. Set thermostat to call for cooling. If thermostat does not have G connection jumper across thermostat terminals R and G. -
Page 11: High Heat Temperature Rise Too Low
Table 2 – Cooling Tonnage vs. Airflow (CFM) AIR CONDITIONING TONS 040, 060, & 5T ---080 & 100 AIRFLOW (CFM) 120 MODEL (12,000 BTU/HR) 3T ---080 MODEL MODEL 1---1/2 2---1/2 1050 3---1/2 1225 1400 1750 2100 BASED ON 350 CFM/TON (SETUP SWITCH SW1-5 OFF) SETUP SWITCH SW2/SW3 POSITIONS MODEL SIZE... -
Page 12: Status Code 11 - - No Previous Code
ACTION GO TO STEP Ensure the gas inlet pressure and burner orifice are correct. Then adjust the gas valve to the proper rate. If it cannot be adjusted to the proper rate, replace the gas valve. Is outdoor condensing unit operating during heating cycle? Check temperature rise and external static pressure with blower access panel in place. -
Page 13: Status Code 13 - - Limit Circuit Lockout
STEP ACTION GO TO Disconnect the R thermostat lead. Do you have less than 19- -vac across R and C V on the variable speed furnace con- OM- - 24 trol? Replace transformer. The thermostat and/or thermostat wires are loading down the transformer. Replace the thermostat or repair thermostat wires. -
Page 14: Status Code 14 - - Ignition Lockout
STEP ACTION GO TO Replace flame rollout switch FRS. Reset flame rollout switch FRS, turn power on, and observe furnace operation for (2) 15 minute cycles. Does the flame rollout switch FRS trip again? Does a different status code flash? You have inadequate combustion- -air supply. -
Page 15: Status Code 22 - - Abnormal Flame- -Proving Signal
Remove blower access panel and depress door switch. Use a piece of tape to hold switch closed. Jumper R and W/W1 thermostat terminals. Does status code 21 start flashing when the low heat pressure switch LPS makes? Replace the variable speed furnace control. Does a different status code flash? Disconnect the jumper wire across R and W/W1 thermostat terminals and wait until the blower stops. -
Page 16: Status Code 24 - - Secondary Voltage Fuse Is Open
STEP ACTION GO TO Replace variable speed furnace control. Is the low heat pressure switch LPS wired correctly? Replace the pressure switch assembly. Is the high heat pressure switch HPS wired correctly? Rewire high heat pressure switch HPS per wiring diagram. Replace the pressure switch assembly and replace the variable speed furnace control. - Page 17 STEP ACTION GO TO Disconnect jumper wire across R and W/W1 thermostat terminals and replace secondary voltage fuse. Disconnect BLUE wire to gas valve GV and jumper R and W/W1 thermostat terminals. Does status code 34 flash? If not, status code 24 should occur when BLUE wire is ener- gized.
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Page 18: Status Code 25 - Model Selection Or Setup Error
Is the model plug PL4 from the old control installed? On PG9UAA furnaces make sure you have installed a furnace control date code 4106 or later. The date code is the last 4 digits printed after the board part number in the WHITE box near the L2 terminals on the right side of the furnace control. - Page 19 - - HIGH HEAT 1. PREPURGE - - If the high heat pressure switch HPS does not make within 45 seconds after the low- -heat pressure switch LPS made the variable speed begins flashing status code 31, shuts unit down, waits 2 minutes, stops flashing status code 31, and restarts heating cycle.
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Page 20: Status Code 32 - - Low- -Heat Pressure Switch Did Not Close Or Reopened
STEP ACTION GO TO Is inducer wheel okay? If possible, replace inducer wheel. Otherwise, replace inducer motor assembly. Is the inducer wheel properly mounted to the inducer motor shaft? Is there any frost build- -up on the combustion- -air inlet? Fix problem. - Page 21 ACTION GO TO STEP You have an open wire or bad terminal on the YELLOW wire from the variable speed fur- nace control to the low heat pressure switch LPS. Repair or replace the main wire harness. Replace the variable speed furnace control. At start of cycle as inducer is ramping up, does low heat pressure switch LPS make then break? The problem is either a sag in vent pipe or a clogged drain trap or line.
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Page 22: Status Code 33 - - Limit Circuit Fault
Status Code 33 LIMIT CIRCUIT FAULT - - This status code indicates the limit, or flame rollout switch is open or the furnace is operating in high- -heat only mode due to 2 successive low heat limit trips. Blower will run for 4 minutes or until the open switch remakes whichever is longer. - Page 23 ACTION GO TO STEP Remove tape from door switch, turn power off at main disconnect, and remove jumper across R and W/W1. Is the blower wheel firmly mounted on motor shaft? Does the model plug PL4 match the part number specified on the Model Plug Chart in the upper left hand corner of wiring schematic? Replace model plug.
-
Page 24: Status Code 34 - - Ignition- -Proving Fault
Status Code 34 IGNITION- -PROVING FAULT - - This status code indicates flame was not sensed during trial for ignition period. The control will repeat ignition sequence 3 more times before going to status code 14 - - IGNITION LOCKOUT. This status code can also indicate flame signal was lost during steady- -state operation. -
Page 25: Status Code 41 - Blower Motor Fault
STEP ACTION GO TO Clean flame sensor with fine sandpaper and make sure it is properly positioned then recheck current. Current is typically 4.0 to 6.0 microamps. Is current near typical value? Replace electrode. Will main burners ignite and stay on? Do you have burner pulsation’s? Check the following: - - Make sure perforated disks are in combustion- -air vent inlet. - Page 26 STEP ACTION GO TO Replace the entire blower motor or blower control module attached to the blower motor. If you replace the blower control module go to step 36. Always inspect failed motor for wa- ter damage. If present, find source of water and fix it. Check A- -coil and/or humidifier. Disconnect jumper wire across R and W/W1 thermostat terminals.
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Page 27: Status Code 42 - Inducer Motor Fault
STEP ACTION GO TO Does the voltage fluctuate as described in step 28? Reconnect PL3 to the variable speed furnace control and connect a DC voltmeter across terminals PL3- -4 BLUE (+) and PL3- -2 GREEN (- -). Does the voltage fluctuate as de- scribed in step 28? Disconnect PL13 from the blower motor and connect a DC voltmeter across the BLUE (+) and GREEN (- -) wires at connector PL13. - Page 28 STEP ACTION GO TO Hook an AC voltmeter across PL2- -4 and NEUTRAL- -L2 on the variable speed furnace control. Is 115- -vac across PL2- -3 and NEUTRAL- -L2? Replace the variable speed furnace control. Do you have 115- -vac across PL11- -6 and PL11- -12? You have an open wire or bad terminal on either the BLACK or WHITE wire between the variable speed furnace control and the inducer motor.
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Page 29: Status Code 43 - - Low- -Heat Pressure Switch Open While High- -Heat Pressure Switch Is Closed
STEP ACTION GO TO Is inducer blower wheel okay? If possible, replace inducer wheel. Otherwise replace inducer motor assembly. Is there any frost build- -up on combustion- -air inlet? The problem is caused by reversed vent and combustion- -air pipes or some other moist air entering combustion- -air pipe. -
Page 30: Cleanup And Start- - Up Instructions
STEP ACTION GO TO Is 24- -vac across ORANGE wire on the low heat pressure switch LPS and C V on OM- - 24 variable speed furnace control? Is 24- -vac across connector terminal PL1- -4 and C V on variable speed furnace con- OM- - 24 trol? Turn power off and disconnect jumper wire across R and W/W1 thermostat terminals. - Page 31 APPENDIX A BOARD LAYOUT AND WIRING SCHEMATICS FACTORY TEST CONTINUOUS FAN CONNECTOR (CF) AIRFLOW MODEL PLUG SETUP SWITCHES CONNECTOR SW1 SETUP SWITCHES AND BLOWER OFF- DELAY AIR CONDITIONING (A/C) AIRFLOW SETUP SWITCHES HUMIDIFIER TERMINAL (24-VAC 0.5 AMP MAX. ACRDJ AIR CONDITIONING RELAY DISABLE JUMPER...
- Page 32 A09683 Fig. 2 - - Wiring Diagram PG9UAA...
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Page 33: Appendix B - - Ecm Blower Motor Description & Operation
APPENDIX B ECM BLOWER MOTOR DESCRIPTION & OPERATION The G.E. Electronically Commutated Motor (ECM) shown in Fig. 3 is different than previous generations of variable speed blower motors. This motor has all of the capabilities of previous ECM blower motors but it does not have to be pre- - programmed at the factory. -
Page 34: Appendix C - - Pressure Check Diagram
APPENDIX C PRESSURE CHECK DIAGRAM PG9UAA PRESSURE SWITCH MAKE/BREAK POINTS HIGH- -HEAT PRESSURE SWITCH LOW- -HEAT PRESSURE SWITCH UNIT SIZE (BTUH) Make Point Break Point Make Point Break Point 60,000 0.86 in. W.C. max 0.71 in. W.C. +/- - 0.05 80,000 0.91 in. - Page 35 APPENDIX D STATIC PRESSURE READING LOCATION DIAGRAMS VENT PIPE COMBUSTION AIR PIPE OUTDOOR UNIT A/C COIL SUPPLY STATIC HUMIDIFIER INCLINE MANOMETER RETURN STATIC GAS-FIRED ELECTRONIC WATER HEATER AIR CLEANER INCLINE MANOMETER AIRFLOW A03091 Fig. 5 - - Upflow Total Static Pressure Reading Locations Tools Needed: Pitot Tube Incline Manometer/Magnahelic...
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Page 36: Appendix E - - Quick Reference Information
Typical Reading: 4 to 6 microamps in high heat Hot Surface Ignitor Reading: PG9UAA – Ohm reading of HSI @ 70°F: 40 to 70 ohms (resistance will remain relatively stable over the life of the igniter). The Silicon Nitride igniter in this furnace is not voltage sensitive and will work within the voltage range of 102 to 132 VAC. Hence, there is no voltage regulation circuits on the furnace control board. -
Page 37: Appendix F - - Furnace Staging Algorithm
APPENDIX F FURNACE STAGING ALGORITHM On initial thermostat call for heat after power- -up, furnace staging algorithm will provide 16 minutes of low heat provided setup switch SW1- -2 is off. If call for heat still exists after operating for 16 minutes in low heat, furnace switches to high heat until the thermostat is satisfied. - Page 38 A02281...
- Page 39 SERVICE TRAINING Packaged Service Training programs are an excellent way to increase your know- ledge of the equipment discussed in this manual, including: • Unit Familiarization • Maintenance • Installation Overview • Operating Sequence A large selection of product, theory, and skills programs is available, using popular video--based formats and materials.
- Page 40 Catalog No: TG ---PG9UAA ---01 E2010 Payne Heating & Cooling Systems D 7310 W. Morris St. D Indianapolis, IN 46231 Printed in U.S.A. Edition Date: 10/10 Replaces: New Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.