ICP 9MPT Service Manual
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ICP 9MPT Service Manual

ICP 9MPT Service Manual

Multi position 2-stage gas furnaces
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See also: User's Information Manual , Installation Insrtuctions
MULTI POSITION
2- - STAGE
GAS FURNACES
*9MPT & *9MPV
"A1 & A2"
This manual supports condensing gas furnaces manufactured in 2001
Manufactured by:
Part Number
440 08 2002 02
4/2002
ã 2001 International Comfort Products Corporation (USA)

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  • Page 1 MULTI POSITION 2- - STAGE GAS FURNACES *9MPT & *9MPV “A1 & A2” This manual supports condensing gas furnaces manufactured in 2001 Manufactured by: Part Number 440 08 2002 02 4/2002 ã 2001 International Comfort Products Corporation (USA)
  • Page 2 *9MPT - - Dual Certified Venting (1 or 2 pipes) *9MPV - - Dual Certified Venting (1 or 2 pipes) Variable Speed ã 2001 International Comfort Products Corporation (USA) 1136 Heil--Quaker Boulevard, LaVergne, TN 37086 All rights reserved throughout the World.

  • Page 3: Table Of Contents

    ........TECHNICAL SERVICE DATA (*9MPT) .

  • Page 4: Introduction

    Service Manual Two- Stage Multi Position Furnace 1. INTRODUCTION This service manual is designed to be used in conjunction ELS”. GENERALLY, the distinction between these two with the installation manual and/or technical support manual groups is based on a difference in the type of Blower Motor provided with each furnace.

  • Page 5: Furnace Theory Of Operation

    Service Manual Two- Stage Multi Position Furnace Figure 1 Component Locations for Four Position Furnaces Furnace Vent Pipe Air Intake Pipe (Vent Pipe Connection through (Dual Certified or Direct Side Panel on Some Models) Vent furnaces) Vent Pipe Grommet Manual Gas Valve Primary Heat Exchanger Rating Plate Secondary Heat Exchanger...

  • Page 6: Electrical Supply

    Service Manual Two- Stage Multi Position Furnace 6. The Combustion Blower Assembly is mounted on the 7. The Combustion Blower Assembly is mounted on the outlet side of the Secondary heat exchanger, This outlet side of the Secondary heat exchanger, This blower creates a partial vacuum (negative pressure) blower creates a partial vacuum (negative pressure) within the heat exchangers drawing the flue products...

  • Page 7: Interlock Switch

    Service Manual Two- 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 Two- Stage Multi Position Furnace CHECKING MANIFOLD PRESSURE 1. Connect manometer or Magnehelic gauge to the Fire or explosion hazard. tapped opening on the outlet side of gas valve. Use a Turn OFF gas at shut off before connecting manometer with a 0 to 12²...

  • Page 9: Pressure Switch

    Service Manual Two- Stage Multi Position Furnace 7. L.P. PRESSURE SWITCH Models converted to operate on L.P. Gas will be installed Figure 6 Typical L.P. Pressure Switch with an L.P. Pressure Switch. The switch will be located in the gas supply line (in a “Tee” fitting), just ahead of the gas valve. The purpose of this switch is to prevent furnace operating un- der low line (Supply) pressure conditions.

  • Page 10: Checking Temperature Rise

    Service Manual Two- Stage Multi Position Furnace 10. CHECKING TEMPERATURE RISE 2- STAGE MODELS Checking Temperature Rise Figure 8 Model Fire Range 35°F -- 65°F Thermometer: 50 Mbtu 50 Mbtu Return Air Temp. Supply 25°F -- 55°F 40°F -- 70°F 75 Mbtu 100 Mbtu &...
  • Page 11 Service Manual Two- Stage Multi Position Furnace trol circuit (“W”) using a low range (0--2.0 Amps) Ammeter. Figure 9 Thermostat Location (See Figure 10) After measuring the current draw, simply set the heat anticipator to match that value. Figure 10 Measuring Current Draw DRAFTS THERMOSTAT...

  • Page 12: Control Wiring

    Service Manual Two- Stage Multi Position Furnace 12. CONTROL WIRING Control wiring is an important part of the total equipment operation, the furnace will shift from low fire to high fire as installation, since it provides the vital communications link requested by the thermostat.
  • Page 13 Service Manual Two- Stage Multi Position Furnace MAIN LIMIT SWITCH If, however, the switch is found to be opening prematurely, then it should be replaced. When replacing ANY limit switch, A “Normally Closed” switch located on the front partition of use ONLY a switch of EXACTLY the same temperature set- the furnace.

  • Page 14: Pressure Switches

    Service Manual Two- Stage Multi Position Furnace 14. PRESSURE SWITCHES TRANSITION PRESSURE SWITCH Figure 13 Pressure Switches Under normal operating conditions, sufficient pressure is de- veloped by the exhaust (combustion) blower to close the switch, and permit the burner to operate. As the condensate Blower drain begins to back--up, however, the pressure begins to re- (Hi- -fire)

  • Page 15: Vent/Combustion Air Piping

    Service Manual Two- Stage Multi Position Furnace Table 3 APPROXIMATE OPERATING PRESSURES (INCHES OF W.C.) @Blower/@Transition Model Vent Length (High Fire) (Low Fire) Short -- (5 Ft. No Elbows) --1.80/--2.60 --1.20/--1.90 50 Mbtu & 50 Mbtu & 75 Mbtu Long -- (40 Ft. + 5 90° Elbows) --1.30/--2.30 --1.00/--1.80 Short -- (5 Ft.

  • Page 16: Standard Vent Termination

    Service Manual Two- Stage Multi Position Furnace DUAL CERTIFIED models require a combustion air inlet Consult the appropriate Venting tables and/or piping chart pipe to bring in all air for combustion from outside the struc- for the model (series) you are servicing. ture only when installed as a Direct Vent Furnace (I.E.
  • Page 17 Service Manual Two- Stage Multi Position Furnace Recommended Alternate Installa- Sidewall Inlet Vent and Exhaust- - Figure 19 Figure 22 tion for Sustained Cold Weather Air Termination (- -0° ° ° ° F & below) “A” OVERHANG 8² ² ² ² Min. 12²...

  • Page 18: Concentric Vent Termination

    Service Manual Two- Stage Multi Position Furnace 17. CONCENTRIC VENT TERMINATION Vent/Combustion Air Piping Charts Concentric Vent Sidewall Figure 24 Attachment Concentric Termination Kit NAHA001CV Table 6 & NAHA002VC Venting Table Dual Piping Strap ONLY 3² x 2² Bushings or (Field Supplied) 3²...

  • Page 19: Exhaust Blower

    Service Manual Two- Stage Multi Position Furnace 18. EXHAUST BLOWER Always check the current “Technical Support Manual” for Exhaust Blower part nos. Figure 25 Vent Fitting Vent Pipe (Top panel exit) & Clamps 90° Elbow Rubber Coupling & Clamps Blower Vent Pipe (Side panel exit) Vent Fitting...

  • Page 20: Honeywell St9162A Fan Timer/Furnace Control

    Service Manual Two- Stage Multi Position Furnace 20. HONEYWELL ST9162A Series FAN TIMER/FURNACE CONTROL The ST9162A Heating Fan“OFF” delay can be set to ei- Figure 27 Honeywell ST9162A ther 60,100,140, or 180 seconds. The control was shipped out in the 140 second position. This may be satisfactory for some installations, but not for others.

  • Page 21: St9162A/Sv9541Q Testing Sequence

    Service Manual Two- Stage Multi Position Furnace 21. ST9162A/SV9541Q TESTING SEQUENCE If furnace successfully passes this testing sequence, it can be assumed that there are no problems with the ST9162A/SV9541Q CONTROL SYS- TEM. If it does not, however, it does not necessarily mean that there are problems with the control SYSTEM. Any malfunctions should be thoroughly investigated before replacing any components.

  • Page 22: Honeywell Sv9541Q System Operation

    Service Manual Two- Stage Multi Position Furnace 23. HONEYWELL SV9541Q SYSTEM OPERATION & DIAGNOSTICS The following is the normal operating sequence for the 2--stage control system. Cooling (Y) Request: 24 VAC signals applied to Y & G terminals of EFT (electronic fan timer) control. ·...
  • Page 23 Service Manual Two- Stage Multi Position Furnace 24 VAC signals applied to W1 and W2 terminals of EFT control. · Same light--off routine as described for the signal stage thermostat operation except that at the end of the selected Heat Fan On Delay, the inducer remains on high fire, the high fire solenoid remains energized and the High Heat fan speed energizes.

  • Page 24: Checking Flame Current

    Note: *9MPT models use PSC motors on circulating blower and on the 125 exhaust blower). Before checking any capacitor, the supply power to the unit should be turned “OFF”.
  • Page 25 Service Manual Two- Stage Multi Position Furnace lected” for each particular installation to insure proper op- Variable Speed Models Figure 32 eration. D.C. Motor Speed Wires Wire Color Motor Speed The criteria for selecting the proper blower speeds IS NOT “High for Cooling, Low for Heating”.
  • Page 26 Service Manual Two- Stage Multi Position Furnace Blower Performance Data 75,000 Checking Static Pressure Figure 34 Table 7 BTUH (PSC Motor) Air Delivery in Cubic Feet per Minute (CFM) Supply (Furnace Rated @ 0.5² W.C. ESP) MED L MED H HIGH 1163 1368...
  • Page 27 Service Manual Two- Stage Multi Position Furnace NO T E: T his same met hod can be used (on models equipped with a P.S.C. motor)to determine the COOLING Checking Temperature Rise Figure 35 airflow, by TEMPORARILY connecting the cooling speed tap wire to the HEAT terminal of the FAN Control.
  • Page 28 Service Manual Two- Stage Multi Position Furnace Figure 36 Blower Motor Control 0 1 0 *EXAMPLE Cooling Airflows Switches 6, 7 & 8: 000 3.5 Ton INPUT SIGNAL OR 001 3.0 Ton THERMOSTAT 010 2.5 Ton CONNECTIONS 011 2.0 Ton *See “Technical Support Manual”...

  • Page 29: Blower Rotation

    Service Manual Two- Stage Multi Position Furnace connection to the control. Their purpose is to provide a place to connect, or “PARK” any “UNUSED” speed tap 2 SPEED MODELS - P.S.C. MOTOR wires (P.S.C. motors ONLY) to keep them out of the way and prevent them from shorting out against the furnace HEATING SPEEDS casing, or each other.
  • Page 30 Service Manual Two- Stage Multi Position Furnace Figure 39 Upflow Installations (Dual Certified *9MPT & *9MPV(A1) Models) LEFT Side Venting RIGHT Side Venting Combustion Air Pipe (optional) Supply Air Vent Pipe Air Intake Coupling Vent Pipe Grommet Plastic Caps Vent Fitting & Clamps...
  • Page 31 Service Manual Two- Stage Multi Position Furnace Figure 40 Horizontal Left Installations (Dual Certified *9MPT & *9MPV(A1) Models) Pressure Switch Hose, Combustion Air Pipe, (optional) Transition Box Blower Pressure Switch, Vent Pipe Blower (Hi Fire) Air Intake Coupling Pressure Switch,...
  • Page 32 20° to 30° Drain Line dwg 25--23--55a Horizontal Right Installations - (Dual Certified *9MPT & *9MPV) (See Figure 41) Relocate the plastic caps and clamps on the condensate drain trap Relocate the plastic caps on the stubs of the plastic transition box from the vertical drain stub to the horizontal drain stubs.
  • Page 33 Service Manual Two- Stage Multi Position Furnace Figure 42 Downflow Installations (Dual Certified *9MPT & *9MPV Models(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)
  • Page 34 Service Manual Two- Stage Multi Position Furnace Upflow Installations (Dual Certified *9MPT & *9MPV- -A2 Models) Figure 43 NOTE: TRAP MUST BE PRIMED BEFORE OPERATION Yellow Plastic Cap Combustion Air TOP Venting Pipe (optional) Vent Pipe Supply Air Intake Coupling Rubber Coupling &...
  • Page 35 Connect the hose to the drain stub on cap. the condensate trap and secure with a ² clamp. Upflow Installations (Dual Certified *9MPT & *9MPV- -A2 Models) Figure 44 NOTE: TRAP MUST BE PRIMED BEFORE OPERATION RIGHT Side Venting...
  • Page 36 Line Preassemble and insert into furnace Horizontal Left Installations - (Dual Certified *9MPT & *9MPV- A2 Models) (See Figure 45) Note: For easier installation of the drain hoses and clamps to the ing Pipe and Fittings section of this manual, page 30.) The PVC pipe...
  • Page 37 Service Manual Two- Stage Multi Position Furnace Figure 46 Horizontal Right Installations (Dual Certified *9MPT & *9MPV- -A2 Models) NOTE: TRAP MUST BE PRIMED BEFORE OPERATION Vent Pipe Gas Pipe Combustion Grommet Yellow Air Pipe Plastic (Optional) Rubber Coupling Vent Fitting &...
  • Page 38 ² clamp. Figure 47 Downflow Installations (Dual Certified *9MPT & *9MPV- -A2 Models) DRAIN SIDE VIEW NOTE: TRAP MUST BE PRIMED BEFORE OPERATION Rotate downward 20°...
  • Page 39 Service Manual Two- Stage Multi Position Furnace Mount the condensate drain trap in a vertical position to either the secure the blower to the transition. Rotate the blower 180° and se- right or left side of the furnace using the two screws and gasket that cure with the four(4) screws.

  • Page 40: Heat Exchanger Removal/Replacement

    Service Manual Two- Stage Multi Position Furnace 28. HEAT EXCHANGER REMOVAL/REPLACEMENT Figure 48 “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 41: Sv9541Q "Smart Valve" -- Sequence Of Operation

    Service Manual Two- Stage Multi Position Furnace HONEYWELL SV9541Q “SMART VALVE” Sequence of Operation POWER APPLIED TO APPLIANCE THERMOSTAT CALLS FOR HEAT HI AND LOW AIR PROVING WAIT FOR PRESSURE SWITCHES TO OPEN SWITCHES PROVED OPEN? COMBUSTION AIR BLOWER ON HIGH SPEED FIVE MINUTE WAIT PERIOD HI AND LOW AIR PROVING SWITCHES COMBUSTION BLOWER DE- - ENERGIZED...

  • Page 42: Sv9541Q "Smart Valve" -- Trouble Shooting

    Service Manual Two- Stage Multi Position Furnace HONEYWELL SV9541Q “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 43 Service Manual Two- Stage Multi Position Furnace HONEYWELL SV9541Q “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 44: Sv9541Q "Smart Valve" -- Electrical Variation

    Service Manual Two- Stage Multi Position Furnace SV9541Q ELECTRICAL VARIATION 2- -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) 120 VAC Line, Line Voltage 115 VAC...
  • Page 45 Service Manual Two- Stage Multi Position Furnace SV9541Q ELECTRICAL VARIATION 2- -STAGE Con’t Connector (Pin #) Description Voltage Signal When Signal is Present C1 (pin 4) Data Line Non- -periodic wave Present when the door interlock switch is closed. Same rectified AC signal as P1 (pin 5).

  • Page 46: Technical Service Data (N9Mpv)

    Service Manual Two- Stage Multi Position Furnace TECHNICAL SERVICE DATA *9MPV (A1 & A2) Specifications *9MPV050F12A *9MPV075F12A *9MPV100J20A *9MPV125L20A General Gas Type L.P. L.P. L.P. L.P. Transformer Size (VA) T’stat Heat Anticipator Input (Btuh) Std/Alt. Hi Fire Lo Fire 50,000 75,000 100,000 125,000...

  • Page 47: Blower Performance Data (*9Mpv)

    Service Manual Two- Stage Multi Position Furnace Circulation Air Blower Data - *9MPV(A1 & A2) Heating, Cooling & Continuous Airflow Settings Continuous Blower (CFM) @ 0.10² ² ² ² Static Lo Heat Air Temperature Adjustment (° ° ° ° F)** Switch Settings Furnace Model Switch Settings...
  • Page 48 Service Manual Two- Stage Multi Position Furnace Circulation Air Blower Data - *9MPV(A1 & A2) Heating, Cooling & Continuous Airflow Settings Figure 1 *9MPV050 COOLING (CFM VS. EXTERNAL STATIC PRESSURE ) 1400 1200 1000 ESP² ² ² ² W.C. Figure 2 *9MPV050 Hi HEAT (CFM VS.
  • Page 49 Service Manual Two- Stage Multi Position Furnace Circulation Air Blower Data - *9MPV(A1 & A2) Heating, Cooling & Continuous Airflow Settings Figure 3 *9MPV050 Lo HEAT (CFM VS. EXTERNAL STATIC PRESSURE ) 1000 ESP² ² ² ² W.C. Figure 4 *9MPV075 COOLING (CFM VS.
  • Page 50 Service Manual Two- Stage Multi Position Furnace Circulation Air Blower Data - *9MPV(A1 & A2) Heating, Cooling & Continuous Airflow Settings Figure 5 *9MPV075 Hi HEAT (CFM VS. EXTERNAL STATIC PRESSURE ) 1400 1200 1000 101,110,111 ESP² ² ² ² W.C. Figure 6 *9MPV075 Lo HEAT (CFM VS.
  • Page 51 Service Manual Two- Stage Multi Position Furnace Circulation Air Blower Data - *9MPV(A1 & A2) Heating, Cooling & Continuous Airflow Settings Figure 7 *9MPV100 COOLING (CFM VS. EXTERNAL STATIC PRESSURE ) 2500 2000 1500 1000 ESP² ² ² ² W.C. Figure 8 *9MPV100 Hi HEAT (CFM VS.
  • Page 52 Service Manual Two- Stage Multi Position Furnace Circulation Air Blower Data - *9MPV(A1 & A2) Heating, Cooling & Continuous Airflow Settings Figure 9 *9MPV100 Lo HEAT (CFM VS. EXTERNAL STATIC PRESSURE ) 1800 1600 1400 1200 1000 ESP² ² ² ² W.C. Figure 10 *9MPV125 COOLING (CFM VS.
  • Page 53 Service Manual Two- Stage Multi Position Furnace Circulation Air Blower Data - *9MPV(A1 & A2) Heating, Cooling & Continuous Airflow Settings Figure 11 *9MPV125 Lo HEAT (CFM VS. EXTERNAL STATIC PRESSURE ) 2500 2000 1500 1000 ESP² ² ² ² W.C. Figure 12 *9MPV125 Hi HEAT (CFM VS.

  • Page 54: Technical Service Data (*9Mpt)

    Service Manual Two- Stage Multi Position Furnace TECHNICAL SERVICE DATA *9MPT (A1 & A2) Specifications *9MPT050F12A *9MPT075F14A *9MPT100J16A *9MPT125L20A General Gas Type L.P. L.P. L.P. L.P. Transformer Size (VA) T’stat Heat Anticipator Input (Btuh) Std/Alt. Hi Fire 50,000 75,000 100,000...

  • Page 55: Blower Performance Data (*9Mpt)

    Service Manual Two- Stage Multi Position Furnace CIRCULATION AIR BLOWER DATA *9MPT (A1 & A2) For 050(A1 & A2) Models 3 Ton Units For 075(A1) Models 3 Ton Units Speed Speed Speed Speed Med L Med H Med L Med H...

  • Page 56: Wiring Diagram (*9Mpv)

    Service Manual Two- Stage Multi Position Furnace Wiring Diagram ( HP DC Blower Motor) *9MPV050(A1) ALWAYS CHECK CURRENT TECHENICAL SUPPORT MANUAL 440 08 2002 02 THIS DATA IS SUBJECT TO CHANGE WITHOUT NOTICE...
  • Page 57 Service Manual Two- Stage Multi Position Furnace Wiring Diagram (1 HP DC Blower Motor) *9MPV075, 100 & 125(A1) ALWAYS CHECK CURRENT TECHENICAL SUPPORT MANUAL 440 08 2002 02...
  • Page 58 Service Manual Two- Stage Multi Position Furnace Wiring Diagram ( HP DC Blower Motor) *9MPV050(A2) ALWAYS CHECK CURRENT TECHENICAL SUPPORT MANUAL 440 08 2002 02 THIS DATA IS SUBJECT TO CHANGE WITHOUT NOTICE...
  • Page 59 Service Manual Two- Stage Multi Position Furnace Wiring Diagram (1 HP DC Blower Motor) *9MPV075, 100 & 125(A2) ALWAYS CHECK CURRENT TECHENICAL SUPPORT MANUAL 440 08 2002 02...

  • Page 60: Wiring Diagram (*9Mpt)

    Service Manual Two- Stage Multi Position Furnace Wiring Diagram *9MPT(A1) ALWAYS CHECK CURRENT TECHENICAL SUPPORT MANUAL 440 08 2002 02 THIS DATA IS SUBJECT TO CHANGE WITHOUT NOTICE...
  • Page 61 Service Manual Two- Stage Multi Position Furnace Wiring Diagram *9MPT(A2) ALWAYS CHECK CURRENT TECHENICAL SUPPORT MANUAL 440 08 2002 02...

  • Page 62: Appendix Of Helpful Information

    INDEX Adjusting Heat Anticipator, 9 Electrical Supply, 4 Adjusting Manifold Pressure, 6 Electrical Variation (SV9541Q), 42 Air Proving Switch, See Pressure Switch Electronic Fan Timer, 20 Exhaust Blower, 19 External Static Pressure, Checking, 28 Blower Assembly, Conditioned Air, 22 Blower Rotation, 27 Blower Speeds, Changing, 25 Fan Timer, Electronic, 18 Blower Speeds, Selecting, 23...
  • Page 63 INDEX Switch, Pressure, 12--13 Switch, Roll Out Limit, 11 Piping, Vent/Combustion Air, 13--16 Polarity, Line Voltage, 4 Pressure Switches, 12--14 Technical Service Data, 44; 52 Pressures, Approximate Operating, 13 Temperature Rise, 8 Testing Sequence, ST9162A/SV9541Q, 21 Thermostat, Room, 8 Roll Out Limit Switch, 11 Troubleshooting Chart, Honeywell SV9541Q, 37--38 Room Thermostat, 8 Unit Identification, 2...

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