Table of Contents
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Modulating, Variable Speed 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)9MAC
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)9MAC0601714A
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(F/G)9MAC0801714A
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(F/G)9MAC1002122A
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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 .
440 04 4201 01
Aug. 2011
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Table of Contents
Related Manuals for Tempstar (F/G)9MAC0601714A
Summary of Contents for Tempstar (F/G)9MAC0601714A
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Page 1: Table Of Contents
SERVICE AND TECHNICAL SUPPORT MANUAL Modulating, Variable Speed Blower Motor 35” Tall, High Efficiency Condensing Gas Furnace (F/G)9MAC Save this manual for future reference. Safety Labeling and Signal Words DANGER, WARNING, CAUTION, and NOTE Signal Words in Manuals signal words DANGER, WARNING, The signal word WARNING is used throughout... -
Page 2: Safety Considerations
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 SUPPORT MANUAL Gas Furnace: (F/G)9MAC START−UP CHECK SHEET For Variable Speed Models (F/G)9MAC (This sheet is optional. Keep for future reference.) Date of Start−Up: Heating Check Measured Line Pressure During High Heat: Dealer Name: Measured Manifold Pressure: High Heat Address: Low Heat...
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Page 4: Start−Up, Adjustment, And Safety Check
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC START−UP, ADJUSTMENT, AND SAFETY 1. Remove blower door. 2. Locate A/C setup switches on furnace control. CHECK 3. Determine air conditioning tonnage used. General 4. Configure the switches for the required cooling airflow. 1. -
Page 5: Purge Gas Lines
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC 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. - Page 6 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC Heat. Do not adjust Intermediate Heat manifold pressure. Table 1 Altitude Derate Multiplier for U.S.A. Intermediate Heat manifold pressure is checked as part of the ALTITUDE PERCENT DERATE MULTIPLIER temperature rise, but is not adjustable. Always adjust Maximum FT.
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Page 7: Adjust Temperature Rise
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC CAUTION CAUTION FURNACE OVERHEATING HAZARD FURNACE DAMAGE HAZARD Failure to follow this caution may result in shortened Failure to follow this caution may result in overheating furnace life. the heat exchangers or condensing flue gases in heat exchanger areas not designed for condensate. -
Page 8: Blower Off Delay/Cooling Airflow/Low Speed Cooling
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC To lock the furnace in Minimum Heat: WARNING 1. Turn SW1−2 ON at the furnace control. Set up switch SW4−2 must be OFF. FIRE HAZARD 2. Connect a jumper across R and W/W1 at the thermostat terminals at the furnace control. -
Page 9: Furnace Setup Switch Description
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC Figure 4 Furnace Setup Switch Description Furnace Setup Switch Description Turn ON to retrieve up to 7 stored status codes for SW1-1 Status Code Recovery troubleshooting assistance when R thermostat lead is disconnected. -
Page 10: Adjust Thermostat Heat Anticipator
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC 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 11 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC Table 3 Orifice Size and Manifold Pressure (in. w.c.) for Gas Input Rate − Modulating MODULATING FURNACE (TABULATED DATA BASED ON 20,000 BTUH MAX-HEAT / 8,000 BTUH MIN-HEAT PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE RANGE HEAT VALUE...
- Page 12 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC Table 3 (CONT.) Orifice Size and Manifold Pressure (in. w.c.) for Gas Input Rate − Modulating MODULATING FURNACE (TABULATED DATA BASED ON 20,000 BTUH MAX-HEAT / 8,000 BTUH MIN-HEAT PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE RANGE HEAT VALUE...
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Page 13: Cooling And Heating Air Delivery
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC Table 4 COOLING AND HEATING AIR DELIVERY - CFM (Bottom Return with Filter) (SW1-5 and SW4-3 set to OFF, except as indicated. See notes 1 and 2) Unit Cooling Switch Settings External Static Pressure (ESP) in. w.c. Size SW2-3 SW2-2... - Page 14 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC Table 4 (CONT.) COOLING AND HEATING AIR DELIVERY - CFM (Bottom Return with Filter) (SW1-5 and SW4-3 set to OFF, except as indicated. See notes 1 and 2) Unit Cooling Switch Settings External Static Pressure (ESP) in.
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Page 15: Service And Maintenance Procedures
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC SERVICE AND MAINTENANCE Figure 6 Multipoise Orientations 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. - Page 16 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC Figure 7 Typical Two−Stage Field Wiring Diagram FIELD 24-VOLT WIRING FIELD 115-, 208/230-, 460-VOLT WIRING FACTORY 24-VOLT WIRING FACTORY 115-VOLT WIRING NOTE 2 1-STAGE THERMOSTAT FIVE FIELD-SUPPLIED TERMINALS WIRE FUSED DISCONNECT BLOWER THREE-WIRE DOOR 208/230- OR...
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Page 17: Blower Motor And Wheel Maintenance
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC Care and Maintenance 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 WARNING qualified service agency. 6. - Page 18 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC d. Separate the pipes from the blower compartment and Figure 8 Blower Assembly set aside. e. Remove the couplings from the pipe adapters and set aside. f. After servicing the blower, reverse steps a through e. g.
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Page 19: Cleaning Burners And Flame Sensor
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC WARNING 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. ELECTRICAL SHOCK HAZARD 5. Disconnect the gas pipe from gas valve and remove pipe Failure to follow this warning could result in personal injury, or from the furnace casing. -
Page 20: Servicing Hot Surface Igniter
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC 8. Check the igniter alignment. See Figure 9, Figure 10 Figure 11 Igniter Position − Side View and Figure 11. Figure 9 Burner Assembly URNER UPT. 2-in. 3/8-in. URNER 3/16-in. (2.5 mm +/- .75 mm) LAME OLL−OUT WITCH... -
Page 21: Flushing Collector Box And Drainage System
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC 10. Replace control door. 4. Attach the relief hose to the relief port on the condensate trap and collector box. Flushing Collector Box and Drainage System 5. Secure tubing to prevent any sags or traps in the tubing. 1. -
Page 22: Winterization
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC improper gas, or a restricted heat exchanger (primary or Winterization secondary). Action must be taken to correct the problem. CAUTION 1. Turn off gas and electrical supplies to furnace. 2. Remove control door. 3. -
Page 23: Service Label
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC Figure 14 Service Label 338316−2 Rev E 440 04 4201 01 Specifications subject to change without notice. - Page 24 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC Figure 15 Wiring Diagram 338316−2 Rev E 440 04 4201 01 Specifications subject to change without notice.
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Page 25: Troubleshooting Guide
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC Figure 16 Troubleshooting Guide 440 04 4201 01 Specifications subject to change without notice. - Page 26 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC Figure 16 (CONT.) Troubleshooting Guide 440 04 4201 01 Specifications subject to change without notice.
- Page 27 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC Figure 16 (CONT.) Troubleshooting Guide 440 04 4201 01 Specifications subject to change without notice.
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Page 28: Sequence Of Operation
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC SEQUENCE OF OPERATION The furnace will start up in either intermediate-, or maximum-heat. The furnace will transition and operate at CAUTION minimum-heat or the calculated modulating rate after starting and operating for 45 seconds at intermediate-heat. furnace control CPU defaults to minimum-heat on the first UNIT OPERATION HAZARD thermostat cycle and calculates the modulating rate that the... - Page 29 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC close the gas valve GV, and the furnace control CPU will from medium range input to maximum-heat, the furnace repeat the ignition sequence for up to three more control CPU will increase the inducer motor speed to the Trials-For-Ignition before going to Ignition-Lockout.
- Page 30 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC HPS will open and the gas rate will be changed to and the R to G-and-Y/Y2 circuits start the furnace blower motor intermediate-heat. The gas valve solenoid GV will remain BLWM at high-cooling airflow. High-cooling airflow is based on energized as long as the low pressure switch LPS the A/C selection shown in Figure 4.
- Page 31 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC When the thermostat “calls for high-cooling”, the blower motor burners ignite then shut OFF and remain OFF for 25 seconds BLWM will operate at high cooling airflow. When the thermostat before coming back on at modulating heat airflow. When the is satisfied, the blower motor BLWM will operate an additional W/W1 input signal disappears, the furnace control begins a 90 seconds at high-cooling airflow before transitioning back to...
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Page 32: Parts Replacement Information Guide
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC 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 33: Product Nomenclature
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC 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...