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Muliti Purpose Single Stage Gas Furnace Service Manual

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Contents

1. 90 Elbow Combustion Blower Return Air Combustion Blower Mounting Screws 4 Pressure Switch Hose 3 4 Hose amp Clamps Q Vent Pipe Grommet Gas Pipe DRAIN SIDE VIEW Grommet 5 8 Hose amp Clamps d Rotate downward 20 to 30 Rubber Coupling amp Clamps Condensate Trap amp Gasket Drain Line Transition Plastic Caps 5 dwg 25 23 54 Horizontal Left Installations Dual Certified 9MPD See Figure 34 Relocate the plastic caps and clamps on the condensate drain trap from the vertical drain stub to the horizontal drain stubs Secure the clamps tightly to prevent condensate leakage Mountthe condensate drain trap in a vertical position to the left side of the furnace using the two screws and gasket that are provided Note The condensate trap will be located underthe furnace in a ver tical position when the furnace is placed horizontally on the leftside If needed remove the hole plugs from the furnace side panel and relocate to the open set of holes in the opposite side panel Drill two 7 64 diameter holes in the casing using the condensate as the template Connect the vent fitting and the 90 elbow to the combustion blower using the rubber coupling and clamps NOTE The vent fitting MUST be installed with the airflow marking arrow pointed towar
2. Support Field Supplied 45 Elbow p Field Supplied Combustion Air 25 22 02 Single Stage Multi Position Furnace Concentric Vent Sidewall Attachment 3 x 2 Bushings or Strap Field 3 x 21 5 Bushings If 3 vent not used __ Combustion A Note A 22 Securing strap must be field installed to prevent movement of termination in side wall 19 EXHAUST BLOWER Flush to 1 max Combustion Air 45 Elbow Field Supplied Vent Pipe Top Panel Exit 11 Section PVC pipe Vent Fitting 8 Clamps 90 Street Combustion Elbow Vent Pipe Side Panel EXit DRAIN SIDE VIEW Rotate downward 20 to 30 20 CONDENSATE DRAIN TRAP The removal of additional heat from the flue products which takes place in the secondary heat exchanger condenser causes them to drop below their dew point resulting in con densation This condensation water then must be drained from the furnace and routed to a remote drain or conden sate pump The combustion blower creates a negative pressure in ex cess of 2 W C while operating Without a condensate drain trap of sufficient depth condensate would be held in the fur nace because of this negative pressure and not be able to drain Figure 26 shows the transition assembly which is mo
3. i Plastic Yellow Plastic i9 Cap Cap Pressure Hose Blower y Vent Fitting amp Clamps 90 Elbow 5 6 Hose amp Clamps P cai Pressure Switch Blower Pressure Switch Hose Transition Pressure Switch Transition Some Models have one pressure switch Plastic Caps Condensate Trap amp Gasket Trap Connection Z Drain Line Clamp ears Pointed OUT Preassemble amp insert into furnace Transition Box Return Air dwg 25 23 57 Upflow Installations Single Pipe amp Direct Vent N9MP1 amp N9MP2 Models See Figure 46 Note For easier installation of the drain hoses and clamps to the condensate trap follow the directions outlined below except do not make any clamp connections to any of the drain stubs and hoses until the hose routing and lengths have been determined Remove the condensate trap and drain hoses from the furnace and secure the drain hoses to the drain stubs on the trap with the hose clamps position the clamps as shown in Figure 46 Install the condensate trap hose assembly to the furnace casing Hook one side of the clamp ears on the drain stub through the hole in the casing and push the condensate trap into position Secure with the two screws Reconnect the drain hose
4. Combustion Blower Rotate 180 for f T Left Side Pressure Hose Blower Pressure Switch el 1 Pressure Switch Hose Transition Pressure Switch Transition DRAIN SIDE VIEW Rotate Bigid downward Return 20 to 30 dwg 25 23 57 Single Stage Multi Position Furnace Upflow Installations Single Pipe amp Direct Vent N9MP1 amp N9MP2 A1 Models RIGHT Side Venting Supply Air y Combustion Air Pipe N9MP2 ONLY Combustion Blower Mounting Screws 4 Rigid Plastic Drain Tube Upflow Installations Single Pipe amp Direct Vent N9MP1 amp N9MP2 Models See Figure 37 Mount the condensate drain trap in a vertical position to either the left or right side ofthe furnace using the two screws and gasketthat are provided If needed remove the hole plugs from the furnace side panel and relocate to the open set of holes in the opposite side panel Drill two 7 64 diameter holes in the casing using the conden sate trap as the template Ensure thatthe vent fitting and the 90 elbow is securely attached to the combustion blower using the rubber coupling and clamps NOTE The vent fitting MUST be installed with the airflow marking arrow pointed toward the vent pipe with the drain stub at a 20 to 30 downward slope This con
5. E 3 o S S o pe g X 440 08 2001 02 56 Adjusting Heat Anticipator 9 Adjusting Manifold Pressure 6 Air Proving Switch See Pressure Switch Auxiliary Limit Switch 11 B Blower Assembly Conditioned Air 22 Blower Rotation 23 Blower Speeds Changing 23 Blower Speeds Selecting 22 Blower Exhaust 17 Burners 7 Capacitors 22 22 Checking Flame Current 21 Checking Grounding and Polarity 4 Checking Input Firing Rate 5 Checking Manifold Pressure 6 Checking Temperature Rise 8 Circulating Air Blower Data 56 Combustion Air Vent Piping 14 17 Combustion Blower See Exhaust Blower Condensate Drain Trap 17 18 Control Wiring 10 D DIP Switch Settings ST9160 19 Drain Trap Condensate 18 INDEX E Electrical Supply 4 Electrical Variation SV9541M 49 Electronic Fan Timer 18 Exhaust Blower 17 F Fan Timer Electronic 18 Flame Current Checking 21 G Gas Valve Ignition Control Honeywell SV9541M 20 Ground Electrical 4 H Heat Anticipators 9 Heat Exchanger Removal Replacement 44 High Altitude Operation 7 Honeywell ST9160B Fan Timer 19 Honeywell SV9540 Gas Valve Ignition Control 20 Inlet Air Restrictor 13 Interlock Switch 5 Introduction 1 K Kits Twinning 10 L Limit Switches 10 P Piping Vent Combustion Air 14 16 Polarity Line Voltage 4 Pressu
6. zZ lt LL AINO SYOLONGNOD M VER L iy NO L 531435 NI Z OLI HOLIMS HOLIMS Svo HOLIMS MOOTH3LINI NO 9NIaN3d3aa SIIAS OL NOILOANNOO WaLNAN 2 09 LOH HOLIMS LNOTION quu SNIOIAH3S 340438 LO3NNOOSIG INVSHOVIO Ha3aqv1i auc MOOHS 1VOIH L03T13 H395NVG ASO NOPED ANNO 18 v SETTING Diagram 90 Single Stage Furnaces A1 COOL ON DELAY 5 SEC COOL OFF DELAY 60 SEC HEAT ON DELAY 30 SEC irin Service Manual 50 440 08 2001 02 Service Manual 180 SEC 69 INO HOLIMS di SLI 38IM 2 601 INMV LSNW LI 38 LSNW JHL SV TVNISTHO JHL 40 31 4LIVLSOWYSHL TE Gr Sqaads lt 9NIT0O9 YIdOYd 348 404 STVNNVW 33S AHOLOVJ 9 OV 31319994 A MONIA SNINIM Q3VOS TVNH3INI M 1315 MOT AYXOLOVA ADVLIOA 1
7. 47 SV9541M SMART VALVE Electrical Variation 49 WIRING DIAGRAM ROC Lona la 50 TECHNICAL SERVICE DATA N9MP1 2 52 TECHNICAL SERVICE DATA SMPDJ AT n mm s 54 TECHNICAL SERVICE DATA 2 55 BLOWER PERFORMANCE DATA N9MP1 or 2 amp 9 56 APPENDIX OF HELPFUL INFORMATION 57 Service Manual 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 These furnaces represent the very latest in high efficiency gas furnace technology Consequently they incorporate the use of certain controls that contain highly sophisticated elec tronic components which are not user serviceable there fore it is essential that only competent qualified service personnel attempt to install service or maintain this prod uct This Service manual was written to assist the professional HVAC service technician to quickly and accurately diagnose and repair any malfunction of this product This service manual covers our new multi position furnaces both Direct Vent 2 pipe Only Indoor combustion 1 pipe Only and Dual Certified 1 or 2 pipe models The overall op eration of all of th
8. SLI 2 505 WMV d iid RO Od odo ONION 38 LSNW 38 LSNW MOTISA Sv JAIM IHL 40 M JHL NI HOLIMS 553 Cae 1 N3dO S3dls 1 SISSVHO lt 131 OL SL IOA 91 81 LIOA IVISOWH3HL AMOLOV 9 ILON IHW 3ONVHO 1 ya MOVIE SRA ode ANO 1 HOSN3S 3000 1 03345 HOLIMS 3009 3unsssuddi ES 1 LVLSOWYSHL 180 YOLOVdVS S1aGOW NO S3lH3S NI Z OL L HOLIMS JYNSSJYd NO SAIMAS OL HOLIMS LNOTION lt lt gt p 0 w3 N I gars 7 JONON ANO 1 HOLIMS gunssaud di 140 SEC S S 5 5 5 f o S o 0 1 9 3813 vs wog 100 SEC HEAT OFF DELAY J 2 gt e c H 2
9. 5 s clamp Route the hoseto the smaller drain stub on the condensate trap Cut off excess hose and discard Connect the hose to the drain stub on the trap and secure with a 5 8 clamp NOTE Ensure hoses maintain a downward slope to the conden sate trap with no kinking or binding for proper condensate drainage 440 08 2001 02 Service Manual Single Stage Multi Position Furnace Figure so Downflow Installations Single Pipe amp Direct Vent N9MP1 amp N9MP2 A2 Models LEFT Side Venting a Return Air Vent Fitting amp Clamps Pressure Switch Hose Transition Combustion Blower Mounting Screws 4 Hose amp A Clamps Plastic Caps Yellow Plastic Cap Transition Box Pressure Switch Blower Pressure Switch Hose Blower Trap Connection Clamp ears Pointed Plastic Caps Condensate Trap amp Gasket 4 Drain Line Preassemble amp insert into furnace RIGHT Side Venting Return Air Vent Pipe Grommet Combustion Blower Rotate 180 for Left Side Combustion Air Pipe N9MP2 ONLY p Vent Pipe Pressure Switch Transition Some Models have one pressure switch DRAIN SIDE VIEW Rotate downward
10. Circulating Air Blower dwg 25 23 29a 3 FURNACE THEORY OF OPERATION The high efficiencies and lower profile compared to previous series ofthis furnace have been obtained using design tech niques not typical of traditional furnace designs A brief de scription of these new design techniques and the purpose they serve follows 1 Reducing the height of the furnace while maintaining the high efficiency of pervious models required main taining the surface area of the heat exchanger and yet minimizing the overall size The design required to achieve these results is the SER PENTINE design wherein the flue gasses must follow a serpent shaped passage through the heat exchanger via convection This Serpentine path is resistive to normal convective flow and requires that a partial vacuum be created at the outlet of the heat exchanger to maintain the flow of flue products through the heat exchanger 2 The serpentine heat exchanger design does not lend itself well to the ribbon type or slotted port type burner found in more traditional design furnaces for the follow ing reasons A The secondary combustion airflows at right angles tothe burner flame making it likely to pull the flame off a ribbon or slotted port type burner B The flame height of a ribbon or slotted port type burner would make it difficult if not impossible to prevent impingement of the flame on the heat ex changer surfaces whole
11. Service Manual cap For left side mounted condensate trap connect the 3 4 OD rubber hose with the 90 bend to the large drain stub on the condensate trap and secure with a 3 4 clamp Route the hose to the drain stub on the bottom of the plastic transi tion box Cut off excess hose and discard Connect the hose to the drain stub on the transition and secure with a 3 4 clamp For right side mounted condensate trap connectthe 3 4 OD rubber hose with the 90 bend to the bottom ofthe plastic transition box and secure with a 3 4 clamp Route the hose to the large drain stub on the condensate pump Cut off excess hose and discard Connect the hose to the drain stub on the condensate trap and secure with a 3 4 clamp Figure 47 Upflow Installations Single Pipe amp Direct Vent 1 amp N9MP2 A2 Models RIGHT Side Venting NOTE TRAP MUST BE PRIMED BEFORE OPERATION Supply Air Some Models have one pressure switch DRAIN SIDE VIEW Rotate downward m 5 to 10 25 24 00 into furnace For left side or right side mounted condensate trap the pres suretap on the condensate trap MUST be connected to the unused pressure tap located on the upper right hand corner ofthe plastic transition box Remove the plastic caps from the pressure taps on the condensate trap and the plastic transiti
12. Upflow Installations Dual Certified 9MPD See Figure 41 Note For easier installation of the drain hoses and clamps to the condensate trap follow the directions outlined below except do not make any clamp connections to any of the drain stubs and hoses until the hose routing and lengths have been determined Remove the condensate trap and drain hoses from the furnace and secure the drain hoses to the drain stubs on the trap with the hose clamps position the clamps as shown in Figure 41 Installthe condensate trap hose assembly to the furnace casing Hook one side of the clamp ears on the drain stub through the hole in the casing and push the condensate trap into position Secure with the two screws Reconnect the drain hoses to the stubs on the vent fitting and the plastic transition and secure with the clamps Mount the condensate drain trap in a vertical position to either the left or right side ofthe furnace using the two screws and gasketthat are provided If needed remove the hole plugs from the furnace side panel and relocate to the open set of holes in the opposite side panel NOTE All gaskets and seals must be in place for sealed combus tion applications 440 08 2001 02 32 Ensure that the vent fitting and the 90 street elbow are securely at tached to the combustion blower using the clamps Plug the upper drain stub on the vent fitting with the yellow plastic cap Gluethe 11 section of PVC pipe to the 90 stree
13. Dual Certified Models ONLY Non Direct Vent Installation Single Piping Chart Pipe Diameter Table ocu Single Piping ONLY 50 000 amp 75 000 Btuh Furnaces 40 amp 5 90 elbows with 2 PVC pipe or 70 amp 5 90 elbows with 3 PVC pipe or 100 000 Btuh Furnace 70 amp 5 90 elbows with 3 PVC pipe 125 000 Btuh Furnace 40 amp 5 90 elbows with 3 PVC pipe Elbows are DWV Long Radius Type for 2 and 3 vents If more than five elbows are required reduce the length of both the inlet and exhaust pipes 5 for each additional elbow used NOTE It is allowable to use larger diameter pipe and fitting than shown in the tables but not smaller diameters than shown All Series Models Direct Vent Installation Dual Piping Chart Pipe Diameter Table Tabios Dual Piping ONLY 50 000 amp 75 000 Btuh Furnaces 40 amp 5 90 elbows with 2 PVC pipe or 70 amp 5 90 elbows with 3 PVC pipe or 100 000 Btuh Furnace 70 amp 5 90 elbows with 3 PVC pipe 125 000 Btuh Furnace 40 amp 5 90 elbows with 3 PVC pipe Elbows are DWV Long Radius Type for 2 and 3 vents 440 08 2001 02 14 Single Stage Multi Position Furnace products to the outside of the structure Direct VENT ONLY models require a combustion air inlet to bring in all air for combustion from outside the struc ture DUAL CERTIFIED models require a combustion air inlet pipe to bring in all air for combust
14. Limit Control Setting F Std Transition Pressure Sw Part No Blower Switch Pressure Close Blower Switch Pressure Open Transition Switch Pressure Close Transition Switch Pressure Open High Altitude Pressure Sw Part No Blower Switch Pressure Close Blower Switch Pressure Open Transition Switch Pressure Close Transition Switch Pressure Open Blower Data Type amp Size Motor Amps Rpm Motor Cap Mfd Volts Filter Type Cool Cap Tons 5 L ML MHi amp Hi 440 08 2001 02 Nat L P Nat L P 2 42 2 54 3 42 3 54 2 2 lt 140 lt 140 1 80 2 60 1 30 2 30 1 80 2 60 1 30 2 30 1013515 0 95 0 80 1 70 1 50 1013165 0 70 0 55 1 40 1 20 1013515 0 95 0 80 1 70 1 50 1013165 0 70 0 55 1 40 1 20 11 8 10 850 1 5 7 51370 16 25 1 11 5 2 21 5 3 11 10 8 0 1050 1 5 7 51370 16 25 1 11 5 2 21 5 3 54 Nat LP 442 4 54 3 lt 140 1 80 2 60 1 70 2 50 1013515 0 95 0 80 1 70 1 50 1013165 0 70 0 55 1 40 1 20 11 10 10 1050 1 5 10 370 16 25 1 11 5 2 3 31 5 Nat LP 442 4 54 3 lt 140 1 80 2 60 1 70 2 50 1013515 0 95 0 80 1 70 1 50 1013165 0 70 0 55 1 40 1 20 11 10 13 900 40 370 16x25x1 31 5 4 41 o 5 Nat L P 5 42 5 54 3 lt 140 1 80 2 60 1 70 2 50 1013166 1 30 1 10 1 80 1 60 1013157 0 85 0 70 1 70 1 50
15. Horizontal Right Installations Single Pipe amp Direct Vent N9MP1 amp N9MP2 Models See Figure 49 Note For easier installation of the drain hoses and clamps to the condensate trap follow the directions outlined below except do not make any clamp connections to any of the drain stubs and hoses until the hose routing and lengths have been determined Remove the condensate trap and drain hoses from the furnace and secure the drain hoses to the drain stubs on the trap with the hose clamps position the clamps as shown in Figure 49 Install the condensate trap hose assembly to the furnace casing Hook one side of the clamp ears on the drain stub through the hole in the casing and push the condensate trap into position Secure with the two screws Reconnect the drain hoses to the stubs on the vent fitting and the plastic transition and secure with the clamps Relocate the plastic caps and clamps on the condensate drain trap from the vertical drain stub to the horizontal drain stubs Secure the clamps tightly to prevent condensate leakage Mount the condensate drain trap in a vertical position to the right side of the furnace using the two screws and gasket that are pro vided Note The condensate trap will be located under the furnace in a vertical position when the furnace is placed horizontally on the right side If needed remove the hole plugs from the furnace side panel and relocate to the open set of holes in the opposite side pan
16. Min Grade Sustained Below 0 or Snow Level Dimension A is touching or 2 maximum separation 15 440 08 2001 02 Service Manual Recommended Alternate Installa tion for Sustained Cold Weather 0 F amp below OVERHANG 12 MIN EXHAUST 90 MEET 12 MIN Ground e ll Level OR Snow Level FRONT VIEW SIDE VIEW ol L Same Joist Space 18 CONCENTRIC VENT TERMINATION Vent Combustion Air Piping Charts Concentric Termination Kit NAHAO01CV Table 6 amp 2 Venting Table Dual Piping ONLY 50 000 amp 75 000 Btuh Furnaces NAHAOO02CV 35 amp 4 90 elbows with 2 PVC pipe NAHAO01CV 65 8 4 90 elbows with 3 PVC pipe 100 000 Btuh Furnace NAHAO010CV 65 amp 4 90 elbows with 3 PVC pipe 125 000 Btuh Furnace NAHAO010CV 35 amp 4 90 elbows with 3 PVC pipe 1 Do not include the field supplied 45 elbow in the total elbow count 2 If more than four elbows are required reduce the length of both the inlet and the exhaust pipes five feet for each additional elbow used 3 Elbows are DWV long radius type for 2 and 3 vents 440 08 2001 02 Single Stage Multi Position Furnace Concentric Vent Roof Installation Maintain 12 min clearance above highest anticipated snow level Max of 24 above Combustion roof Air d Roof Boot Flashing 5 Field Supplied 9 000
17. el NOTE All gaskets and seals must be in place for sealed combus tion applications Ensure that the vent fitting is securely attached to the combustion blower using the clamps NOTE The vent fitting MUST be installed with the airflow marking arrow pointed toward the vent pipe 41 Plug the left drain stub on the vent fitting with the yellow plastic cap Remove the pressure switch hose from the upper stub on the plastic transition box Relocate the plastic caps on the stubs of the plastic transition from the lower stubs to the upper stubs and secure tightly with the clamps Route the pressure switch hose to the lower stub on the plastic tran sition box Cut off excess hose and discard Connect the pressure Switch hose to the lower stub on the plastic transition box Ensure that the hose is routed above the stub on the transition box so that condensate does not collect in the hose NOTE Failure to correctly installthe pressure switch hose tothe transition can adversely affect the safety control operation Connectthe 3 OD rubber hose with the 90 bend to the large drain stub on the condensate trap and secure with a 3 4 clamp Route the hose to the drain stub on the bottom ofthe plastic transi tion box Cut off excess hose and discard Connect the hose to the drain stub on the transition and secure with a 3 4 clamp Connect the 5 5 OD rubber hose with the 90 bend to the right stub on the vent fitting and secure with
18. 2001 02 42 This configuration allows right side venting from the furnace If the left side venting is required the combustion blower must be relo cated on the plastic transition box Remove the four 4 screws that secure the blower to the transition Rotate the blower 180 and se cure with the four 4 screws Use caution to not over tighten the Screws to prevent stripping out of the plastic mounting holes NOTE The vent fitting MUST be installed with the airflow marking arrow pointed toward the vent pipe with the drain stub ata 20 to 30 downward slope Plug the upper drain stub on the vent fitting with the yellow plastic cap Remove the pressure switch hose from the upper stub on the plastic transition box Relocate the plastic caps on the stubs of the plastic transition box from the lower stubs to the upper stubs and secure tightly with the clamps Route the pressure switch hose to the lower stub on the plastic tran sition box Cut off excess hose and discard Connect the pressure Switch hose to the lower stub on the plastic transition box NOTE Failure to correctly install the pressure switch hose to the transition box can adversely affect the safety control operation Single Stage Multi Position Furnace Connectthe 3 4 OD rubber hose with the 90 bend to the drain stub on the bottom of the plastic transition box and secure with a 3 4 clamp Route the hose to the large drain stub on the condensate trap Cut off e
19. N9MP1100F14 N9MP1100J20 9 1125 20 General Gas Type Input Btuh Output Btuh Transformer Size VA T stat Heat Anticipator Temp Rise F Electrical Volts Hz FLA 115 60 9 8 Gas amp Ignition Gas Type Gas Valve Regulation Type IgnitionType Series Manifold Press Inch s WC Std Main Orifices No Size Pilot Orifice Size Fan Controls Fan Control Type Fan Control Timed secs Combustion Flue Outlet Size Inches Std Outlet Temp 5 No Elbows Blower Pressure 5 No Elbows WC Blower Pressure 40 5 90 DWV Elbows WC Transition Bx Pressure 5 No Elbows WC Transition Bx Pressure 40 5 90 DWV Elbows WC Limits amp Controls Rollout Switch Limit Control Setting F Standard Pressure Sw Part No Blower Switch Pressure Close W Blower Switch Pressure Open W Transition Switch Pressure Close Transition Switch Pressure Open High Altitude Pressure Sw Part No Blower Switch Pressure Close Blower Switch Pressure Open W Transition Switch Pressure Close Transition Switch Pressure Open WC Long Vent Kit Part No Pressure Switch Part No Blower Switch Pressure Close Blower Switch Pressure Open Transition Switch Pressure Close Transition Switch Pressure Open WC High Altitude Long Vent Kit Part No Pressure Switch Part No Blower Switch Pressure Close Blower Switch Pressure Open Transit
20. NAHFOOLP 1009509 NAHFOO2NG 1009510 11 10 13 900 PSCfSJ 40 370 16x25x1 31 5 4 41 5 5 HW SV9541M SNAP HW HSP HW ST9160 30 60 100 140 180 1013166 1 3 1 1 1 8 1 6 1013157 0 9 13 900 PSCfSJ 40 370 16x25x1 31 5 4 41 5 5 440 08 2001 02 Service Manual Manufacturers Number Mfr No See Rating Plate ALL Models Specifications General Gas Type Transformer Size VA T stat Heat Anticipator Gas amp Ignition Gas Valve Regulation Type Manifold Press Inch s WC Pilot Orifice Size Fan Controls Fan Control Type Fan Control Timed secs Gas Conversion Kits Models Nat to LP NAHFOO2LP LP to Nat Order from Service Parts 1009509 NAHFO002NG 1009510 HW SV9541M SNAP 3 5 SNAP 10 0 HW ST9160 30 60 100 140 180 HW ST9160 30 Specifications Single Stage Multi Position Furnace HW SV9541M 60 100 140 180 9MPDO5OF12A1 9MPDO75F12A1 9MPD100J14A1 9MPD100J20A1 9MPD125L20A1 General Input Btuh Output Btuh Temp Rise 100 000 92 000 40 70 100 000 92 000 40 70 125 000 115 000 40 70 Electrical Volts Hz FLA 115 60 9 8 115 60 8 9 115 60 9 0 115 60 10 5 115 60 11 2 Gas amp Ignition Gas Type Std Main Orifices No Size Combustion Flue Outlet Size Inches Std Outlet Temp F Blower Transition Box Std Pressures of WC 5 No Elbows 40 45 90 DWV Elbows Limits amp Controls Rollout Switch F
21. and the plastic transition and secure with the clamps Relocate the plastic caps and clamps on the condensate drain trap from the vertical drain stub to the horizontal drain stubs Secure the clamps tightly to prevent condensate leakage Mount the condensate drain trap in a vertical position to the right side of the furnace using the two screws and gasket that are pro vided Note The condensate trap will be located under the furnace in a vertical position when the furnace is placed horizontally on the right side If needed remove the hole plugs from the furnace side panel and relocated to the open set of holes in the opposite side panel NOTE All gaskets and seals must be in place for sealed combus tion applications Remove the 90 street elbow and vent fitting from the combustion blower by loosening the clamps on the vent fitting Connect the 90 street elbow to the combustion blower using the rubber coupling and clamps Cut a 2 section of PVC pipe from the PVC pipe pro vided with the furnace Glue the 2 section of PVC pipe to the 90 35 street elbow after checking the fit up Follow the procedures out lined in the Joining Pipe and Fittings section of this manual page 30 Connect the vent fitting to the end ofthe 2 section of PVC pipe using the clamp NOTE The vent fitting MUST be installed with the airflow marking arrow pointed toward the vent pipe with the drain stub at a 20 to 30 downward slope Plug the upper
22. box due to con densate buildup After the trap is primed the condensate will start draining from the furnace The combustion blower will clear out any remaining condensate in the blower housing through the vent fitting downstream of the blower Note that the condensate trap can also be primed by pouring water into the vent drain side of the trap Remove the small plastic cap and clamps from the unused drain stub on the vent drain side of the condensate Connecta section of the 5 3 OD hose with a funnel to the drain stub and pour eight 8 ounces of wa ter into the trap Remove the hose and replace the plastic cap and clamp This will prime both the vent and the transition sides of the trap e startup ofa furnace will have milky or oily looking con densate coming from the furnace This is residual drawing lube in the secondary heat exchanger that is being washed out by the condensate The condensate will clear up as the 23 Service Manual HONEYWELL ST9160B HEATING SPEED Should it be necessary to change blower speeds to obtain proper temperature rise simply take the appropriate speed tap wire and plug it on to the terminal marked HEAT COOLING SPEED When the proper speed has been determined simply plug it on to the terminal of the control marked COOL UNUSED TERMINALS There are two 2 terminals marked UNUSED MOTOR LEADS on the Honeywell ST9160B which has no internal connection to the co
23. condensate drain trap in a vertical position to the left side of the furnace using the two screws and gasket that are provided Note The condensate trap will be located underthe furnace in a ver tical position when the furnace is placed horizontally on the leftside If needed remove the hole plugs from the furnace side panel and relocated to the open set of holes in the opposite side panel Drill two 7 64 diameter holes in the casing using the condensate as the template Relocate the combustion blower on the plastic transition box Re move the four 4 screws that secure the blower to the transition box Rotate the blower 180 so the blower snout is pointing up and se cure with the four 4 screws Use caution to not over tighten the Screws to prevent stripping out of the plastic mounting holes Ensure thatthe vent fitting and the 90 elbow is securely attached to the combustion blower using the rubber coupling and clamps 29 NOTE The vent fitting MUST be installed with the airflow marking arrow pointed toward the vent pipe with the drain stub at a 20 to 30 downward slope Plug the left drain stub on the vent fitting with the rubber plug Use a blunt pointed screwdriver to push the plug into the stub Connect the 3 4 OD rubber hose with the 90 bend to the drain stub on the bottom of the plastic transition box and secure with a 3 4 clamp Route the hose to the large drain stub on the condensate trap Cut off excess ho
24. hose to the lower stub on the plastic transition box NOTE Failure to correct ly install the pressure switch hose to the transition can adversely af fect the safety control operation Connectthe 3 4 OD rubber hose with the 90 bend to the drain stub on the bottom of the plastic transition box and secure with a 3 4 clamp Route the hose to the large drain stub on the condensate trap Cut off excess hose and discard Connect the hose to the drain stub on the trap and secure with a 3 4 clamp Connect the OD rubber hose with the 90 bend to the right stub on the vent fitting and secure with a 5 8 clamp Route the hoseto the smaller drain stub on the condensate trap Cut off excess hose and discard Connect the hose to the drain stub on the trap and secure with a 5 8 clamp NOTE Ensure hoses maintain a downward slope to the conden sate trap with no kinking or binding for proper condensate drainage Single Stage Multi Position Furnace Service Manual Figure 40 Downflow Installations Single Pipe amp Direct Vent NOMP1 amp N9MP2 A1 Models LEFT Side Venting SE Vent Fitting Return Air amp Clamps Pressure Switch Hose Transition Combustion Blower Mounting Screws 4 5 8 Hose amp Clamps Plastic Caps Transition Box Pressure Switch Blower Hose Blower Plastic Caps e Condensate Trap amp Gaske
25. hose to the drain stub on the bottom ofthe plastic transition box and secure with a 3 4 clamp For right side mounted condensate trap the rigid plastic drain tube MUST be used Cut two 2 long sections from the 3 4 OD rub ber hose Connectthe plastic drain tube to the drain stub on the bot tom of the plastic transition box and to the stub on the condensate trap using the two hose sections and 3 4 clamps NOTE The support leg on the plastic drain tube MUST be posi tioned on the blower partition Connect the 5 8 OD rubber hose with the 90 bend to the left drain stub on the vent fitting and secure with a 5 8 clamp Route the hose to the small drain stub on the condensate trap Cut off excess hose and discard Connect the hose to the drain stub on the trap and secure with a 5 8 clamp NOTE Ensure hoses maintain a downward slope to the conden sate trap with no kinking or binding for proper condensate drainage Single Stage Multi Position Furnace Service Manual Horizontal Left Installations Dual Certified 9MPD A1 Models Air Intake Coupling Combustion Air Pipe optional Vent Pipe Plastic Caps Transition Box Pressure Switch Hose Blower Pressure Switch Blower Pressure Switch Transition Rubber Vent Fitting Plug amp Clamps a v Ac
26. indicated in either the reg ulator or pipe sizing Table 1 Gas Pressures Below 2000 Gas Supply Pressure Manifold Type Recommended Wax J Win Pressure Important Note With Propane gas the rated input is obtained when the BTU content is 2 500 BTU per cubic foot and manifold pressure set at 10 W C If Propane gas has a different BTU content orifices MUST be changed by licensed Propane installer Measured input can NOT exceed rated input Any major change in gas flow requires changing burner orifice size CHECKING INPUT FIRING RATE Once it has been determined that the gas supply is correct to the furnace it is necessary to check the input firing rate This can be done in two 2 ways First by checking and ad justing as necessary the manifold Outlet pressure The second way is to Clock the gas meter WVARNING Fire or explosion hazard Turn OFF gas at shut off before connecting manometer Failure to turn OFF gas at shut off before connecting manometer can result in death personal injury and or property damage 440 08 2001 02 Single Stage Multi Position Furnace CHECKING MANIFOLD PRESSURE Gas Pressure Testing Devices 1 Connect a manometer or Magnehelic gauge 0 12 W C range to the pressure tap on the OUTLET side of the gas valve 2 Turn gas fire the furnace and remove adjust ment cover screw cap 3 Turn adjustment screw clo
27. on the vent drain stub Mountthe condensate drain trap in a vertical position to the left side of the furnace using the two screws and gasket that are provided Note The condensate trap will be located underthe furnace in aver tical position when the furnace is placed horizontally on the leftside If needed remove the hole plugs from the furnace side panel and relocate to the open set of holes in the opposite side panel NOTE All gaskets and seals must be in place for sealed combus tion applications Remove the 90 street elbow and vent fitting from the combustion blower by loosening the clamps on the vent fitting Connect the 90 street elbow to the combustion blower using the rubber coupling and clamps Glue the 11 section of PVC pipe to the 90 street elbow after checking the fit up Follow the procedures outlined in the Join 440 08 2001 02 34 ing Pipe and Fittings section ofthis manual page 30 The PVC pipe will extend through the top panel about 11 2 Connect the vent fit ting to the end of the 11 section of PVC pipe using the clamp NOTE The vent fitting MUST be installed with the airflow marking arrow pointed toward the vent pipe with the drain stub at a 20 to 30 downward slope Plug the upper drain stub on the vent fitting with the yellow plastic cap Connect the 98 OD rubber hose with the 90 bend to the lower drain stub on the vent fitting and secure with a 5 8 clamp Route the hose to the horizonta
28. than for testing purposes should never be jumped out Limit switches are normally closed electrical switches de signed to open when their predetermined limit setting has been reached It should also be remembered that when a limit switch opens it more than likely is not due to a bad switch The cause of the opening limit must be found and corrected be fore the furnace can resume proper operation WARNING Fire hazard Limit controls are factory preset and MUST NOT be adjusted Use ONLY manufacturer s authorized replacement parts Failure to do so can result in death personal injury and or property damage The specific functions of the two 2 limit switches used in this series of furnaces are as follows MAIN LIMIT SWITCH A Normally Closed switch located on the front partition of the furnace It monitors supply air temperature and inter rupts furnace burner operation when a supply air tempera ture is sensed which would result in the furnace exceeding 440 08 2001 02 10 Single Stage Multi Position Furnace COOLING speed on a call for cooling from the thermostat The HEATING speed will be energized instead via the G terminal simultaneously Models equipped with a HONEYWELL ST9160B series Fan Timer Furnace Control may be twinned using a model twinning kit To assist troubleshooting efforts of Twinned installations TYPICAL control wiring diagrams are pro
29. tight Service Manual The best method to obtain the required setting for the heat anticipator is to measure the actual current draw in the con trol circuit using a low range 0 2 0 Amps Ammeter See Figure 10 After measuring the current draw simply set the heat anticipator to match that value If a low range ammeter is not available a Clamp on type meter may be used as follows 1 Wrap EXACTLY ten 10 turns of wire around the jaws of a clamp on type ammeter 2 Connect one end of the wire to the W terminal of the thermostat sub base and the other to the R termi nal 3 Turn power on and wait approximately 1 minute then read meter 4 Divide meter reading by 10 to obtain correct anticipator setting If an ammeter is not available a setting of 0 30 amps may be used for models equipped with the HONEYWELL SV9541M Gas Valve Ignition Control They should howev er provide satisfactory operation in most cases Electronic thermostats do not use a resistance type anticipa tor These thermostats use a microprocessor computer that determines a cycle rate based on a program loaded into it at the factory These cycle rates are normally field adjustable for different types to equipment The method of adjustment however varies from one thermostat manufacturer to another Check with the thermostat manufacturer to find out the proper way of adjusting the cycle rate to insure trouble free opera
30. to 60 100 140 or 180 seconds 440 08 2001 02 18 Single Stage Multi Position Furnace Heating OFF Delay DIP switch Setting COOL ON DELAY 6 SEC COOL OFF DELAY 60 SEC HEAT ON DELAY 30 SEC HEAT OFF DELAY ON OFF 12 12 12 12 60 SEC 100SEC 140SEC 180 22 ST9160B TESTING SEQUENCE If furnace successfully passes this testing sequence it can be assumed that there are no problems with the ST9160B FAN TIMER FURNACE CONTROL If it does not however it does not necessarily mean that there are problems with the control Any malfunctions should be thoroughly investigated before replacing and components CHECKING COOLING FUNCTIONS 1 JUMPER Y amp TO 2 CHECK COOLING FAN DELAY ON 3 CHECK COOLING SPEED FAN OPERATION 4 REMOVE JUMPER 5 CHECK COOLING FAN OFF DELAY Service Manual Setting OFF and ON 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 switches to obtain the desired setting See Figure 29 The ST9160B Heating OFF delay can be set to 60 100 140 or 180 The control was shipped out in the 140 position This may be satisfactory for some installations but not for others The Heating ON delay is fixed at 30 seconds is not ad justable The OFF delay should be set as lon
31. 11 10 13 900 40 370 16 25 1 31 5 4 41 o 5 Single Stage Multi Position Furnace Service Manual Manufacturers Number Mfr No See Rating Plate ALL Models Specifications 9MPD A2 BEER 9MPDO50F12A 9MPDO75F12A 9MPD050J16A 9MPD100J14A 9MPD100J20A 9MPD125L20A General Gas Type Nat LP Nat LP Nat LP Nat LP Nat LP Input Btuh 50 000 80 000 100 000 100 000 125 000 Output Btuh 46 000 73 600 115 000 Transformer Size VA 40 40 T stat Heat Anticipator 10 10 C F 35 65 Electrical Volts Hz FLA 115 60 9 8 115 60 8 9 115 60 9 0 115 60 9 0 115 60 10 5 115 60 11 2 Gas amp Ignition Gas Type Gas Valve HW SV9541M HW SV9541M HW SV9541M HW SV9541M HW SV9541M HW SV9541M Regulation Type SNAP SNAP SNAP SNAP SNAP SNAP IgnitionType Series HW HSP HW HSP HW HSP HW HSP HW HSP HW HSP Manifold Press Inch s WC Std Main Orifices No Size Pilot Orifice Size Fan Controls Fan Control Type HW ST9160 HW ST9160 HW ST9160 HW ST9160 HW ST9160 HW ST9160 Fan Control 30 30 30 30 30 30 Timed secs 60 100 140 180 60 100 140 180 60 100 140 180 60 100 140 180 60 100 140 180 60 100 140 180 Combustion Flue Outlet Size Inches Std Outlet Temp 5 No Elbows Blower Pressure 5 No Elbows WC Blower Pressure 40 5 90 DWV Elbows WC Transition Bx Pressure 5 No Elbows WC Transition Bx Pressure 40 5 90 DWV Elbows WC Limits amp Controls Rollout Switc
32. 20 to 30 Supply Air Td 25 23 60 NOTE TRAP MUST PRIMED BEFORE OPERATION Downflow Installations Single Pipe amp Direct Vent N9MP1 amp N9MP2 Models See Figure 50 Note For easier installation of the drain hoses and clamps to the condensate trap follow the directions outlined below except do not make any clamp connections to any of the drain stubs and hoses until the hose routing and lengths have been determined Remove the condensate trap and drain hoses from the furnace and secure the drain hoses to the drain stubs on the trap with the hose clamps position the clamps as shown in Figure 50 Install the condensate trap hose assembly to the furnace casing Hook one side of the clamp ears on the drain stub through the hole in the casing and push the condensate trap into position Secure with the two screws Reconnect the drain hoses to the stubs on the vent fitting and the plastic transition and secure with the clamps Mount the condensate drain trap in a vertical position to either the right or left side ofthe furnace using the two screws and gasketthat are provided If needed remove the hole plugs from the furnace side panel relocated to the open set ofholes in the opposite side panel NOTE All gaskets and seals must be in place for sealed combus tion applications Ensure that the vent fitting is securely attached to the combustion blower using the rubber coupling and clamps 440 08
33. 315 39VLTOA 9 J39VLTOA ANI OTQ3H ania O ania 1 Md Ovid 3000 1 daads ADVLIOA OV AHL NI HOLIMS 3H01SS33d NAdO dO SAdIS HLOS NO SISSVHO OLSLIOA 9L L SH313IN LIOA LSOW HLON 3009 LVLSOWYSHL 440 08 2001 02 5 140 TOYLNOD NO 9NIGN3d3a S3lH3S NIZOLL HOLIMS 33nSS3Hd 3 NO NI OLI HOLIMS 100 TION HOLON 100 lt AINO 1 HOLIMS SER 6 NO 5915435 NI Z OL I HOLIMS JYNSSIYd 2 gt 2 2 lt LL SYOLONGNOD H3ddOo NOLLO3NNOO 91313 ANWA SVO NIV 5 LO3NNOOSIG QHVZVH MOOHS WOIYLDATS S3lH3S OL 4 HOLIMS LNOTION HOLIMS MOOTHSLNI SETTING ZHO9 ASLL LOH COOL ON DELAY 5 SEC COOL OFF DELAY 60 SEC HEAT ON DELAY 30 SEC INVHOVIG aqdqv1 Diag
34. 80 2 60 1 80 2 60 1 80 2 60 1 80 2 60 1 80 2 60 40 5 90 DWV Elbows 1 30 2 30 1 30 2 30 1 70 2 50 1 70 2 50 1 70 2 50 Limits amp Controls Rollout Switch Limit Control Setting Std Transition Pressure Sw Part No 1013518 1013518 1013518 1013518 1013166 Blower Switch Pressure Close 0 95 0 95 0 95 0 95 1 30 Blower Switch Pressure Open 0 80 0 80 0 80 0 80 1 10 Transition Switch Pressure Close 2 00 2 00 2 00 2 00 1 80 Transition Switch Pressure Open 1 80 1 80 1 80 1 80 1 60 High Altitude Pressure Sw Part No 1013165 1013165 1013165 1013165 1013157 Blower Switch Pressure Close 0 70 0 70 0 70 0 70 0 85 Blower Switch Pressure Open 0 55 0 55 0 55 0 55 0 70 Transition Switch Pressure Close 1 40 1 40 1 40 1 40 1 70 Transition Switch Pressure Open 1 20 1 20 1 20 1 20 1 50 Blower Data Type amp Size 11 8 11 8 11 10 11 10 11 10 Motor Amps Rpm 10 850 8 0 1050 10 1050 13 900 13 900 Motor Type H p PSC 1 2 PSC 1 2 PSC 1 2 PSC 3 4 PSC S Cap Mfd Volts 7 5370 7 5370 10 370 40 370 40 370 Filter Type 16x25x1 16x25x1 16x25x1 16x25x1 16x25x1 Cool Cap Tons 5 L ML MHi amp Hi 11 5 2 21 5 3 11 5 2 21 5 3 11 2 2 3 31 2 31 2 4 41 9 5 31 4 41 9 5 440 08 2001 02 52 Single Stage Multi Position Furnace Service Manual Manufacturers Number Mfr No See Rating Plate ALL Models Specifications N9MP1 A2 SES 9 1050 12 9 1075 12 9 1080 16
35. ED PRESSURE SWITCHES CLOSED WITHIN NOT COMBUSTION BLOWER DE ENERGIZED FIVE MINUTE WAIT PERIOD 30 SECONDS 3 SECOND PRE PURGE AA PILOT VALVE OPENS THREE SECOND FLAME IGNITOR POWERED 1 FAILURE RECYCLE DELAY PILOT LIGHTS AND FLAME IS SENSED PILOT VALVE CLOSES DURING 90 SECOND TRAIL FOR PILOT IGNITOR OFF IGNITION YES MAIN VALVE OPENS HEATING FAN ON DELAY BEGINS AFTER DELAY CIRCULATING BLOWER STARTS YES CIRCULATING BLOWER OFF AFTER FLAME SENSE LOST PILOT AND MAIN VALVE CLOSE DELAY THERMOSTAT CALL FOR HEAT ENDS FLAME SENSE LOST MORE THAN FIVE COMBUSTION AIR BLOWER OFF AFTER TIMES IN THIS CALL FOR HEAT NO POST PURGE NO YES PILOT AND MAIN VALVE CLOSE 1 Ignitor ON for first 30 seconds of trial for ignition then OFF for next 30 seconds COMBUSTION BLOWER DE ENERGIZED If the pilot has not lit it turns back ON for the final 30 seconds The pilot valve remains AFTER 30 SECOND POST PURGE energized during the entire 90 second trial for ignition NOTE If main limit string opens and takes longer than 2 minutes to close system goes CIRCULATING BLOWER OFF AFTER into 1 hour wait period indicating circulating blower DELAY WAIT FOR NEXT CALL FOR HEAT 440 08 2001 02 46 Single Stage Multi Position Furnace Service Manual HONEYWELL SV9541 SMART VA
36. High for Cooling Low for Heating Although that may be how it works out SOMETIMES it can in many cases be ex actly the opposite I E a Lower speed for Cooling and a Higher speed for Heating The PROPER CRITERIA FOR SELECTING BLOWER SPEEDS is as follows HEATING A blower speed must be selected that will provide proper temperature rise through the furnace See checking tem perature rise found elsewhere in this manual The required CFM for a particular temperature rise can also be calculated using the following formula Output BTU Temp Rise X 1 08 EXAMPLE using a 75 Mbtu furnace of this series with an output of 67 500 Btuh and a desired temperature rise of 50 F range of 40 70 F allowable and a measured external static pressure of 0 2 W C with a dry coil 67 500 or 67 500 50 X 1 08 54 1250 Checking the blower performance data for this model see Figure 36 indicates that 0 2 W C E S P medium high speed will deliver 1249 CFM Accordingly medium speed should be used in this example for the HEATING speed COOLING A blower speed must be selected that will provide proper air flow Nominal 400 CFM per ton for the size capacity air conditioning coil being used at the external static pressure of the Duct system installation This requires CHECKING THE EXTERNAL STATIC PRESSURE then consulting the BLOWER PERFORMANCE DATA to determine the re quired speed tap EXAMPLE A 24 000 BTU 2 TO
37. ICAL SUPPORT MANUAL FOR PART NOS Under normal operating conditions sufficient negative pres sure will be created to close the pressure switch and keep it closed to keep furnace operating Under abnormal condi tions however such as arestricted vent pipe or aleak in one of the heat exchangers sufficient negative pressure will not be created This will result in the switch failing to close or fail ing to remain closed during furnace operation When servicing a unit whose pressure switch will not close or remain closed during operation the operating pressure of that furnace should be checked and compared to approximate operating pressures listed in Table 3 and the switch setting s listed above for the model family you are servicing It is important to remember that greater negative pressures are created by the furnace when HOT I E upon initial start up than when COLD I E after furnaces has been in operation for a few minutes Because of this furnace pres sure should ONLY be checked when to insure accu rate readings Table 3 lists approximate operating pressures for Direct Vent I E Two Pipe installations of models in this series They were obtained in a test lab under controlled conditions using two 2 specific vent lengths They are included in this manual to provide you with a Barometer to gauge our pres sures against The pressures you obtain in the field will differ slightly from these figures b
38. LVE 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 LED INDICATES CHECK REPAIR Line voltage inputat L1 and Neutral connectors on ST9160B Fan Timer off No power to system control Low voltage 24V power at 24 VAC and COM terminals on ST9160B System wiring harness is in good condition and securely connected Heartbeat Normal indication whenever the system is powered unless some abnormal event has occurred Md a MIL dd when it should be open Pressure switches stuck closed system will wait for pres 2 Flashes when call for heat begins sure switch to open Combustion blower is not energized until pressure 2 switches opens Pressure switches miswired or jumpered Pressure switches open when they should be closed i e longer than 30 seconds after combustion blower inducer is energized Ignition system control switch must be in the ON position 3 Flashes Pressure switches operation tubing and wiring System goes into 5 minute delay period with com Restrictions in furnace air intake or vent piping bustion blower inducer off At end of the 5 minute delay another cycle will begin Main limit switch Main Limit or Roll Out Switch i n i oll Out Switeh is Manual reset burne
39. MULTI POSITION SINGLE STAGE GAS FURNACES Service Mamua N9MP1 N9MP2 amp 9MPD A amp A2 This manual supports condensing gas furnaces manufactured in 2001 Manufactured by Up Part Number Products 440 08 2001 02 4 2002 2001 International Comfort Products Corporation USA 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 Single Stage Multi Position Furnace Service Manual TABLE OF CONTENTS 1 INTRODUCTION ER 2 2 UNIT IDENTIFICATION ee ER aay merca 2 3 FURNACE THEORY OF OPERATION eed bese aban 3 a ELEOTRIGAL SUP REY ee ile Cao e 4 5 INTERLOCK SWITCH blow bss te Dee drum 5 p GAS SUPPLY az Ido DC PII M etn eed 5 7 DURINERS sete was Sekine ate ee ut Cel du ede ata 7 8 L P PRESSURE SWITCH lt etg ce a nod xt rrr bac e e aus vind xin 7 9 HIGH ALTITUDE OPERATION 2 2 R0 e eaa tebe 7 10 CHECKING TEMPERATURE RISE 2 8 Ti ROOM THERMOSTAT Cem add vow aur pe See qe por c Laus 8 12 CONTROL WIRING s ior ette ios eese tee o t en Reb dae s 9 TWINNING KITS
40. N air conditioning system using the same 75 000 BTU furnace as in the previous ex 440 08 2001 02 22 Single Stage Multi Position Furnace ample The external static pressure is measured and found to be 0 4 W C 400 CFM nominal per TON required 400 x 2 800 required Checking the blower performance data see Figure 36 for this model indicates that 0 4 W C ESP low speed will de liver 788 CFM Accordingly low speed should be usedin this example for the COOLING speed Blower Performance Data Table 7 75 0000 BTUH Air Delivery in Cubic Feet per Minute CFM Furnace Rated 0 5 W C ESP KARA L 1576 1532 1489 sw we pn ve sw we pee SAMPLE ONLY External Static Pressure Inches of W C CHANGING BLOWER SPEED The procedure for changing blower speeds if needed is shoun in Table 8 A WARNING Electrical shock hazard Turn OFF power to furnace before changing speed taps Failure to do so can result in death and or personal injury iw Single Stage Multi Position Furnace Figures Honeywell ST9160B 25 23 63 29 BLOWER ROTATION e startup of a furnace will involve a cycle or two of the fur nace to properly prime the condensate trap with water Until the trap is fully primed some condensate will be pulled into the combustion blower The furnace may cycle on the pres sure switch connected to the plastic transition
41. URE RISE Checking Temperature Rise Thermometer Return Air Temp Thermometer Supply Air Temp Air Flow The furnace is designed to operate within a certain specified range of temperature rise Operating the furnace outside the specified range may result in lower efficiency and or comfort levels as well as prema ture combustion component failures Simply stated the temperature rise through the furnace is the difference in temperature between the return air and the supply air NOTE BEFORE CHECKING TEMPERATURE RISE BE CERTAIN THAT MANIFOLD PRESSURE IS PROPERLY ADJUSTED 11 ROOM THERMOSTATS Room thermostats are available from several different manufactures in a wide variety of styles They range from the very simple and inexpensive Bi metallic type to the complex They are simply a switch or series of switches designed to turn equipment or components ON or OFF at the de sired conditions An improperly operating or poorly located room thermostat can be the source of perceived equipment problems A care ful check of the thermostat and wiring must be made then to insure that it is not the source of problems 440 08 2001 02 Single Stage Multi Position Furnace ALLOWABLE TEMPERATURE RISE ALL MODELS NENNEN NN 50 Mbtu 35 F 65 F 75 100 amp 125 Mbtu 40 F 70 F Operate the furnace for 15 minutes before taking tempera ture readings Subtract the return air temperature from the s
42. Vent Pipes MUST supported Horizontally Single Pipe Vent Pipes MUST be E Vertically Min Min Max Max same same atmospheric zone atmospheric zone supported Horizontal VENT PIPE ly and Vertically DISCHARGE AIR 0 Y Increase minimum from 8 to 18 for cold climates sustained temperatures Increase minimum from 8 to 18 for cold climates sustained temperatures below below 0 F 0 25 23 33 25 23 33a 13 440 08 2001 02 Service Manual 16 VENT COMBUSTION AIR PIPING Vent and combustion air piping are an extremely important part of the total furnace installation Improperly installed or inadequately sized vent and or combustion air piping can be the source of many perceived furnace problems For example most problems associated with pressure switch operation can normally be traced to short comings in the vent and or combustion air piping Anytime these type problems arise a thorough inspection of the vent and or combustion air piping should be conducted ALL MODELS require a vent exhaust pipe to carry flue 17 STANDARD VENT TERMINATION Vent Combustion Air Piping Charts
43. ally within the device IT IS NOT REPAIRABLE and must be replaced The Pilot Hardware includes the pilot burner the hot surface element that lights the pilot burner the flame rod that senses pilot flame and the cable that attaches to the system control The hot surface element is made of tough break resistant ce ramic composite material It operates on 24 Volts A C The Igniter Flame Rod assembly can be replaced independently from the pilot burner assembly The system operation is quite simple and forgiving I E nui sance lockouts are eliminated 25 HONEYWELL SV9541M SYSTEM OPERATION Connecting the furnace to the line voltage supply with the blower door interlock switch closed provides 24 volts to pow er the system This is accomplished by the connections from terminals pins 4 amp 42 from the ST9160B fan timer to terminals 1 amp 3 of the SV9541M gas valve When the thermostat calls for heat the combustion blower starts causing the pressure switch to close completing the circuit to the ignition system control there will be approxi mately a two 2 second delay while the ignition system con trol runs a self check Part of the self check is to see if a flame signal is detected If aflame signal is detected upon a call for heat and naturally there shouldn t be the ignition system control will energize the electronic fan timer output causing the conditioned air blower to start after the fixed 60 second ON de
44. amp Hi 11 5 2 21 5 3 11 5 2 21 5 3 21 5 3 31 5 4 11 2 2 3 31 5 31 5 4 41 5 5 31 2 4 41 9 5 Gas Conversion Kits Nat to LP NAHFOO2LP 1009509 NAHF003LP NAHFOO2LP 1009509 LP to Nat 1009510 1013815 1009510 Order from Service Parts NAHF003NG 1013816 55 440 08 2001 02 Service Manual Single Stage Multi Position Furnace CIRCULATION AIR BLOWER DATA For 050 Models 3 Ton Units For 080 Models 4 Ton 19 amp 223 Units Co we we pue pue puso es oe oes ses vm s oer ome se we CFM OW ws we sm ses 985 1153 153 1237 237 s p m me we NN ow o sepe qw 5 om ee we pe pee For 100 Models 5 223 4 Units Inches of W C o I 3 o 2 5 o T x Im 2 X Exterrnal Static Pressure Inches of W C Lo T ager EEE EE T 1 19 Med L Loos e pue pes IHE mc Exterrnal Static Pressure Inches of W C Exterrnal Static Pressure Inches of W C ss we pee pee pe oss p pm pe pss For 125 Models 5 Ton Units Reps esq os se per see ee os ome pm pee pm pe pe Ew pep Exterrnal Static Pressure Inches of W C 9 5
45. an be used for this purpose The condition of the capacitor should then be verified with a capacitor analyzer one that indicated the capacitor s value in microfarads rather than with an Ohmmeter The reason forthis is that an Ohmmeter test can only indicate if a capac itor is OPEN or SHORTED it cannot verify if its value mi crofarads is within an acceptable range Capacitor should test to within 10 of its rated value Capac itors testing outside this range should be replaced A weak capacitor can be the cause of a motor failing to start 440 08 2001 02 Service Manual 28 BLOWER ASSEMBLY All models use a multi speed permanent split capacitor mo tor direct drive blower assembly Different size HP mo tors and or different diameter blower wheels are used in each model to obtain the required air flow The entire blower assembly slides out on rails for servicing after removing the two screws at the front SELECTING BLOWER SPEEDS The wide variety of applications and installations of furnaces throughout the country makes it impossible to Factory Se lect blower speeds that will provide proper operation for all installations This means then that the blower speeds for both heating and cooling must be Field Selected for each particular installation to insure proper operation is to prevent wide swings in room temperature during furnace operation The criteria for selecting the proper blower speeds IS NOT
46. ap as the template Ensure thatthe vent fitting and the 90 elbow is securely attached to the combustion blower using the rubber coupling and clamps Plug the right drain stub ofthe ventfitting with the rubber plug Usea blunt pointed screwdriver to push the plug into the stub For left side venting remove vent fitting assembly from combustion blower Remove 90 elbow and rubber tubing from the vent fitting by loosening the clamp on the ventfitting Securely attach vent fitting to combustion blower NOTE The vent fitting MUST be installed with the airflow marking arrow pointed toward the vent pipe with the drain stub ata 20 to 30 downward slope This configuration allows left side venting from the furnace If right side venting is required the combustion blower must be relocated on the plastic transition box Remove the four 4 screws that secure the blower to the transition Rotate the blower 180 and secure with the four 4 screws Use caution to notovertighten the screws to pre vent stripping out of the plastic mounting holes 440 08 2001 02 24 Plug the upper drain stub on the ventfitting with the rubber plug Use a blunt pointed screwdriver to push the plug into the stub Route the hose to the large drain stub on the condensate trap Cut off excess hose and discard Connectthe hose with the 90 bend to the drain stub on the trap and secure with a 3 4 clamp For left side mounted condensate trap connect the 3 4 OD rubber
47. ard slope to the conden sate trap with no kinking or binding for proper condensate drainage Downflow Installations Dual Certified 9MPD A2 Models DRAIN SIDE VIEW Rotate downward 20 to 30 LEFT Side Venting FM 4 ST Return Air Pressure Switch Hose Transition Some Models have one pressure switch Combustion Blower dp em 4 Switch Switch Hose Blower Supply Air NOTE TRAP MUST PRIMED BEFORE OPERATION RIGHT Side Venting Me Se SS Return Air Pressure Blower Pressure Air Intake Coupling Combustion Combustion Blower Air Pipe Optional Rotate 180 for Left Side Yellow Pressure Switch Plastic Cap Transition Plastic Cap Transition Vent Pipe Grommet Vent Fitting amp Clamps Plastic Caps Condensate Trap amp Gasket 5 8 Hose amp Clamps Gas Pipe Grommet Drain Line Trap Connection Clamp ears Supply Air Dni dwg 25 23 56 Preassemble and insert into furnace Downflow Installations Dual Certified 9MPD Models See Figur
48. ased upon vent length gas pres sure operating temperature etc Major discrepancies in pressures will normally cause problems with pressure switch operation These Major dis crepancies should be investigated as follows Single Stage Multi Position Furnace Service Manual Table 3 APPROXIMATE OPERATING PRESSURES OF W C 50 Mbtu 75 Mbtu 100 Mbtu 125 Mbtu Lower Lesser Negative Pressures Higher Greater Negative Pressures Lower than normal negative pressures measured at the Higher than normal negative pressures measured at the Combustion Blower may be caused by Combustion Blower may be caused by 1 Restriction on the Outlet side ofthe combustion blow 4 Restriction on the Inlet side of the combustion blower Vent too long Heat Exchanger ILE Plugged Heat Exchanger air inlet orifice too small 2 Leak lack of restriction on the Inlet side of the com bustion blower Typical Vent Combustion Air Piping Installation UPFLOW DOWNFLOW See Vent Termination Shielding Coupling on inside 48 Min Aluminum or non rusting shield recommended Section aie 1e 20 Max See Vent Termination Shielding for dimensions Inlet Pipe 8 Min atmospheric zone Inlet Pipe iol usd on 20 Max not used Coupling on ends ex Single Pi in same on haust pipe Total pipe amp ingle FIPE J as atmospheric coupling outside struc models zone ture 8 4 f n
49. ause ofthe over temperature must be determined and corrected If however the switch is found to be opening prematurely then it should be replaced When replacing ANY limit switch use ONLY a switch of EXACTLY the same temperature set ting Use of a different temperature limit switch can create a dangerous situation Some of the main limit switches used in this series are SIMILAR IN APPEARANCE DIFFERENT TEMPERATURE SETTINGS HOWEVER ARE USED for different models Be certain you have the correct control for the model you are servicing ROLL OUT LIMIT A Normally Closed switch wired in series with the Main Limit switch mounted on the burner box This switch may be of the manual type depending upon the particular model and or family Different temperature OPENING settings are also used on different models When replacing this switch be absolutely certain the correct one is used Figure 12 Typical Roll Out Limit Switch CAUTION NEVER use an automatic reset roll out switch to replace a manual reset type roll out switch Doing so may cause potentially unsafe and or intermit tent operation 11 Service Manual The roll out switch monitors the temperature inside the burn er box and interrupts furnace burner operation when its temperature indicates flame roll out has occurred If the roll out switch has opened the cause must be deter mined Some possible reasons for flame roll out include a re stricted primary
50. be equipped with one or more different components MODEL NUMBER IDENTIFICATION GUIDE Brand Identifier T Tempstar C Comfortmaker H Heil A Arcoaire X Evaluation Brand Identifier 8 Non Condensing 80 Gas Furnace 9 Condensing 90 Gas Furnace Installation Configuration UP Upflow HZ Horizontal DN Downflow UH Upflow Horizontal DH Downflow Horizontal MP Multiposition Upflow Downflow Horizontal Major Design Feature 1 One Single Pipe N Single Stage P PVC Vent T Two Stage V Variable Speed 2 Two Pipe D 1 or 2 Pipe L Low NOx 440 08 2001 02 Engineering Rev Denotes minor changes Marketing Digit Denotes minor change Cooling Airflow 08 800 CFM 12 1200 CFM 14 1400 CFM 16 1600 CFM 20 2000 CFM Cabinet Width B 15 5 Wide F 19 1 Wide J 22 8 Wide L 24 5 Wide Input Nominal MBTUH Single Stage Multi Position Furnace Service Manual Component Locations for Four Position Furnaces Furnace Vent Pipe Vent Pipe Grommet Manual Gas Valve Gas Valve Ignition Module Vent Drain Fitting Diagnostic Light Combustion Bio Wwe Pipe Drain Hose 3 4 OD Transition Box Drain Hose Door Interlock Switch Fan Delay Control Rating Plate Air Intake Pipe Dual Certified or Direct Vent Model Primary Heat Exchanger Secondary Heat Exchanger Pressure Switch Plastic Transition Box
51. bic BTU Per 3 Time how many seconds it takes the smallest normal BTU Content PerHour Footin seconds Mour ly 1 cfh dial on the gas meter to make one complete 1 000 3 600 75 000 revolution 1 000 x 3 600 48 75 000 BTUH 440 08 2001 02 6 Single Stage Multi Position Furnace 7 BURNERS Burners used in this series of furnace are of the INSHOT type Their operation can be compared to that of a torch in that they produce a hard sharp somewhat noisy flame Noise should not be an issue however because of the closed compartment design In order to insure that the burn ers are operating properly and at their design noise level proper adjustment of the gas manifold pressure is essen tial See page 6 for further information on manifold pressure adjustments The burners used in this series ARE NOT EQUIPPED WITH AIR SHUTTERS as none are required Proper operation flame characteristics is obtained by insuring that the orifice size and manifold pressure are correct for the fuel being used and the altitude of the installation 8 L P PRESSURE SWITCH Models converted to operate on L P Gas will be installed with an L P Pressure Switch If so equipped the switch will be located in the gas supply line in a Tee fitting just ahead of the gas valve The purpose ofthis switch is to preventfurnace operating un der low line Supply pressure conditions Operating under low line pressure conditions can create problems su
52. c fan timer output causes the OFF delay timing to begin and whenthe pre selected time 90 100 140 or 180 seconds expires the blower will turn off TROUBLESHOOTING Malfunctions of the HONEYWELL SV9541M Smart Pilot system may be easily diagnosed using a voltmeter and a spare igniter flame rod assembly The igniter itself can also be checked using an Ohmmeter Resistance of a Good igniter should be 10 Ohms or less See trouble shooting flow chart and the sequence of opera tion flow chart on pages 36 and 37 ofthis manual for addition al information on the operation and troubleshooting of this system the difference in size between the flame probe and the burn er ground area this current flows mostly in one direction This creates a pulsating Direct Current that flows back to the igni tion control proving flame This flame current D C Microamps may be checked while flame is present using a D C Flame Sensor kit is available from outside vendors Capacitors are used for both the circulating conditioned air blower motor and the exhaust combustion blower Before replacing one of these motors assumed to be bad the con dition of its capacitor should be verified since it and not the motor may be the source of the problem Before checking any capacitor the supply power to the unit should be turned OFF The capacitor should then be dis charged through a resistor before testing A 20 000 Ohm 2 Watt resistor c
53. ch as in complete combustion flashback sooting etc The switch is a Normally Open pressure operated switch thatis wired in series with the furnace vent pressure switch The Pressure Switch closes when line Supply pres sure is 8 0 W C or higher the L P Pressure Switch Opens if line pressure falls below 6 0 0 6 W C interrupting power to the gas valve On some models it is located electrically between the Fur nace vent pressure switch and the gas Valve 9 HIGH ALTITUDE OPERATION Thesefurnaces are designed to operate in the majority of the country without modifications At altitudes over 2 000 above sea level however certain measures need to be taken to in sure continued safe reliable operation For example units must be de rated for altitude by adjusting manifold pres sure and or changing orifice size based upon the type of fuel Natural Gas or L P gas Btu content of the gas and installed altitude Service Manual Burner Face 10 10 78 ALL UNITS must have a high altitude pressure switch installed at altitudes above 4 000 above sea level When servicing a unit installed at altitudes above 2 000 in sure that it has been properly modified to operate at that alti tude See the sections on Gas pressure Page and pres sure switches Page to obtain specific information for you particular installation altitude 440 08 2001 02 Service Manual 10 CHECKING TEMPERAT
54. ckwise IN to INCREASE pressure and counterclockwise OUT to DECREASE INCHES OF WATER pressure 4 At altitudes BELOW 2 000 set manifold pressure to AGNEHELIC 3 5 W C for Natural Gas and 10 W C for L P Gas PRESSURE 15 PSIG 5 For Natural Gas units ABOVE 2 000 set manifold pressure according to TABLE 2 a7 6 For L P Gas units ABOVE 2 000 insure that orifice size has been changed per National Fuel Gas Code Typical Appendix F if gas supply has not already been de rated for altitude by the gas supplier 7 For ALL UNITS ABOVE 8 000 contact the factory for SPECIFIC de rating information MANIFOLD PRESSURE AND ORIFICE SIZE FOR HIGH ALTITUDE APPLICATIONS Table 2 NATURAL GAS Po Elevation Above Sea Leve Above Sea Level Heat Value Btu Cu Ft LES amar a MOSES T TS 1999 2000 2999 3000 3999 4000 4999 5000 5999 6000 6999 7000 7999 35 38 38 owes e e 9 1 9 CLOCKING GAS METER NATURAL GAS 4 Calculate input rate by using ACTUAL BTU content of gas in formula shown in example 1 Check with gas supplier to obtain ACTUAL BTU con tent of gas 2 Turn OFF gas supply to ALL other gas appliances No of Seconds Time Per Cu
55. connected to this terminal when the furnace is shipped CONTINUOUS fan should not be confused with FAN ON which is obtained by switching the fan selector switch on the Single Stage Multi Position Furnace thermostat sub base to FAN ON energizing the G ter minal which causes the blower to run on the HEATING speed The ST9160B Electronic Air Cleaner terminal EAC IS ONLY energized in conjunction with the HEATING and COOLING speed terminals The maximum allowable con nected load to the HUM terminal is 0 8 eight tenths Amp The combined connected loads of the EAC and HUM termi nals cannot exceed a total of 0 8 eight tenths amp 24 HONEYWELL SV9541M GAS VALVE IGNITION CONTROL Pilot Burner Sensor Honeywell ST9541M Ignition System Ignition Sensor Gas Valve Ignition Control dwg 25 23 31a The system consists basically of only two 2 components The Ignition System Control and the Pilot Hardware The op erate on Two 2 24 volt power circuits received from the ST9160B Fan Timer Furnace Control One is the power sup ply to the ignitor the second is to activate the ignition se quence The Ignition System Control manages the ignition sequence and the flow of gas to the pilot and main burners It is in es sence a combination Gas Valve and Ignition control It contains sophisticated electronic components internally and has NO USER SERVICEABLE COMPONENTS Should a problem be verified intern
56. d from the opening of the main gas valve the control will delay 30 seconds before switching the fan to Heat speed W signal removed from EFT The gas valve de energizes and the main burners go out The inducer runs at its present speed for a 30 second postpurge period Timed from the gas valve de energizing the Heat fan speed de energizes after the selected Heat Fan Delay time expires Heating Request with Gas Supply Line Shut Off 24 VAC signals applied to W terminal of EFT control Inducer motor turns on The gas valve solenoid energizes Following a 3 second prepurge delay the pilot valve opens and the ignitor begins to warm up The ignitor glows red hot for 30 seconds then turns off The igniter stays off for 25 seconds then begins to warm up again The igniter glows red hot for 30 seconds then turns off The pilot valve closes seconds after the igniter de energizes The inducer de energizes 5 seconds after the pilot valve closes The SmartValve proceeds to soft lockout and flashes error code 6 The control exits soft lockout after 5 minutes and begins another ignition sequence 45 440 08 2001 02 Service Manual Single Stage Multi Position Furnace HONEYWELL SV9541M SMART VALVE Sequence of Operation POWER APPLIED TO APPLIANCE THERMOSTAT CALLS FOR HEAT WAIT FOR PRESSURE SWITCHES TO OPEN PRESSURE SWITCHES PROVED OPEN COMBUSTION BLOWER ENERGIZ
57. d the vent pipe with the drain stub at a 20 to 30 downward slope 25 Plug the upper drain stub on the ventfitting with the rubber plug Use a blunt pointed screwdriver to push the plug into the stub Connectthe 3 4 OD rubber hose with the 90 bend to the drain stub on the bottom of the plastic transition box and secure with a 3 4 clamp Route the hose to the large drain stub on the condensate trap Cut off excess hose and discard Connect the hose to the drain stub on the trap and secure with a 3 4 clamp Connectthe 5 5 OD rubber hose with the 90 bend to the small drain stub on the trap and secure with a 5 8 clamp Route the hose to the lower drain stub on the vent fitting Cut off ex cess hose and discard Connect the hose to the drain stub on the vent fitting and secure with 5 8 clamp NOTE Ensure hoses maintain a downward slope to the conden sate trap with no kinking or binding for proper condensate drainage 440 08 2001 02 Service Manual Plastic Caps 5 8 Hose amp Clamps Rubber Coupling amp Clamps 90 Elbow Rubber Plug Single Stage Multi Position Furnace Horizontal Right Installations Dual Certified 9MPD A1 Models Vent Fitting amp Clamps Combustion Air Pipe P id Optional Gas Pipe Grommet Combustion Return Blower Air Combustion Blower Mounting Screws 4 Pressure Switch Hose Transition _ Pressure Swi
58. de of the furnace using the two screws and gasket that are provided Note The condensate trap will be located underthe furnace in aver tical position when the furnace is placed horizontally on the leftside If needed remove the hole plugs from the furnace side panel and relocated to the open set of holes in the opposite side panel NOTE All gaskets and seals must be in place for sealed combus tion applications 440 08 2001 02 40 Relocate the combustion blower on the plastic transition box Re move the four 4 screws that secure the blower to the transition box Rotate the blower 180 so the blower snout is pointing up and se cure with the four 4 screws Use caution to not over tighten the Screws to prevent stripping out of the plastic mounting holes Ensure that the vent fitting is securely attached to the combustion blower using the rubber coupling and clamps NOTE The vent fitting MUST be installed with the airflow marking arrow pointed toward the vent pipe Plug the left drain stub on the vent fitting with the yellow plastic cap Connectthe 3 4 OD rubber hose with the 90 bend to the large drain stub on the condensate trap and secure with a 3 4 clamp Route the hose to the drain stub on the bottom ofthe plastic transi tion box Cut off excess hose and discard Connect the hose to the drain stub on the transition and secure with a 3 4 clamp Connect the 5 8 OD rubber hose with the 90 bend to the right drain stub on
59. drain stub on the vent fitting with the yellow plastic cap Remove the pressure switch hose from the upper stub on the plastic transition box Relocate the plastic caps on the stubs of the plastic transition box from the lower stubs to the upper stubs and secure tightly with the clamps Route the pressure switch hose to the lower stub on the plastic tran sition box Cut off excess hose and discard Connect the pressure Switch hose to the lower stub on the plastic transition box Ensure that the hose is routed above the stub on the transition box so that condensate does not collect in the hose NOTE Failure to correctly installthe pressure switch hose tothe transition can adversely affect the safety control operation Connect the 3 4 OD rubber hose with the 90 bend to the large drain stub on the condensate trap and secure with a 3 4 clamp Route the hose to the drain stub on the bottom of the plastic transi tion box Cut off excess hose and discard Connect the hose to the drain stub on the transition and secure with a 3 4 clamp Connect the 5 5 OD rubber hose with the 90 bend to the lower drain stub on the vent fitting and secure with a 5 8 clamp 440 08 2001 02 Service Manual Route the hose to the smaller drain stub on the condensate trap Cut off excess hose and discard Connect the hose to the drain stub on the trap and secure with a 5 g clamp Single Stage Multi Position Furnace NOTE Ensure hoses maintain a downw
60. e 42 Connect the 5 8 OD rubber hose with the 90 bend to the lower 33 NOTE TRAP MUST BE PRIMED BEFORE OPERATION Trap Connection Clamp ears Pointed OUT rs and insert into furnace drain stub on the vent fitting and secure with 5 g clamp Route the hose to the small drain stub on the condensate trap Cut off excess hose and discard Connect the hose to the drain stub on the trap and secure with 5 s clamp NOTE Ensure hoses maintain a downward slope to the conden sate trap with no kinking or binding for proper condensate drainage 440 08 2001 02 Service Manual Combustion Air Pipe optional n Some Models have one Air Intake Vent Pipe Coupling Hose Blower Plastic Cap Pressure Switch Pressure d Transition Box Single Stage Multi Position Furnace Horizontal Left Installations Dual Certified 9MPD A2 Models NOTE TRAP MUST BE PRIMED BEFORE OPERATION Pressure Switch Pressure Switch Blower Transition Xe RENI Yellow Plastic Vent Fitting Clamps Combustion Blower Return Air Combustion Blower Mounting Screws 4 Pressure Switch Hose Transition 3j Hose amp Cla
61. e 45 Note For easier installation of the drain hoses and clamps to the condensate trap follow the directions outlined below except do not make any clamp connections to any of the drain stubs and hoses until the hose routing and lengths have been determined Remove the condensate trap and drain hoses from the furnace and secure the drain hoses to the drain stubs on the trap with the hose clamps position the clamps as shown in Figure 45 Install the condensate trap hose assembly to the furnace casing Hook one side of the 440 08 2001 02 36 clamp ears on the drain stub through the hole in the casing and push the condensate trap into position Secure with the two screws Reconnect the drain hoses to the stubs on the vent fitting and the plastic transition and secure with the clamps Mount the condensate drain trap in a vertical position to either the right or left side ofthe furnace using the two screws and gasketthat are provided If needed remove the hole plugs from the furnace Single Stage Multi Position Furnace side panel and relocated to the open set of holes in the opposite side panel NOTE All gaskets and seals must be in place for sealed combus tion applications For both rightand leftside vent remove the 90 street elbow from the vent fitting by loosening the clamp on the vent fitting Ensure that the vent fitting is securely attached to the combustion blower using the rubber coupling and clamps This configuratio
62. ent N9MP1 amp N9MP2 Models See Figure 39 Relocate the plastic caps and clamps on the condensate drain trap from the vertical drain stub to the horizontal drain stubs Secure the clamps tightly to prevent condensate leakage Mount the condensate drain trap in a vertical position to the right side of the furnace using the two screws and gasket that are pro vided Note The condensate trap will be located under the furnace in a vertical position when the furnace is placed horizontally on the right side If needed remove the hole plugs from the furnace side panel and relocate to the open set of holes in the opposite side pan el Drill two 7 64 diameter holes in the casing using the condensate trap as the template Ensure thatthe vent fitting and the 90 elbow is securely attached to the combustion blower using the rubber coupling and clamps NOTE The vent fitting MUST be installed with the airflow marking arrow pointed toward the vent pipe Plug the left drain stub on the vent fitting with the rubber plug Use a blunt pointed screwdriver to push the plug into the stub Remove the pressure switch hose from the upper stub on the plastic transition box 440 08 2001 02 30 Relocate the plastic caps on the stubs of the plastic transition from the lower stubs to the upper stubs and secure tightly with the clamps Route the hose to the large drain stub on the condensate trap Cut off excess hose and discard Connect the pressure switch
63. ese models is essentially the same This manual therefore will deal with all subjects in a general nature all text will pertain to all models unless that sub ject is unique to a particular model or family in which case it will be so indicated 2 UNIT IDENTIFICATION The unit s rating plate contains important information for the service technician It also lists the complete Model Manufac turing and Serial Numbers These complete numbers are required to obtain correct re Single Stage Multi Position Furnace WARNING The information contained in this manual is intended for use by a qualified service technician who is familiar with the safety procedures required in installation and repair and who is equipped with the proper tools and test instruments Installation or repairs made by the unqualified persons can result in hazards subjecting the unqualified person making such repairs to the risk of injury or electrical shock which can be serious or even fatal not only to them but also to persons being served by the equipment If you install or perform service on equipment you must assume responsibility for any bodily injury or property damage which may result to you or others We will not be responsible for any injury or property damage arising from improper installation service and or service procedures placement parts example in certain model families a unit having a MARKET REVISION of C is likely to
64. essure Switch return wave rectified AC Present when the door interlock switch is closed This AC voltage decreases when the Low Pressure Switch closes Data Line Present when the door interlock switch is closed Same rectified AC signal as P1 pin 5 Present when the door interlock switch is closed 24 VAC with igniter present Present when HSI is not turned on When HSI is on this signal is 0 VAC to 10 VAC depending on input line volt age potential 24 VAC Present when the door interlock switch is closed gt 80 VAC Present when the door interlock switch is closed Inducer supply 115 VAC Present when the inducer draft blower motor is on Heat modes Open Limit mode 115 VAC Present when the door interlock switch is closed Inducer return 0 VAC Always present neutral connection L2 neutral 0 VAC Always present With a motor tap connected voltage appears at unpowered fan terminals whenever the motor is running due to feedback through the motor windings Voltage appears on the unpowered inducer terminal whenever the inducer motor is running due to feedback through the motor windings NOTE1 Using a Fluke 79 digital Multi Meter DMM 12 wave rectified AC voltage typically measures about 14 The Fluke 79 is not a true RMS meter 49 440 08 2001 02 2501 6101 509395 SNILV3H 4 HOS SdV L 03395 ONILSNPAV 804 STVNNVW 338
65. figuration allows left side venting from the furnace If right side venting is required the combustion blower must be relocated on plastic transition box Remove the four 4 screws that secure the blower to the transition Rotate the blower 180 and secure with the four 4 screws Use caution to notovertighten the screws to pre vent stripping out of the plastic mounting holes Plug the upper drain stub ofthe vent fitting with the rubber plug Use a blunt pointed screwdriver to push the plug into the stub 440 08 2001 02 28 For left side mounted condensate trap connect the 3 4 OD rubber hose with the 90 bend to the drain stub on the bottom ofthe plastic transition box and secure with a 3 4 clamp Route the hose to the large drain stub on the condensate trap Cut off excess hose and discard Connect the hose to the drain stub on the trap and secure with a 3 4 clamp For right side mounted condensate trap the rigid plastic drain tube MUST be used Cut two 2 long sections from the 3 4 OD rub ber hose Connectthe plastic drain tube to the drain stub on the bot tom of the plastic transition box and to the stub on the condensate trap using the two hose sections and 3 4 clamps NOTE The support leg on the plastic drain tube MUST be posi tioned on the blower partition Connect the 98 OD rubber hose with the 90 bend to the lower drain stub on the vent fitting and secure with 5 8 clamp Route the hose to the smalle
66. g as possible without creating COLD AIR complaints at the end of the cycle Troubleshooting The operation of the HONEYWELL ST9160B series FAN TIMER FURNACE CONTROL as well as the operation of the furnace in general can be verified in a few minutes by using two 2 jumper wires to jumper terminals of the low voltage terminal strip and the TEST SEQUENCE below CHECKING HEATING FUNCTIONS 1 JUMPER W TO CHECK COMBUSTION BLOWER START UP CHECK IGNITION SYSTEM ACTIVATION WHEN MAIN BURNER LIGHTS CHECK HEATING FAN ON DELAY CHECK HEATING SPEED FAN OPERATION REMOVE JUMPER CHECK POST PURGE DELAY CHECK HEATING FAN OFF DELAY o 23 ST9160B UNIQUE CONTROL FUNCTIONS RESPONSES There are some unique responses from these controls that differ from what one would normally expect and may be somewhat confusing See Figure 28 Specifically these are as follows Energizing the G terminal of this control will cause the blow er to run on the HEATING speed With most other furnaces the blower relay is energized via the G terminal normally causing the blower to run on the cooling speed Energizing the amp Y terminals together will cause the blower to run on the COOLING speed It is important that you take note of this since control wiring improperly connected can cause perceived as well as real equipment problems For example in the past the Y termina
67. ge 26 Single Stage Multi Position Furnace Fiueas Downflow Installations Dual Certified 9MPD A1 Models LEFT Side Venting SE Return Air Exhaust gt Combustion Blower Mounting Screws 4 RIGHT Side Venting p Return Air Pressure Switch Transition Pressure Switch Hose Transition Pressure Switch Blower Pressure Switch Hose Blower 3 4 Hose amp Clamps 5 8 Hose amp Clamps Combustion Blower Rotate 180 for Left Side Rubber Transition Plug Box Plastic Caps Service Manual Air Intake Coupling Combustion Air Pipe Optional Vent Pipe Vent Fitting amp Clamps Vent Pipe Grommet amp Plastic Caps Condensate Trap amp Gasket DRAIN SIDE VIEW f y j Rotate downward 20 to 30 Gas Pipe Grommet Drain Line dwg 25 23 56 Downflow Installations Dual Certified 9MPD Models See Figure 36 Mount the condensate drain trap in a vertical position to either the right or left side of the furnace using the two screws and gasket that are provided If needed remove the hole plugs from the furnace side panel and relocated to the open set ofholes in the opposite side panel Drill two 7 64 diameter h
68. ge Multi Position Furnace Upflow Installations Dual Certified 9MPD A1 Models LEFT Side Venting Supply Air Vent Pipe Vent Pipe Grommet Vent Fitting amp Clamps Gas Pipe Grommet 90 Elbow q Rubber Coupling amp Clamps 5 8 amp Combustion Air Pipe optional Air Intake Coupling Plastic Caps Pressure Switch Hose Blower Pressure Switch Hose Transition RIGHT Side Venting Supply Air Clamps Combustion Blower Plastic Caps Pressure Switch Blower Transition Box Condensate Trap amp Gasket Combustion Blower Air 25 23 53 Return Left or Right Side Drain Line Mounting Screws 4 3 Vent Drain Pressure Switch Transition DRAIN SIDE Upflow Installations Dual Certified 9MPD See Figure 33 Mount the condensate drain trap in a vertical position to either the left or right side ofthe furnace using the two screws and gasketthat are provided If needed remove the hole plugs from the furnace side panel and relocate to the open set of holes in the opposite side panel Drill two 7 64 diameter holes in the casing using the conden sate tr
69. h F Limit Control Setting Standard Pressure Sw Part No 1013802 1013802 1013166 Blower Switch Pressure Close WC 13 Blower Switch Pressure Open WC 1 1 Transition Switch Pressure Close WC 2 2 2 2 2 2 1 8 Transition Switch Pressure Open WC 2 0 2 0 2 0 1 6 High Altitude Pressure Sw Part No 1013803 1013803 1013803 1013157 Blower Switch Pressure Close WC ES ES TES 0 9 Blower Switch Pressure Open WC lt E Transition Switch Pressure Close WC 2 0 2 0 2 0 Transition Switch Pressure Open WC E 2 1 8 Long Vent Part No NAHA002LV Pressure Switch Part No 1013518 Blower Switch Pressure Close WC 1 0 Blower Switch Pressure Open WC 0 8 Transition Switch Pressure Close WC 2 0 Transition Switch Pressure Open WC 1 8 High Altitude Long Vent Kit Part No NAHAO03LV Pressure Switch Part No 1013165 Blower Switch Pressure Close WC 0 7 Blower Switch Pressure Open WC 0 6 Transition Switch Pressure Close WC 14 Transition Switch Pressure Open WC 12 Blower Data Type amp Size 11 10 11 10 Motor Amps Rpm 10 850 8 0 1050 10 1050 10 1050 13 900 13 900 Motor Type H p PSC 1 PSC gt PSC 5 PSC 5 9 4 8 4 Cap Mfd Volts 7 5 370 7 5 370 10 370 10 370 40 370 40 370 Filter Type 16x25x1 16x25x1 16x25x1 16x25x1 16x25x1 16x25x1 Cool Cap Tons 5 W C 1 ML MHi
70. ion Switch Pressure Close C Transition Switch Pressure Open Blower Data Type amp Size Motor Amps Rpm Motor Cap Mfd Volts Filter Type Cool Cap Tons 5 L ML MHi amp Hi Gas Conversion Kits Nat to LP LP to Nat Order from Service Parts Nat LP 50 000 45 500 40 10 35 65 HW SV9541M SNAP HW HSP HW ST9160 30 60 100 140 180 1013802 2 2 10 850 PSC 1 7 5 370 16x25x1 11 5 2 21 5 3 NAHFOO LP 1009509 NAHFOO2NG 1009510 Nat LP 80 000 72 000 40 10 115 60 8 9 115 60 9 0 HW SV9541M SNAP HW HSP HW SV9541M SNAP HW HSP HW 5 9160 HW 5 9160 30 30 60 100 140 180 60 100 140 180 1013811 2 2 2 0 1013803 1 8 1 6 1013812 2 0 11 8 8 0 1050 PSC gt 7 5 370 16x25x1 11 5 2 21 5 3 11 10 10 1050 PSC 1 10 370 16x25x1 21 5 3 31 5 4 1013815 NAHFO03NG 1013816 53 Nat LP 100 000 Nat LP 100 000 Nat LP 125 000 113 750 115 60 9 0 115 60 10 5 115 60 11 2 HW SV9541M SNAP HW HSP HW ST9160 30 60 100 140 180 1013801 2 3 2 1 1013803 2 0 1 8 NAHAOO1LV 1013518 1 0 0 8 2 0 1 8 HW SV9541M SNAP HW HSP HW ST9160 30 60 100 140 180 1013802 2 2 2 0 1013803 2 0 1 8 NAHA002LV 1013515 1 0 0 8 217 15 1013165 0 7 0 6 1 4 1 2 11 10 10 1050 PSC gt 10 370 16x25x1 11 5 2 3 31 5
71. ion from outside the struc ture only when installed as a Direct Vent Furnace I E Two Pipe Installation Consult the appropriate Venting tables and or piping chart for the model series you are servicing If more than five elbows are required reduce the length of both the inlet and exhaust pipes 5 1 5m for each additional elbow used Feet of pipe is whichever pipe run is the longest either inlet or outlet side Standard Termination Rooftop Termination Inlet is optional on Dual Certified models 12 Above roof or snow accumulation level 8 Min 20 Maximum except in areas with extreme cold temperatures sustained below 0 F the 18 Min 5 00 06 Sidewall Termination 12 or More Above Snow Level or Grade Level 18 Minimum for cold climates substained below 0 F 25 00 05F GRADE LEVEL SNOW LEVEL Single Stage Multi Position Furnace Service Manual Fi Concentric Vent and Combustion Sidewall Inlet Vent and Exhaust Air gure 17 H eS Air Roof Termination Termination with Exterior Risers 18 Min for Cold Climates Sustained Below 0 F 12 Min Grade or 12 Min Grade or Snow Level Concentric Vent and Combustion Air Sidewall Termination 18 Min for Cold Climates _ Sustained Below 0 F 8 Min Inlet 20 Max Dos Vent 25 22 02d 25 22 43 Dimension A is touching or 2 maximum separation D 18 Min for Cold Climates 12
72. l begin to Cycle On and Off on the pressure switch If the condensate level rises high enough in the trap the pressure switch may not close at all and wa ter may be heard Paddling inside the combustion blower 21 HONEYWELL ST9160B Series FAN TIMER FURNACE CONTROL The Honeywell ST9160B Electronic Fan Timer Furnace Figure28 Honeywell ST9160B Control contains NO USER SERVICEABLE COM PONENTS It is as its name implies a fan timer and a fur nace control of sorts In addition to controlling the fan opera tion for heating it also takes the place of the blower relay the combustion air relay and or the system relay The ST9160B is used in models equipped with the SV9541M GAS VALVE IGNITION CONTROL It provides the power source to begin the ignition sequence through a monitored safety circuit It also serves as a low voltage terminal strip Accessory terminals for connecting a Humidifier and or Electronic Air cleaner are also provided as well as a Contin uous fan terminal which allows for continuous fan operation Dip at a speed other than either the heating or cooling speed Switch The control provides a fixed non adjustable 60 second ON and 60 second OFF delay for the circulating blower in COOLING and a 30 second ON delay for the circulating blower in HEATING The ST9160B control also provides an adjustable HEATING 25 23 63 OFF delay for the circulating blower which can be field ad justed
73. l drain stub on the condensate trap Cut off excess hoses and discard Connect the hose to the drain stub on the condensate and secure with 5 8 clamp Connectthe 3 4 OD rubber hose with the 90 bend to the large drain stub on the condensate trap and secure with a 3 4 clamp Route the hose to the drain stub on the bottom ofthe plastic transi tion box Cut off excess hose and discard Connect the hose to the drain stub on the transition and secure with a 3 4 clamp The pressure tap on the condensate trap MUST be connected to the unused pressure tap located on the top of the plastic transition box Remove the plastic caps from the pressure taps on the con densate trap and the plastic transition and connect with the 5 5 OD rubber hose NOTE This will require drilling a 546 OD hole in the furnace casing next to the condensate trap NOTE Ensure hoses maintain a downward slope to the conden sate trap with no kinking or binding for proper condensate drainage Single Stage Multi Position Furnace Service Manual Figure 44 Horizontal Right Installations Dual Certified 9MPD A2 Models NOTE TRAP MUST BE PRIMED BEFORE OPERATION Vent Pipe Gas Pipe Yellow Grommet Plastic Cap Combustion Rubber Couplin amp Clamps 2 Section PVC Pipe Vent Fitting amp Clamps Air Pipe Optional 90 Street Elbow Plastic Blower 5 3 Hose a
74. l in nearly all fur naces was simply a binding post There was no electrical connection between this terminal and the rest of the furnace 19 Consequently many installers would not use this terminal to connect the Y signal from the thermostat but would run it directly from the thermostat to the condensing unit the run the Common signal back to the furnace C terminal This method of wiring will result in improper operation from this control The control MUST receive a Y signal in order for it to energize the COOL terminal bringing on the blower in the cooling speed If it is wired as above the condensing unit will come on but the blower will run on the HEATING speed NO TERMINALS ENERGIZED on low voltage terminal strip If a speed tap wire has been connected to the CONT continuous terminal operational terminal pro vided on the ST9160B series controls the blower will run on this speed Maximum allowable connected load for this ter minal is 8 0 FLA 440 08 2001 02 Service Manual The CONTINUOUS terminal of the ST9160B control is en ergized ONLY when there is NO OTHER CALL FOR OP ERATION of any kind If there is a call for HEAT COOL or FAN ON this terminal is DE ENERGIZED The purpose of this terminal is to provide a means of air circulation during OFF CYCLES at a different speed than either heating or cooling The use ofthis terminal is operational and there will be no speed tap wires
75. lay and will keep the valve and ignitor to circuit off Assuming that no flame signal is detected upon the call for heat Normal operation the ignition system control will power the ignitor circuit 24 volts causing the ignitor to heat up 440 08 2001 02 20 If the ignitor circuit is not proven I E the ignitor is missing broken or the connections are loose their will be no re sponse from the ignition system control Lockout Once the ignitor circuit has been proven and the ignitor be gins to heat up the pilot valve will be energized allowing gas to flow to the pilot burner With the ignitor now hot and gas flowing to the pilot the pilot should light and the sensor should sense flame If no flame is sensed I E no gas pilot not lit flame not en veloping sensor etc the ignitor will stay on and the pilot valve will remain open until it does sense flame or until the call for heat is satisfied THE SYSTEM WILL NOT LOCK OUT under this condition Assuming that the pilot does light and flame is sensed nor mal operation the ignition system control will turn the ignitor off while energizing the main valve This will allow the pilot to light the main burner It will also energize the electronic fan timer output causing the conditioned air blower to start after the fixed 60 second ON delay Single Stage Multi Position Furnace If a flame outage I E loss of gas supply blown out etc should occur duri
76. maintaining the low profile heat exchanger For these reasons an INSHOT type burner is used in this series The inshot burner also called a jet burner fires a flame straight out its end This burner is designed to fire into atube style heat exchanger making it an ideal application in the tube like passages of the serpentine heat exchanger 3 In order to extract the maximum amount of heat pos sible from the flue gasses a secondary heat exchang er condenser is connected to the outlet of the primary heat exchanger This condenser removes additional heat from the flue gasses causing their temperature to drop below dew point This results in the forming of condensation water which then must be routed to a drain 4 The placement of the secondary heat exchanger at the outlet of the primary heat exchanger creates additional resistance to the flow of gasses 5 To overcome the resistance to convective flow of the Primary and Secondary heat exchangers requires the use of an Induced Draft Combustion Blower Assembly 440 08 2001 02 Service Manual 6 The Combustion Blower Assembly is mounted on the outlet side of the Secondary heat exchanger This blower creates a partial vacuum negative pressure within the heat exchangers drawing the flue products out of the furnace 4 ELECTRICAL SUPPLY WARNING Electrical shock hazard Turn OFF electric power at fuse box or service panel before making any electrical connections a
77. mp Clamps Combustion Mounting Screws 4 Pressure Switch Transition Vent Pipe Grommet Air Intake Coupling Supply Air Some Models have one pressure switch Plastic Cap Condensate Trap amp Gasket dwg 25 23 55b 3 4 Hose amp Clamps Pressure Switch Horizontal Trap Connection Hose Blower Pressure Switch Blower Transition Box Clamp ears Pointed OUT Pressure Switch Hose Transition Preassemble and insert into furnace Horizontal Right Installations Dual Certified 9MPD See Figure 44 Note For easier installation of the drain hoses and clamps to the condensate trap follow the directions outlined below except do not make any clamp connections to any of the drain stubs and hoses until the hose routing and lengths have been determined Remove the condensate trap and drain hoses from the furnace and secure the drain hoses to the drain stubs on the trap with the hose clamps position the clamps as shown in Figure 44 Install the condensate trap hose assembly to the furnace casing Hook one side of the clamp ears on the drain stub through the hole in the casing and push the condensate trap into position Secure with the two screws Reconnect the drain hoses to the stubs on the vent fitting
78. mps Vent Pipe Grommet 5 8 Hose amp Clamps Condensate Lx Trap amp Gasket 11 Section PVC Pipe Gas Pipe Grommet 90 Street Elbow Rubber Coupling amp Clamps dwg 25 24 00b Horizontal Trap Connection dow nwa rd 20 1030 E Clamp ears Pointed OUT Preassemble and insert into furnace Horizontal Left Installations Dual Certified 9MPD See Figure 43 Note For easier installation of the drain hoses and clamps to the condensate trap follow the directions outlined below except do not make any clamp connections to any of the drain stubs and hoses until the hose routing and lengths have been determined Remove the condensate trap and drain hoses from the furnace and secure the drain hoses to the drain stubs on the trap with the hose clamps position the clamps as shown in Figure 43 Installthe condensate trap hose assembly to the furnace casing Hook one side of the clamp ears on the drain stub through the hole in the casing and push the condensate trap into position Secure with the two screws Reconnect the drain hoses to the stubs on the vent fitting and the plastic transition and secure with the clamps Relocate the plastic cap and clamp on the condensate drain trap from the vertical transition drain stub to the horizontal transition drain stub Secure the clamps tightly to prevent condensate leak age Do not change the cap and clamp
79. n allows right side venting from the furnace If the left side venting is required the combustion blower must be relo cated on the plastic transition box Remove the four 4 screws that secure the blower to the transition Rotate the blower 180 and se cure with the four 4 screws Use caution to not over tighten the Screws to prevent stripping out of the plastic mounting holes NOTE The vent fitting MUST be installed with the airflow marking arrow pointed toward the vent pipe with the drain stub ata 20 to 30 downward slope Plug the upper drain stub on the vent fitting with the yellow plastic cap Remove the pressure switch hose from the upper stub on the plastic transition box Relocate the plastic caps on the stubs of the plastic transition box from the lower stubs to the upper stubs and secure tightly with the clamps 37 Service Manual Route the pressure switch hose to the lower stub on the plastic tran sition box Cut off excess hose and discard Connect the pressure switch hose to the lower stub on the plastic transition box NOTE Failure to correctly install the pressure switch hose to the transition box can adversely affect the safety control operation Connectthe 3 OD rubber hose with the 90 bend to the drain stub on the bottom of the plastic transition box and secure with a 3 4 clamp Route the hose to the large drain stub on the condensate trap Cut off excess hose and discard Connect the hose to the drai
80. n stub on the transition and secure with a 3 4 clamp Connect the 5 8 OD rubber hose with the 90 bend to the lower drain stub on the vent fitting and secure with 5 s clamp Route the hose to the smaller stub on the condensate trap Cut off excess hose and discard Connect the hose to the drain stub on the trap and secure with 5 g clamp For left side or right side mounted condensate trap the pres suretap on the condensate trap MUST be connected to the unused pressure tap located on the top ofthe plastic transition box Remove the plastic caps from the pressure tap on the condensate trap and the plastic transition and connect the 5 45 OD rubber hose See Figure 45 NOTE Ensure hoses maintain a downward slope to the conden sate trap with no kinking or binding for proper condensate drainage 440 08 2001 02 Service Manual Single Stage Multi Position Furnace Figure 46 Upflow Installations Single Pipe amp Direct Vent NSMP1 8 N9MP2 A2 Models DRAIN SIDE VIEW NOTE TRAP MUST BE PRIMED BEFORE OPERATION LEFT Side Venting Rotate downward 20 to 30 Supply Air Combustion Air Pipe N9MP2 ONLY Vent GN Combustion Blower Combustion Blower Rotate 180 for Right Side Gas Pipe Grommet Mou y Screws 4 I Tung Vent Pipe Grommet
81. n the manifold or as an alter native the four 4 screws on the manifold bracket 7 Move the manifold bracket and valve up enough so the secondary heat exchanger will clear the flange on the baffle 8 Remove machine screws securing secondary heat ex changer inlet flange to lower partition 9 Remove screws around perimeter of lower partition 10 Removed screws securing secondary heat exchanger to the supports 11 Coil can now be removed from furnace 12 Reverse procedure to reinstall making sure that any gaskets that have been torn during disassembly are replaced with new ones Primary Heat Exchanger 1 Turn OFF electrical power and gas supply to furnace 2 Disconnect vent pipe to furnace at flexible coupling 440 08 2001 02 44 3 Disconnect combustion air inlet pipe at top panel if needed 4 Remove furnace top panel 5 Disconnect gas piping to furnace at gas valve Note Be fore performing next step insure that the wiring dia gram is available and readable or tag all wires first 6 Disconnect tubing and wiring to pressure switch limit switches and gas valve 7 Remove screws securing burner box to front partition 8 Remove combustion blower 9 Remove machine screws securing transition assembly to furnace partition 10 Remove the collector box 11 Remove machine screws securing secondary heat ex changer inlet flange to lower partition 12 Remove screws around perimeter of both the
82. nd en sure a proper ground connection is made before connecting line voltage Failure to do so can result in death personal injury and or property damage SUPPLY CIRCUIT The furnace cannot be expected to operate correctly unless itis properly connected wired to an adequately sized 15 amp single branch circuit SUPPLY VOLTAGE Supply voltage to the furnace should be a nominal 115 volts It MUST be between 97 volts and 132 volts Supply voltage to the furnace should be checked WITH THE FURNACE IN OPERATION Voltage readings outside the specified range can be expected to cause operating problems Their cause MUST be investigated and corrected ELECTRICAL GROUND Grounding of the electrical supply to ALL FURNACES IS REQUIRED for safety reasons CHECKING GROUNDING AND POLARITY Grounding may be verified as follows 1 Turn the power supply OFF 2 Using an Ohmmeter check for continuity between the Neutral white wire and Ground wire green of the supply circuit 3 Withthe Ohmmeter set on the R x 1 scale the reading should be zero Ohms 4 A zero Ohm reading indicates that the neutral is grounded back to the main panel 5 An alternate check would be to check for continuity from the Neutral to a cold water pipe Pipe must be metal and must have a continuous uninterrupted con nection to ground or to a continuous uninterrupted connection to ground or to a driven ground rod Any readings other than
83. ng a run cycle Main burner operation the ignition system immediately de energize the main valve and re power the ignitor circuit placing the system back in to the Trial For Ignition mode As previously it will remain in this Trial For Ignition mode Ignitor powered and pilot valve open either until the pilot lights and flame is sensed or until the call for heat ends The SV9541M systemis not sensitive to furnace grounding or line voltage polarity Accordingly you cannot experience a lockout due to those reasons Assuming that the main burner did not experience any prob lems during the run cycle normal operation it would contin ue to operate as long as the call for heat remained Once the call for heat ended the ignition system control 26 CHECKING FLAME CURRENT The Honeywell SV9541Q Ignition system used in this furnace series proves verifies flame via the Flame Rectification method Flame Rectification is a process of converting Alternating Current A C into Direct Current D C During the ignition sequence an alternating current A C Voltage is applied to the Flame probe When the burner lights the flame conducts an electrical cur rent between the flame probe and the burner ground Due to 27 CAPACITORS Figures Checking Capacitor Microfarads 21 Service Manual would immediately close the main and pilot valves and de energize the electronic fan timer output De energizing the electroni
84. ntrol Their purpose is to provide a place to connect UNUSED speed tap wires to keep them out of the way and prevent them from shorting out against the fur nace casing or each other furnace operates Poisonous carbon monoxide gas hazard e Theuseofaventtee atthe outlet ofthe condensate trap is not required if the condensate drain line from the trap to the open drain is properly sloped 1 4 per foot downward slope Do nottrap the drain line in any other location than the conden sate trap combustion blowers and blower gaskets are different some of the furnace models There are two part numbers of the combustion blower for the 2 stage furnace models See the Tech Manual for the correct part number for the furnace Besides the part number difference the 50M 75M and 100M BTUH models use the shaded pole motor version with the 17 8 diameter back plate with a raised lip The blower gasket is approximately 23 4 outside diameter and is positioned into the recessed opening in the transition The 125M BTUH mod els use the PSC motor version with the 2 diameter back plate with no lip The blower gasket is approximately 31 4 outside diameter and is positioned on the flat surface ofthe transition A mismatch of blower backplated and or gaskets can cause the furnace to cycle on the pressure switch or to not operate This could be misread as a condensate drainage problem 440 08 2001 02 Service Manual Single Sta
85. oles in the casing using the conden sate trap as the template Ensure thatthe vent fitting and the 90 elbow is securely attached to the combustion blower using the rubber coupling and clamps This configuration allows right side venting from the furnace If the left side venting is required the combustion blower must be relo cated on the plastic transition box Remove the four 4 screws that secure the blower to the transition Rotate the blower 180 and se cure with the four 4 screws Use caution to not over tighten the Screws to prevent stripping out of the plastic mounting holes For right side venting remove vent fitting assembly from combus tion blower Remove 90 elbow and rubber tubing from the vent fit ting by loosening the clamp on the vent fitting Securely attach vent fitting to combustion blower NOTE The vent fitting MUST be installed with the airflow marking arrow pointed toward the vent pipe with the drain stub ata 20 to 30 downward slope Plug the upper drain stub ofthe vent fitting with the rubber plug Use a blunt pointed screwdriver to push the plug into the stub 27 Remove the pressure switch hose from the upper stub on the plastic transition box Relocate the plastic caps on the stubs of the plastic transition box from the lower stubs to the upper stubs and secure tightly with the clamps Route the pressure switch hose to the lower stub on the plastic tran sition box Cut off excess hose and disca
86. ompartment door of all models is equipped with 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 This interlock switch is a safe ty device and SHOULD NEVER BE BY PASSED Since this is a single pole switch breaking only one side of the line proper line voltage is essential to insure that furnace components are not HOT when switch is open See Checking Grounding and Polarity 6 GAS SUPPLY Pilot Pressure Adjustment Hid Manifold Pressure Adjustment dwg 25 23 31a An adequately sized gas supply to the furnace is required for proper operation Gas piping which is undersized will not provide sufficient capacity for proper operation Piping should be sized in accordance with accepted industry stan dards NATURAL GAS Inlet Supply pressure to the furnace should be checked at the gas valve with ALL OTHER GAS FIRED APPLIANCES OPERATING Inlet Supply pressure to the furnace under these conditions MUST be a minimum of 4 5 W C Water Column If the inlet pressure is less it may be an indication of undersized piping or regulator problems L P GAS Inlet Supply pressure to the furnace should be checked in the same manner as for Natural Gas however with L P Gas Service Manual Typical Interlock Switch 10 12 96 the inlet pressure MUST be a minimum of 11 W C If this cannot be obtained problems are
87. on and connect with the 5 16 OD rubber hose See Figure 46 and Figure 47 Connect the 5 5 OD rubber hose with the 90 bend to the lower Clamp ears Pointed OUT Return Air drain stub on the vent fitting and secure with a 5 8 clamp Route the hose to the smaller drain stub on the condensate trap Cut off excess hose and discard Connect the hose to the drain stub on the trap and secure with 5 8 clamp NOTE Ensure hoses maintain a downward slope to the conden sate trap with no kinking or binding for proper condensate drainage 39 440 08 2001 02 Service Manual Single Stage Multi Position Furnace Figure 48 Horizontal Left Installations Single Pipe amp Direct Vent N9MP1 amp N9MP2 A2 Models NOTE TRAP MUST BE PRIMED BEFORE OPERATION Plastic Caps Vent Pipe Grommet Vent Pipe Exhaust gt Yellow Plastic Cap Vent Fitting amp Clamps gt Inlet Combustion Air Pipe CO p pee E _ Pressure Switch Hose Transition RS Y Return Air Pressure Switch Transition J Some Models have one pressure switch Pressure Switch Blower Pressure Switch Hose Blower Transition Box c ln 5 g Hose amp Clamps N9MP2 ONLY 3 4 Hose amp Clam
88. onnected blower is de energized after the OFF delay Cycling pressure switch Condensate drain blocked After 5 minute delay time control system will reset Pressure switches operation tubing and wiring and initiate a new ignition sequence 47 440 08 2001 02 Service Manual Single Stage Multi Position Furnace HONEYWELL SV9541 SMART VALVE Trouble shooting continued INDICATES CHECK REPAIR LED STATUS 6 Flashes 3 Flashes 6 Flashes 4 Flashes 7 Flashes 440 08 2001 02 Soft Lockout Last failure was pressure switch Maximum recycle count exceeded Combustion air blower is de energized Circulating blower is de energized after the OFF delay After 5 minute delay time control system will reset and initiate a new ignition sequence Soft Lockout Last failure was limit circuit opened during run Combustion air blower is de energized Circulating blower is de energized after the OFF delay After 5 minute delay time control system will reset and initiate a new ignition sequence Soft Lockout Blower failure typical Limit trip took longer than 2 minutes to reset System will start a new ignition sequence after 1 hour if call for heat still present 48 Ignition system control switch must be in the ON position Pressure switches operation tubing and wiring Restrictions in furnace air intake or vent piping High winds blowing against vent Main limit switch Limi
89. or secondary heat exchanger or over fired furnace MANUAL RESET SWITCH MODELS Furnace models which are equipped with a Honeywell ST9160 Fan timer furnace control use a manual reset roll out Switch Once the roll out switch has opened burner opera tion will be prevented until the roll out switch is Manually Re set by pressing the red button located on the switch While the roll out switch is open Depending upon the particular model the combustion blower and or circulating blower will be energized continuously AUXILIARY LIMIT SWITCHES All models are equipped with one 1 additional AUXILIARY limit switch mounted on the blower deck Its purpose is to monitor return air temperature and interrupt burner opera tion when a temperature is sensed which could result in the filter surface s exceeding allowable temperatures Depend ing uponthe particular model the combustion blower and or circulating blower may be energized continuously while the auxiliary limit switch remains open This control is an Automatic reset control which will reset itself when the temperature drops to a safe level See the Tech Service Data Sheet for the model you are servicing to obtain its specific auxiliary limit switch setting 440 08 2001 02 Service Manual 15 PRESSURE SWITCHES Transition Pressure Switch This switch is designed to monitor a blockage of the conden sate drain line It uses a single tap port Normally Open pressure s
90. ostats MUST be level to control tem perature accurately to the desired set point Electronic digi tal type thermostats SHOULD be level for aesthetics HEAT ANTICIPATORS Heat anticipators are small resistance heaters built into most electric mechanical thermostats Their purpose is to pre vent wide swings in room temperature during furnace opera tion In order to accomplish this the heat output from the anticipa tor must be the same regardless of the current flowing through it Consequently most thermostats have an adjust ment to compensate for varying current draw in the thermo stat circuit The proper setting of heat anticipators then is important to insure proper temperature control and customer satisfac tion Figure 10 Measuring Current Draw Q Subbase Ammeter 12 CONTROL WIRING Control wiring is an important part of the total equipment installation since it provides the vital communications link between the thermostat and the equipment malfunctions Control wiring that is either too long undersized or improp erly connected be it simply loose or on the wrong terminal can in fact be the source of many equipment problems ALWAYS check to make sure that the control wiring is con nected to the proper terminal s of the equipment and ther mostat you are using Remember also that the thermostat terminals are not always identified alike by different thermo stat manufacturers Connections MUST be clean and
91. ps Combustion Blower Mounting Screws 4 Drain Line rod f y Combustion Blower Rotate 180 for Right Side N Condensate Trap amp Gasket Horizontal Trap Connection Plastic Cap Clamp ears Pointed OUT Preassemble and insert dwg 25 23 58 into furnace Horizontal Left Installations Single Pipe amp Direct Vent N9MP1 amp N9MP2 Models See Figure 48 Note For easier installation of the drain hoses and clamps to the condensate trap follow the directions outlined below except do not make any clamp connections to any of the drain stubs and hoses until the hose routing and lengths have been determined Remove the condensate trap and drain hoses from the furnace and secure the drain hoses to the drain stubs on the trap with the hose clamps position the clamps as shown in Figure 48 Installthe condensate trap hose assembly to the furnace casing Hook one side of the clamp ears on the drain stub through the hole in the casing and push the condensate trap into position Secure with the two screws Reconnect the drain hoses to the stubs on the vent fitting and the plastic transition and secure with the clamps Relocate the plastic caps and clamps on the condensate drain trap fromthe vertical drain stubs to the horizontal drain stubs Secure the clamps tightly to prevent condensate leakage Mountthe condensate drain trap in a vertical position to the left si
92. r drain stub on the condensate trap Cut off excess hose and discard Connect the hose to the drain stub on the trap and secure with 5 8 clamp NOTE Ensure hoses maintain a downward slope to the conden sate trap with no kinking or binding for proper condensate drainage Single Stage Multi Position Furnace Service Manual Figure 38 Horizontal Left Installations Single Pipe amp Direct Vent N9MP1 amp N9MP2 A1 Models Pressure Switch Blower Rubber Plastic Plug Caps Transition Box Exhaust gt Vent Pipe ut Vent Pipe t Gromme Pressure Switch Hose Transition Pressure Switch Transition Vent Fitting amp Clamps Return Combustion Air Pipe N9MP2 ONLY Air Pressure Switch Hose Blower Combustion Blower Mounting Screws 4 5 3 Hose amp Clamps 3 4 Hose amp Clamps Condensate Trap amp Gasket Combustion Blower Rotate 180 for Right Side Drain Line E Plastic Caps dwg 25 23 58 Horizontal Left Installations Single Pipe amp Direct Vent N9MP1 amp N9MP2 Models See Figure 38 Relocate the plastic caps and clamps on the condensate drain trap fromthe vertical drain stubs to the horizontal drain stubs Secure the clamps tightly to prevent condensate leakage Mountthe
93. r rollout switch 4 Flashes Limit and rollout switch wiring is in good condition and se Combustion blower is energized Circulating blower is 2 curely connected energized heat speed Duct restriction overfire Flame signal sensed out of proper sequence Flame at pilot burner 5Flashes Combustion blower is energized Circulating blower is energized heat speed after the ON delay Soft Lockout Gas supply off or pressure too low or high for appliance to ORUM operate 6 Flashes Failed to light pilot during 90 sec trial for ignition Damaged or broken HIS element 4 Flame sense contaminated in incorrect position Combustion air blower is de energized Circulating Pilot burner located in incorrect position 1 Flash is de i 5 52 an blower 1s after the OFF delay Pilot burner lead wires are in good condition and popery con nected After 5 minute delay time control system will reset Pressure switches operation tubing and wiring and initiate a new ignition sequence Soft Lockout Gas supply off or pressure too low or high for appliance to Last failure was Flame Sense lost during run operate Flame sense rod contaminated or in incorrect position 6 Flashes Maximum recycle count exceeded Pilot burner located in incorrect position Pilot burner lead wires are in good condition and properly 2 Flashes Combustion air blower is de energized Circulating c
94. ram 90 Single Stage Furnaces A2 INVNHOVIG NOILOANNOO irin 5 re 2 5 S 9 W 51 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 amp Ignition Gas Valve HW SV9541M HW SV9541M Regulation Type SNAP SNAP Manifold Press Inch s WC 3 5 10 0 Pilot Orifice Size Fan Controls Fan Control Type HW ST9160 HW ST9160 Fan Control 30 30 Timed secs 60 100 140 180 60 100 140 180 Gas Conversion Kits Models Nat to LP NAHFOO2LP 1009509 LP to Nat 1009510 Order from Service Parts Specifications 9MP1050B12A1 9MP1075B12A1 9MP1100F14A1 9MP1100J20A1 9MP1125J20A1 9MP2050B12A1 9MP2075B12A1 9MP2100F14A1 9MP2100J20A1 9MP2125J20A1 General Input Btuh 75 000 100 000 100 000 125 000 Output Btuh 68 000 91 000 96 500 113 750 Temp Rise 40 70 40 70 40 70 40 70 Electrical Volts Hz FLA 115 60 9 8 115 60 8 9 115 60 9 0 115 60 10 5 115 60 11 2 Gas amp Ignition Gas Type Nat L P Nat L P Nat L P Nat L P Nat L P Std Main Orifices No Size 2 42 2 54 3 42 3 54 4 42 4 54 4 42 4 54 5 42 5 54 Combustion Flue Outlet Size Inches 2 2 3 3 3 Std Outlet Temp F lt 140 lt 140 lt 140 lt 140 lt 140 Blower Transition Box Std Pressures of WC 5 No Elbows 1
95. rd Connect the pressure Switch hose to the lower stub on the plastic transition box NOTE Failure to correctly install the pressure switch hose to the transition box can adversely affect the safety control operation Connectthe 3 4 OD rubber hose with the 90 bend to the drain stub on the bottom of the plastic transition box and secure with a 3 4 clamp Route the hose to the large drain stub on the condensate trap Cut off excess hose and discard Connect the hose to the drain stub on the trap and secure with a 3 4 clamp Connect the 5 5 OD rubber hose with the 90 bend to the left drain stub on the vent fitting and secure with a 5 g clamp Route the hose to the smaller stub on the condensate trap Cut off excess hose and discard Connectthe hose to the drain stub on the trap and secure with 5 8 clamp NOTE Ensure hoses maintain a downward slope to the conden sate trap with no kinking or binding for proper condensate drainage 440 08 2001 02 Service Manual Figure 37 LEFT Side Venting Supply Air Combustion Air Pipe N9MP2 ONLY Vent Pipe Plastic Caps Vent Pipe Grommet x Vent Fitting amp Clamps Blower 5 g Hose amp Clamps Plastic Caps Condensate Trap amp Gasket Transition Box Drain Line 3 4 Hose Clamps Return Air
96. re Switches 12 14 Pressures Approximate Operating 14 R Roll Out Limit Switch 11 Room Thermostat 8 S Sequence of Operation Chart SV9541M 46 ST9160 Testing Sequence 19 Supply Electrical 4 Supply Gas 5 SV9541M System Operation 20 Switch Blower Door Interlock 5 Switch DIP ST9140 19 Switch Auxiliary Limit 11 Switch Transition Pressure 12 Switch L P Gas Pressure 7 Switch Main Limit 10 Switch Pressure 12 13 INDEX Switch Roll Out Limit 11 Switches Limit 10 T Technical Service Data 52 60 Temperature Rise 8 Testing Sequence ST9160 20 Thermostat Room 8 Transition Pressure Switch 12 Troubleshooting Chart Honeywell SV9541M 47 Twinning Kits 10 U Unit Identification 2 V Vent Termination Concentric 16 Vent Termination Standard 14 15 Vent Combustion Air Piping 14 Wiring Diagram 50 51 Wiring Control 9
97. s to the stubs on the vent fitting and the 440 08 2001 02 38 plastic transition and secure with the clamps Mount the condensate drain trap in a vertical position to either the left or right side ofthe furnace using the two screws and gasketthat are provided If needed remove the hole plugs from the furnace side panel and relocate to the open set of holes in the opposite side panel NOTE All gaskets and seals must be in place for sealed combus tion applications Ensure that the vent fitting is securely attached to the combustion blower using the rubber coupling and clamps Single Stage Multi Position Furnace NOTE For left side venting the vent fitting MUST be installed with the airflow marking arrow pointed toward the vent pipe with the drain stub at a 20 to 30 downward slope This configuration allows left side venting from the furnace If right side venting is required the combustion blower must be relocated on the plastic transition box Remove the four 4 screws that secure the blower to the transition Rotate the blower 180 and secure with the four 4 screws Use caution to not over tighten the screws to pre vent stripping out of the plastic mounting holes NOTE For right side venting the vent fitting MUST be installed with the airflow marking arrow pointed toward the vent pipe with the drain stub at a 5 to 10 downward slope See Figure 46 Plug the upper drain stub on the vent fitting with the yellow plastic
98. se and discard Connect the hose to the drain stub on the trap and secure with a 3 4 clamp Connect the 5 s OD rubber hose with the 90 bend to the right drain stub on the vent fitting and secure with 5 s clamp Route the hose to the smaller drain stub on the condensate trap Cut off excess hose and discard Connect the hose to the drain stub on the vent fitting and secure with 5 8 clamp NOTE Ensure hoses maintain a downward slope to the conden sate trap with no kinking or binding for proper condensate drainage 440 08 2001 02 Service Manual Single Stage Multi Position Furnace Figwese Horizontal Right Installations Single Pipe amp Direct Vent N9MP1 amp N9MP2 A1 Models Transition Box Plasti Caps Vent Pipe p Rubber Plug Vent Pipe Grommet Vent Fitting amp Clamps Combustion Air Pipe N9MP2 ONLY Exhaust gt Combustion Blower 5 8 Hose Return Clamps Air Combustion Blower Mounting Screws 4 Pressure Switch Hose Blower Supply Air Plastic m Caps Condensate Trap amp Gasket Pressure Switch Transition Drain Line Pressure Switch Hose Transition Pressure Switch Blower dwg 25 23 59 Horizontal Right Installations Single Pipe amp Direct V
99. t A Drain Line v 3 4 Hose amp Clamps RIGHT Side Venting S Return Air Vent Pipe Grommet Pressure Switch Combustion Blower Rotate 180 for Left Side Combustion Air Pipe Pressure N9MP2 ONLY Switch Transition 5 Vent Pipe DRAIN SIDE VIEW Rotate downward 20 to 30 Supply Air dwg 25 23 60 Downflow Installations Single Pipe amp Direct Vent N9MP1 amp N9MP2 Models See Figure 40 Mount the condensate drain trap in a vertical position to either the right or left side ofthe furnace using the two screws and gasketthat are provided If needed remove the hole plugs from the furnace side panel and relocated to the open set of holes in the opposite side panel Drill two 7 64 diameter holes in the casing using the conden sate trap as the template Ensure thatthe vent fitting and the 90 elbow is securely attached to the combustion blower using the rubber coupling and clamps NOTE The vent fitting MUST be installed with the airflow marking arrow pointed toward the vent pipe with the drain stub at a 20 to 30 downward slope This configuration allows right side venting from the furnace If the left side venting is required the combustion blower must be relo cated on the plastic transition box Remove the fo
100. t and rollout switch wiring is in good condition and se curely connected Restriction in duct work Dirty filter Overfire Dead blower Blocked duct work Single Stage Multi Position Furnace Service Manual V9541M ELECTRICAL VARIATION SINGLE STAGE Connector Pin Voltage Signal When Signal is Present Neutrals Neutral 0 VAC Always present 5 1 4 QC s Neutral and earth ground should be at the same potential L1 Line Voltage 115 VAC Present when blower door interlock switch is closed 2 1 4 QC s HEAT Fan power 115 VAC Present when Heat fan speed is on Open Limit mode 4 COOL Fan power 115 VAC Present when Cool fan speed is on Cool Y mode 1 4 EAC Electronic Air 115 VAC Present when High Heat or Cool fan speed is on 1 4 QC s Cleaner power CONSTANT FAN Continuous Fan 115 VAC Present when other fan speeds is off 4 power HUM Humidifier power 115 VAC Present when the Heat speeds is on 1 4 1 1 Line Voltage 115 VAC Present when the door interlock switch is closed P1 pin 2 Data Line Non periodic 2 wave rectified AC Present when the door interlock switch is closed measures as an unstable AC volt age bouncing between 12 VAC and 16 VAC commen ERG voltage decreases when a limit switch is open Pressure Switch supply wave rectified AC Present when the door interlock switch is closed This signal is the same as the C1 pin 1 Pr
101. t elbow after check ingthe fitup Follow the procedures outlined in the Joining Pipe and Fittings section of this manual page 30 The PVC pipe will extend through the top panel about 11 2 Connect the rubber coupling to the end of the 11 section of PVC pipe using the clamp Note There will be some misaligment of the PVC pipe inside the fur nace The rubber coupling will straighten out the misalignment at the vent pipe connection at the top of the furnace For left side venting remove 90 street elbow from the vent fitting by loosening the clamp on the ventfitting Securely attach vent fitting to combustion blower NOTE For left side venting the vent fitting MUST be installed with the airflow marking arrow pointed toward the vent pipe with the drain stub at a 20 to 30 downward slope Single Stage Multi Position Furnace This configuration allows left side venting from the furnace If right side venting is required the combustion blower must be relocated on plastic transition box Remove the four 4 screws that secure the blower to the transition Rotate the blower 180 and secure with the four 4 screws Use caution to notovertighten the screws to pre vent stripping out of the plastic mounting holes NOTE For right side venting the vent fitting MUST be installed with the airflow marking arrow pointed toward the vent pipe with the drain stub at a 5 to 10 downward slope See Figure 41 Plug the upper drain stub on
102. tch Transition v 3 x V Vent Pipe Grommet LN Air Intake Coupling Transition Box Plastic Caps D ad Condensate Trap amp Gasket Drain Line Pressure Switch Blower 3 4 Hose Clamps Pressure Switch Hose Blower Em VIEW Rotate downward 20 to 30 dwg 25 23 55 Horizontal Right Installations Dual Certified 9MPD See Figure 35 Relocate the plastic caps and clamps on the condensate drain trap from the vertical drain stub to the horizontal drain stubs Secure the clamps tightly to prevent condensate leakage Mount the condensate drain trap in a vertical position to the right side of the furnace using the two screws and gasket that are pro vided Note The condensate trap will be located under the furnace in a vertical position when the furnace is placed horizontally on the right side If needed remove the hole plugs from the furnace side panel and relocated to the open set of holes in the opposite side panel Drill two g4 diameter holes in the casing using the conden sate trap as the template Connect the vent fitting and the 90 elbow to the combustion blower using the rubber coupling and clamps NOTE The vent fitting MUST be installed with the airflow marking arrow pointed toward the vent pipe with the drain stub at a 20 to 30 down
103. the vent fitting and secure with 5 8 clamp Route the hose to the smaller drain stub on the condensate trap Cut off excess hose and discard Connect the hose to the drain stub on the vent fitting and secure with 5 s clamp NOTE Ensure hoses maintain a downward slope to the conden sate trap with no kinking or binding for proper condensate drainage Single Stage Multi Position Furnace Figure 49 NOTE TRAP MUST BE PRIMED BEFORE OPERATION Transition Box Vent Pipe Yellow Plastic Caps Vent Pipe Grommet Vent Fitting amp Clamps Service Manual Horizontal Right Installations Single Pipe amp Direct Vent N9MP1 amp N9MP2 A2 Models Combustion Plastic Cap Exhaust gt Air Pipe N9MP2 ONLY Combustion Blower 5 8 Hose amp Clamps Combustion Blower Mounting Screws 4 Pressure Switch Hose Blower Some Models have one M pressure switch ELS 4 TUIT Inlet lt ee Horizontal Trap Connection Plastic Caps Clamp ears i Condensate Trap amp Gasket Preassemble and insert into furnace Pressure Switch Transition Pressure Switch Hose Transition ia Hose amp Clamps Pressure Switch Blower Drain Line dwg 25 23 59a
104. the vent fitting with the yellow plastic cap Service Manual For left side mounted condensate trap connect the 3 OD rubber hose with the 90 bend to the large drain stub on the condensate trap and secure with 3 4 clamp Route the hose to the drain stub on the bottom ofthe plastic transi tion box Cut off excess hose and discard Connect the hose to the drain stub on the transition and secure with a 3 4 clamp For right side mounted condensate trap connectthe 3 4 OD rubber hose with the 90 bend to the bottom ofthe plastic transition box and secure with a 3 4 clamp Route the hose to the large drain stub on the condensate pump Cut off excess hose and discard Connect the hose to the drain stub on the condensate trap and secure with 3 4 clamp Figure a2 Upflow Installations Dual Certified 9MPD A2 Models RIGHT Side Venting Supply Air Some Models have one pressure switch DRAIN SIDE VIEW Rotate downward ml 5 to 10 For left or right side mounted condensate trap the pressure tap on the condensate trap MUST be connected to the unused pres sure tap located on the upper right hand corner of the plastic transi tion box Remove the plastic caps from the pressure taps on the condensate trap and the plastic transition and connect with the 5 46 OD rubber hose See Figure 41 and Figur
105. tion For years installers have run a wire from the Y terminal of the room thermostat and connected it directly to the contact on coil of a condensing unit not making any connection to the furnace with this wiring Then run the low voltage mon wire from the condensing unit back to the terminal of the furnace With the HONEYWELL ST9160B electronic Fan Timer Fur nace Control the Y terminal of the furnace does in fact serve a particular purpose Failure to connect it will result in certain improper operation as follows 440 08 2001 02 Service Manual The COOLING fan speed is energized via the Y terminal Failure to connect the thermostat Y terminal to the Y ter minal on the control will result in the failure to energize the 13 TWINNING KITS Some installations may require a Heating capacity or Airflow capabilities greater than a single furnace of this series can provide When this is necessary furnaces may be installed in a Twinned configuration The Twinning Kit allows the two 2 furnaces to be controlled by the same room thermostat When Twinned the circulat ing conditioned air blowers of BOTH furnaces will operate 14 LIMIT SWITCHES Two 2 different kinds of limit switches are used on this se ries of furnaces They are the main limit and roll out limit switches The main limit and roll limit switches are used on all models NOTE All limit switches are safety devices and other
106. tub on the trap and secure with 5 8 clamp NOTE Ensure hoses maintain a downward slope to the conden sate trap with no kinking or binding for proper condensate drainage 440 08 2001 02 Service Manual Figure 41 Single Stage Multi Position Furnace Upflow Installations Dual Certified 9MPD A2 Models NOTE TRAP MUST BE PRIMED BEFORE OPERATION Yellow Plastic Cap Vent Pipe Supply Air Rubber Coupling amp TOP Venting Combustion Air Pipe optional dow ward p 20 1030 y Air Intake Coupling Vent Fitting Clamps Vent Pipe Grommet amp Clamps 11 Section PVC Pipe Combustion Blower Gas Pipe Mounting Screws 4 Grommet Plastic Cap Some Models have one pressure switch 90 Street Elbow Sla Hose amp Clamps Combustion Blow er Plastic Cap Pressure Switch Hose Blower Pressure Switch Blower Pressure Switch Hose Transition SERI Trap Connection Clamp ears E Pointed OUT Condensate Trap amp Gasket Left or Right Side Preassemble amp insert into furnace 3 4 Hose amp Clamps Drain Line Transition Box Pressure Switch Transition Return Air 25 24 00a
107. tube Tot Agreed s aerei t 10 14 CIMIT SWITCHE S acad ated sas oie ce m Ca E ce eas 10 15 PRESSURE SWITCHES ss atn Fewer E qut E du WX E Sein Ceu 12 16 VENT COMBUSTION AIR PIPING 14 17 STANDARD VENT TERMINATION 14 18 CONCENTRIC VENT TERMINATION 16 EXHAUST BLOWER was betes Sateen n ave ate wae vais eue ole ee ent 17 20 CONDENSATE DRAIN TRAP eee bee Rn 17 21 HONEYWELL ST9160B FAN TIMER FURNACE CONTROL 18 22 ST9160B TESTING 2 aes hah ives ex DE ERR 19 23 ST9160B UNIQUE CONTROL FUNCTIONS RESPONSES 19 24 HONEYWELL SV9541M GAS VALVE IGNITION SYSTEM 20 25 HONEYWELL SV9541M SYSTEM OPERATION 20 26 CHECKING FLAME CURRENT 42 2 59 D xad e ERRARE ERE SEX RE 21 27 CAPACITORS auti oe mad ede nA hae ae Ode vienna Doe ose RAUS 22 28 BLOWER ASSEMBLY ed a ev M 22 29 BLOWER ROTATION tative Pa Ret puse ER uS 23 30 HEAT EXCHANGER REMOVAL REPLACEMENT 44 SV9541M SMART VALVE Sequence of Operation 45 SV9541M SMART VALVE Trouble shooting
108. unted between the combustion blower and the front parti tion 17 Service Manual The condensate drain trap supplied with the furnace MUST be used The drain line between the condensate drain trap and the drain location must be constructed of 3 4 PVC or CPVC pipe In standard Upflow Counterflow and or horizontal installations the external drain trap provides sufficient depth 4 to insure proper drainage of condensate from the furnace Additional traps are NOT required and should NOT be used The use of additional traps will PREVENT proper drainage of condensate from the furnace Care should be taken with the routing of the condensate drain hose to elimi nate all dips or sagging tubing which can create another trap and cause drainage problems 440 08 2001 02 Service Manual Single Stage Multi Position Furnace Figurezs Transition Assembly Condensate Drain Trap Vent Pipe Vent Drain 7 Side panel exit Lg Y 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 downward slope See Figure 27 Floats and or condensate sensors are NOT usediin the drain trap If the drain line becomes clogged the condensate level will rise higher in the external trap When the level rises suffi ciently the furnace wil
109. upper and lower partitions leaving the screws across the center of the two panels in place 13 Primary Heat Exchanger can now be removed with both upper and lower partitions attached 14 Reverse procedure to reinstall making sure that any gaskets that have been torn during disassembly are replaced with new ones 15 After reassembly turn the gas supply on and check for leaks All leaks must be repaired immediately 16 Perform an operational check of the furnace Single Stage Multi Position Furnace Service Manual 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 amp G terminals of EFT electronic fan timer control Cool motor speed energized after 6 second Cool Fan On Delay time Y amp G signals removed from EFT Cool motor speed de energized after 60 second Cool Fan Off Delay time Circulating Fan G Request 24 VAC signals applied to G terminals of EFT control Heat motor speed energized without delay G signal removed from EFT Heat motor speed de energized without delay Heating W Request 24 VAC signals applied to W terminal of EFT control Inducer motor turns on The gas valve solenoid energizes Following a 3 second prepurge delay the pilot valve opens and the ignitor begins to warm up After the pilot lights the main burners energize and light Time
110. upply air temperature The result is the temperature rise Compare with the allowable rise listed for the model size you are checking Temperature Rise can be checked by placing a thermometer inthe return air duct within 6 of furnace Place a second ther mometer in the supply duct at lease two 2 ft away from the furnace This will prevent any false readings caused by radi ation from the furnace heat exchanger Make sure that the FILTER IS CLEAN and that ALL REGISTERS AND OR DAMPERS ARE OPEN If the rise is not within the specified range it will be necessary to change the heating blower speed If the rise is too high it will be necessary to increase the blower speed If the rise is too low it will be necessary to reduce the blower speed Example Supply Temp 170 Return Temp 70 Temperature Rise 100 Too High Solution Increase Blower Speed res Thermostat Location THERMOSTAT 5 ft Single Stage Multi Position Furnace LOCATION The thermostat should not be mounted where it may be af fected by drafts discharge air from registers hot or cold or heat radiated from the sun of appliances Never install in al coves bathrooms or bedrooms The thermostat should be located about 5 ft above the floor in an area of average temperature with good air circulation Normally an area in close proximity to the return air grille is the best choice Mercury bulb type therm
111. ur 4 screws that secure the blowertransition box Rotate the blower 180 and secure with the four 4 screws Use caution to not overtighten the screws to prevent stripping out of the plastic mounting holes Plug the upper drain stub on the ventfitting with the rubber plug Use a blunt pointed screwdriver to push the plug into the stub Remove the pressure switch hose from the upper stub on the plastic transition 31 Relocate the plastic caps on the stubs of the plastic transition box from the lower stubs to the upper stubs and secure tightly with the clamps Route the pressure switch hose to the lower drain stub on the plastic transition box Cut off excess hose and discard Connect the pres sure switch hose to the lower stub on the plastic transition box NOTE Failure to correctly install the pressure switch hose to the transition can adversely affect the safety control operation Connectthe 3 4 OD rubber hose with the 90 bend to the drain stub on the bottom of the plastic transition box and secure with a 3 4 clamp Route the hose to the large drain stub on the condensate trap Cut off excess hose and discard Connect the hose to the drain stub on the trap and secure with a 3 4 clamp Connect the 5 8 OD rubber hose with the 90 bend to the lower stub on the vent fitting and secure with 3 4 clamp Route the hose to the smaller stub on the condensate trap Cut off excess hose and discard Connectthe hose to the drain s
112. vided on pages through Maximum allowable outlet air temperature While the main limit is open combustion blower and or the circulating blow er will be energized continuously This control is an Auto matic reset control which will reset itself when the tempera ture sensed drops to a safe level If furnace burner cycles on this limit switch I E switch opens and closes during furnace operation it is more than likely due to a high temperature rise through the furnace See checking temperature on page 8 of this manual High temperature rise can be caused by either OVER FIRING high manifold pressure incorrect orifices etc or LOW AIR FLOW dirty filter blower speed too low excessive static in duct system etc Figure 1 Typical Limit Switch LO Single Stage Multi Position Furnace To verify this the cut out opening point ofthe switch should be checked using a thermocouple type thermometer con nected to the face of the switch as follows 1 Operate furnace for several minutes 2 Block return air grille s to furnace 3 Observe temperature at which switch opens burner operation ceases 4 Remove blockage from return grille s 5 Observe temperature at which switch closes burner operation resumes 6 Compare readings with the limit setting listed in the appropriate chart for the model you are servicing If switch is opening within the specified range then it is sim ply doing its job and the c
113. ward slope Plug the upper drain stub on the ventfitting with the rubber plug Use a blunt pointed screwdriver to push the plug into the stub Remove the pressure switch hose from the upper stub on the plastic transition box 440 08 2001 02 Relocate the plastic caps on the stubs of the plastic transition box from the lower stubs to the upper stubs and secure tightly with the clamps Route the pressure switch hose to the lower stub on the plastic tran sition box Cut off excess hose and discard Connect the pressure switch hose to the lower stub on the plastic transition box NOTE Failure to correctly install the pressure switch hose to the transition can adversely affect the safety control operation Connectthe 3 4 OD rubber hose with the 90 bend to the drain stub on the bottom of the plastic transition box and secure with a 3 4 clamp Route the hose to the large drain stub on the condensate trap Cut off excess hose and discard Connect the hose to the drain stub on the trap and secure with a 3 4 clamp Connect the 98 OD rubber hose with the 90 bend to the lower drain stub on the vent fitting and secure with a 5 g clamp Route the hose to the smaller drain stub on the condensate trap Cut off excess hose and discard Connect the hose to the drain stub on the trap and secure with a 5 8 clamp NOTE Ensure hoses maintain a downward slope to the conden sate trap with no kinking or binding for proper condensate draina
114. witch wired in series with the furnace air proving pressure switch The switch Closes at a negative pres sure setting for the switch associated with that particular model furnace See unit specitications 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 drain begins to back up however the pressure begins to re duce Whenthe pressure drops sufficiently burner operation will be prevented until the condition is corrected Blower Pressure Switch An air proving switch pressure switch is used on all models to insure that a draft has been established through the heat exchanger before allowing burner operation To insure continued SAFE RELIABLE operation NEVER SUBSTITUTE a pressure switch with one that is similar in appearance ONLY FACTORY PROVIDED or AUTHORIZED SUBSTITUTES ARE ACCEPTABLE All models installed at altitudes of 4 000 above sea level or higher require replacing the standard pressure switch with a high altitude pressure switch The different pressure switch settings allow continued SAFE RELIABLE high altitude operation Figure 13 Pressure Switches Transition 25 23 72 440 08 2001 02 12 Single Stage Multi Position Furnace HIGH ALTITUDE PRESSURE SWITCHES ALL MODELS Max Close Upflow 140 W C 1 18 0 10 CHECK CURRENT TECHN
115. xcess hose and discard Connect the hose to the drain stub on the transition and secure with a 3 4 clamp Connect the 5 8 OD rubber hose with the 90 bend to the left drain stub on the vent fitting and secure with 5 clamp Route the hose to the smaller stub on the condensate trap Cut off 43 Service Manual excess hose and discard Connectthe hose to the drain stub on the trap and secure with 5 8 clamp For left side or right side mounted condensate trap the pres sure tap on the condensate trap MUST be connected to the unused pressure tap located on the top of the plastic transition box Remove the plastic caps from the pressure tap on the condensate trap and the plastic transition and connect the 5 45 OD rubber hose See Figure 50 NOTE Ensure hoses maintain a downward slope to the conden sate trap with no kinking or binding for proper condensate drainage 440 08 2001 02 Service Manual Single Stage Multi Position Furnace 30 HEAT EXCHANGER REMOVAL REPLACEMENT Exploded Parts View Typical Four Position Furnaces 25 23 43a Secondary Heat Exchanger 1 Turn OFF electrical power and gas supply to furnace 2 Disconnect vent pipe to furnace at flexible coupling 3 Remove combustion blower 4 Remove machine screws securing transition assembly to furnace front partition 5 Remove the collector box 6 Loosen the four 4 screws o
116. zero Ohms would indicate a poor ground or no ground 440 08 2001 02 Single Stage Multi Position Furnace 7 A pressure switch Air Proving Switch is used as a safety device that prevents the ignition system from fir ing the furnace until it senses that a proper draft has been established through the furnace Polarity may be verified as follows 1 Turn the power supply 2 Using a Voltmeter check for voltage between the Hot Black and Neutral White wire of supply circuit POLARITY CORRECT POLARITY of the line voltage supply to all fur naces is also required for safety reasons 3 Reading should be Line Supply Voltage 4 Check for Voltage between the Neutral White wire and Ground wire of the supply circuit 5 Reading should be zero Volts if line voltage is read polarity is reversed 6 Azero Volt reading indicates there is no voltage poten tial on Neutral wire 7 Double check by checking for voltage between the Hot Black wire and Ground wire of the supply circuit 8 Reading should be Line supply Voltage if zero volts is read there is no ground or polarity is re versed NOTE Junction Box can be mounted to either the left or right side 115V 60Hz 18 Connection Box Ground Low Voltage Terminal Board 25 23 42 Single Stage Multi Position Furnace 5 INTERLOCK SWITCH The blower c

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