ICP C9MPD Service Manual - 13. Twinning Kits

Summary of C9MPD

  • Page 1

    Multi position single stage gas furnaces part number 440 08 2001 02 n9mp1, n9mp2 & *9mpd “a1 & a2” manufactured by: this manual supports condensing gas furnaces manufactured in 2001 ã 2001 international comfort products corporation (usa) 4/2002.

  • Page 2: N9Mp1

    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).

  • Page 3: Table Of Contents

    Service manual single stage multi position furnace table of contents 1. Introduction 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. Unit identification 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 4: 1. Introduction

    Single stage multi position furnace service manual 2 440 08 2001 02 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 furna...

  • Page 5

    Single stage multi position furnace service manual 3 440 08 2001 02 circulating air blower rating plate gas valve/ignition module d oor interlock switch pressure switch component locations for four position furnaces fan/delay control furnace vent pipe combustion air blower vent pipe grommet primary ...

  • Page 6: 4. Electrical Supply

    Single stage multi position furnace service manual 4 440 08 2001 02 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. 7. A ...

  • Page 7: 5. Interlock Switch

    Single stage multi position furnace service manual 5 440 08 2001 02 5. Interlock switch the blower compartment 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. Th...

  • Page 8

    Single stage multi position furnace service manual 6 440 08 2001 02 gas pressure testing devices figure 5 magnehelic max. Pressure 15 psig 0 5 10 15 inches of water pressure connections typical "u" tube manometer 0 1 1 2 2 3 3 checking manifold pressure 1. Connect a manometer or magnehelic gauge (0-...

  • Page 9: 7. Burners

    Single stage multi position furnace service manual 7 440 08 2001 02 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 ...

  • Page 10: 11. Room Thermostats

    Single stage multi position furnace service manual 8 440 08 2001 02 10. Checking temperature rise checking temperature rise figure 8 thermometer: return air temp. Thermometer; supply air temp. Supply air flow air flow return the furnace is designed to operate within a certain specified range of temp...

  • Page 11: 12. Control Wiring

    Single stage multi position furnace service manual 9 440 08 2001 02 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 ther...

  • Page 12: 13. Twinning Kits

    Single stage multi position furnace service manual 10 440 08 2001 02 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 cooling speed on a call for cooling from the th...

  • Page 13

    Single stage multi position furnace service manual 11 440 08 2001 02 to verify this, the cut--out (opening) point of the 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 gril...

  • Page 14: 15. Pressure Switches

    Single stage multi position furnace service manual 12 440 08 2001 02 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 switch (wired in series with the furnace air provin...

  • Page 15

    Single stage multi position furnace service manual 13 440 08 2001 02 table 3 approximate operating pressures (²²²² of w.C.) model vent length @blower @ transition 50 mbtu short -- (5¢ no. Elbows) --1.80 --2.60 50 mbtu long -- (40¢ + 5 90° elbows) --1.30 --2.30 75 mbtu short -- (5¢ no. Elbows) --1.80...

  • Page 16

    Single stage multi position furnace service manual 14 440 08 2001 02 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...

  • Page 17

    Single stage multi position furnace service manual 15 440 08 2001 02 figure 17 concentric vent and combustion- air roof termination “a” combustion air exhaust 12²²²² min. Grade or snow level dimension “a” is touching or 2² maximum separation. Figure 18 concentric vent and combustion-- air sidewall t...

  • Page 18

    Single stage multi position furnace service manual 16 440 08 2001 02 figure 22 recommended alternate installa- tion for sustained cold weather (--0°°°° f & below) overhang 12 ²²²² min. 12² min. Ground level or snow level inlet exhaust 90 °°°° same joist space front view side view 25--23--73 12² 18. ...

  • Page 19: 19. Exhaust Blower

    Single stage multi position furnace service manual 17 440 08 2001 02 combustion air vent combustion air figure 24 concentric vent sidewall attachment 3² x 2² bushings or 3² x 2 1 / 2 ² bushings if 3² vent not used (field supplied) vent 45° elbow (field supplied) 25--22--02 strap (field supplied) flu...

  • Page 20

    Single stage multi position furnace service manual 18 440 08 2001 02 figure 26 (transition assembly) 25--23--62 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 s...

  • Page 21

    Single stage multi position furnace service manual 19 440 08 2001 02 25--23--47 figure 29 heating “off” delay dip switch setting cool on delay: 6 sec. Cool off delay: 60 sec. Heat on delay: 30 sec. Setting “off” and “on” setting the st9160b heating fan “off” delay is accom- plished by the positionin...

  • Page 22

    Single stage multi position furnace service manual 20 440 08 2001 02 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 termi...

  • Page 23: 27. Capacitors

    Single stage multi position furnace service manual 21 440 08 2001 02 if a flame outage (i.E. Loss of gas supply, blown out, etc.) should occur during a run cycle (main burner operation), the ignition system immediately de--energize the main valve and re--power the ignitor circuit placing the system ...

  • Page 24: 28. Blower Assembly

    Single stage multi position furnace service manual 22 440 08 2001 02 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 require...

  • Page 25: 29. Blower Rotation

    Single stage multi position furnace service manual 23 440 08 2001 02 figure 32 honeywell st9160b dip switch 25--23--63 fuse m1 m2 heat cool honeywell st9160b heating speed should it be necessary to change blower speeds to obtain proper temperature rise, simply take the appropriate speed tap wire, an...

  • Page 26

    Single stage multi position furnace service manual 24 440 08 2001 02 rotate downward 20° to 30° figure 33 upflow installations (dual certified *9mpd(a1) models) supply air ex ha us t inle t return air vent pipe vent pipe grommet vent fitting & clamps rubber plug drain line 90°°°° elbow plastic caps ...

  • Page 27

    Single stage multi position furnace service manual 25 440 08 2001 02 combustion blower mounting screws (4) figure 34 horizontal left installations (dual certified *9mpd(a1) models) supply air ex ha us t inle t vent pipe vent pipe grommet vent fitting & clamps rubber plug drain line 90°°°° elbow plas...

  • Page 28

    Single stage multi position furnace service manual 26 440 08 2001 02 figure 35 horizontal right installations (dual certified *9mpd(a1) models) supply air ex ha us t inle t vent pipe vent pipe grommet vent fitting & clamps rubber plug drain line 90°°°° elbow plastic caps rubber coupling & clamps 5 /...

  • Page 29

    Single stage multi position furnace service manual 27 440 08 2001 02 plastic caps figure 36 downflow installations (dual certified *9mpd(a1) models) vent pipe vent pipe grommet vent fitting & clamps combustion air pipe, (optional) dwg 25--23--56 supply air ex ha us t inle t air intake coupling combu...

  • Page 30

    Single stage multi position furnace service manual 28 440 08 2001 02 clamp rubber hose rubber hose clamp rigid plastic drain tube rotate downward 20° to 30° drain side view figure 37 upflow installations (single pipe & direct vent n9mp1 & n9mp2(a1) models) vent pipe vent pipe grommet vent fitting & ...

  • Page 31

    Single stage multi position furnace service manual 29 440 08 2001 02 figure 38 horizontal left installations (single pipe & direct vent n9mp1 & n9mp2(a1) models) vent pipe vent pipe grommet vent fitting & clamps dwg 25--23--58 combustion blower (rotate 180°°°° for right side) return air drain line p...

  • Page 32

    Single stage multi position furnace service manual 30 440 08 2001 02 figure 39 horizontal right installations (single pipe & direct vent n9mp1 & n9mp2(a1) models) vent pipe vent pipe grommet vent fitting & clamps dwg 25--23--59 combustion blower return air drain line pressure switch, transition pres...

  • Page 33

    Single stage multi position furnace service manual 31 440 08 2001 02 figure 40 downflow installations (single pipe & direct vent n9mp1 & n9mp2(a1) models) vent pipe vent pipe grommet vent fitting & clamps dwg 25--23--60 return air drain line pressure switch, transition pressure switch hose, transiti...

  • Page 34

    Single stage multi position furnace service manual 32 440 08 2001 02 ai r f lo w ai r fl o w supply air ex ha us t inle t return air vent pipe vent pipe grommet vent fitting & clamps yellow plastic cap drain line 90°°°° street elbow plastic cap rubber coupling & clamps 5 / 8 ²²²² hose & clamps combu...

  • Page 35

    Single stage multi position furnace service manual 33 440 08 2001 02 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 transit...

  • Page 36

    Single stage multi position furnace service manual 34 440 08 2001 02 ai r f lo w combustion blower mounting screws (4) figure 43 horizontal left installations (dual certified *9mpd--a2 models) supply air ex ha us t inle t vent pipe vent pipe grommet vent fitting & clamps yellow plastic cap drain lin...

  • Page 37

    Single stage multi position furnace service manual 35 440 08 2001 02 figure 44 horizontal right installations (dual certified *9mpd--a2 models) supply air ex ha us t inle t vent pipe vent pipe grommet vent fitting & clamps yellow plastic cap drain line 90°°°° street elbow plastic caps rubber couplin...

  • Page 38

    Single stage multi position furnace service manual 36 440 08 2001 02 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 ² clamp. Note: ensure hoses maintain a downward slope to the c...

  • Page 39

    Single stage multi position furnace service manual 37 440 08 2001 02 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 right and left side vent, remove the 90° street elbow from th...

  • Page 40

    Single stage multi position furnace service manual 38 440 08 2001 02 ai r f lo w ai r f lo w left side venting supply air inle t combustion air pipe, n9mp2 only combustion blower (rotate 180°°°° for right side) plastic cap pressure hose, blower pressure switch, blower pressure switch, transition pre...

  • Page 41

    Single stage multi position furnace service manual 39 440 08 2001 02 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 f...

  • Page 42

    Single stage multi position furnace service manual 40 440 08 2001 02 horizontal left installations (single pipe & direct vent n9mp1 & n9mp2--a2 models) dwg 25--23--58 figure 48 horizontal trap connection preassemble and insert into furnace “clamp ears” pointed out note: trap must be primed before op...

  • Page 43

    Single stage multi position furnace service manual 41 440 08 2001 02 horizontal right installations (single pipe & direct vent n9mp1 & n9mp2--a2 models) vent pipe vent pipe grommet vent fitting & clamps dwg 25--23--59a combustion blower return air drain line pressure switch, transition pressure swit...

  • Page 44

    Single stage multi position furnace service manual 42 440 08 2001 02 figure 50 downflow installations (single pipe & direct vent n9mp1 & n9mp2--a2 models) vent pipe vent pipe grommet vent fitting & clamps dwg 25--23--60 return air drain line pressure switch, transition pressure switch hose, transiti...

  • Page 45

    Single stage multi position furnace service manual 43 440 08 2001 02 connect the 3 / 4 ² 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 ² clamp. Route the hose to the large drain stub on the condensate trap. Cut off excess hose ...

  • Page 46

    Single stage multi position furnace service manual 44 440 08 2001 02 30. Heat exchanger removal/replacement “exploded” parts view -- typical four position furnaces figure 51 25--23--43a secondary heat exchanger 1. Turn ”off” electrical power and gas supply to furnace. 2. Disconnect vent pipe to furn...

  • Page 47

    Single stage multi position furnace service manual 45 440 08 2001 02 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 & g terminals of eft (electronic fan timer) control. · co...

  • Page 48

    Single stage multi position furnace service manual 46 440 08 2001 02 honeywell sv9541m “smart valve” sequence of operation power applied to appliance thermostat calls for heat combustion blower energized pressure switches closed within 30 seconds? Combustion blower de--energized pilot valve opens: i...

  • Page 49

    Single stage multi position furnace service manual 47 440 08 2001 02 honeywell sv9541 “smart valve” trouble shooting the 6 + x designation indicates a combination of flash codes: 6 flashes shows the control is in soft lockout, followed by x flashes to indicate the reason the control went into soft l...

  • Page 50

    Single stage multi position furnace service manual 48 440 08 2001 02 honeywell sv9541 “smart valve” trouble shooting continued led status indicates check/repair 6 flashes + 3 flashes soft lockout. Last failure was pressure switch maximum recycle count exceeded combustion air blower is de--energized,...

  • Page 51

    Single stage multi position furnace service manual 49 440 08 2001 02 sv9541m electrical variation single stage connector (pin #) description voltage signal when signal is present neutrals (5-- 1 / 4 ² qc’s) neutral 0 vac (neutral and earth ground should be at the same potential) always present l1 (2...

  • Page 52

    Single stage multi position furnace service manual 50 440 08 2001 02 wiring diagram (90+ single stage furnaces)(a1) y g th ermost at 2 3 4 mai n l im it ga s va lve n n g n y 1 5 indu ce r mot o r ea c 115v ro llou t sw it c h 1 to 3 i n s eri es de pen ding on m o de l 3 6 4 2 tr an sf o r m er l1 ...

  • Page 53

    Single stage multi position furnace service manual 51 440 08 2001 02 wiring diagram (90+ single stage furnaces)(a2) y g th er m o st at 2 3 4 m a in l im it ga s va lve n n g n y 1 5 in d u c e r m o to r ea c 115v ro llou t s w it c h 1 to 3 i n s eri es de pen ding on m o de l 3 6 4 2 tr a n sf o ...

  • Page 54

    Single stage multi position furnace service manual 52 440 08 2001 02 manufacturers number (mfr no --see rating plate) all models specifications general gas type nat lp transformer size (va) t’stat heat anticipator 40 .10 40 .10 gas & ignition gas valve regulation type manifold press. (inch’s wc) hw ...

  • Page 55

    Single stage multi position furnace service manual 53 440 08 2001 02 manufacturers number (mfr no --see rating plate) all models specifications (n9mp1)(a2) n9mp1050b12 n9mp1075b12 n9mp1080f16 n9mp1100f14 n9mp1100j20 n9mp1125j20 general gas type input (btuh) output (btuh) transformer size (va) t’stat...

  • Page 56

    Single stage multi position furnace service manual 54 440 08 2001 02 manufacturers number (mfr no --see rating plate) all models specifications general gas type nat lp transformer size (va) t’stat heat anticipator 40 .10 40 .10 gas & ignition gas valve regulation type manifold press. (inch’s wc) hw ...

  • Page 57

    Single stage multi position furnace service manual 55 440 08 2001 02 manufacturers number (mfr no --see rating plate) all models specifications (*9mpd)(a2) *9mpd050f12a *9mpd075f12a *9mpd080j16a *9mpd100j14a *9mpd100j20a *9mpd125l20a general gas type input (btuh) output (btuh) transformer size (va) ...

  • Page 58

    Single stage multi position furnace service manual 56 440 08 2001 02 circulation air blower data for 050 models 3 ton units speed cfm speed tap low med l med h hi re 0.1 826 1083 1301 1408 essu r . 0.2 804 1050 1242 1347 c pr es w .C . 0.3 770 1028 1195 1295 tat ic s of w 0.4 735 985 1153 1237 als t...

  • Page 59: Index

    Index a 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 c capacitors, 22 ...

  • Page 60: Index

    Index p piping, vent/combustion air, 14--16 polarity, line voltage, 4 pressure 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 syst...