N8MPN100F14B1 44108201001
User Manual: N8MPN100F14B1
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MULTI POSITION SINGLE STAGE 2--STAGE GAS FURNACES N8MPN, N8MPL, *8MPN, *8MPL, *8DNL, *8MPT & *8MPV This manual supports condensing gas furnaces manufactured in 2003 Manufactured by: Part Number 441 08 2010 01 10/2004 ã 2001 International Comfort Products Corporation (USA) N8MPN -- Non--Condensing Single Stage N8MPL -- Non--Condensing Single Stage Low Nox * 8MPN -- Non--Condensing Single Stage Deluxe * 8MPL -- Non--Condensing Single Stage Deluxe Low Nox *8DNL -- Non--Condensing Single Stage Downflow * 8MPT -- Non--Condensing Two Stage PSC Motor * 8MPV -- Non--Condensing Two Stage Variable Speed * Denotes Brand (T, C or H) Multi Position Furnace Service Manual TABLE OF CONTENTS 1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. UNIT IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. FURNACE THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. ELECTRICAL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. INTERLOCK SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. GAS SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. BURNERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8. L.P. PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9. HIGH ALTITUDE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10. CHECKING TEMPERATURE RISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11. ROOM THERMOSTATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12. CONTROL WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13. TWINNING KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14. LIMIT SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15. PRESSURE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16. ST9160B -- UNIQUE CONTROL FUNCTIONS/RESPONSES . . . . . . . . . . . . . . . . . . . 17. HONEYWELL SV9541M GAS VALVE/IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . 18. HONEYWELL SV9541M SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19. CHECKING FLAME CURRENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20. CAPACITORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21. BLOWER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22. HEAT EXCHANGER REMOVAL/REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SV9541M “SMART VALVE” -- Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SV9541M “SMART VALVE” -- Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SV9541M “SMART VALVE” -- Electrical Variation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TECHNICAL SERVICE DATA (N8MPN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TECHNICAL SERVICE DATA (N8MPL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TECHNICAL SERVICE DATA (*8MPN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TECHNICAL SERVICE DATA (*8MPL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TECHNICAL SERVICE DATA (*8DNL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TECHNICAL SERVICE DATA (*8MPV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TECHNICAL SERVICE DATA (*8MPT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BLOWER PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX OF HELPFUL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2 3 4 5 6 8 8 9 9 10 11 11 11 12 16 17 17 17 17 17 20 21 23 25 26 30 31 32 33 34 35 36 37 43 Service Manual Single Stage Multi Position Furnace 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. ! 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. These furnaces represent the very latest in mid--efficiency gas furnace technology. Consequently, they incorporate the use of certain controls that contain highly sophisticated electronic components which are not user serviceable. therefore, it is essential that only competent, qualified, service personnel attempt to install, service, or maintain this product. 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. 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. The overall operation of all of these models is essentially the same. 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. This manual, therefore, will deal with all subjects in a general nature (I.E. all text will pertain to all models) unless that subject is unique to a particular model or family, in which case it will be so indicated. 2. UNIT IDENTIFICATION placement parts (example, in certain model families a unit having a MARKET REVISION of “C” is likely to be equipped with one or more different components. The unit’s rating plate contains important information for the service technician. It also lists the complete Model Manufacturing and Serial Numbers. These complete numbers are required to obtain correct reMODEL NUMBER IDENTIFICATION GUIDE * 8 MP D 0 75 B 12 A 1 Engineering Rev. Brand Identifier T = Tempstar Denotes minor changes Marketing Digit C = Comfortmaker H = Heil Denotes minor change A = Arcoaire Cooling Airflow X = Evaluation 08 = 800 CFM Brand Identifier 8 = Non--Condensing, 80+% Gas Furnace 12 = 1200 CFM 9 = Condensing, 90+% Gas Furnace 14 = 1400 CFM Installation Configuration UP = Upflow 16 = 1600 CFM DN = Downflow HZ = Horizontal UH = Upflow/Horizontal 20 = 2000 CFM DH = Downflow/Horizontal Cabinet Width MP = Multiposition, Upflow/Downflow/Horizontal B = 15.5² Wide Major Design Feature 1 = One (Single) Pipe N = Single Stage F = 19.1² Wide 2 = Two Pipe P = PVC Vent J = 22.8² Wide D = 1 or 2 Pipe T = Two Stage L = Low NOx V = Variable Speed 441 08 2010 01 L = 24.5² Wide Input (Nominal MBTUH) 2 Service Manual Multi Position Furnace Figure 1 Component Locations for Four Position Furnaces Combustion Blower Heat Exchanger Pressure Switch (2 switches on some models) Manual Gas Valve Circulating Blower Gas Valve Main Burners Drip Leg Fan/Delay Control Circulating Blower Motor 25-- 24-- 30V Rating Plate Representative drawing only, some models may vary in appearance. 3. FURNACE THEORY OF OPERATION A. 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 exchanger surfaces whole 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 a tube style heat exchanger, making it an ideal application in the tube--like passages of the serpentine heat exchanger. 3. To overcome the resistance to convective flow of the heat exchanger requires the use of an Induced Draft Combustion Blower Assembly. The high efficiencies and lower profile (compared to previous series) of this furnace have been obtained using design techniques not typical of traditional furnace designs. A brief description 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 maintaining the surface area of the heat exchanger and yet minimizing the overall size. The design required to achieve these results is the “SERPENTINE” 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 following reasons: 4. The Combustion Blower Assembly is mounted on the outlet side of the heat exchanger, This blower creates a partial vacuum (negative pressure) within the heat exchangers drawing the flue products out of the furnace. 5. A pressure switch (Air Proving Switch) is used as a safety device that prevents the ignition system from firing the furnace until it senses that a proper draft has been established through the furnace. 3 441 08 2010 01 Service Manual Single Stage Multi Position Furnace 4. ELECTRICAL SUPPLY 1. Turn the power supply “ON”. ! 2. Using a Voltmeter check for voltage between the Hot (Black) and Neutral (White) wire of supply circuit. ELECTRICAL SHOCK HAZARD. POLARITY Failure to do so can result in death, personal injury and/or property damage. CORRECT POLARITY of the line voltage supply to all furnaces is also required for safety reasons. Turn OFF electric power at fuse box or service panel before making any electrical connections and ensure a proper ground connection is made before connecting line voltage. 3. Reading should be Line (Supply) Voltage. 4. Check for Voltage between the Neutral (White) wire and Ground wire of the supply circuit. SUPPLY CIRCUIT 5. Reading should be zero Volts. (if line voltage is read, polarity is reversed) The furnace cannot be expected to operate correctly unless it is properly connected (wired) to an adequately sized (15 amp.) single branch circuit. 6. A zero Volt reading indicates there is no voltage potential on Neutral wire. 7. Double check by checking for voltage between the Hot (Black) wire and Ground wire of the supply 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. 8. Reading should be Line (supply) Voltage. (if zero volts is read, there is no ground, or polarity is reversed.) Figure 2 Electrical Connections Single Stage ELECTRICAL GROUND Grounding of the electrical supply to ALL FURNACES IS REQUIRED for safety reasons. CHECKING GROUNDING AND POLARITY HOT NEUT. 115V. 60Hz. Grounding may be verified as follows: W BK 1. Turn the power supply “OFF”. G 2. Using an Ohmmeter check for continuity between the Neutral (white) wire and Ground wire (green) of the supply circuit. Ground G Thermostat 3. With the Ohmmeter set on the R x 1 scale, the reading should be zero Ohms. G 4. A zero Ohm reading indicates that the neutral is grounded back to the main panel. C 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 connection to ground) or to a continuous, uninterrupted connection to ground) or to a driven ground rod. Y G Y W R W R Low Voltage Terminal Board 25-- 24-- 33 NOTE: 115 VAC/60Hz/single--phase Operating voltage range*: 127 max, 104 min. 6. Any readings other than zero Ohms would indicate a poor ground, or no ground. * Permissible limits of voltage at which unit will operate satisfactorily Polarity may be verified as follows: 441 08 2010 01 Connectio n Box 4 Service Manual Multi Position Furnace Electrical Connections *8MPV Figure 3 NOTE: Junction Box can be mounted to either the left or right side. NOTE: Junction Box can be mounted to either the left or right side. 115V. 50 Hz. HOT NEUT. HOT 115V. 50 Hz. W BK G G Correction Box Ground Low Voltage Terminal Board R C W2 Low Voltage Terminal Board W1 W W2 W1 G W2 W1 G Y G R Single Stage Thermostat R Low Voltage Terminal Board R R C W1 W G W BK Correction Box Ground R Electrical Connections *8MPT Figure 4 W G Single Stage Thermostat R C Low Voltage Terminal Board C W2 W2 W1 W1 Y G Two Stage Thermostat 24-- 24-- 33a R W2 Two Stage W1 Thermostat G G NOTE: 115 VAC/60Hz/single--phase Operating voltage range*: 127 max, 104 min. NOTE: 115 VAC/60Hz/single--phase Operating voltage range*: 127 max, 104 min. * Permissible limits of voltage at which unit will operate satisfactorily * Permissible limits of voltage at which unit will operate satisfactorily 25-- 24-- 33 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 operation when the door is open. This interlock switch is a safety 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) Figure 5 Typical Interlock Switch 10--12--96 5 441 08 2010 01 Service Manual Single Stage Multi Position Furnace 6. GAS SUPPLY Figure 6 OPERATING. Inlet (Supply) pressure to the furnace under these conditions MUST be a minimum of 4.5² W.C. (Water Column). If the inlet pressure is less, it may be an indication of undersized piping or regulator problems. Typical Gas Valve Honeywell OUTLET Single Stage Pilot Pressure LP GAS Adjustment (Hidden) Inlet (Supply) pressure to the furnace should be checked in the same manner as for Natural Gas, however with LP Gas, the inlet pressure MUST be a minimum of 11² W.C. If this cannot be obtained, problems are indicated in either the regulator or pipe sizing. On\Off Switch Table 1 Gas Type T Recommended Max. Min. Manifold Pressure P Natural 7² 14² 4.5² 3.5² LP 11² 14² 11² 10² INLET Manifold Pressure Adjustment LO · With Propane gas, the rated input is obtained when the BTU content is 2,500 BTU per cubic foot and manifold pressure set at 10²² 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. Two--Stage HI Gas Supply Pressure Tap on Inlet Boss Behind Coil OUTLET Supply Pressure Important Note: dwg 25-- 23-- 31a Diagnostic Light Gas Pressures Below 2000¢¢ 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 adjusting (as necessary) the manifold (Outlet) pressure. The second way is to “Clock” the gas meter. INLET ! 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 standards. FIRE OR EXPLOSION HAZARD. Failure to turn OFF gas at shut off before connecting manometer can result in death, personal injury and/or property damage. NATURAL GAS Turn OFF gas at shut off before connecting manometer. Inlet (Supply) pressure to the furnace should be checked (at the gas valve) with ALL OTHER GAS FIRED APPLIANCES 441 08 2010 01 6 Service Manual Multi Position Furnace Figure 7 6. For LP Gas units ABOVE 2,000¢¢, insure that orifice size has been changed (per “National Fuel Gas Code” -- Appendix “F”) if gas supply has not already been de-rated for altitude by the gas supplier. Gas Pressure Testing Devices 7. For ALL UNITS ABOVE 8,000¢, contact the factory for SPECIFIC de--rating information. Pressure Connections 3 CHECKING MANIFOLD PRESSURE for Two Stage INCHES OF WATER 2 5 10 1. Connect manometer or Magnehelic gauge to the tapped opening on the outlet side of gas valve. Use a manometer with a 0 to 12² minimum water column range. 1 0 0 15 1 MAGNEHELIC 2 MAX. PRESSURE 15 PSIG 2. Turn gas ON. Operate the furnace on high fire by using a jumper wire on the R to W1 & W2 thermostat connections on the fan board. 3 3. Remove the adjustment cover on the gas valve. Turn adjusting screw counterclockwise to decrease the manifold pressure and clockwise to increase. See Figure 6. Typical "U" Tube Manometer 4. Set the manifold pressure to value shown in Table 1 or Table 3. 5. Operate the furnace on low fire by using a jumper wire on the R to W1 thermostat connections on the fan board. Note: The fourth (4th) DIP switch should be in the on position to set the low fire manifold pressure. (See wiring digram) CHECKING MANIFOLD PRESSURE For Single Stage 1. Connect a manometer or Magnehelic gauge (0--12² W.C. range) to the pressure tap on the “OUTLET” side of the gas valve. 2. Turn gas “ON”, fire the furnace, and remove adjustment cover (screw--cap). 6. Repeat steps 4 and 5 for low fire operation. 7. When the manifold pressures are properly set, replace the adjustment screw covers on the gas valve. 3. Turn adjustment screw clockwise (IN) to INCREASE pressure, and counterclockwise (OUT) to DECREASE pressure. 8. Remove the jumper wires from the thermostat connections on the fan board. Remove manometer and replace plug in gas valve. 4. At altitudes BELOW 2,000¢¢ set manifold pressure to 3.5² W.C. for Natural Gas, and 10² W.C. for LP Gas. 9. Reture fourth (4th) DIP switch to previous setting. 5. For Natural Gas units ABOVE 2,000¢¢, set manifold pressure according to Table 2. 10. Replace the burner compartment door. MANIFOLD PRESSURE AND ORIFICE SIZE FOR HIGH ALTITUDE APPLICATIONS For Single Stage Table 2 Heat Value Btu/Cu.Ft. NATURAL GAS Elevation Above Sea Level 0-- 1999 (²² ×wc) 2000-- 2999 (²² ×wc) 3000-- 3999 (²² ×wc) 4000-- 4999 (²² ×wc) 5000-- 5999 (²² ×wc) 6000-- 6999 (²² ×wc) 7000-- 7999 (²² ×wc) 800 3.5 3.5 3.5 3.5 3.5 3.5 3.5 850 3.5 3.5 3.5 3.5 3.5 3.5 3.5 900 3.5 3.5 3.5 3.5 3.5 3.5 3.4 950 3.5 3.5 3.5 3.5 3.3 3.2 3.1 1000 3.5 3.4 3.3 3.2 3.0 2.9 2.8 1050 3.2 3.1 3.0 2.9 2.7 2.6 2.5 1100 2.9 2.8 2.7 2.6 2.5 2.4 2.3 Orifice Size #42 #42 #42 #42 #42 #42 #42 7 441 08 2010 01 Service Manual Single Stage Multi Position Furnace MANIFOLD PRESSURE AND ORIFICE SIZE FOR HIGH ALTITUDE APPLICATIONS For Two- Stage High Altitude Pressure Chart 2000--8000 ft. (Natural Gas) Table 3 Heatt Value H V l Btu/Cu.Ft. Elevation Above Sea Level 0--1999 2000--2999 3000--3999 4000--4999 5000--5999 6000--6999 7000--7999 High Low High Low High Low High Low High Low High Low High Low 800 3.5 1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.5 1.7 850 3.5 1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.5 1.7 900 3.5 1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.4 1.7 950 3.5 1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.3 1.6 3.2 1.6 3.1 1.5 1000 3.5 1.7 3.4 1.7 3.3 1.6 3.2 1.5 3.0 1.5 2.9 1.4 2.8 1.4 1050 3.2 1.6 3.1 1.5 3.0 1.5 2.9 1.4 2.7 1.3 2.6 1.3 2.5 1.2 1100 2.9 1.4 2.8 1.4 2.7 1.3 2.6 1.3 2.5 1.2 2.4 1.2 2.3 1.1 Orifice Size #42 #42 #42 #42 “CLOCKING” GAS METER (NATURAL GAS) #42 #42 #42 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 content of gas. Example 2. Turn “OFF” gas supply to ALL other gas appliances. Natural Gas BTU Content 3. Time how many seconds it takes the smallest (normally 1 cfh) dial on the gas meter to make one complete revolution. 1,000 No. of Seconds Per Hour Time Per Cubic Foot in Seconds BTU Per Hour 3,600 48 75,000 1,000 x 3,600 ¸ 48 = 75,000 BTUH 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 burners are operating properly, and at their design noise level, proper adjustment of the gas (manifold) pressure is essential. See page 6 for further information on manifold pressure adjustments. Figure 8 Main Burner Burner Face 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. 10--10--78 8. LP PRESSURE SWITCH The switch is a “Normally Open” pressure operated switch that is wired in series with the furnace (vent) pressure switch. The LP Pressure Switch closes when line (Supply) pressure is 8.0² W.C. or higher. the LP Pressure Switch Opens if line pressure falls below 6.0² + 0.6² W.C. interrupting power to the gas valve. On some models, it is located (electrically) between the Furnace (vent) pressure switch and the gas Valve. Models converted to operate on LP Gas will be installed with an LP 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 of this switch is to prevent furnace operating under low line (Supply) pressure conditions. Operating under low line pressure conditions, can create problems such as incomplete combustion, flashback, sooting, etc. 441 08 2010 01 8 Service Manual Multi Position Furnace Figure 9 Typical LP Pressure Switch 9. HIGH ALTITUDE OPERATION 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¢ insure that it has been properly modified to operate at that altitude. See the sections on Gas pressure (Page 9), and pressure switches (Page 12) to obtain specific information for you particular installation altitude. These furnaces 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 insure continued, safe reliable operation. For example, units must be de--rated for altitude (by adjusting manifold pressure and/or changing orifice size) based upon the type of fuel (I.E. Natural Gas or LP gas), Btu content of the gas, and installed altitude. 10. CHECKING TEMPERATURE RISE Figure 10 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. Checking Temperature Rise Thermometer: Return Air Temp. Supply Air Flow TYPICAL OPERATING TEMPERATURE RISE RANGE Thermometer; Supply Air Temp. Single-- Stage Model Range 50 Mbtu 35°F -- 65°F 75, 100 & 125 Mbtu 40°F -- 70°F Return Two-- Stage Model Air Flow 50 Mbtu 75 Mbtu, Mbtu 100 Mbtu & 125 Mbtu Fire Range HI 35°F -- 65°F LOW 35°F -- 65°F HI 40°F -- 70°F LOW 40°F -- 70°F For specific temperature rise check pages 30 thru 36 of this manual. Always check current “Technical Support Manual” The furnace is designed to operate within a certain specified range of temperature rise. Operate the furnace for 15 minutes before taking temperature readings. Subtract the return air temperature from the supply air temperature. The result is the temperature rise. Compare with the allowable rise listed for the model (size) you are checking. Operating the furnace outside the specified range may result in lower efficiency and/or comfort levels, as well as premature combustion component failures. 9 441 08 2010 01 Service Manual Single Stage Multi Position Furnace Temperature Rise can be checked by placing a thermometer in the return air duct within 6¢ of furnace. Place a second thermometer in the supply duct at lease two (2) ft. away from the furnace. (This will prevent any false readings caused by radiation 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 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 desired conditions. An improperly operating, or poorly located room thermostat can be the source of perceived equipment problems. A careful check of the thermostat and wiring must be made then to insure that it is not the source of problems. Figure 11 The proper setting of heat anticipators then is important to insure proper temperature control and customer satisfaction. Figure 12 Measuring Current Draw W Amps Thermostat Location R DRAFTS Subbase THERMOSTAT Ammeter SUN The best method to obtain the required setting for the heat anticipator, is to measure the actual current draw in the control circuit (“W”) using a low range (0--2.0 Amps) Ammeter. (See Figure 12) 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: SHIELD 5 ft. LIGHT LOCATION The thermostat should not be mounted where it may be affected by drafts, discharge air from registers (hot or cold), or heat radiated from the sun of appliances. Never install in alcoves, 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 thermostats MUST be level to control temperature accurately to the desired set--point. Electronic digital 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 prevent wide swings in room temperature during furnace operation. In order to accomplish this, the heat output from the anticipator must be the same regardless of the current flowing through it. Consequently, most thermostats have an adjustment to compensate for varying current draw in the thermostat circuit. 441 08 2010 01 10 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” terminal. 3. Turn power on, and wait approximately 1 minute, then read meter. 4. Divide meter reading by 10 to obtain correct anticipator setting. NOTE: For 2 Stage heating thermostats the above procedure MUST be performed twice. Once for first stage (W 1 ), and once for second stage (W 2 ), if both stages have adjustable heat anticipators. 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, however, provide satisfactory operation in most cases. Electronic thermostats do not use a resistance type anticipator. These thermostats use a microprocessor (computer) that determines a cycle rate based on a program loaded into it at the factory. Service Manual Multi Position Furnace 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. 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 improperly 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 connected to the proper terminal(s) of the equipment and thermostat you are using. Remember, also, that the thermostat terminals are not always identified alike by different thermostat manufacturers. Connections MUST be clean and tight to insure trouble--free operation. 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 “Common” wire from the condensing unit back to the “C” terminal of the furnace. With the HONEYWELL ST9160B electronic Fan Timer/Furnace 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: The COOLING fan speed is energized via the “Y” terminal. Failure to connect the thermostat “Y” terminal to the “Y” terminal on the control will result in the failure to energize the COOLING speed on a call for cooling from the thermostat. (The HEATING speed will be energized instead via the “G” terminal) 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 circulating (conditioned air) blowers of BOTH furnaces will operate si- multaneously. Models equipped with a HONEYWELL ST9160B series Fan Timer/Furnace Control may be twinned using a model NAHA003WK01 twinning kit. To assist troubleshooting efforts of “Twinned” installations, “TYPICAL” control wiring diagrams are provided on pages ** through **. 14. LIMIT SWITCHES Two (2) different kinds of limit switches are used on this series 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 than for testing purposes, should never be jumped out! Limit switches are “normally closed” electrical switches, designed 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, before the furnace can resume proper operation. ! 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 interrupts furnace (burner) operation when a supply air temperature is sensed which would result in the furnace exceeding Maximum allowable outlet air temperature. While the main limit is open, combustion blower, and/or the circulating blower will be energized continuously. This control is an “Automatic” reset control, which will reset itself when the temperature 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) FIRE HAZARD. Failure to do so can result in death, personal injury and/or property damage. 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.) Limit controls are factory preset and MUST NOT be adjusted. Use ONLY manufacturer’s authorized replacement parts. 11 441 08 2010 01 Service Manual Figure 13 Single Stage Multi Position Furnace Figure 14 Typical Limit Switch To verify this, the cut--out (opening) point of the switch should be checked (using a thermocouple type thermometer connected 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. 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 intermittent operation. The roll out switch monitors the temperature inside the burner 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 determined. Some possible reasons for flame roll out include a restricted primary or secondary heat exchanger or over fired furnace. MANUAL RESET SWITCH MODELS If switch is opening within the specified range, then it is simply doing its job, and the cause of the 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 setting. 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. 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 operation will be prevented until the roll out switch is “Manually Reset” 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 operation when a temperature is sensed which could result in the filter surface(s) exceeding allowable temperatures. Depending upon the 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. 15. PRESSURE SWITCHES 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 ap441 08 2010 01 12 pearance. 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 Service Manual Multi Position Furnace settings allow continued SAFE, RELIABLE, high altitude operation. Figure 15 Pressure Switches sure should ONLY be checked when “HOT” to insure accurate readings. Table 4 lists approximate operating pressures. They are included in this manual to provide you with a “Barometer” to gauge our pressures against. The pressures you obtain in the field will differ slightly from these figures based upon vent length, gas pressure, operating temperature, etc. Major discrepancies in pressures, will normally cause problems with pressure switch operation. These Major discrepancies should be investigated as follows: Table 4 APPROXIMATE OPERATING PRESSURES (²² OF W.C.) Model Single Stage ALL Models Vent Length Close --0.69 Open --0.59 Hi Fire (Close) --0.60 2--Stage & Variable Speed ALL Models 10--13--04a Under normal operating conditions, sufficient negative pressure will be created to close the pressure switch, and keep it closed to keep furnace operating. Under abnormal conditions, however, such as a restricted vent pipe, or a leak in one of the heat exchangers, sufficient negative pressure will not be created. This will result in the switch failing to close or failing 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 4 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- 13 Hi Fire (Open) --0.59 Lo Fire (Close) --0.40 Lo Fire (Open) --0.30 Lower (Lesser) Negative Pressures Lower than normal negative pressures measured at the Combustion Blower may be caused by: 1. Restriction on the Outlet side of the combustion blower. (I.E. Blocked Flue, Vent too long, Heat Exchanger leak, etc.) 2. Leak (lack of restriction) on the Inlet side of the combustion blower. Higher (Greater) Negative Pressures Higher than normal negative pressures measured at the Combustion Blower may be caused by: 1. Restriction on the Inlet side of the combustion blower. (I.E. Plugged Heat Exchanger, air inlet orifice too small) 441 08 2010 01 Service Manual Figure 16 Single Stage Multi Position Furnace Typical Vent/Combustion Air Piping Installation This installation NOT approved in Canada Gable Vent Gas Vent Gas Vent Ventilated Attic Top Above Insulation Optional Inlet Air (1) Gable Vent Ventilated Attic Outlet Air (1) Outlet Air (1) Soffit Vent Inlet Air (1) Furnace Gas Vent Top Above Insulation Inlet Air (1) Furnace Soffit Vent Outlet Air (1) Inlet Air (2) Ventilated Crawl Space Inlet Air (1) Outlet Air (2) Furnace Inlet Air (2) Minimum One Inlet and One Outlet Air Supply is Required May be in and Combination Shown Inlet Air Opening Must be Within12²(300mm) of floor Outlet Air Opening Must be Within12²(300mm) of ceiling (1) 1 Square Inch (6cm2) per 4000 BTUH (2) 1 Square Inch (6cm2) per 2000 BTUH 16. HONEYWELL ST9160B Series FAN TIMER/FURNACE CONTROL Figure 17 fan terminal which allows for continuous fan operation at a speed other than either the heating or cooling speed. 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 “OFF” delay for the circulating blower which can be field adjusted to 60, 100, 140, or 180 seconds. Honeywell ST9160B Figure 18 Dip Switch Heating “OFF” Delay DIP switch Setting COOL ON DELAY: 6 SEC. COOL OFF DELAY: 60 SEC. HEAT ON DELAY: 30 SEC. FUSE 25-- 23-- 63 The Honeywell ST9160B Electronic Fan Timer/Furnace Control contains NO USER SERVICEABLE COMPONENTS. It is, as its name implies, a fan timer and a furnace control of sorts. In addition to controlling the fan operation 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 Continuous 441 08 2010 01 14 25--23--47 Setting “OFF” and “ON” Setting the ST9160B Heating Fan “OFF” Delay is accomplished 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 18) Service Manual Multi Position Furnace 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 adjustable. The “OFF” delay should be set as long 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. 17. 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” & “G” TO “R” CHECKING HEATING FUNCTIONS 1. JUMPER “W” TO “R” 2. CHECK COMBUSTION BLOWER START--UP 3. CHECK IGNITION SYSTEM ACTIVATION 4. WHEN MAIN BURNER LIGHTS, CHECK HEATING FAN “ON” DELAY 2. CHECK COOLING FAN DELAY “ON” 5. CHECK HEATING SPEED FAN OPERATION 3. CHECK COOLING SPEED FAN OPERATION 6. REMOVE JUMPER 4. REMOVE JUMPER 7. CHECK POST PURGE DELAY 5. CHECK COOLING FAN “OFF” DELAY 8. CHECK HEATING FAN “OFF” DELAY 18. 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 17) Specifically, these are as follows: Energizing the “G” terminal of this control will cause the blower 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 “G” & “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” terminal in nearly all furnaces was simply a binding post. There was no electrical connection between this terminal and the rest of the furnace. The “CONTINUOUS” terminal of the ST9160B control is energized ONLY when there is NO OTHER CALL FOR OPERATION 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 of this terminal is operational, and there will be no speed tap wires 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 15 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 provided on the ST9160B series controls) the blower will run on this speed. Maximum allowable connected load for this terminal is 8.0 FLA. thermostat sub--base to “FAN ON”, (energizing the “G” terminal) 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 connected load to the HUM terminal is 0.8 (eight tenths) Amp.* *The combined connected loads of the EAC and HUM terminals cannot exceed a total of 0.8 (eight tenths) amp. 441 08 2010 01 Service Manual Single Stage Multi Position Furnace 19. HONEYWELL SV9541M GAS VALVE/IGNITION CONTROL Figure 19 The system consists basically of only two (2) components. The Ignition System Control and the Pilot Hardware. The operate on Two (2) 24 volt power circuits received from the ST9160B Fan Timer/Furnace Control. One is the power supply to the ignitor, the second is to activate the ignition sequence. Honeywell ST9541M Ignition System Ignition/Sensor The Ignition System Control manages the ignition sequence, and the flow of gas to the pilot and main burners. It is in essence a combination Gas Valve and Ignition control. Pilot Burner/Sensor It contains sophisticated electronic components (internally) and has NO USER SERVICEABLE COMPONENTS. Should a problem be verified internally 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 ceramic 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. nuisance lockouts are eliminated) Gas Valve/Ignition Control dwg 25-- 23-- 31a 20. HONEYWELL SV9541M SYSTEM OPERATION Connecting the furnace to the line voltage supply with the blower door interlock switch closed provides 24 volts to power the system. (This is accomplished by the connections from terminals [pins] #4 & #2 from the ST9160B fan timer to terminals #1 & #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 approximately a two (2) second delay, while the ignition system control runs a self check. Part of the self check is to see if a flame signal is detected. If a flame 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” delay) 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. 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 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 system is not sensitive to furnace grounding or line voltage polarity. Accordingly, you cannot experience a lockout due to those reasons. 441 08 2010 01 16 If the ignitor circuit is not proven (I.E. the ignitor is missing, broken, or the connections are loose) their will be no response from the ignition system control. (Lockout) Once the ignitor circuit has been proven, and the ignitor begins 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 enveloping 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, (normal 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). Assuming that the main burner did not experience any problems during the run cycle (normal operation) it would continue to operate as long as the call for heat remained. Once the call for heat ended, the ignition system control would immediately close the main and pilot valves, and de-energize the electronic fan timer output. De--energizing the electronic fan timer output causes the “OFF” delay timing to begin, and when the pre--selected time (90, 100, 140, or 180 seconds) expires, the blower will turn off. Service Manual Multi Position Furnace TROUBLESHOOTING Resistance of a “Good” igniter should be 10 Ohms or less. 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. See trouble shooting flow chart and the sequence of operation flow chart on pages 36 and 37 of this manual for additional information on the operation and troubleshooting of this system. 21. 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 current between the flame probe and the burner ground. Due to the difference in size between the flame probe and the burner ground area this current flows mostly in one direction. This creates a pulsating Direct Current that flows back to the ignition 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. Minimum Micro Amp Current is 0.2 micro amps. 22. CAPACITORS Figure 20 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 condition 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 discharged (through a resistor) before testing. A 20,000 Ohm 2 Watt resistor can 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 for this, is that an Ohmmeter test can only indicate if a capacitor is “OPEN’, or “SHORTED”, it cannot verify if its value (microfarads) is within an acceptable range. Capacitor should test to within 10% of its rated value. Capacitors testing outside this range should be replaced. A weak capacitor can be the cause of a motor failing to start. Checking Capacitor Microfarads 5 mp 100 m¦ 1000 m¦ 10 m¦ + 10000 m¦ 23. BLOWER ASSEMBLY All models use a multi--speed, permanent split capacitor motor, direct--drive, blower assembly. Different size (HP) motors 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 Select” 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 17 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 “High for Cooling, Low for Heating”. Although that may be how it works out SOMETIMES, it can (in many cases) be exactly 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 tem441 08 2010 01 Service Manual Single Stage Multi Position Furnace 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 = CFM Air Delivery in Cubic Feet per Minute (CFM) (Furnace Rated @ 0.5² W.C. ESP) or 67,500 54 = 1250 CFM Checking the blower performance data for this model, (see Figure 36) indicates that @ 0.2² 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. LOW MED L MED H HIGH .10 778 984 1263 1576 .20 786 1003 1249 1532 .30 790 1003 1244 1489 .40 788 1001 1215 1432 .50 781 982 1186 1371 .60 765 962 1146 1308 .70 743 923 1094 1229 SAMPLE ONLY CHANGING BLOWER 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 required speed tap. EXAMPLE: A 24,000 BTU (2 TON) air conditioning system, using the same 75,000 BTU furnace as in the previous example. The external static pressure is measured and found to be 0.4² W.C. 400 CFM (nominal) per TON required 400 x 2 = 800 CFM required Checking the blower performance data (see Figure 36) for this model indicates that @ 0.4² W.C. ESP low speed will deliver 788 CFM. Accordingly, low speed should be used in this example for the COOLING speed. 441 08 2010 01 TAP Exte ernall Stati tic Prressu ure Inch hes o of W.C .C. 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 0.2² W.C. with a dry coil. 67,500 50 X 1.08 Blower Performance Data 75,0000 BTUH Table 5 18 The procedure for changing blower speeds (if needed) is shoun in Table 6. ! ELECTRICAL SHOCK HAZARD. Failure to do so can result in death and/or personal injury. Turn OFF power to furnace before changing speed taps. Table 6 Blower Speed Chart Wire Color Motor Speed Black High Orange* Med--High Blue Medium Red Low *Med--High speed may not be provided on all models. Service Manual Multi Position Furnace Figure 21 HONEYWELL ST9160B 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”. Cool COOLING SPEED Heat M2 When the proper speed has been determined, simply plug it on to the terminal of the control marked “COOL”. M1 “UNUSED” TERMINALS There are two (2) terminals (marked “UNUSED MOTOR LEADS” on the Honeywell ST9160B which has no internal connection to the control. 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 furnace casing, or each other. Dip Switch FUSE 25-- 23-- 63 19 441 08 2010 01 Service Manual Single Stage Multi Position Furnace 24. HEAT EXCHANGER REMOVAL/REPLACEMENT Figure 22 “Exploded” Parts View -- Typical Four Position Furnaces 25--41--61 Primary Heat Exchanger 10. Remove the collector box. 1. Turn ”OFF” electrical power and gas supply to furnace. 2. Disconnect vent pipe to furnace at flexible coupling. 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: Before performing next step, insure that the wiring diagram 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. 441 08 2010 01 20 11. Remove machine screws securing secondary heat exchanger inlet flange to lower partition. 12. Remove screws around perimeter of both the 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. Service Manual Multi Position Furnace 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. · Cool motor speed energized after 6 second Cool Fan On Delay time. Y & 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. · Timed 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 3 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. 21 441 08 2010 01 Service Manual Single Stage Multi Position Furnace HONEYWELL SV9541M “SMART VALVE” Sequence of Operation POWER APPLIED TO APPLIANCE THERMOSTAT CALLS FOR HEAT PRESSURE SWITCHES PROVED OPEN? NO WAIT FOR PRESSURE SWITCHES TO OPEN COMBUSTION BLOWER ENERGIZED PRESSURE SWITCHES CLOSED WITHIN 30 SECONDS? NO COMBUSTION BLOWER DE-- ENERGIZED FIVE MINUTE WAIT PERIOD 3 SECOND PRE-- PURGE PILOT VALVE OPENS: IGNITOR POWERED (1) PILOT LIGHTS AND FLAME IS SENSED DURING 90 SECOND TRAIL FOR IGNITION? THREE SECOND FLAME FAILURE RECYCLE DELAY NO PILOT VALVE CLOSES; PILOT IGNITOR OFF YES MAIN VALVE OPENS, HEATING FAN “ON” DELAY BEGINS AFTER DELAY: CIRCULATING BLOWER STARTS YES FLAME SENSE LOST? PILOT AND MAIN VALVE CLOSE CIRCULATING BLOWER OFF AFTER DELAY THERMOSTAT CALL FOR HEAT ENDS FLAME SENSE LOST MORE THAN FIVE TIMES IN THIS CALL FOR HEAT? COMBUSTION AIR BLOWER OFF AFTER POST PURGE NO YES PILOT AND MAIN VALVE CLOSE COMBUSTION BLOWER DE-- ENERGIZED AFTER 30 SECOND POST PURGE CIRCULATING BLOWER OFF AFTER DELAY (1) Ignitor “ON” for first 30 seconds of trial for ignition, then “OFF” for next 30 seconds. If the pilot has not lit, it turns back “ON” for the final 30 seconds. The pilot valve remains 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 into 1 hour wait period (indicating circulating blower). WAIT FOR NEXT CALL FOR HEAT 441 08 2010 01 NO 22 Service Manual Multi Position Furnace 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 LED STATUS Off indicate the reason the control went into soft lockout. Last status code indicates repair to address first INDICATES CHECK/REPAIR No power to system control. Line voltage input at L1 and Neutral connectors on ST9160B Fan Timer. 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, Bright – Not Applicable -- Normal Operation (stand by or call for heat) unless some abnormal event has occurred. Dim 2 Flashes Pressure switches closed when it should be open Pressure switches stuck closed (system will wait for pres(i.e. when call for heat begins). sure switch to open). (Combustion blower is not energized until pressure Pressure switches miswired or jumpered. switches opens) 3 Flashes Pressure switches , open when they should be closed (i.e. longer than 30 seconds after combustion blower/ Ignition system control switch must be in the ON position. inducer is energized). 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. 4 Flashes Main limit switch. Manual reset burner rollout switch. Limit and rollout switch wiring is in good condition and seCombustion blower is energized, Circulating blower is curely connected. energized heat speed. Duct restriction/overfire. 5 Flashes Flame at pilot burner. Flame signal sensed out of proper sequence. Combustion blower is energized, Circulating blower is energized heat speed after the “ON” delay. Main Limit or Roll Out Switch is open. Soft Lockout. Gas supply off or pressure too low or high for appliance to operate. Failed to light pilot during 90 sec. trial for ignition Damaged or broken HIS element 6 Flashes Flame sense rod contaminated or in incorrect position. + Combustion air blower is de--energized, Circulating Pilot burner located in incorrect position. 1 Flash blower is de--energized after the “OFF” delay. Pilot burner lead wires are in good condition and popery connected. 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 operate. Last failure was Flame Sense lost during run. Flame sense rod contaminated or in incorrect position. 6 Flashes Pilot burner located in incorrect position. Maximum recycle count exceeded + Pilot burner lead wires are in good condition and properly 2 Flashes Combustion air blower is de--energized, Circulating connected. Cycling, pressure switch blower is de--energized after the “OFF” delay. After 5--minute delay time, control system will reset Pressure switches operation, tubing, and wiring. and initiate a new ignition sequence, 23 441 08 2010 01 Service Manual Single Stage Multi Position Furnace HONEYWELL SV9541 “SMART VALVE” Trouble shooting continued LED STATUS INDICATES CHECK/REPAIR Soft Lockout. Last failure was pressure switch 6 + Flashes 3 Flashes Ignition system control switch must be in the ON position. Pressure switches operation, tubing, and wiring. Combustion air blower is de--energized, Circulating High winds blowing against vent. blower is de--energized after the “OFF” delay. Maximum recycle count exceeded After 5--minute delay time, control system will reset and initiate a new ignition sequence, Soft Lockout. Main limit switch. Limit and rollout switch wiring is in good condition and se6 Flashes curely connected. + Combustion air blower is de--energized, Circulating Restriction in duct work. 4 Flashes blower is de--energized after the “OFF” delay. Dirty filter Overfire After 5--minute delay time, control system will reset and initiate a new ignition sequence, Last failure was limit circuit opened during run. Soft Lockout. 7 Flashes Blower failure (typical) Limit trip took longer than 2 minutes to reset. Dead blower. Blocked duct work. System will start a new ignition sequence after 1 hour, if call for heat still present. 441 08 2010 01 24 Service Manual Multi Position Furnace SV9541M ELECTRICAL VARIATION SINGLE STAGE Connector (Pin #) Description Voltage Signal Neutrals (5-- 1/4² QC’s) Neutral 0 VAC (Neutral and earth ground should be at the same potential) When Signal is Present L1 (2-- 1/4² QC’s) Line Voltage 115 VAC Present when blower door interlock switch is closed. HEAT (1/4² QC’s) Fan power *115 VAC Present when Heat fan speed is on (Open Limit mode) COOL (1/4² QC’s) Fan power *115 VAC Present when Cool fan speed is on (Cool (Y) mode). EAC (1/4² QC’s) Electronic Air-Cleaner power 115 VAC Present when High Heat or Cool fan speed is on. CONSTANT FAN (1/4² QC’s) Continuous Fan power *115 VAC Present when other fan speeds is off. HUM (1/4² QC’s) Humidifier power 115 VAC Present when the Heat speeds is on. P1 (pin 1) Line Voltage 115 VAC Present when the door interlock switch is closed. P1 (pin 2) Data Line Non--periodic 1/2 wave rectified AC (measures as an unstable AC voltage bouncing between 12 VAC and 16 VAC Present when the door interlock switch is closed. P1 (pin 3) C (xfmr common) 0 VAC Always present P1 (pin 4) Neutral 0 VAC Always present P1 (pin 5) 24 VAC 24 VAC Present when the door interlock switch is closed. P1 (pin 6) R 24 VAC Present when the door interlock switch is closed. Always present C1 (pin 1) Limit return 1 /2 C1 (pin 2) Pressure Switch supply 1 /2 wave rectified AC Present when the door interlock switch is closed. This signal is the same as the C1 (pin 1) C1 (pin 3) Pressure Switch return 1 /2 wave rectified AC Present when the door interlock switch is closed. This AC voltage decreases when the Low Pressure Switch closes. C1 (pin 4) Data Line C1 (pin 5) Limit Supply C1 (pin 6) C (xfmr common) 0 VAC Always present C1 (pin 7) R 24 VAC Present when the door interlock switch is closed. C1 (pin 8) 24 VAC 24 VAC Present when the door interlock switch is closed. C2 (pin 1) HSI return 24 VAC (with igniter present) C2 (pin 2) HSI supply 24 VAC Present when the door interlock switch is closed. C2 (pin 3) Not connected 0 VAC Not connected C2 (pin 4) Flame sense >80 VAC Present when the door interlock switch is closed. C3 (pin 1) Inducer supply 115 VAC Present when the inducer draft blower motor is on (Heat modes, Open Limit mode). C3 (pin 2) L1 115 VAC Present when the door interlock switch is closed. C3 (pin 3) Inducer return 0 VAC Always present (neutral connection). C3 (pin 4) L2 (neutral) 0 VAC Always present wave rectified AC Present when the door interlock switch is closed. This voltage decreases when a limit switch is open. Non--periodic 1/2 wave rectified AC 1 /2 wave rectified AC Present when the door interlock switch is closed. Same signal as P1 (pin 5). Present when the 24 VAC transformer is powered. Present when HSI is not turned on. When HSI is on, this signal is 0 VAC to 10 VAC depending on input line voltage potential. * 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), 1/2 wave rectified AC voltage typically measures about 14 VAC. The Fluke 79 is not a “true” RMS meter. 25 441 08 2010 01 441 08 2010 01 GND NEUTRAL 26 BR BR BK W W NOTE 2 BLACK-HI BLUE-MLO ORANGE-MHI RED-LO BVSS 4 L1 C 4 W Y 2 3 1 G 24V FURNACE CONTROL 5 6 L1 L1 HUM EAC 4 3 2 1 4 2 3 1 W SENSOR IGNITER GAS VALVE 8 4 1 2 3 5 6 7 N N N ROLLOUT SWITCH 1 TO 3 IN SERIES DEPENDING ON MODEL N N NOTE 2 BVSS (FIELD INSTALLED) LP PRESSURE SWITCH (LP MODELS ONLY) NOTE 2 PRESSURE SWITCH 1 TO 2 IN SERIES DEPENDING ON MODEL MAIN LIMIT HUM EAC CAPACITOR (SOME MODELS) 1 CAPACITOR BLOWER MOTOR THERMOSTAT 4 32 1 R G Y N GAS VALVE INDUCER MOTOR 4321 TRANSFORMER M2 LO (R) MLO (BL) M1 HI (BK) MHI (O) HEAT COOL GND. NEUTRAL ON 12 12 12 12 12 FACTORY SETTING 60 SEC. 100 SEC. 140 SEC. 180 SEC. IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED, IT MUST BE REPLACED WITH TYPE AWM - 105°C WIRE OR ITS EQUIVALENT. R L1 L1 115V 24VAC L1 5A FUSE COM L1 115V-60HZ 1014484 S1 SEE MANUALS FOR ADJUSTING SPEED TAPS FOR PROPER HEATING, COOLING & CIRCULATING SPEEDS. BLACK BK BLUE BL BROWN BR GREEN G ORANGE O RED R WHITE W YELLOW Y PURPLE P COLOR CODE CAPACITOR (SOME MODELS) BR BR (FIELD INSTALLED) INDUCER MOTOR SPEED TAP CODE BK BK NOTE 2 PRESSURE SWITCH 1 TO 2 IN SERIES DEPENDING ON MODEL LP PRESSURE BL SWITCH (LP MODELS ONLY) LINE VOLTAGE FACTORY LINE VOLTAGE FIELD LOW VOLTAGE FACTORY LOW VOLTAGE FIELD INTERNAL CIRCUIT BOARD WIRING RECTIFIED AC VOLTAGE FACTORY W BK O C2 4 3 2 1 BL BL HOT INTERLOCK SWITCH FAN CONTROL MODULE * O BLOWER MOTOR HUM NOTE: 1. MOST VOLT METERS WILL READ 13-16 VOLTS TO CHASSIS ON BOTH SIDES OF AN OPEN LIMIT OR PRESSURE SWITCH IN THE RECTIFIED AC VOLTAGE CIRCUIT 2. FACTORY CONNECTED WHEN BVSS, (CHIMNEY ADAPTER ACCESSORY KIT) OR LP PRESSURE SWITCH IS NOT INSTALLED. CAPACITOR R COOL CONT L1 L1 EAC THERMOSTAT Y M1 BL M2 G G 2 1 FURNACE CONTROL 12 ON DATA 3 4 HEAT W G Y W C R 5A FUSE 6 5 C3 NEUTRAL Y W Y COM 3 1 1 GAS VALVE 2 3 4 ROLLOUT SWITCH 1 TO 3 IN SERIES DEPENDING ON MODEL HEAT ON DELAY: 30 SEC. R R BL 24 VAC 2 4 W BK BL SENSOR 5 6 7 8 R 1 2 3 4 24V SECONDARY W BL Y P IGNITOR C1 R LADDER DIAGRAM 5 6 7 8 TRANSFORMER W BK INTERLOCK SWITCH R MAIN LIMIT WARNING: ELECTRICAL SHOCK HAZARD DISCONNECT BEFORE SERVICING COOL ON DELAY: 5 SEC COOL OFF DELAY: 90 SEC 115V PRIMARY COPPER CONDUCTORS ONLY 115V 60HZ HOT FIELD CONNECTION BOX CONNECTION DIAGRAM Service Manual Multi Position Furnace 25. Wiring Diagram N8MPN/L, *8MPN/L & *8DNL HEAT OFF DELAY GND NEUTRAL BL 27 IND HI 115V NEUTRAL JUMPER, 115V JUMPER, 115V 5 4 3 2 1 10 9 8 7 6 1 2 3 4 BLACK BLUE BROWN GREEN ORANGE RED WHITE YELLOW PURPLE 24VAC 4 2 3 1 1 3 4 7 8 6 2 5 DC MOTOR CONTROL JUMPER, 115V JUMPER, 115V 115V NEUTRAL JUMPER, SURGE JUMPER, SURGE 115V HOT GAS 4 3 2 1 VALVE 2 STAGE SENSOR MAIN LIMIT HIGH PRESSURE SWITCH 5 4 3 2 1 10 9 8 7 6 1 2 3 4 1 2 3 4 NOTE 2 LOW PRESSURE SWITCH DC BLOWER MOTOR NOTE 2 LP PRESSURE SWITCH (LP MODELS ONLY) ROLLOUT SWITCH 1 TO 3 IN SERIES DEPENDING ON MODEL N IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED, IT MUST BE REPLACED WITH TYPE AWM-105ºC WIRE OR EQUIV. 2-STAGE THERMOSTAT R G W1 W2 Y R C W2 W1 Y G P2 3 5 6 4 2 1 2 8 1 9 P1 6 3 5 4 7 24VAC 5 A FUSE IGNITER CAPACITOR (SOME MODELS) N EAC N HUM N 1 N DC BLOWER MOTOR 12 3 4 12 3 4 SINGLE STAGE 2 STAGE * BK BL BR G O R W Y P COLOR CODE R DC Y BLOWER BL MOTOR G LINE VOLTAGE FACTORY LINE VOLTAGE FIELD NOTE: 1. MOST VOLT METERS WILL READ 13-16 VOLTS TO LOW VOLTAGE FACTORY CHASSIS ON BOTH SIDES OF AN OPEN LIMIT OR PRESSURE SWITCH IN THE RECTIFIED AC VOLTAGE CIRCUIT. LOW VOLTAGE FIELD 2. FACTORY CONNECTED WHEN BVSS, (CHIMNEY ADAPTOR INTERNAL CIRCUIT BOARD WIRING ACCESSORY KIT) OR LP PRESS. SWITCH, IS NOT INSTALLED. RECTIFIED AC VOLTAGE FACTORY SEE MANUALS FOR ADJUSTING SWITCHES FOR PROPER HEATING, COOLING & CIRCULATING SPEEDS. G BL JUMPER, SURGE JUMPER, SURGE 1 2 3 4 CAPACITOR (SOME MODELS) BR BR COM 24V N INDUCER LO MOTOR HIGH TRANSFORMER HUM 115V EAC L1 L1 L1 INDL INDH 2 STAGE 4 3 2 1 10 9 8 7 6 12 3 4 5 6 78 Y G R Y BL G BK R BK R NOTE 2 XFMR INDIN L1 4 3 2 1 GAS VALVE *AIRFLOW DIP SWITCHES SINGLE STAGE THERMOSTAT Y G W G DC MOTOR CONTROL BVSS BL (FIELD INSTALLED) INDUCER MOTOR P P1 4 CIRCUIT BOARD JUMPER, 115V JUMPER, 115V 5 4 3 2 1 1 2 3 4 12 3 4 W W 115V HOT O W W BL LP PRESSURE BL SWITCH (LP MODELS ONLY) SHIELD BEAD JUMPER, SURGE 115V NEUTRAL 1 2 3 4 EAC +HUM: 0.8 A MAX. COMBINED 1014486 SWITCH 3 NOT DEFINED OR SWITCH 3 NOT USED R Y SHIELD BEAD IND LOW R C W2 W1 Y G BL M1 M2 W W 12 3 4 5 6 7 8 *AIRFLOW DIP SWITCHES R BK IND IN HUMIDISTAT BR (OPTIONAL) BK HEAT HI COOL EAC HUM 1 120 VAC LINE 2-STAGE THERMOSTAT 6 5 HEAT LOW Y 3 XFMR DC MTR CONT 4 3 2 O W BK L1 115V HOT JUMPER, SURGE 12 3 4 180 SEC. 2 7 6 5 R W 4 3 2 1 GND. INTERLOCK SWITCH NEUTRAL DC MOTOR CONTROL 12 3 4 140 SEC. Y P2 9 8 3 1 HIGH PRESSURE SWITCH NOTE 2 115V-60HZ 12 3 4 100 SEC. 1 4 ON P1 BK 4 2 W BK LOW PRESSURE SWITCH BL R HOT 12 3 4 60 SEC. G G Y2 COM SENSOR IGNITER 1 GAS VALVE 2 3 4 2 STAGE R ROLLOUT SWITCH 1 TO 3 IN SERIES DEPENDING ON MODEL 12 3 4 FACTORY SETTING Y R R C W2 W1 Y G 24 VAC BK BL Y R 5 6 7 8 MAIN LIMIT HEAT OFF DELAY W Y W BK INTERLOCK SWITCH R ON S1 W2 W1 R R BL 24V SECONDARY TRANSFORMER 115V PRIMARY (HI VOLT FIELD) COPPER CONDUCTORS ONLY 115V 60HZ HOT FIELD CONNECTION BOX 5A FUSE LADDER DIAGRAM 1 2 3 4 + - WARNING: ELECTRICAL SHOCK HAZARD DISCONNECT BEFORE SERVICING + - 5 6 7 8 NEUTRAL COOL ON DELAY: 5 SEC COOL OFF DELAY: 90 SEC HEAT ON DELAY: 30 SEC FURNACE CONTROL 12 3 4 5 6 7 8 *AIRFLOW DIP SWITCHES + - CONNECTION DIAGRAM Multi Position Furnace Service Manual Wiring Diagram (1/2 HP DC Blower Motor) FAN CONTROL MODULE THERMOSTAT TYPE 440 08 2010 01 GND NEUTRAL 28 Y Y G BL G DC MOTOR CONTROL IND HI JUMPER, 115V 5 4 3 2 1 10 9 8 7 6 G R Y BL 1 2 3 4 5 1 2 3 4 5 G 24VAC 4 2 3 1 1 3 8 4 7 6 2 5 JUMPER, 115V JUMPER, 115V 115V NEUTRAL JUMPER, SURGE JUMPER, SURGE DC MOTOR CONTROL 5 4 3 2 1 10 9 8 7 6 1 2 3 4 5 1 2 3 4 5 LOW PRESSURE SWITCH HIGH PRESSURE SWITCH GAS 4 3 2 1 VALVE 2 STAGE 115V HOT SENSOR DC BLOWER MOTOR NOTE 2 BVSS (FIELD INSTALLED) LP PRESSURE SWITCH (LP MODELS ONLY) ROLLOUT SWITCH 1 TO 3 IN SERIES DEPENDING ON MODEL N N N 2-STAGE THERMOSTAT IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED, IT MUST BE REPLACED WITH TYPE AWM-105ºC WIRE OR EQUIV. R G W1 W2 Y R C W2 W1 Y G P2 3 5 6 4 2 1 2 8 1 9 P1 6 3 5 4 7 24VAC 5 A FUSE MAIN LIMIT HUM EAC SINGLE STAGE THERMOSTAT TYPE 2 STAGE 12 3 4 12 3 4 1014487 REV. 2 EAC + HUM: 0.8 A MAX. COMBINED * BK BL BR G O R W Y P COLOR CODE MOTOR R DC Y BL BLOWER CAPACITOR (SOME MODELS) BR BR COM IGNITER 1 CAPACITOR (SOME MODELS) 1234567 8 JUMPER, 115V 115V NEUTRAL JUMPER, SURGE JUMPER, SURGE 115V HOT BK R BK R INDUCER MOTOR 24V N INDUCER LO MOTOR HIGH TRANSFORMER HUM L1 115V EAC L1 L1 INDL *AIRFLOW DIP SWITCHES BLACK BLUE SINGLE STAGE G BROWN THERMOSTAT GREEN LINE VOLTAGE FACTORY ORANGE NOTE: 1. MOST VOLT METERS WILL READ 13-16 VOLTS TO LINE VOLTAGE FIELD RED CHASSIS ON BOTH SIDES OF AN OPEN LIMIT OR PRESSURE LOW VOLTAGE FACTORY WHITE SWITCH IN THE RECTIFIED AC VOLTAGE CIRCUIT. LOW VOLTAGE FIELD 2. FACTORY CONNECTED WHEN BVSS, (CHIMNEY ADAPTOR INTERNAL CIRCUIT BOARD WIRING YELLOW ACCESSORY KIT), OR LP PRESSURE SWITCH IS NOT INSTALLED. RECTIFIED AC VOLTAGE FACTORY PURPLE SEE MANUALS FOR ADJUSTING SWITCHES FOR PROPER HEATING, COOLING & CIRCULATING SPEEDS. W W G SHIELD BEAD 1234567 8 W BL *AIRFLOW DIP SWITCHES R Y BK O W NOTE 2 XFMR INDIN 2 STAGE 4 3 2 1 N N 12 3 4 R C W2 W1 Y G HUMIDISTAT BR (OPTIONAL) HEAT LOW BK M1 M2 W W W (FIELD INSTALLED) BVSS BL INDH 4 3 2 1 GAS VALVE 10 9 8 7 6 DC BLOWER MOTOR SWITCH 3 NOT DEFINED SWITCH 3 NOT USED 2-STAGE THERMOSTAT R Y IND LOW Y R HEAT HI COOL EAC HUM 1 120 VAC LINE G G XFMR DC MTR Y 4 7 2 P L1 P1 4 CIRCUIT BOARD JUMPER, 115V JUMPER, 115V 5 4 3 2 1 1 2 3 4 5 12 3 4 180 SEC. 1 2 3 4 5 6 P2 5 8 3 O BL LP PRESSURE BL SWITCH (LP MODELS ONLY) N SHIELD BEAD 115V NEUTRAL JUMPER, SURGE JUMPER, SURGE 1 2 3 4 5 12 3 4 140 SEC. CONT 6 IND IN 9 R W W C L1 NEUTRAL DC MOTOR CONTROL 12 3 4 100 SEC. 12 34 ON 3 1 BK LOW NOTE 2 PRESSURE HIGH SWITCH PRESSURE SWITCH INTERLOCK SWITCH 115V HOT 115V-60HZ 12 3 4 60 SEC. W1 Y2 P1 BK 4 2 4 3 2 1 W BK R BL GND. HOT 12 3 4 FACTORY SETTING W2 BL R C W2 W1 Y G COM SENSOR IGNITER 1 GAS VALVE 2 3 4 2 STAGE ROLLOUT SWITCH 1 TO 3 IN SERIES DEPENDING ON MODEL R HEAT OFF DELAY R R Y 24 VAC BK BL Y R 5 6 7 8 MAIN LIMIT ON S1 W BL 24V SECONDARY TRANSFORMER W BK INTERLOCK SWITCH R 1 2 3 4 115V PRIMARY (HI VOLT FIELD) COPPER CONDUCTORS ONLY 115V 60HZ HOT FIELD CONNECTION BOX LADDER DIAGRAM 5 6 7 8 + - WARNING: ELECTRICAL SHOCK HAZARD DISCONNECT BEFORE SERVICING + - 5A FUSE 12345678 NEUTRAL COOL ON DELAY: 5 SEC COOL OFF DELAY: 90 SEC HEAT ON DELAY: 30 SEC FURNACE CONTROL *AIRFLOW DIP SWITCHES + 441 08 2010 01 - CONNECTION DIAGRAM Service Manual Multi Position Furnace Wiring Diagram (1 HP DC Blower Motor) FAN CONTROL MODULE HOT GND NEUTRAL 29 W1 Y G SPEED TAP CODE BLACK-HI BLUE-MLO ORANGE-MHI RED-LO W2 W1 Y G 3 1 R W1 G Y W2 2 STAGE HIGH PRESSURE SWITCH 4 32 1 GAS VALVE 8 4 1 2 3 5 6 7 THERMOSTAT 4 2 SENSOR NOTE 2 BVSS (FIELD INSTALLED) LP PRESSURE SWITCH (LP MODELS ONLY) NOTE 2 LOW PRESSURE SWITCH MAIN LIMIT ROLLOUT SWITCH 1 TO 3 IN SERIES DEPENDING ON MODEL N 2 STAGE 12 3 4 1014485 REV. 2 THERMOSTAT TYPE IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED, IT MUST BE REPLACED WITH TYPE AWM - 105°C WIRE OR ITS EQUIVALENT. R C P2 1 2 3 4 5 6 2 8 1 9 P1 6 3 5 4 7 24VAC IGNITER N N EAC + HUM: 0.8 A MAX. COMBINED SEE MANUALS FOR ADJUSTING SPEED TAPS FOR PROPER HEATING, COOLING & CIRCULATING SPEEDS. BLACK BK BLUE BL BROWN BR GREEN G ORANGE O RED R WHITE W YELLOW Y PURPLE P COLOR CODE CAPACITOR (SOME MODELS) BK R BK R 5A FUSE COM 24V TRANSFORMER HUM 115V HUM 12 3 4 LINE VOLTAGE FACTORY LINE VOLTAGE FIELD LOW VOLTAGE FACTORY LOW VOLTAGE FIELD INTERNAL CIRCUIT BOARD WIRING RECTIFIED AC VOLTAGE FACTORY W O BR BR XFMR EAC EAC CAPACITOR (SOME MODELS) L1 LO N INDUCER MOTOR HIGH L1 L1 INDL INDH 1 FAN CONTROL MODULE * R BK O M1 M2 INDUCER MOTOR NOTE 2 INDIN L1 CIRCUIT BOARD 2 STAGE 4 3 2 1 CAPACITOR N SINGLE STAGE NOTE: 1. MOST VOLT METERS WILL READ 13-16 VOLTS TO CHASSIS ON BOTH SIDES OF AN OPEN LIMIT OR PRESSURE SWITCH IN THE RECTIFIED AC VOLTAGE CIRCUIT 2. FACTORY CONNECTED WHEN BVSS, (CHIMNEY ADAPTOR ACCESSORY KIT) OR LP PRESS. SWITCH IS NOT INSTALLED. SINGLE STAGE THERMOSTAT Y BR HEAT LOW BR IND HI PSC BLOWER MOTOR IND IN G W IND LOW BL 120 VAC LINE W R C W2 W1 Y G CAPACITOR HEAT HI W BL BVSS, (FIELD INSTALLED) 4 3 2 1 GAS VALVE PSC BLOWER MOTOR N 12 3 4 R G EAC COOL W W P P1 4 M2 M1 LO (R) HEAT L CONT (OPT) MHI (O) MLO (BL) HEAT H SWITCH 3 NOT DEFINED OR SWITCH 3 NOT USED R 2-STAGE THERMOSTAT Y 1 2 3 4 5 6 P2 XFMR DC MTR HUM 1 O BL L1 L1 HI (BK) COOL 12 3 4 180 SEC. 1234 ON 4 7 2 W NOTE 2 LP PRESSURE BL SWITCH (LP MODELS ONLY) N L1 L1 NEUTRAL 12 3 4 140 SEC. CONT 5 8 3 R W C L1 GND. 115V-60HZ 12 3 4 100 SEC. G Y2 6 9 3 1 BK LOW PRESSURE SWITCH HIGH PRESSURE SWITCH BL HOT INTERLOCK SWITCH 12 3 4 60 SEC. R R C W2 W1 Y G P1 BK 4 2 4 3 2 1 W BK 1 GAS VALVE 2 3 4 2 STAGE R HEAT OFF DELAY Y W Y COM SENSOR R 5 6 7 8 ROLLOUT SWITCH 1 TO 3 IN SERIES DEPENDING ON MODEL ON S1 W2 R BL BL 24V SECONDARY 24 VAC BK BL Y IGNITER R R A TRANSFORMER W BK MAIN LIMIT LADDER DIAGRAM 1 2 3 4 115V PRIMARY CONDUCTORS ONLY (HI VOLT FIELD) COPPER 115V 60HZ INTERLOCK SWITCH + FIELD CONNECTION BOX WARNING: ELECTRICAL SHOCK HAZARD DISCONNECT BEFORE SERVICING + - 5 6 7 8 5A FUSE 12 3 4 NEUTRAL COOL ON DELAY: 5 SEC COOL OFF DELAY: 90 SEC HEAT ON DELAY: 30 SEC FURNACE CONTROL FACTORY SETTING + - - CONNECTION DIAGRAM Multi Position Furnace Service Manual Wiring Diagram *8MPT 440 08 2010 01 Service Manual Multi Position Furnace 26. Model Specifications Manufacturers Number (Mfr No - See Rating Plate) ALL Models (N8MPN) Specifications General Input (Btuh) Output (Btuh) Temp. Rise (°F) Electrical (Volts/Hz/FLA) N8MPN 050B12 N8MPN 075B12 N8MPN 075F16 N8MPN 100F14 N8MPN 100F20 N8MPN 100J22 N8MPN 125J20 N8MPN 125J22 50,000 40,000 35-- 65 75,000 60,000 35-- 65 75,000 60,000 25-- 55 100,000 80,000 30-- 60 100,000 80,000 35-- 65 100,000 81,000 30-- 60 125,000 100,000 30-- 60 125,000 100,000 30-- 60 115/60/9.8 115/60/8.9 115/60/10.6 115/60/9.0 115/60/12.0 115/60/12.0 115/60/12.0 115/60/12.0 Gas Type Nat LP Nat LP Nat LP Nat LP Nat LP Nat LP Nat LP Nat LP Transformer Size (VA) T’stat Heat Anticipator 40 .10 40 .10 40 .10 40 .10 40 .10 40 .10 40 .10 40 .10 40 .10 40 .10 40 .10 40 .10 40 .10 40 .10 40 .10 40 .10 Gas & Ignition Std. Main Orifices (No/Size) 2/#42 2/#54 3/#42 3/#54 3/#42 3/#54 4/#42 4/#54 4/#42 4/#54 4/#42 4/#54 5/#42 5/#54 5/#42 5/#54 Gas Valve Honeywell SV Regulation Type Manifold Press. (Inch’s WC) 9541 SNAP 3.5 9541 SNAP 10.0 9541 SNAP 3.5 9541 SNAP 10.0 9541 SNAP 3.5 9541 SNAP 10.0 9541 SNAP 3.5 9541 SNAP 10.0 9541 SNAP 3.5 9541 SNAP 10.0 9541 SNAP 3.5 9541 SNAP 10.0 9541 SNAP 3.5 9541 SNAP 10.0 9541 SNAP 3.5 9541 SNAP 10.0 .018 .011 .018 .011 .018 .011 .018 .011 .018 .011 .018 .011 .018 .011 .018 .011 Pilot Orifice Size Ignition Type/Series Lock-- Out Time HW HSP NA HW HSP NA HW HSP NA HW HSP NA HW HSP NA HW HSP NA HW HSP NA HW HSP NA 4 4 4 4 4 4 4 4 300 See Parts List 300 See Parts List 300 See Parts List 300 See Parts List 300 See Parts List 300 See Parts List 300 See Parts List 300 See Parts List 1013529 - 0.69 - 0.59 1013529 - 0.69 - 0.59 1013529 - 0.69 - 0.59 1013529 - 0.69 - 0.59 1013529 - 0.69 - 0.59 1013529 - 0.69 - 0.59 1013529 - 0.69 - 0.59 1013529 - 0.69 - 0.59 HW ST9160 30 60,100,140,180 HW ST9160 30 60,100,140,180 HW ST9160 30 60,100,140,180 HW ST9160 30 60,100,140,180 HW ST9160 30 60,100,140,180 HW ST9160 30 60,100,140,180 HW ST9160 30 60,100,140,180 HW ST9160 30 60,100,140,180 11-- 8 10.3/1100 PSC/1/2 10/370 Washable 14x25x1 -1.5 3 11-- 8 8/1050 PSC/1/2 7.5/370 Washable 14x25x1 -1.5 3 11-- 10 10.3/1100 PSC/1/2 10/370 Washable 16x25x1 16x25 (2) 3 4 11-- 10 8/900 PSC/1/2 7.5/370 Washable 16x25x1 -2 3.5 11-- 10 10/1050 PSC/1/2 10/370 Washable 16x25x1 (2) 16x25 (2) 3 5 11-- 10 11.9/900 PSC/3/4 40/370 Washable 20x25x1 16x25 (2) 3 5.5 11-- 10 10/1050 PSC/1/2 10/370 Washable 20x25x1 16x25 (2) 3 5 11-- 10 11.9/900 PSC/3/4 40/370 Washable 20x25x1 16x25 (2) 3 5.5 Combustion Flue Outlet Size (Inches) Limits & Controls Thermal Sensor (°F) Limit Control Std. Pressure Sw. (Part No) Press (Close) Press (Open) Fan Control (Type) Fan Control On (Timed-- secs) Off Blower Data Type & Size Motor Amps/Rpm Motor Type/H.p. Cap. Mfd/Volts Filter Type (600 FPM) Filter Size (²) (Not Supplied) 1600 CFM and over Min. Cool Cap. (Tons) Max. Cool Cap. (Tons) Gas Conversion Kits Nat to LP NAHF002LP or *1009509 LP to Nat NAHF002NG, *1009510 * Must be ordered from Service Parts Two side filter racks (left and right) required for upflow applications. Side returns are not permitted with downflow or horizontal furnace applications. 441 08 2010 01 30 Service Manual Multi Position Furnace Manufacturers Number (Mfr No - See Rating Plate) ALL Models (N8MPL) Specifications N8MPL 050B12 N8MPL 075B12 N8MPL 075F16 N8MPL 100F20 N8MPL 100J22 N8MPL 125J20 N8MPL 125J22 50,000 40,000 35-- 65 75,000 60,000 35-- 65 75,000 60,000 25-- 55 100,000 80,000 35-- 65 100,000 80,000 30-- 60 125,000 100,000 30-- 60 125,000 100,000 30-- 60 115/60/9.8 115/60/8.9 115/60/10.6 115/60/12.0 115/60/12.0 115/60/12.0 115/60/12.0 General Input (Btuh) Output (Btuh) Temp. Rise (°F) Electrical (Volts/Hz/FLA) Gas Type Nat LP Nat LP Nat LP Nat LP Nat LP Nat LP Nat LP Transformer Size (VA) T’stat Heat Anticipator 40 .10 40 .10 40 .10 40 .10 40 .10 40 .10 40 .10 40 .10 40 .10 40 .10 40 .10 40 .10 40 .10 40 .10 Gas & Ignition Std. Main Orifices (No/Size) 2/#42 2/#54 3/#42 3/#54 3/#42 3/#54 4/#42 4/#54 4/#42 4/#54 5/#42 5/#54 5/#42 5/#54 Gas Valve Honeywell SV Regulation Type Manifold Press. (Inch’s WC) 9541 SNAP 3.5 9541 SNAP 10.0 9541 SNAP 3.5 9541 SNAP 10.0 9541 SNAP 3.5 9541 SNAP 10.0 9541 SNAP 3.5 9541 SNAP 10.0 9541 SNAP 3.5 9541 SNAP 10.0 9541 SNAP 3.5 9541 SNAP 10.0 9541 SNAP 3.5 9541 SNAP 10.0 .018 .011 .018 .011 .018 .011 .018 .011 .018 .011 .018 .011 .018 .011 Pilot Orifice Size Ignition Type/Series Lock-- Out Time HW HSP NA HW HSP NA HW HSP NA HW HSP NA HW HSP NA HW HSP NA HW HSP NA 4 4 4 4 4 4 4 300 See Parts List 300 See Parts List 300 See Parts List 300 See Parts List 300 See Parts List 300 See Parts List 300 See Parts List 1013529 - 0.69 - 0.59 1013529 - 0.69 - 0.59 1013529 - 0.69 - 0.59 1013529 - 0.69 - 0.59 1013529 - 0.69 - 0.59 1013529 - 0.69 - 0.59 1013529 - 0.69 - 0.59 HW ST9160 30 60,100,140,180 HW ST9160 30 60,100,140,180 HW ST9160 30 60,100,140,180 HW ST9160 30 60,100,140,180 HW ST9160 30 60,100,140,180 HW ST9160 30 60,100,140,180 HW ST9160 30 60,100,140,180 11-- 8 10.3/1100 PSC/1/2 10/370 Washable 14x25x1 -1.5 3 11-- 8 8/1050 PSC/1/2 7.5/370 Washable 14x25x1 -1.5 3 11-- 10 10.3/1100 PSC/1/2 10/370 Washable 16x25x1 16x25 (2) 3 4 11-- 10 10/1050 PSC/1/2 10/370 Washable 16x25x1 -3 5 11-- 10 11.9/900 PSC/3/4 40/370 Washable 20x25x1 16x25 (2) 3 5.5 11-- 10 10/1050 PSC/1/2 10/370 Washable 20x25x1 16x25 (2) 3 5 11-- 10 11.9/900 PSC/3/4 40/370 Washable 20x25x1 16x25 (2) 3 5.5 Combustion Flue Outlet Size (Inches) Limits & Controls Thermal Sensor (°F) Limit Control Std. Pressure Sw. (Part No) Press (Close) Press (Open) Fan Control (Type) Fan Control On (Timed-- secs) Off Blower Data Type & Size Motor Amps/Rpm Motor Type/H.p. Cap. Mfd/Volts Filter Type (600 FPM) Filter Size (²) (Not Supplied) 1600 CFM and over Min. Cool Cap. (Tons) Max. Cool Cap. (Tons) Gas Conversion Kits Nat to LP NAHF002LP, *1009509 LP to Nat NAHF002NG, *1009510 * Must be ordered from Service Parts Two side filter racks (left and right) required for upflow applications. Side returns are not permitted with downflow or horizontal furnace applications. 31 440 08 2010 01 Service Manual Multi Position Furnace Manufacturers Number (Mfr No - See Rating Plate) ALL Models (*8MPN) Specifications *8MPN 050B12 *8MPN 075B12 *8MPN 075F16 *8MPN 100F14 *8MPN 100F20 *8MPN 100J20 *8MPN 125J20 *8MPN 150J20 50,000 40,000 35-- 65 75,000 60,000 30-- 60 75,000 60,000 30-- 60 100,000 81,000 35-- 65 100,000 81,000 35-- 65 100,000 81,000 35-- 65 125,000 101,000 35-- 65 150,000 121,000 35-- 65 General Input (Btuh) Output (Btuh) Temp. Rise (°F) Electrical (Volts/Hz/FLA) 115/60/12.0 115/60/12.0 115/60/12.0 115/60/12.0 Gas Type Nat LP Nat LP Nat LP Nat LP Nat LP Nat LP Nat LP Nat LP Transformer Size (VA) T’stat Heat Anticipator 40 .30 40 .30 40 .30 40 .30 40 .30 40 .30 40 .30 40 .30 40 .30 40 .30 40 .30 40 .30 40 .30 40 .30 40 .30 40 .30 Gas & Ignition Std. Main Orifices (No/Size) 2/#42 2/#54 3/#42 3/#54 3/#42 3/#54 4/#42 4/#54 4/#42 4/#54 4/#42 4/#54 5/#42 5/#54 6/#42 6/#54 Gas Valve Honeywell SV Regulation Type Manifold Press. (Inch’s WC) 9541 SNAP 3.5 9541 SNAP 10.0 9541 SNAP 3.5 9541 SNAP 10.0 9541 SNAP 3.5 9541 SNAP 10.0 9541 SNAP 3.5 9541 SNAP 10.0 9541 SNAP 3.5 9541 SNAP 10.0 9541 SNAP 3.5 9541 SNAP 10.0 9541 SNAP 3.5 9541 SNAP 10.0 9541 SNAP 3.5 9541 SNAP 10.0 .018 .011 .018 .011 .018 .011 .018 .011 .018 .011 .018 .011 .018 .011 .018 .011 Pilot Orifice Size Ignition Type/Series Lock-- Out Time 115/60/9.8 Std. Pressure Sw. (Part No) Press (Close) Press (Open) Fan Control (Type) Fan Control On (Timed-- secs) Off Blower Data Type & Size Motor Amps/Rpm Motor Type/H.p. Cap. Mfd/Volts Filter Type (600 FPM) Filter Size (²) (Not Supplies) 1600 CFM and over Min. Cool Cap. (Tons) Max. Cool Cap. (Tons) 115/60/10.0 115/60/9.0 HW HSP NA HW HSP NA HW HSP NA HW HSP NA HW HSP NA HW HSP NA HW HSP NA HW HSP NA 4 4 4 4 4 4 4 4 300 See Parts List 130 300 See Parts List 130 300 See Parts List 130 300 See Parts List 130 300 See Parts List 130 300 See Parts List 130 300 See Parts List 130 300 See Parts List 130 1013529 - 0.69 - 0.59 1013529 - 0.69 - 0.59 1013529 - 0.69 - 0.59 1013529 - 0.69 - 0.59 1013529 - 0.69 - 0.59 1013529 - 0.69 - 0.59 1013529 - 0.69 - 0.59 1013529 - 0.69 - 0.59 HW ST9160 30 60,100,140,180 HW ST9160 30 60,100,140,180 HW ST9160 30 60,100,140,180 HW ST9160 30 60,100,140,180 HW ST9160 30 60,100,140,180 HW ST9160 30 60,100,140,180 HW ST9160 30 60,100,140,180 HW ST9160 30 60,100,140,180 11-- 8 10.3/1100 PSC/1/2 10/370 Washable 14x25x1 -1.5 3 11-- 8 8/1050 PSC/1/2 7.5/370 Washable 14x25x1 -1.5 3 11-- 10 10.3/1100 PSC/1/2 10/370 Washable 16x25x1 16x25 (2) 3 4 11-- 10 8/900 PSC/1/2 7.5/370 Washable 16x25x1 -2 3.5 11-- 10 10/1050 PSC/1/2 10/370 Washable 16x25x1 16x25 (2) 3 5 11-- 10 11.9/900 PSC/3/4 40/370 Washable 20x25x1 16x25 (2) 3 5 11-- 10 10/1050 PSC/1/2 10/370 Washable 20x25x1 16x25 (2) 3 5 12-- 12 11.9/900 PSC/3/4 40/370 Washable 20x25x1 16x25 (2) 3 5 Combustion Flue Outlet Size (Inches) Limits & Controls Thermal Sensor (°F) Limit Control Auxiliary Limit (°F) 115/60/8.9 Gas Conversion Kits Nat to LP NAHF002LP, *1009509 LP to Nat NAHF002NG, *1009510 * Must be ordered from Service Parts Two side filter racks (left and right) required for upflow applications. Side returns are not permitted with downflow or horizontal furnace applications. 441 08 2010 01 32 Service Manual Multi Position Furnace Manufacturers Number (Mfr No - See Rating Plate) ALL Models (*8MPL) Specifications *8MPL 050B12 *8MPL 075B12 *8MPL 075F16 *8MPL 100F20 *8MPL 100J20 *8MPL 125J20 50,000 40,000 35-- 65 75,000 60,000 30-- 60 75,000 60,000 30-- 60 100,000 81,000 35-- 65 100,000 81,000 35-- 65 125,000 101,000 35-- 65 General Input (Btuh) Output (Btuh) Temp. Rise (°F) Electrical (Volts/Hz/FLA) 115/60/9.8 115/60/8.9 115/60/10.0 115/60/12.0 115/60/12.0 115/60/12.0 Gas Type Nat LP Nat LP Nat LP Nat LP Nat LP Nat LP Transformer Size (VA) T’stat Heat Anticipator 40 .30 40 .30 40 .30 40 .30 40 .30 40 .30 40 .30 40 .30 40 .30 40 .30 40 .30 40 .30 Gas & Ignition Std. Main Orifices (No/Size) 2/#42 2/#54 3/#42 3/#54 3/#42 3/#54 4/#42 4/#54 4/#42 4/#54 5/#42 5/#54 Gas Valve Honeywell SV Regulation Type Manifold Press. (Inch’s WC) 9541 SNAP 3.5 9541 SNAP 10.0 9541 SNAP 3.5 9541 SNAP 10.0 9541 SNAP 3.5 9541 SNAP 10.0 9541 SNAP 3.5 9541 SNAP 10.0 9541 SNAP 3.5 9541 SNAP 10.0 9541 SNAP 3.5 9541 SNAP 10.0 .018 .011 .018 .011 .018 .011 .018 .011 .018 .011 .018 .011 Pilot Orifice Size Ignition Type/Series Lock-- Out Time HW HSP NA HW HSP NA HW HSP NA HW HSP NA HW HSP NA HW HSP NA 4 4 4 4 4 4 300 See Parts List 130 300 See Parts List 130 300 See Parts List 130 300 See Parts List 130 300 See Parts List 130 300 See Parts List 130 Std. Pressure Sw. (Part No) Press (Close) Press (Open) 1013529 - 0.69 - 0.59 1013529 - 0.69 - 0.59 1013529 - 0.69 - 0.59 1013529 - 0.69 - 0.59 1013529 - 0.69 - 0.59 1013529 - 0.69 - 0.59 Fan Control (Type) Fan Control On delay (Timed-- secs) Off delay HW ST9160 30 60,100,140,180 HW ST9160 30 60,100,140,180 HW ST9160 30 60,100,140,180 HW ST9160 30 60,100,140,180 HW ST9160 30 60,100,140,180 HW ST9160 30 60,100,140,180 Blower Data Type & Size Motor Amps/Rpm Motor Type/H.p. Cap. Mfd/Volts Filter Type Filter Size (²) (Not Supplied) 1600 CFM and over Min. Cool Cap. (Tons) Max. Cool Cap. (Tons) 11-- 8 10.3/1100 PSC/1/2 10/370 Washable 14x25x1 -1.5 3 11-- 8 8/1050 PSC/1/2 7.5/370 Washable 14x25x1 -1.5 3 11-- 10 10.3/1100 PSC/1/2 10/370 Washable 16x25x1 16x25 (2) 3 4 11-- 10 10/1050 PSC/1/2 10/370 Washable 16x25x1 16x25 (2) 3 5 11-- 10 11.9/900 PSC/3/4 40/370 Washable 20x25x1 16x25 (2) 3 5 11-- 10 10/1050 PSC/1/2 10/370 Washable 20x25x1 16x25 (2) 3 5 Combustion Flue Outlet Size (Inches) Limits & Controls Thermal Sensor (°F) Limit Control Auxiliary Limit (°F) Gas Conversion Kits Nat to LP NAHF002LP, *1009509 LP to Nat NAHF002NG, *1009510 * Must be ordered from Service Parts Two side filter racks (left and right) required for upflow applications. Side returns are not permitted with downflow or horizontal furnace applications. 33 440 08 2010 01 Service Manual Multi Position Furnace Manufacturers Number (Mfr No - See Rating Plate) ALL Models Specifications *8DNL050B12 *8DNL075B12 *8DNL075F16 *8DNL100F14 *8DNL100L20 *8DNL125L20 50,000 40,000 35-- 65 75,000 60,000 35-- 65 75,000 60,000 35-- 65 100,000 80,000 35-- 65 100,000 80,000 30-- 60 125,000 100,000 35-- 65 General Input (Btuh) Output (Btuh) + Temp. Rise (°F) Electrical (Volts/Hz/FLA) 115/60/8.9 115/60/7.6 115/60/10.6 115/60/8.9 115/60/11.2 115/60/11.2 Gas Type Nat LP Nat LP Nat LP Nat LP Nat LP Nat LP Transformer Size (VA) T’stat Heat Anticipator 40 .10 40 .10 40 .10 40 .10 40 .10 40 .10 40 .10 40 .10 40 .10 40 .10 40 .10 40 .10 Gas & Ignition Std. Main Orifices (No/Size) 2/#42 2/#54 3/#42 3/#54 3/#42 3/#54 4/#42 4/#54 4/#42 4/#54 5/#42 5/#54 Gas Valve Honeywell SV Regulation Type Manifold Press. (Inch’s WC) 9541 SNAP 3.5 9541 SNAP 10.0 9541 SNAP 3.5 9541 SNAP 10.0 9541 SNAP 3.5 9541 SNAP 10.0 9541 SNAP 3.5 9541 SNAP 10.0 9541 SNAP 3.5 9541 SNAP 10.0 9541 SNAP 3.5 9541 SNAP 10.0 .018 .011 .018 .011 .018 .011 .018 .011 .018 .011 .018 .011 Pilot Orifice Size Ignition Type/Series Lock-- Out Time HW HSP NA HW HSP NA HW HSP NA HW HSP NA HW HSP NA HW HSP NA 4 <480 4 <480 4 <480 4 <480 4 <480 4 <480 300 See Parts List 300 See Parts List 300 See Parts List 300 See Parts List 300 See Parts List 300 See Parts List Std. Pressure Sw. (Part No) Press (Close) Press (Open) 1013529 - 0.69 - 0.59 1013529 - 0.69 - 0.59 1013529 - 0.69 - 0.59 1013529 - 0.69 - 0.59 1013529 - 0.69 - 0.59 1013529 - 0.69 - 0.59 Hi. Alt. Pressure Sw. (Part # ) 6,000¢ to 10,000¢ Press (Close) Press (Open) 1014051 - .57 - .47 1014051 - .57 - .47 1014051 - .57 - .47 1014051 - .57 - .47 1014051 - .57 - .47 1014051 - .57 - .47 Fan Control (Type) Fan Control On (Timed-- secs) Off HW ST9160 30 60,100,140,180 HW ST9160 30 60,100,140,180 HW ST9160 30 60,100,140,180 HW ST9160 30 60,100,140,180 HW ST9160 30 60,100,140,180 HW ST9160 30 60,100,140,180 Blower Data Type & Size Motor Amps/Rpm Motor Type/H.p. Cap. Mfd/Volts Filter Type Filter Size (²) Min. Cool Cap. (Tons) Max. Cool Cap. (Tons) 11-- 8 8/1050 PSC/1/2 7.5/370 Washable 16x18x1 (2) 1.5 3 11-- 8 8/1050 PSC/1/3 5.0/370 Washable 16x18x1 (2) 1.5 3 11-- 10 10/1050 PSC/1/2 10/370 Washable 16x18x1 (2) 3 4 11-- 10 8/900 PSC/1/2 7.5/370 Washable 16x18x1(2) 2 3.5 11-- 10 11.9/900 PSC/3/4 40/370 Washable 16x18x1 (2) 3 5 11-- 10 11.9/900 PSC/3/4 40/370 Washable 16x18x1 (2) 3 5 Combustion Flue Outlet Size (Inches) Std. Outlet Temp (°F) Limits & Controls Thermal Sensor (°F) Limit Control Gas Conversion Kits Nat to LP NAHF002LP (*1009509) or NAHL002LP (*1160991) LP to Nat NAHF002NG, *1009510* LP High Altitude *1160992 * Must be ordered from Service Parts + Tentative 441 08 2010 01 34 Service Manual Multi Position Furnace Manufacturers Number (Mfr No --See Rating Plate) ALL Models Specifications *8MPV050B12A *8MPV075F14A *8MPV100J20A *8MPV125J20A General Gas Type Nat LP Nat LP Nat LP Nat LP Transformer Size (VA) T’stat Heat Anticipator 40 .10 40 .10 40 .10 40 .10 40 .10 40 .10 40 .10 40 .10 Input (Btuh) Std/Alt. Hi Fire Lo Fire Output (Btuh) Std/Alt. Hi Fire Lo Fire Temp. Rise (°F) Hi Fire Lo Fire Electrical (Volts/Hz/FLA) Gas & Ignition Gas Type Std. Main Orifices (No/Size) Gas Valve (Honeywell) Regulation Type Manifold Press. Hi Fire (² WC) Lo Fire (² WC) Pilot Orifice Size Ignition Type/Series 50,000 35,000 40,000 28,000 30--60 25--55 75,000 52,500 60,000 42,000 30--60 25--55 100,000 70,000 81,000 61,000 35--65 35--65 125,000 87,500 101,000 71,000 30--60 25--55 115/60/8.2 115/60/9 115/60/12 115/60/12 Nat 2/#42 LP 2/#54 Nat 3/#42 LP 3/#54 Nat 4/#42 LP 4/#54 Nat 5/#42 LP 5/#54 SV 9541 SNAP 3.5 1.7 SV 9541 SNAP 10.0 4.9 SV 9541 SNAP 3.5 1.7 SV 9541 SNAP 10.0 4.9 SV 9541 SNAP 3.5 1.7 SV 9541 SNAP 10.0 4.9 SV 9541 SNAP 3.5 1.7 SV 9541 SNAP 10.0 4.9 .018 .011 .018 .011 .018 .011 .018 .011 HW HSP HW HSP HW HSP HW HSP HW HSP HW HSP HW HSP HW HSP Combustion Flue Outlet Size (Inches) 4 4 4 4 4 4 4 4 Limits & Controls Fan Control (Type) Fan Control On delay (Timed--secs) Off delay HW ST9162 30 60,100,140,180 HW ST9162 30 60,100,140,180 HW ST9162 30 60,100,140,180 HW ST9162 30 60,100,140,180 300 See Limit in Parts List 300 See Limit in Parts List 300 See Limit in Parts List 300 See Limit in Parts List Std. Pressure Sw. (Part #) Hi Fire Press (Close) Hi Fire Press (Open) 1013862 --0.69 --0.59 1013862 --0.69 --0.59 1013862 --0.69 --0.59 1013862 --0.69 --0.59 Lo Fire Press (Close) Lo Fire Press (Open) --0.40 --0.30 --0.40 --0.30 --0.40 --0.30 --0.40 --0.30 Blower Data Type & Size Motor Amps/Rpm Motor Type/H.p. Filter Type Filter Size (²) Min. Cool Cap. (Tons) Max. Cool Cap. (Tons) 11--8 4.6/1050 DC/1/2 Washable 14x25x1/2 1.5 3 11--10 12/900 DC/1 Washable 16x25x1/2 1.5 3.5 11--10 12/900 DC/1 Washable 16x25x1/2 (2) 3 5 11--10 12/900 DC/1 Washable 16x25x1/2 (2) 3 5 Gas Conversion Kits Nat to LP LP to Nat *1011789 *1011787 *1011789 *1011787 *1011789 *1011787 *1011789 *1011787 Thermal Sensor (°F) Limit Control Setting (°F) *Must be ordered from Service Parts Use the Fuel Gas Code to establish proper vent sizing. 35 440 08 2010 01 Service Manual Multi Position Furnace Manufacturers Number (Mfr No --See Rating Plate) ALL Models Specifications *8MPT050B12A General Gas Type Input (Btuh) Std/Alt. Output (Btuh) Std/Alt. Temp. Rise (°F) Nat LP Hi Fire Lo Fire Hi Fire Lo Fire Hi Fire Lo Fire Electrical (Volts/Hz/FLA) Transformer Size (VA) T’stat Heat Anticipator Gas & Ignition GStd. Main Orifices (No/Size) Gas Valve (Honeywell) Regulation Type Manifold Press. Hi Fire (² WC) Lo Fire (² WC) *8MPT075F14A Nat LP *8MPT100F14A Nat LP *8MPT100J20A *8MPT125J20A Nat Nat LP LP 50,000 35,000 40,000 28,000 30-- 60 25-- 55 75,000 52,500 60,000 42,000 30-- 60 25-- 55 100,000 70,000 81,000 57,000 35-- 65 35-- 65 100,000 70,000 81,000 61,000 35-- 65 35-- 65 125,000 87,500 101,000 71,000 30-- 60 25-- 55 115/60/5.3 115/60/9.2 115/60/9.2 115/60/12 115/60/12 40 .30 40 .30 40 .30 40 .30 40 .30 40 .30 40 .30 40 .30 40 .30 40 .30 2/#42 2/#54 3/#42 3/#54 4/#42 4/#54 4/#42 4/#54 5/#42 5/#54 SV 9541 SNAP 3.5 1.7 SV 9541 SNAP 10.0 4.9 SV 9541 SNAP 3.5 1.7 SV 9541 SNAP 10.0 4.9 SV 9541 SNAP 3.5 1.7 SV 9541 SNAP 10.0 4.9 SV 9541 SNAP 3.5 1.7 SV 9541 SNAP 10.0 4.9 SV 9541 SNAP 3.5 1.7 SV 9541 SNAP 10.0 4.9 Pilot Orifice Size .018 .011 .018 .011 .018 .011 .018 .011 .018 .011 Ignition Type/Series (Honeywell) HSP HSP HSP HSP HSP HSP HSP HSP HSP HSP 4 4 4 4 4 4 4 4 4 4 Combustion Flue Outlet Size (Inches Limits & Controls Fan Control (Type) Fan Control (Timed--secs) HW ST9162A 30 60,100,140,180 HW ST9162A 30 60,100,140,180 HW ST9162A 30 60,100,140,180 HW ST9162A 30 60,100,140,180 HW ST9162A 30 60,100,140,180 300 See Limit in Parts List 300 See Limit in Parts List 300 See Limit inParts List 300 See Limit in Parts List 300 See Limit in Parts List 1013862 - 0.69 - 0.59 - 0.40 - 0.30 1013862 - 0.69 - 0.59 - 0.40 - 0.30 1013862 - 0.69 - 0.59 - 0.40 - 0.30 1013862 - 0.69 - 0.59 - 0.40 - 0.30 1013862 - 0.69 - 0.59 - 0.40 - 0.30 Blower Data Type & Size Motor Amps/Rpm Motor Type/H.p. Cap. Mfd/Volts Filter Type Filter Size (²) Min. Cool Cap. (Tons) Max. Cool Cap. (Tons) 11-- 8 10.3/1100 PSC/1/2 10/370 Washable 14x25x1 1.5 3 11-- 10 10.3/1100 PSC/1/2 10/370 Washable 16x25x1 1.5 3.5 11-- 10 8/900 PSC/1/2 7.5/370 Washable 16x25x1 1.5 3.5 11-- 10 10/1050 PSC/3/4 40/370 Washable 16x25x1 (2) 3 5 11-- 10 10/1050 PSC/1/2 40/370 Washable 16x25x1 (2) 3 5 Gas Conversion Kits Nat to LP LP to Nat *1011789 *1011787 *1011789 *1011787 *1011789 *1011787 *1011789 *1011787 *1011789 *1011787 On delay Off delay Thermal Sensor (°F) Limit Control Setting (°F) Std. Pressure Sw. (Part No) Hi Fire Press (Close) Hi Fire Press (Open) Lo Fire Press (Close) Lo Fire Press (Open) *Must be ordered from Service Parts Use the Fuel Gas Code to establish proper vent sizing. 441 08 2010 01 36 Service Manual Multi Position Furnace 27. Circulation Air Blower Data N8MPN/L100J22 Air Delivery in Cubic Feet per Minute (C.F.M.) Air Delivery in Cubic Feet per Minute (C.F.M.) (Furnace Rated @0.5²² WC ESP) TAP LOW MED L MED H HIGH .10 454 672 1116 1335 .30 351 609 1055 1237 .50 278 550 991 1160 .70 201 498 897 1029 .90 ------ 422 783 903 1.00 ------ 353 718 822 Exterrnal Static Pressure Inches of W.C. Exterrnal Static Pressure Inches of W.C. N8MPN/L050B12 & *8MPN/L050B12 (Furnace Rated @0.5²² WC ESP) TAP LOW MED L MED H HIGH .10 665 925 1171 1501 .30 616 893 1136 1407 .50 563 840 1074 1307 .70 517 741 977 1200 .90 442 650 866 1050 1.00 394 593 804 963 (Furnace Rated @0.5²² WC ESP) MED L MED H HIGH .10 803 1091 1548 2194 .30 760 1082 1557 2070 .50 699 1028 1500 1913 .70 618 934 1369 1708 .90 502 772 1138 1447 1.00 423 661 984 1254 (Furnace Rated @0.5²² WC ESP) MED L MED H HIGH .10 742 916 1287 1723 .30 625 845 1195 1638 .50 525 747 1079 1515 .70 440 662 1006 .90 348 553 868 1185 1.00 297 490 787 1066 Exterrnal Static Pressure Inches of W.C. N8MPN/L100F20, *8MPN/L100F20, N8MPL100J20 & *8MPN/L100J20 Air Delivery in Cubic Feet per Minute (C.F.M.) (Furnace Rated @0.5²² WC ESP) LOW MED L MED H HIGH .10 1845 2058 2285 2508 .30 1790 1992 2189 2379 .50 1714 1903 2066 2232 .70 1592 1769 1914 2049 .90 1404 1571 1711 1839 1.00 * Denotes Brand 1291 1444 1541 1694 .10 1820 2144 2218 2252 .30 1747 1982 2135 2254 .50 1680 1862 1996 2092 .70 1551 1668 1819 1899 .90 1353 1448 1584 1744 1.00 1253 1380 1504 1633 (Furnace Rated @0.5²² WC ESP) TAP LOW MED L MED H HIGH .10 839 1211 1584 2267 .30 829 1188 1559 2151 .50 798 1111 1553 2049 .70 734 1079 1505 1912 .90 651 1015 1400 1704 1.00 595 897 1308 1585 (Furnace Rated @0.5²² WC ESP) TAP LOW MED L MED H HIGH .10 1832 2041 2257 2366 .30 1766 1958 2144 2291 .50 1700 1864 2001 2116 .70 1567 1705 1812 1956 .90 1393 1507 1639 1750 1.00 1284 1395 1529 1618 Air Delivery in Cubic Feet per Minute (C.F.M.) 1371 TAP HIGH *8MPN150J20 Exterrnal Static Pressure Inches of W.C. Exterrnal Static Pressure Inches of W.C. Air Delivery in Cubic Feet per Minute (C.F.M.) LOW MED H Air Delivery in Cubic Feet per Minute (C.F.M.) N8MPN100F14 & *8MPN100F14 TAP MED L N8MPN/L125J22 Exterrnal Static Pressure Inches of W.C. Exterrnal Static Pressure Inches of W.C. Air Delivery in Cubic Feet per Minute (C.F.M.) LOW LOW Air Delivery in Cubic Feet per Minute (C.F.M.) N8MPN/L075F16 & *8MPN/L075F16 TAP TAP N8MPN/L125J20 & *8MPN/L125J20 Air Delivery in Cubic Feet per Minute (C.F.M.) Exterrnal Static Pressure Inches of W.C. Exterrnal Static Pressure Inches of W.C. N8MPN/L075B12 & *8MPN/L075B12 (Furnace Rated @0.5²² WC ESP) 37 (Furnace Rated @0.5²² WC ESP) TAP LOW MED L MED H HIGH .10 1590 1827 2073 2283 .30 1519 1708 1993 2262 .50 1440 1623 1904 2150 .70 1331 1525 1774 1991 .90 1163 1381 1579 1813 1.00 1079 1277 1494 1694 440 08 2010 01 Service Manual Multi Position Furnace *8DNL050B12/075F16 *8DNL100F14 Air Delivery in Cubic Feet per Minute (C.F.M.) (Furnace Rated @0.5²² WC ESP) (Furnace Rated @0.5²² WC ESP) TAP LOW MED L MED H HIGH .10 673 929 1211 1481 .30 599 815 1138 1365 .50 490 733 1049 1266 .70 394 595 884 1068 .90 297 451 641 910 1.00 238 420 510 777 Exterrnal Static Pressure Inches of W.C. Exterrnal Static Pressure Inches of W.C. Air Delivery in Cubic Feet per Minute (C.F.M.) *8DNL075B12 MED L MED H .10 649 748 975 1390 .30 540 668 926 1317 .50 445 575 1172 1201 .70 379 463 733 1056 .90 216 300 592 882 1.00 168 192 524 768 *8MDNL100F14 Exterrnal Static Pressure Inches of W.C. Air Delivery in Cubic Feet per Minute (C.F.M.) (Furnace Rated @0.5²² WC ESP) TAP LOW MED L MED H HIGH .10 714 963 1310 1812 .30 553 845 1216 1658 .50 463 742 1125 1546 .70 365 658 989 1425 .90 ------ 629 834 1233 1.0 ------ 419 733 1083 * Denotes Brand 441 08 2010 01 MED L MED H HIGH .10 1738 1963 2150 2288 .30 1651 1839 2015 2125 .50 1560 1722 1859 1975 .70 1421 1566 1699 1789 .90 1239 1385 1500 1583 1.00 1030 1225 1361 1451 Air Delivery in Cubic Feet per Minute (C.F.M.) HIGH Exterrnal Static Pressure Inches of W.C. Exterrnal Static Pressure Inches of W.C. (Furnace Rated @0.5²² WC ESP) LOW LOW *8DNL125L20 Air Delivery in Cubic Feet per Minute (C.F.M.) TAP TAP 38 (Furnace Rated @0.5²² WC ESP) TAP LOW MED L MED H HIGH .10 1860 2085 2226 .30 1776 1954 2138 2246 .50 1662 1830 1981 2084 .70 1478 1629 1787 1878 .90 1279 1432 1539 1623 1.00 1168 1301 1369 1478 Service Manual Multi Position Furnace Circulation Air Blower Data - *8MPV Heating, Cooling & Continuous Airflow Settings Cooling (CFM) @ 0.50²² Static (See Figure 1 - 3 for complete Airflow Range) Continuous Blower (CFM) @ 0.10²² Static Furnace Model Switch Settings #1 #2 50K 75K Switch Settings 100/125K Furnace Model 0* 0* 911 1046 1174 #6 #7 #8 50K 75K 100/125K 0 1 777 903 1032 0* 0* 0* 1167 1414 2169 0 1 1115 1306 2003 1209 1806 1 0 664 771 858 0 1 1 542 632 698 0 1 0 1000 0 1 1 907 1105 1601 1 0 0 810 1009 1408 *Factory Setting Heating Air Temperature Adjustment (°° F)* Switch Settings Furnace Model 1 0 1 760 907 1204 #3 #4 #5 50K 75K 100K 125K 1 1 0 703 842 1006 0** 0** 0** 0 0 0 0 1 1 1 656 816 813 0 0 1 1 1 3 3 0 1 0 2 2 5 5 0 1 1 3 4 7 8 1 0 0 6 5 8 10 1 0 1 --3 --3 --5 --1 1 1 0 --5 --6 --8 --2 1 1 1 --7 --9 --12 --4 *Factory setting *Approximate air temperature change from factory setting @ 0.20² static on high heat )low heat speed changes with change of high heat speed on most settings) **Factory setting Blower Motor Settings 010 *EXAMPLE Cooling Airflows Switches 6, 7 & 8: INPUT SIGNAL OR THERMOSTAT CONNECTIONS 39 000 001 010 011 3.5 Ton 3.0 Ton 2.5 Ton 2.0 Ton *See “Technical Support Manual” for correct airflow rates. 440 08 2010 01 Service Manual Multi Position Furnace Circulation Air Blower Data - *8MPV Heating, Cooling & Continuous Airflow Settings Figure 1 *8M PV050B12 COOLING 1400 1200 1000 000 001 010 SCFM 800 011 100 600 101 110 111 400 200 0 0.1 0.2 0.3 0.5 0.7 1.0 " w.c. ESP Figure 2 *8M PV075F14 COOLING 1800 1600 1400 000 1200 001 010 1000 CFM 011 100 800 101 110 600 111 400 200 0 0.1 0.2 0.3 0.5 " w.c. ESP 441 08 2010 01 40 0.7 1.0 Service Manual Multi Position Furnace Circulation Air Blower Data - *8MPV Heating, Cooling & Continuous Airflow Settings Figure 3 8M PV100J20 COOLING 2500 2000 000 001 1500 010 CFM 011 100 101 1000 110 111 500 0 0.1 0.2 0.3 0.5 0.7 1.0 "w .c. ESP Figure 4 8M PV125J20 COOLING 2500 2000 000 001 1500 010 CFM 011 100 101 1000 110 111 500 0 0.1 0.2 0.3 0.5 0.7 1.0 "w.c. ESP 41 440 08 2010 01 Service Manual Multi Position Furnace CIRCULATION AIR BLOWER DATA *8MPT050B *8MPT100J20 Air Delivery in Cubic Feet per Minute (C.F.M.) Air Delivery in Cubic Feet per Minute (C.F.M.) (Furnace Rated @0.5²² WC ESP) (Furnace Rated @0.5²² WC ESP) TAP LOW MED L MED MED H HIGH .10 675 859 ---- 1015 1394 .20 662 846 ---- 999 1342 .30 651 819 ---- 977 1289 .40 636 795 ---- 952 1227 .50 608 765 ---- 914 1163 .60 564 735 ---- 870 1086 .70 514 685 ---- 818 1002 TAP LOW MED L MED MED H HIGH .10 1210 1441 ---- 1773 2104 .20 1201 1430 ---- 1740 2078 .30 1197 1453 ---- 1740 2061 .40 1191 1441 ---- 1718 2020 .50 1167 1425 ---- 1707 2005 .60 1160 1390 ---- 1676 1953 .70 1130 1365 ---- 1654 1917 *8MPT125J20 *8MPT075F14 & *8MPT100F14 Air Delivery in Cubic Feet per Minute (C.F.M.) (Furnace Rated @0.5²² WC ESP) Air Delivery in Cubic Feet per Minute (C.F.M.) (Furnace Rated @0.5²² WC ESP) TAP LOW MED L MED MED H HIGH TAP LOW MED L MED MED H HIGH .10 1264 1520 ---- 1841 2161 .10 691 882 ---- 1211 1633 .20 1251 1506 ---- 1803 2132 .30 591 850 ---- 1155 1544 .30 1249 1486 ---- 1772 2079 .50 536 785 ---- 1089 1464 .40 1219 1456 ---- 1736 2042 .70 433 711 ---- 982 1307 .50 1168 1427 ---- 1702 1991 .90 342 856 ---- 850 1120 .60 1178 1415 ---- 1672 1914 1.00 308 527 ---- 763 1041 .70 1143 1358 ---- 1614 1838 441 08 2010 01 42 INDEX A F Adjusting Heat Anticipator, 10 Fan Timer, Electronic, 15 Adjusting Manifold Pressure, 7 Flame Current, Checking, 17 Air Proving Switch, See Pressure Switch Auxiliary Limit Switch, 12 B G Gas Valve/Ignition Control, Honeywell SV9541M, 16 Ground, Electrical, 4 Blower Assembly, Conditioned Air, 18 Blower Speeds, Changing, 18 Blower Speeds, Selecting, 18 Burners, 8 C Capacitors, 17 H Heat Anticipators, 10 Heat Exchanger Removal/Replacement, 20 High Altitude Operation, 7 Honeywell ST9160B Fan Timer, 19 Honeywell SV9541 Gas Valve/Ignition Control, 16 Checking Capacitors, 17 Checking Flame Current, 17 Checking Grounding and Polarity, 4 Checking Input (Firing) Rate, 6 Checking Manifold Pressure, 7 Checking Temperature Rise, 9 Circulating Air Blower Data, 37 Combustion Air/Vent Piping, 14 Combustion Blower. See Exhaust Blower I Inlet Air Restrictor, 10 Interlock Switch, 5 Introduction, 1 K Kits, Twinning, 11 Control Wiring, 11 D L Limit Switches, 11 “DIP” Switch Settings, ST9160, 15 E P Piping, Vent/Combustion Air, 14 Electrical Supply, 4 Polarity, Line Voltage, 4 Electrical Variation (SV9541M), 25 Pressure Switches, 13 Electronic Fan Timer, 15 Pressures, Approximate Operating, 13 INDEX R T Roll Out Limit Switch, 12 Technical Service Data , 30 -- 36 Room Thermostat, 10 Temperature Rise, 9 Testing Sequence, ST9160, 15 S Thermostat, Room, 10 Transition Pressure Switch, 13 Sequence of Operation Chart, SV9541M, 21 Troubleshooting Chart, Honeywell SV9541M, 23 ST9160 Testing Sequence, 15 Twinning Kits, 11 Supply, Electrical, 4 Supply, Gas, 6 SV9541M System Operation, 16 U Unit Identification, 2 Switch, Blower Door Interlock, 5 Switch, “DIP”-- ST9140, 15 Switch, Auxiliary Limit, 12 Switch, Transition Pressure, 12 Switch, L.P. Gas Pressure, 8 Switch, Main Limit, 11 Switch, Pressure, 12--13 V Vent Termination, Standard, 14 Vent/Combustion Air Piping, 14 W Switch, Roll Out Limit, 12 Wiring Diagram, 26 -- 29 Switches, Limit, 11 Wiring, Control, 10
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