Table of Contents
Advertisement
Modulating, Variable Speed Blower Motor
35" Tall, High Efficiency Condensing Gas Furnace
DANGER, WARNING, CAUTION, and NOTE
The
signal
words
CAUTION, and NOTE are used to identify levels of
hazard seriousness. The signal word DANGER is
only used on product labels to signify an immediate
hazard. The signal words WARNING, CAUTION,
and NOTE will be used on product labels and
throughout this manual and other manual that may
apply to the product.
DANGER − Immediate hazards which will result in
severe personal injury or death.
WARNING − Hazards or unsafe practices which
could result in severe personal injury or death.
CAUTION − Hazards or unsafe practices which
may result in minor personal injury or product or
property damage.
NOTE − Used to highlight suggestions which will
result in enhanced installation, reliability, or
operation.
TABLE OF CONTENTS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Printed in U.S.A.
SERVICE AND TECHNICAL
SUPPORT MANUAL
(F/G)9MAC
Save this manual for future reference.
Safety Labeling and Signal Words
DANGER,
WARNING,
. . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . .
. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
. . . .
. . . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Signal Words in Manuals
The signal word WARNING is used throughout
this manual in the following manner:
WARNING
!
The signal word CAUTION is used throughout
this manual in the following manner:
CAUTION
!
Signal Words on Product Labeling
Signal words are used in combination with
colors and/or pictures or product labels.
Safety−alert symbol
When you see this symbol on the unit and in
instructions or manuals, be alert to the
potential for personal injury.
4
(F/G)9MAC0601714A
4
4
(F/G)9MAC0602120A
5
(F/G)9MAC0801714A
5
(F/G)9MAC0802120A
8
(F/G)9MAC1002122A
9
9
(F/G)9MAC1202422A
9
11
12
12
17
21
21
23
25
26
27
27
28
29
31
32
34
38
39
MODELS
Use of the AHRI Certified TM Mark indicates a
manufacturer's participation in the program.
For verification of certification for individual
products, go to www.ahridirectory.org .
440 04 4201 03
July 2012
Advertisement
Table of Contents
Troubleshooting
Related Manuals for KeepRite F9MAC Series
Summary of Contents for KeepRite F9MAC Series
-
Page 1: Table Of Contents
SERVICE AND TECHNICAL SUPPORT MANUAL Modulating, Variable Speed Blower Motor 35” Tall, High Efficiency Condensing Gas Furnace (F/G)9MAC Save this manual for future reference. Safety Labeling and Signal Words DANGER, WARNING, CAUTION, and NOTE Signal Words in Manuals signal words DANGER, WARNING, The signal word WARNING is used throughout... - Page 2 SAFETY CONSIDERATIONS WARNING Improper ins t allation, adjus t ment, alteration, serv ic e, maintenance, or use can cause explosion, fire, electrical shock, PERSONAL INJURY, AND/OR PROPERTY DAMAGE or other conditions which may cause death, personal injury, or HAZARD property damage. Consult a qualified installer, service agency, Failure to carefully read and follow this warning could or your distributor or branch for information or assistance.
- Page 3 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC START−UP CHECK SHEET For Variable Speed Models (F/G)9MAC (This sheet is optional. Keep for future reference.) Date of Start−Up: Heating Check Measured Line Pressure During High Heat: Dealer Name: Measured Manifold Pressure: Max Heat Address: Min Heat...
-
Page 4: Start−Up, Adjustment, And Safety Check
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC START−UP, ADJUSTMENT, AND SAFETY when a two−stage outdoor unit is used. Refer to Figure 4 and the Adjustments section for set up switch configurations. CHECK To set the desired cooling airflow: General 1. -
Page 5: Purge Gas Lines
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC 3. Pour one quart (liter) of water into funnel/tube. Water Figure 2 Orifice Hole should run through collector box, overfill condensate trap, and flow into open field drain. 4. Remove funnel; replace collector box drain plug. 5. - Page 6 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC To do this: NOTE: For Canadian altitudes of 2000 to 4500 ft. (610 to 1372 M), use USA altitudes of 2001 to 3000 ft. (610 to 914 1. Obtain average heat value (at installed altitude) from local gas supplier.
- Page 7 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC 2. Remove the 1/8 inch NPT plug from the outlet pressure 11. Re-install cap over adjustment screw on the top of the tap on the gas valve. gas valve. Clocking the Meter 3.
-
Page 8: Adjust Temperature Rise
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC Figure 3 Variable Speed Furnace Control for ECM Blower Motor (Modulating) COMMUNICATION CONTINUOUS FAN OUTDOOR SW4 SETUP (CF) AIRFLOW IR TEMP SWITCHES CONNECTOR SETUP SWITCHES CONNECTOR MODEL PLUG MODULATING CONNECTOR GAS VALVE CONNECTOR SW1 SETUP SWITCHES AND... -
Page 9: Adjust Blower Off Delay (Heat Mode)
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC Adjust Blower Off Delay (Heat Mode) 2. Wait until the blower off delay is completed. 3. Turn 115 VAC power off. a. Remove blower door if installed. 4. Check the position of Set up switch SW1−3. When set to b. - Page 10 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC Figure 4 Furnace Setup Switch Description Furnace Setup Switch Description Turn ON to retrieve up to 7 stored status codes for SW1-1 Status Code Recovery troubleshooting assistance when R thermostat lead is disconnected.
-
Page 11: Adjust Thermostat Heat Anticipator
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC Table 3 Airflow Switch Table NOMINAL AIRFLOW BASED ON 350 CFM/TON (Factory Default - SW1-5 = OFF, SW4-3 = OFF) SW2 Clg Default SW3 CF Default COOLING (SW2) AND CONTINUOUS FAN (SW3) AIRFLOW: SET-UP SWITCH POSITIONS Model Size 1050 1050... -
Page 12: Check Safety Controls
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC b. Gradually block off return air with a piece of Figure 5 Amp. Draw Check with Ammeter cardboard or sheet metal until the limit trips. THERMOSTAT SUBBASE c. Unblock return air to permit normal circulation. TERMINALS WITH d. - Page 13 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC Orifice Size and Manifold Pressure (in. w.c.) for Gas Input Rate Table 4 TO BE USED WITH MODULATING FURNACES EXCEPT THE (F/G)9MAC0602120 MODULATING FURNACE (TABULATED DATA BASED ON 20,000 BTUH MAX-HEAT / 8,000 BTUH MIN-HEAT PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE RANGE...
- Page 14 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC Orifice Size and Manifold Pressure (in. w.c.) for Gas Input Rate Table 4 (Cont.) TO BE USED WITH MODULATING FURNACES EXCEPT THE (F/G)9MAC0602120 MODULATING FURNACE (TABULATED DATA BASED ON 20,000 BTUH MAX-HEAT / 8,000 BTUH MIN-HEAT PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE RANGE...
- Page 15 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC Orifice Size and Manifold Pressure (in. w.c.) for Gas Input Rate Table 5 TO BE USED WITH MODULATING FURNACES (F/G)9MAC0602120 FURNACE ONLY (TABULATED DATA BASED ON 20,200 BTUH MAX-HEAT / 8,000 BTUH MIN-HEAT PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE AVG.
- Page 16 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC Orifice Size and Manifold Pressure (in. w.c.) for Gas Input Rate Table 5 (Cont.) TO BE USED WITH MODULATING FURNACES (F/G)9MAC0602120 FURNACE ONLY (TABULATED DATA BASED ON 20,200 BTUH MAX-HEAT / 8,000 BTUH MIN-HEAT PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE AVG.
-
Page 17: Cooling And Heating Air Delivery
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC Table 6 COOLING AND HEATING AIR DELIVERY - CFM (Bottom Return with Filter) (SW1-5 and SW4-3 set to OFF, except as indicated. See notes 1 and 2) Clg/CF Switch Settings External Static Pressure (ESP) Unit Size SWx-3 SWx-2... - Page 18 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC Table 6 (Cont.) COOLING AND HEATING AIR DELIVERY - CFM (Bottom Return with Filter) Clg/CF Switch Settings External Static Pressure (ESP) Unit Size SWx-3 SWx-2 SWx-1 080-14 Clg Default: 1055 1065 1080 1075 1065 1050...
- Page 19 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC Table 6 (Cont.) COOLING AND HEATING AIR DELIVERY - CFM (Bottom Return with Filter) Clg/CF Switch Settings External Static Pressure (ESP) Unit Size SWx-3 SWx-2 SWx-1 100-22 Clg Default: 1820 1825 1840 1845 1840 1835...
- Page 20 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC Table 7 Gas Rate (CU ft./hr) SECONDS G SIZE OF TEST DIAL SECONDS SIZE OF TEST DIAL 1 Cu Ft. 2 Cu Ft. 5 Cu Ft. 1 Cu Ft. 2 Cu Ft. 5 Cu Ft.
-
Page 21: Service And Maintenance Procedures
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC SERVICE AND MAINTENANCE Figure 6 Multipoise Orientations PROCEDURES WARNING FIRE, INJURY OR DEATH HAZARD Failure to follow this warning could result in personal injury, death and/or property damage. The ability to properly perform service and maintenance on this equipment requires certain knowledge, mechanical skills, tools, and equipment. - Page 22 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC Figure 7 Heating and Cooling Application Wiring Diagram with Single−Stage Thermostat FIELD 24-VOLT WIRING FIELD 115-, 208/230-, 460-VOLT WIRING FACTORY 24-VOLT WIRING FACTORY 115-VOLT WIRING NOTE 2 1-STAGE THERMOSTAT FIVE FIELD-SUPPLIED TERMINALS WIRE FUSED DISCONNECT BLOWER...
-
Page 23: Cleaning And/Or Replacing Air Filter
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC Care and Maintenance 5. Inspect the vent pipe/vent system before each heating season for water leakage, sagging pipes or broken fittings. Have vent pipes/vent system serviced by a WARNING qualified service agency. 6. - Page 24 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC d. Separate the pipes from the blower compartment and Figure 8 Blower Assembly set aside. e. Remove the couplings from the pipe adapters and set MOTOR SHAFT FLAT aside. f. After servicing the blower, reverse steps a through e. g.
-
Page 25: Cleaning Burners And Flame Sensor
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC WARNING 2. Turn off gas at external shut-off or gas meter. 3. Remove outer doors and set aside. 4. Turn electric switch on gas valve to OFF. ELECTRICAL SHOCK HAZARD 5. Disconnect the gas pipe from gas valve and remove pipe Failure to follow this warning could result in personal injury, or from the furnace casing. -
Page 26: Servicing Hot Surface Igniter
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC Figure 9 Burner Assembly Figure 11 Igniter Position − Side View URNER UPT. 2 in. 50 mm URNER 3/8 in. 9.6 mm LAME OLL−OUT WITCH 3/16 in. 4.6 mm LAME ENSOR ELOW URNER) + 1/32 1/10 in. -
Page 27: Flushing Collector Box And Drainage System
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC 8. Turn on gas and electrical supplies to furnace. 2. Install gasket on collector box 9. Verify igniter operation by initiating control board self−test 3. Align the condensate trap with the drain opening on the feature or by cycling thermostat. -
Page 28: Winterization
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC corrected, such as improper adjustment of manifold pressure, Secondary Heat Exchangers insufficient or poor quality combustion air, improper vent The condensing side (inside) of the secondary heat exchanger termination, incorrect size or damaged manifold orifice(s), CANNOT be serviced or inspected without complete removal of improper gas, or a restricted heat exchanger (primary or the heat exchanger assembly. -
Page 29: Service Label
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC Figure 14 Service Label 338316−2 Rev I 440 04 4201 03 Specifications subject to change without notice. - Page 30 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC Figure 15 Wiring Diagram 338316−2 Rev I 440 04 4201 03 Specifications subject to change without notice.
-
Page 31: Troubleshooting Chart − Flow Chart
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC Figure 16 Troubleshooting Chart − Flow Chart 440 04 4201 03 Specifications subject to change without notice. -
Page 32: Troubleshooting Guide − Flow Chart
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC Figure 16 (CONT.) Troubleshooting Guide − Flow Chart 440 04 4201 03 Specifications subject to change without notice. - Page 33 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC Figure 16 (CONT.) Troubleshooting Chart − Flow Chart 440 04 4201 03 Specifications subject to change without notice.
-
Page 34: Sequence Of Operation
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC SEQUENCE OF OPERATION The furnace will start up in either intermediate-, or maximum-heat. The furnace will transition and operate at CAUTION minimum-heat or the calculated modulating rate after starting and operating for 45 seconds at intermediate-heat. furnace control CPU defaults to minimum-heat on the first UNIT OPERATION HAZARD thermostat cycle and calculates the modulating rate that the... - Page 35 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC close the gas valve GV, and the furnace control CPU will from medium range input to maximum-heat, the furnace repeat the ignition sequence for up to three more control CPU will increase the inducer motor speed to the Trials-For-Ignition before going to Ignition-Lockout.
- Page 36 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC HPS will open and the gas rate will be changed to high-cooling speed, and the R to G-and-Y/Y2 circuits start the intermediate-heat. The gas valve solenoid GV will remain furnace blower motor BLWM high-cooling airflow.
- Page 37 SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC is satisfied, the blower motor BLWM will operate an additional lowest. The blower motor BLWM will remain on until the main 90 seconds at low-cooling airflow before transitioning back to burners ignite then shut OFF and remain OFF for 25 seconds continuous-blower airflow.
-
Page 38: Parts Replacement Information Guide
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC PARTS REPLACEMENT INFORMATION GUIDE Casing Group Gas Control Group Control door Manifold Blower door Burner Top filler plate Orifice Bottom filler plate Flame sensor Door Knob Assembly Hot surface igniter Gas valve Electrical Group Heat Exchanger Group Control box... -
Page 39: Product Nomenclature
SERVICE AND TECHNICAL SUPPORT MANUAL Gas Furnace: (F/G)9MAC PRODUCT NOMENCLATURE DIGIT POSITION 6, 7, 8 9, 10 11, 12 G = Mainline Look 1 F = Mainline Look 2 N = Entry 9 = 90% − 100% EFFICIENCY M = Multiposition H = Horizontal U = Upflow D = Downflow...
Need help?
Do you have a question about the F9MAC Series and is the answer not in the manual?
Questions and answers