ICP G9MAE1002122A User Manual

Printed in U.S.A. 440 04 4700 00 Aug. 2012
SERVICE AND TECHNICAL
SUPPORT MANUAL
Modulating, Variable Speed Blower Motor
35” Tall, High Efficiency Condensing Gas Furnace
(
F/G
)
9MAE
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Safety Labeling and Signal Words
DANGER, WARNING, CAUTION, and NOTE
The signal words DANGER, WARNING,
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.
!
WARNING
Signal Words in Manuals
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.
The signal word WARNING is used throughout
this manual in the following manner:
Safety−alert symbol
When you see this symbol on the unit and in
instructions or manuals, be alert to the
potential for personal injury.
TABLE OF CONTENTS
START−UP, ADJUSTMENT, AND SAFETY CHECK 4...........
SELECT SETUP SWITCH POSITIONS 4.....................
PRIME CONDENSATE TRAP WITH WATER 4.................
PURGE GAS LINES 5......................................
ADJUSTMENTS 5.........................................
ADJUST TEMPERATURE RISE 8............................
ADJUST BLOWER OFF DELAY (HEAT MODE) 9..............
ADJUST COOLING AIRFLOW 9.............................
ADJUST CONTINUOUS FAN AIRFLOW 9....................
ADJUST THERMOSTAT HEAT ANTICIPATOR 11...............
CHECK SAFETY CONTROLS 12.............................
CHECKLIST 12.............................................
COOLING AND HEATING AIR DELIVERY - CFM 17.............
SERVICE AND MAINTENANCE PROCEDURES 21.............
ELECTRICAL CONTROLS AND WIRING 21...................
CLEANING AND/OR REPLACING AIR FILTER 23..............
CLEANING BURNERS AND FLAME SENSOR 25...............
SERVICING HOT SURFACE IGNITER 26......................
FLUSHING COLLECTOR BOX AND DRAINAGE SYSTEM 27....
CLEANING CONDENSATE DRAIN AND TRAP 27..............
WINTERIZATION 28........................................
SERVICE LABEL 29.........................................
TROUBLESHOOTING CHART − FLOW CHART 31.............
TROUBLESHOOTING GUIDE − FLOW CHART 32..............
SEQUENCE OF OPERATION 34.............................
PARTS REPLACEMENT INFORMATION GUIDE 38.............
PRODUCT NOMENCLATURE 39.............................
MODELS
(F/G)9MAE0601714A
(F/G)9MAE0602120A
(F/G)9MAE0801714A
(F/G)9MAE0802120A
(F/G)9MAE1002122A
(F/G)9MAE1202422A
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 .

ICP G9MAE1002122A Specifications

General

Model	G9MAE1002122A
Fuel Type	Natural Gas
Ignition Type	Hot Surface Ignition
Input BTU	100, 000 BTU/h
Vent Type	Direct Vent
Warranty	10-Year Parts, Limited Lifetime Heat Exchanger

Summary

Safety Labeling and Signal Words

Signal Words in Manuals

Defines signal words like DANGER, WARNING, CAUTION, and NOTE used in manuals.

Safety Considerations

Personal Injury, and/or Property Damage Hazard

Warns about hazards causing personal injury or death from improper operation.

Electrical Shock Hazard

Warns about potential injury or death from electrical shock during service.

Carbon Monoxide Poisoning and Fire Hazard

Warns about hazards leading to injury, death, or property damage.

START-UP, ADJUSTMENT, AND SAFETY CHECK

Select Setup Switch Positions

Prime Condensate Trap with Water

Check Inlet Gas Pressure

Adjust Manifold Pressure-Maximum Heat

Adjust Manifold Pressure-Minimum Heat

Adjust Temperature Rise

Determine air temperature rise

To lock the furnace in Minimum Heat

Procedure to set the furnace to operate in minimum heat mode.

Adjust Cooling Airflow – High-Speed and Low-Speed Cooling

Cooling Air Delivery CFM

Adjust Continuous Fan Airflow/Low Speed Cooling Airflow

Continuous Fan CFM Setup

Furnace Setup Switch Description

SW1

AIR CONDITIONING (A/C) SETUP SWITCHES (SW2)

CONTINUOUS FAN (CF) SETUP SWITCHES (SW3)

Airflow Switch Table

NOMINAL AIRFLOW BASED ON 350 CFM/TON

Table for selecting airflow based on CFM/ton for cooling and continuous fan.

NOMINAL AIRFLOW BASED ON 400 CFM/TON

Table for selecting airflow based on CFM/ton for cooling and continuous fan.

NOMINAL AIRFLOW BASED ON 325 CFM/TON

Table for selecting airflow based on CFM/ton for cooling and continuous fan.

NOMINAL AIRFLOW BASED ON 370 CFM/TON

Table for selecting airflow based on CFM/ton for cooling and continuous fan.

Check Safety Controls

Check Main Limit Switch

Procedure to test the main limit switch for proper operation.

Check Pressure Switch (es)

Procedure to test the pressure switch(es) for draft inducer operation.

Table 4 Orifice Size and Manifold Pressure

Table 4 (Cont.) Orifice Size and Manifold Pressure

MODULATING FURNACE

Data for selecting orifices and setting pressures for furnaces.

Table 5 Orifice Size and Manifold Pressure

Table 5 (Cont.) Orifice Size and Manifold Pressure

MODULATING FURNACES (F/G)9MAE0602120 FURNACE ONLY

Data for a specific model's orifices and manifold pressures.

Table 6 COOLING AND HEATING AIR DELIVERY - CFM

060-14

Airflow data for model 060-14 across various settings and static pressures.

060-20

Airflow data for model 060-20 across various settings and static pressures.

Table 6 (Cont.) COOLING AND HEATING AIR DELIVERY - CFM

080-14

Airflow data for model 080-14 across various settings and static pressures.

100-22

Airflow data for model 100-22 across various settings and static pressures.

080-20

Airflow data for model 080-20 across various settings and static pressures.

120-22

Airflow data for model 120-22 across various settings and static pressures.

SERVICE AND MAINTENANCE PROCEDURES

WARNING FIRE, INJURY OR DEATH HAZARD

General safety warning for performing service.

WARNING ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

Warning about electrical hazards during service.

Electrical Controls and Wiring

WARNING ELECTRICAL SHOCK HAZARD

Warning about electrical shock hazards during servicing.

Figure 7 Wiring Diagram

Heating and Cooling Application Wiring Diagram with Single-Stage Thermostat

Illustrates wiring for single-stage thermostat operation.

Retrieving Stored Fault Codes

Procedure for Retrieving Status Codes

Component Self-Test

Component Test Sequence

Care and Maintenance

Cleaning and/or Replacing Air Filter

Filter Cleaning and Replacement Procedure

Blower Wheel and Motor Cleaning

Cleaning Burners and Flame Sensor

Burner Cleaning Procedure

Servicing Hot Surface Igniter

Igniter Resistance Check

Procedure for checking igniter resistance before removal.

Cleaning Condensate Drain and Trap

Condensate Trap Re-installation

Cleaning Heat Exchangers

Primary Heat Exchangers Cleaning

Figure 14 Service Label

Service Information Overview

Component Test Initiation

Instructions for initiating the component test sequence.

Figure 15 Wiring Diagram

Connection Diagram

Schematic Diagram

Figure 16 Troubleshooting Guide – Flow Chart

Initial Troubleshooting Steps

Status Code Retrieval Procedure

Figure 16 (CONT.) Troubleshooting Guide – Flow Chart

Troubleshooting Pressure Switch Issues

Diagnostic steps for pressure switch faults.

Troubleshooting Limit and Flame Proving Faults

Steps for diagnosing limit and flame proving faults.

Gas Valve, Igniter, and Flame Sensor Diagnosis

Guide to diagnose issues with gas valve, igniter, or flame sensor.

Figure 16 (CONT.) Troubleshooting Guide – Flow Chart

Troubleshooting Lockout and Motor Faults

Troubleshooting Pressure Switch Cross-Connections

SEQUENCE OF OPERATION

Modulating Heating with Communicating Controls

Modulating Heating with Single-Stage Thermostat

SEQUENCE OF OPERATION (CONT.)

Two-Stage Heating Operation

Cooling Mode

Single-Speed Cooling Operation

Two-Speed Cooling Operation

PARTS REPLACEMENT INFORMATION GUIDE

Critical Safety Warning for Parts Handling

Critical safety warning regarding hazards during installation/service.