Heating & Air Conditioning ® C om fort. Q uality. Tru st. Two-Stage Variable Speed Gas-Fired Furnace Installation Instructions This Forced Air Central Furnace design complies with requirements embodied in The American National Standard / National Standard of Canada shown below: ANSI Z21.47·CSA-2.3 Gas Fired Central Furnaces DESIG N CE R T I F I E D CE Part No. 10759833 Printed in USA R TI FIE D Goodman Company, L.P. 1810 Wilson Parkway • Fayetteville, Tennessee 37334 www.amana-hac.
Table of Contents Safety Instructions ......................................................................................................................... 4 Recognize Safety Symbols, Words, and Labels ................................................................................................... 4 General Information ....................................................................................................................... 6 Shipping and Handling .......................................
Table of Contents Startup Adjustments and Measurements ................................................................................... 26 Furnace Operation ................................................................................................................................................ 26 Measure Gas Supply Pressure ............................................................................................................................ 27 Measure and Adjust Gas Manifold Pressure .......
Safety Instructions Recognize Safety Symbols, Words, and Labels Please adhere to the following warnings and cautions when installing, adjusting, altering, servicing, or operating the furnace. Failure to heed safety information increases the risk of personal injury, property damage, and/or product damage. WARNING If the information in these instructions is not followed exactly, fire or explosion may result causing property damage, personal injury or loss of life.
Safety Instructions WARNING To prevent possible death or personal injury due to asphyxiation, this Non-Condensing Gas Fired Warm Air Furnaces must be Category I vented. Do not vent any of these furnaces using Category III venting. Provisions must be made for venting combustion products outdoors through a proper venting system. The length of flue pipe could be a limiting factor in locating the furnace.
General Information Shipping and Handling All units are securely packed in shipping containers tested according to International Safe Transit Association specifications. The carton must be checked upon arrival for external damage. If damage is found, a request for inspection by carrier’s agent must be made in writing immediately. The furnace must be carefully inspected on arrival for damage and bolts or screws which may have come loose in transit. In the event of damage the consignee should: 1.
General Information Product Application (cont’d) WARNING Possible death, personal injury or property damage due to fire, explosion, smoke, soot, condensation, electrical shock or carbon monoxide may result from improper installation, repair, operation, or maintenance of this product. WARNING To prevent death, personal injury or property damage due to fire, do not install this furnace in a mobile home, trailer, or recreational vehicle.
General Information Location Requirements and Considerations WARNING To prevent possible death, personal injury, equipment damage, or property damage the following bullet points must be observed when installing the unit. Follow the instructions listed below when selecting a furnace location. Refer also to the guidelines provided in the section Combustion and Ventilation Air Requirements. • • • • • • • Centrally locate the furnace with respect to the proposed or existing air distribution system.
General Information FURNACE SUSPENSION above, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous conditions of use; If suspending the furnace from rafters or joist, use 3/8" threaded rod and 2”x2”x1/8” angle iron as shown below. The length of rod will depend on the application and the clearances necessary. g. If improper venting is observed during any of the above tests, the common venting system must be corrected.
Combustion and Ventilation Air Requirements WARNING Possible death, personal injury or property damage may occur if the furnace is not provided with enough fresh air for proper combustion and ventilation of flue gases. Most homes require outside air to be supplied to the furnace area. Improved construction and additional insulation in buildings have reduced heat loss by reducing air filtration and escape around doors and windows.
Combustion and Ventilation Air Requirements 5.3.3 Equipment Located in Confined Spaces: (a) All Air from Inside the Building: The confined space shall be provided with two permanent openings communicating directly with an additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space. The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination.
Combustion and Ventilation Air Requirements NOTE: The single opening must have a free area of not less than one square inch per 3000 BTU of the total input rating of all equipment in the enclosure, but not less than the sum of the areas of all vent connectors in the confined space. 5.3.4 Specially Engineered Installations: Chimney or Gas Vent The requirements of 5.3.
Category I Venting (Vertical Venting) WARNING To prevent possible death or personal injury due to asphyxiation, this Non-Condensing Gas Fired Warm Air Furnace must be Category I vented. Do not vent using Category III venting. Category I Venting is venting at a non-positive pressure. A furnace vented as Category I is considered a fan-assisted appliance and the vent system does not have to be “gas tight.
Category I Venting (Vertical Venting) INDUCED DRAFT BLOWER RELOCATION Upflow Upright or Horizontal units are shipped with the induced draft blower discharging from the top of the furnace. (“Top” is as viewed for an upflow installation.) The induced draft blower can be rotated 90 degrees counterclockwise for Category I venting, with the airflow horizontal left to right.
Category I Venting (Vertical Venting) WARNING To prevent death, personal injury or property damage due to fire or explosion, a qualified servicer must determine the reason the rollout protection device opened before the device is reset. ROLLOUT PROTECTION DEVICE RELOCATION Furnaces installed horizontal right-to-left airflow, require the rollout protection device be relocated. This device closes the gas valve if the burner flames are not drawn into the heat exchanger.
Electrical Connections WARNING To avoid the risk of electrical shock, wiring to the unit must be properly polarized and grounded. WARNING To avoid electrical shock, injury or death, disconnect electrical power before servicing or changing any electrical wiring. CAUTION Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.
Electrical Connections 6. Rotate the junction box 180 degrees so the access panel continues to face forward. The open snap bushing should now be on the left. NOTE: Do not use gas piping as an electrical ground. To confirm proper unit grounding, turn off the electrical power and perform the following check. 7. Attach pressure switch bracket to left side of furnace where the junction box was using the screws saved in Step 4. The “L” bracket must point toward the front of the furnace.
Electrical Connections W2 ( W1 Y The furnace’s integrated ignition control is equipped with line voltage accessory terminals for controlling power to an optional field-supplied humidifier and/or electronic air cleaner. Thermostat Two-Stage Heating with Single-Stage Cooling ) The accessory load specifications are as follows: YLO Y B/C R G R W1 W2 DEHUM TWIN Humidifier Electronic Air Cleaner Furnace Integrated Control Module Turn OFF power to the furnace before installing any accessories.
Gas Supply and Piping Proper Piping Practice The gas line installation must comply with local codes, or in the absence of local codes, with the latest edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1. IMPORTANT NOTE: This unit is factory set to operate on natural gas at the altitudes shown on the rating plate. The plate is stamped with the model number, type of gas and gas input rating. Make sure the unit is equipped to operate on the type of gas available.
Gas Supply and Piping High Altitude Derate When this furnace is installed at high altitude, the appropriate High Altitude orifice kit must be applied. This is required due to the natural reduction in the density of both the gas fuel and combustion air as altitude increases. The kit will provide the proper design certified input rate within the specified altitude range. High altitude kits are purchased according to the installation altitude and usage of either natural or propane gas.
Gas Supply and Piping 9. • • • • The unit must be connected to the building piping by one of the following methods: Rigid metallic pipe and fittings Semirigid metallic tubing and metallic fittings (Aluminum alloy tubing must not be used in exterior locations) Listed gas appliance connectors used in accordance with the terms of their listing that are completely in the same room as the equipment Protect connectors and semirigid tubing against physical and thermal damage when installed.
Gas Supply and Piping Gas Piping Checks WARNING To avoid the possibility of explosion or fire, never use a match or open flame to test for leaks. CAUTION To prevent personal injury or property damage due to fire, the following instructions must be performed regarding gas connections, pressure testing, location of shutoff valve and installation of gas piping. Before placing unit in operation, leak test the unit and gas connections.
Propane Gas Tanks and Piping WARNING PERSONAL INJURY HAZARD To prevent death, personal injury, or property damage due to fire or explosion from a propane gas leak, install a gas detecting warning device. A gas detecting warning device is the only reliable way to detect a propane gas leak. Do not rely on smell as rust can reduce the level of odorant in propane gas. Remember: • • • Propane gas is heavier than air and leaking gas can settle in any low area or confined space.
Propane Gas Tanks and Piping Sizing Between First and Second Stage Regulator* Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting. Capacities in 1,000 BTU/hour. Pipe or Nominal Pipe Size Tubing Tubing Size, O.D.
Circulating Air and Filters NOTE: An undersized opening will cause reduced airflow. Ductwork Sizing Duct systems and register sizes must be properly designed for the CFM and external static pressure rating of the furnace. Ductwork should be designed in accordance with the recommended methods of “Air Conditioning Contractors of America” Manual D.
Startup Adjustments and Measurements Furnace must have a 115 VAC power supply properly connected and grounded. Proper polarity must be maintained for correct operation. An interlock switch prevents furnace operation if the blower door is not in place. Keep the blower access door in place except for inspection and maintenance. This furnace is also equipped with a self-diagnosing electronic control module.
Startup Adjustments and Measurements Measure Gas Supply Pressure 4. Measure furnace gas supply pressure with burners firing. Supply pressure must be within the range specified in the “Inlet Gas Supply Pressure” table . If supply pressure differs from the table, make necessary adjustments to pressure regulator, gas piping size, etc., and/or consult with local gas utility.
Startup Adjustments and Measurements Measure and Adjust Temperature Rise 6. Turn the adjustment screw clockwise to increase the pressure, or counterclockwise to decrease the pressure. Air temperature rise is the temperature difference between supply and return air. Temperature rise must be within the range specified on the unit rating plate. An incorrect temperature rise could cause condensing in or overheating of the heat exchanger.
Startup Procedure and Adjustment 4. Locate the blower speed selection DIP switches on the integrated control module. Select the desired “cooling” speed tap by positioning switches 1 and 2 appropriately. Select the desired “adjust” tap by positioning switches 3 and 4 appropriately. Refer to the following figure for switch positions and their corresponding taps. Turn off power to furnace for a minimum of 10 seconds, allowing motor to reset and recognize new speed selection. Turn on power to furnace.
Startup Procedure and Adjustment 8 7 Cooling Speed Tap A Normal 8 7 Cooling Speed Tap B O F F 4 3 2 8 7 4 3 2 1 8 7 O F F 4 8 7 O O F N F 4 3 2 1 Adjust Blower Heat Off Delay * O F F 1 O F F 3 2 1 The integrated control module provides a selectable heat off delay function. The heat off delay period may be set to 60, 90, 120, 180 seconds using the DIP switches or jumper provided on the control module.
Normal Sequence of Operation Power Up The normal power up sequence is as follows: • 115 VAC power applied to furnace. • Integrated control module performs internal checks. • Integrated control module flashes LED one time. • Integrated control module monitors safety circuits continuously. • Furnace awaits call from thermostat. Heating Mode The normal operational sequence in heating mode is as follows: • R and W1 (or R and W1/W2) thermostat contacts close, initiating a call for heat.
Normal Sequence of Operation Cooling Mode Fan Only Mode The normal operational sequence in cooling mode is as follows: The normal operational sequence in fan only mode is as follows: • R and YLO/G or Y/G thermostat contacts close, initiat- • R and G thermostat contacts close, initiating a call for ing a call for cool. • Integrated control module performs safety circuit checks. • Outdoor fan and compressor are energized to their appropriate speed.
Timing Charts For Normal Heating Operation Example 1: Continuous Call For Low Stage Heat Only High Low Off Gas Valve On Off Igniter On Off Pressure Switches Induced Draft Blower Thermostat (Call for Heat) PS2 Closed PS1 Closed Open High Low Off High Low Off 0 10 30 33 34 { Circulator Blower 4-second maximum trial for ignition period 64 94 0 15 30 60, 90 120, or 180 90, 120, 150, or 210 30 60, 90 120, or 180 90, 120, 150, or 210 Time (sec) Example 2: Continuous Call For High Stage H
Timing Charts for Normal Heating Operation Example 3: Initial Call For Low Heat, Change In Call To High Heat Call Change to High Heat Gas Valve Igniter Pressure Switches High Low Off High Low Off On Off PS2 Closed PS1 Closed Open Induced Draft Blower High Low Off Thermostat (Call For Heat) High Low Off 0 10 30 33 34 { Circulator Blower 4-second maximum trial for ignition period 64 94 0 15 Time (sec) 30 60, 90 120, or 180 90, 120, 150, or 210 Example 4: Initial Call For High Heat, Subs
Timing Charts for Normal Cooling Operation Example 1: Continuous Call For Low Stage Cooling Only Circulator Blower Outdoor Fan And Compressor Thermostat (Call For Cool) High Low Off (88% of Low) High Low Off High Low Off 0 5 Time (sec) 35 0 45 Example 2: Continuous Call For High Stage Cooling Only Circulator Blower Outdoor Fan And Compressor Thermostat (Call For Cool) High Low Off (88% of High) High Low Off High Low Off 0 5 Time (sec) 35 0 Timing Chart for Normal Fan Operation Circul
Operational Checks These checks establish that the primary limit control is functioning and will respond to a restriction in the return air, or a circulator blower failure. If the primary limit control does not function during this test, the cause must be determined and corrected. WARNING To prevent personal injury or death, do not remove any internal compartment covers or attempt any adjustment. Electrical components are contained in both compartments.
Operational Checks High or Primary Limit 3. Remove the return air blockage to clear overheating condition. After an acceptable temperature is reached during the cool down period, the limit control will reset and allow the furnace to resume normal operation. The primary limit control guards against overheating resulting from insufficient conditioned air passing over the heat exchanger. If the primary limit control does not function during this test, the cause must be determined and corrected.
Safety Circuit Description A number of safety circuits are employed to ensure safe and proper furnace operation. These circuits serve to control any potential safety hazards and serve as inputs in the monitoring and diagnosis of abnormal function. These circuits are continuously monitored during furnace operation by the integrated ignition control. Rollout Limit Integrated Ignition Control The rollout limit controls are mounted on the burner/ manifold assembly and monitor the burner flame.
Troubleshooting Electrostatic Discharge (ESD) Precautions NOTE: Discharge body’s static electricity before touching unit. An electrostatic discharge can adversely affect electrical components. Use the following precautions during furnace installation and servicing to protect the integrated ignition control from damage. By putting the furnace, the control, and the person at the same electrostatic potential, these steps will help avoid exposing the integrated ignition control to electrostatic discharge.
Troubleshooting Chart Symptoms of Abnormal Operation Associated LED Code2 • Furnace fails to operate. • Integrated control module diagnostic LED provides no signal. NONE Fault Description(s) • No 115 volt power to • Manual disconnect switch furnace, or no 24 volt OFF, door switch open, or power to integrated 24 volt wires improperly control module. connected or loose. • Blown fuse or circuit • Blown fuse or circuit breaker. breaker. • No signal from thermostat. • Furnace fails to operate.
Troubleshooting Chart Symptoms of Abnormal Operation • Circulator blower runs continuously. No furnace operation. • Integrated control module diagnostic LED is flashing FOUR (4) flashes. Associated Fault Description(s) LED Code2 4 • Primary or auxiliary limit circuit is open. 4 FLASHES • Rollout limit circuit is open. • Furnace fails to operate. • Integrated control module diagnostic LED is flashing SIX (6) flashes. 6 6 FLASHES • Induced draft blower runs continuously. No furnace operation.
Maintenance WARNING To avoid electrical shock, injury or death, disconnect electrical power before performing any maintenance. If you must handle the igniter, handle with care. Touching the igniter element with bare fingers, rough handling, or vibration could damage the igniter resulting in premature failure. Only a qualified servicer should ever handle the igniter. The furnace should be inspected by a qualified installer, or service agency at least once per year.
Maintenance FILTER REMOVAL Depending on the installation, differing filter arrangements can be applied. Filters can be installed in the central return register, the bottom of the blower compartment, or a side panel external filter rack kit. A media air filter or electronic air cleaner can be used as an alternate filter. The filter sizes given in the Specifications Sheet must be followed to ensure proper unit performance. Refer to the following for removal and installation of filters.
Maintenance Burners FLUE PASSAGES Inspect the heat exchanger flue passageways at the beginning of each heating season. If it is necessary to clean them, follow the steps outlined below. 1. Turn OFF the electrical power and gas supply to the furnace. 2. Remove burner assembly by disconnecting the gas line and removing the manifold brackets from the partition panel. 3. Remove the flue from the induced draft blower and the collector box from the partition panel. 4.
Before Leaving an Installation • Cycle the furnace with the thermostat at least three times. Verify cooling and fan only operation. • Review the Owner’s Manual with the homeowner and discuss proper furnace operation and maintenance. • Leave literature packet near furnace. Repair and Replacement Parts • When ordering any of the listed functional parts, be sure to provide the furnace model, manufacturing, and serial • numbers with the order.
