GUCA/GCCA ® High Efficiency Gas Fired Warm Air Furnace Installation Instructions Affix this manual, Specification Sheet and Users Information Manual adjacent to the furnace. Amana Forced Air Central Furnace design complies with requirements embodied in The American National Standard / National Standard of Canada shown below: ANSI Z21.47·CAN/CGA-2.3 Gas Fired Central Furnaces Type FSP Category IV Direct or Non Direct Vent Forced Air Furnace. ! RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION.
Table of Contents I. Component Identification ............................................................................................................................................ 5 II. Safety ............................................................................................................................................................................ 6 ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ...............................................................................................
Table of Contents XII. Gas Supply and Piping ........................................................................................................................................... 25 GENERAL ........................................................................................................................................................................................................... 25 High Altitude Derate ........................................................................................
TO THE INSTALLER Before installing this unit, please read this manual thoroughly to familiarize yourself with specific items which must be adhered to, including but not limited to: unit maximum external static pressure, gas pressures, BTU input rating, proper electrical connections, circulating air temperature rise, minimum or maximum CFM, and motor speed connections.
I.
2. Firmly touch a clean, unpainted, metal surface of the furnaces near the control. Any tools held in a person’s hand during grounding will be discharged. 3. Service integrated control module or connecting wiring following the discharge process in step 2. Use caution not to recharge your body with static electricity; (i.e., do not move or shuffle your feet, do not touch ungrounded objects, etc.). If you come in contact with an ungrounded object, repeat step 2 before touching control or wires. 4.
National Fuel Gas Code (NFPA 54/ANSI Z223.1), and/or CAN/CGA B149 Installation Codes, local plumbing or waste water codes, and other applicable codes. A copy of the National Fuel Gas Code (NFPA 54/ANSI Z223.
• • • ments for details. If the furnace is used in connection with a cooling unit, install the furnace upstream or in parallel with the cooling unit. Premature heat exchanger failure will result if the cooling unit is placed ahead of the furnace. If the furnace is installed in a residential garage, position the furnace so that the burners and ignition source are located not less than 18 inches (457 mm) above the floor. Protect the furnace from physical damage by vehicles.
If resizing is required on any portion of the venting system, use the appropriate table in Appendix G in the latest edition of the National Fuel Gas Code ANSI Z223.1 and/or CAN/CGA B149 Installation Codes. a problem supplying combustion and ventilation air for gas fired and other fuel burning appliances. Appliances that pull air out of the house (clothes dryers, exhaust fans, fireplaces, etc.) increase the problem by starving appliances for air.
methods described in 5.3.3-b or 5.3.4. Space, Unconfined. For purposes of this Code, a space whose volume is not less than 50 cubic feet per 1,000 BTU per hour of the aggregate input rating of all appliances installed in that space. Rooms communicating directly with the space in which the appliances are installed through openings not furnished with doors, are considered a part of the unconfined space. 5.3.
back of the furnace. Refer to the product Specifications Sheet for proper airflow requirements and number of required ductwork connections. Refer to “Recommended Installation Positions” figure for appropriate installation positions, ductwork connections, and resulting airflow arrangements. VII.
ALTERNATE VENT/FLUE AND COMBUSTION AIR CONNECTIONS In horizontal installations provisions for alternate flue and combustion air piping are available for upflow furnaces with left discharge and counterflow furnaces with right air discharge. In these positions the flue and combustion air piping can be run vertically through the side of the furnace. Refer to the “Recommended Installation Positions” figure for further detail. The standard piping connections may also be used in these positions.
fittings meeting ASTM D2665 and ASTM D3311. Carefully follow the manufacturer’s instructions for cutting, cleaning, and solvent cementing of PVC. WARNING Upon completion of the furnace installation, carefully inspect the entire flue system both inside and outside the furnace to assure it is properly sealed. Leaks in the flue system can result in serious personal injury or death due to exposure to flue products, including carbon monoxide.
• All terminations must be located at least 12 inches • The vent can be run through an existing unused chimney provided the space between the vent pipe and the chimney is insulated and closed with a weather-tight, corrosion-resistant flashing. above ground level or the anticipated snow level. Vent terminations must terminate at least 3 feet above any forced air inlet located within 10 feet. NOTE: This provision does not apply to the combustion air intake termination of a direct vent application.
ent blockage. COMBUSTION AIR PIPE (DIRECT VENT ONLY) 90 PVC ELBOW (NON-DIRECT VENT) COMBUSTION AIR PIPE (DIRECT VENT ONLY) VENT/FLUE PIPE RUBBER COUPLING WITH WORM GEAR CLAMPS 90 PVC ELBOW (NON-DIRECT VENT) Remove the vent/flue pipe from the furnace. 4. Cut the vent/ flue pipe at the elbow nearest the coupling end of the pipe (see “ Vent/Flue Pipe Cuts” figure). The section of pipe attached to the coupling will reach through the side panel to the induced draft blower. Discard unused pipe and elbows.
7. Upflow and Counterflow units. For upright installations, externally mount the rubber elbow to the vent/flue coupling using a worm gear hose clamp. Secure field supplied vent/flue piping to the rubber elbow using a worm gear hose clamp. NOTE: Use of the alternate vent/flue location for upright installations, requires the drain trap be installed on the same side of the unit as the flue pipe. 8. Upflow and Counterflow units.
1 REMOVE 4 SCREWS 2 REMOVE 2 REMOVE AND CUT 1 3 REMOVE REMOVE 3 SCREWS AND 3 RELOCATE ADDITIONAL PLUG FROM DRAIN KIT UPFLOW 4 SECURE TO CABINET 1 REMOVE 4 SCREWS Non-Direct Vent (Single Pipe) Maximum Allowable Length of Vent/Flue Pipe (ft) (1) (2) 5 2" CLEARANCE REQUIRED (NON-DIRECT VENT) Pipe (3) Number of Elbows Size (inc.
the chimney must be closed with a weather tight, corrosion resistant flashing. Both the combustion air intake and a vent/flue pipe terminations must be in the same atmospheric pressure zone. Refer to Section IX, Vent/Flue and Combustion Air Pipe - Termination Locations or Concentric Vent Termination for specific details on termination construction.
TEE 90º MEDIUM RADIUS ELBOWS COMBUSTION AIR INTAKE 12" MIN. 12" MIN. TO ROOF OR HIGHEST ANTICIPATED SNOW LEVEL 12" MIN. 3" MIN. 24" MAX. VENT/FLUE VENT/FLUE TEE SUPPORT STRAPS SCREEN COMBUSTION AIR INTAKE. 90° SCREEN MEDIUM RADIUS ELBOWS 24" MAX. 3" MIN. Standard Vertical Terminations (Dual Pipe) 12" MIN. ABOVE HIGHEST ANTICIPATED SNOW LEVEL 12" MIN.
In horizontal installations, the drain hoses will exit through the bottom (down side) of the unit with the drain trap suspended beneath the furnace. The field-supplied drain system must be in accordance with all local codes and the instructions in the following sections. NOTE: Refer to Section X, Condensate Drain Lines and Drain Trap - Alternate Vent/Flue Hose Connections for upright installations using an alternate vent/flue outlet.
Alternate Vent/Flue Drain Hose Connections Upright installations using the alternate vent/flue outlet will require “right-side only” drain hoses to be connected as follows. Refer to Section IX, Vent/Flue Pipe and Combustion Air Pipe for details on alternate vent/flue pipe connection. LEFT SIDE PANEL FRONT COVER DRAIN PORT RUBBER ELBOW RED HOSE CLAMP RUBBER ELBOW DRAIN PORT HOSE A 1. Remove the rubber plug from the front cover right-side drain port. Save for use in step 3. 2.
2. Secure drain trap to side panel at the mounting holes (dimples or crosshairs on Counterflow models) located below the grommet drain holes. 3. Attach PVC drain line to drain trap outlet with either a 90° elbow or coupling. 5. Cut 17 3/4 inches from the long end of Hose B and discard. 6. Secure remaining end of Hose B to exposed end of Tube 1 with a green hose clamp. Route hose to front right down side panel grommet holes. 7. Cut 5 1/2 inches straight length from the long end of each Tube 2. 8.
4. Cut “X” inches from the long end of Hose B and discard. Refer to table below for appropriate length to cut. Cabinet Width (inches) 16 1/2 20 1/2 24 1/2 Model GUCA & GCCA (kBTU Tons) 045__30 070__30 070__40 090__40 090__50 115__50 XI. Electrical Connections "X" Length to Cut From Long End of Hose B WARNING To avoid the risk of electrical shock, wiring to the unit must be properly polarized and grounded. 19 1/8 inches 14 3/4 inches 11 1/4 inches 5.
WARNING WARNING In upright upflow installations, the drain trap must be mounted on the opposite side of the unit from the junction box. This will reduce the risk of water reaching the junction box in the event of a blocked drain condition. To avoid the risk of electrical shock, injury, or death, the furnace must be electrically grounded in accordance with local codes or, in their absence, with the latest edition of The National Electric Code.
115 VOLT LINE CONNECTION OF ACCESSORIES (HUMIDIFIER AND ELECTRONIC AIR CLEANER) XII. Gas Supply and Piping WARNING GENERAL The furnace rating plate includes the approved furnace gas input rating and gas types. The furnace must be equipped to operate on the type of gas applied. This includes any conversion kits required for alternate fuels and/or high altitude. To avoid electrical shock, injury or death, disconnect electrical power before servicing, or changing any electrical wiring.
MANUAL SHUT OFF VALVE (UPSTREAM FROM GROUND JOINT PIPE UNION) GAS VALVE MANUAL SHUT OFF VALVE (UPSTREAM FROM GROUND JOINT PIPE UNION) * * GROMMET IN STANDARD GAS LINE HOLE * * * GROUND JOINT PIPE UNION * * PLUG IN ALTERNATE GAS LINE HOLE HEIGHT REQUIRED BY LOCAL CODE HEIGHT REQUIRED BY LOCAL CODE * PLUG IN ALTERNATE GAS LINE HOLE * ALTERNATE GAS LINE LOCATION ALTERNATE GAS LINE LOCATION * BURNERS * MANIFOLD GAS VALVE GROMMET IN STANDARD GAS LINE HOLE MANIFOLD DRIP LEG DRIP LEG COUNT
A different pressure switch may be required at high altitude regardless of the BTU/ft3 content of the fuel used. Refer to the product Specification Sheet or an Amana distributor for a tabular listing of appropriate altitude ranges and corresponding manufacturer’s pressure switch kits.
• Protect connectors and semirigid tubing against physi- NOTE: Never exceed specified pressures for testing. Higher pressure may damage the gas valve and cause subsequent overfiring, resulting in heat exchanger failure. Disconnect this unit and shutoff valve from the gas supply piping system before pressure testing the supply piping system with pressures in excess of 1/2 psig (3.48 kPa). cal and thermal damage when installed.
Propane Gas Installation (Typ.) PROPANE GAS PIPING CHARTS 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.
To ensure proper unit performance follow the filter sizes given in the Specifications Sheet. XIII. Circulating Air and Filters UPRIGHT INSTALLATIONS Depending on the installation and/or customer preference, differing filter arrangements can be applied. Filters can be installed in the central return register, the bottom of the blower compartment (upflows), a side panel external filter rack kit (upflows), inside the side panel (upflows), or the ductwork above a counterflow furnace.
air. 7. If you smell gas after five minutes, immediately follow the instructions on page 4 of this manual. If you do not smell gas after five minutes, move the furnace gas valve manual control to the ON position. 8. Replace the burner compartment door. 9. Open the manual gas shut-off valve external to the furnace. 10. Turn on the electrical power to the furnace. 11. Adjust the thermostat to a setting above room temperature. 12. After the burners are lit, set the thermostat to desired temperature.
Gas Valve On/Off Selector Switch GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT O F F INLET M 1 P 3 C 2 CAUTION OUTLET To prevent unreliable operation or equipment damage, the gas manifold pressure must be as specified on the unit rating plate. Only minor adjustments should be made by adjusting the gas valve pressure regulator.
Timing Chart for Normal Heating Mode CIRCU LA TO R BL OW E R ON OFF G A S V AL VE OP EN CL OS ED IG NIT ER ON OFF P RES SU RE S W ITC H CO N TA CT S OP EN CL OS ED IN DUC ED DR AF T BL OW E R ON OFF THE R M OS TA T ON OFF S ECO NDS 0 t ign IG N IT ER W A R M U P P E R IO D (se e n ote) t circ 0 15 FIX E D H E A T O N D E LA Y : 30 S E CO N D S N O T E: H E A TC R A FT IN T EG R ATE D C O N TR O L M O D U LE H A S A FIXED STAN D AR D S EVEN -SE C O N D IG NITE R W AR M U P PE R IO D (M IN
ft3) of gas being delivered to the furnace. If the dial is a one cubic foot dial, divide the number of seconds recorded in step 2 by one. If the dial is a two cubic foot dial, divide the number of seconds recorded in step 2 by two. 4. Calculate the furnace input in BTUs per hour (BTU/hr). Input equals the sum of the installation’s gas heating value and a conversion factor (hours to seconds) divided by the number of seconds per cubic foot.
as indicated in the Specifications Sheet. These blower speeds should be adjusted by the installer to match the installation requirements so as to provide the correct heating temperature rise and the correct cooling CFM. XV. Normal Sequence of Operation POWER UP The normal power up sequence is as follows: To adjust the circulator blower speed, proceed as follows: 1. Turn OFF power to the furnace. 2.
• • • • • a fixed five second on delay. Electronic air cleaner terminals are energized with circulator blower. Furnace circulator blower and outdoor cooling unit run, integrated control module monitors safety circuits continuously. R and Y thermostat contacts open, completing the call for cool. Outdoor fan and compressor are de-energized. Circulator blower is de-energized following a fixed forty five second cool off delay period. Electronic air cleaner terminals are de-energized.
ungrounded objects, etc.). If you come in contact with an ungrounded object, repeat step 2 before touching control or wires. 4. Discharge your body to ground before removing a new control from its container. Follow steps 1 through 3 if installing the control on a furnace. Return any old or new controls to their containers before touching any ungrounded object. AUXILIARY LIMIT The auxiliary limit controls are located on or near the circulator blower and monitors heat exchanger compartment temperatures.
Troubleshooting Chart Symptoms of Abnormal Operation - Furnace fails to operate. and - Integrated control module diagnostic LED provides no signal. - Furnace fails to operate. and - Integrated control module diagnostic LED is lit continuously. - Furnace is not operating and - Integrated control module diagnostic LED is flashing one flash. 38 - Furnace fails to operate. and - Integrated control module diagnostic LED is flashing two flashes.
Troubleshooting Chart Symptoms of Abnormal Operation Associated LED Code (See Note 2) Fault Description(s) Corrective Action Possible Causes Cautions and Notes - Turn power OFF prior to repair. 7 - Normal furnace operation. but - Integrated control module diagnostic LED is flashing seven flashes. 7 Flashes White-Rodgers Control Only - Flame sensor is coated/oxidized. - Flame sense micro-amp signal is low. - Sand flame sensor if coated/oxidized. Inspect for proper sensor alignment.
not remove. To access the filter, tilt the wire filter retainer upwards. 4. Slide filter forward and out. Vacuum blower compartment. 5. Replace filter and secure retainer opposite of removal. 6. Replace blower compartment door and turn ON thermostat or electrical power to furnace. ANNUAL INSPECTION The furnace should be inspected by a qualified installer, or service agency at least once per year. This check should be performed at the beginning of the heating season.
Upright Counterflow Filter Removal To remove filters from the ductwork above an upright counterflow installation: 1. Set thermostat to the OFF position or turn OFF electrical power to furnace. 2. Remove access door in ductwork above furnace. 3. Remove filters. 4. Replace filters opposite of removal. Replace access door in ductwork. 5. Turn ON thermostat or electrical power to furnace.
XX. Before Leaving an Installation XXI. Repair and Replacement Parts • Cycle the furnace with the thermostat at least three • When ordering any of the listed functional parts, be 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. sure to provide the furnace model, manufacturing, and serial numbers with the order.