Service Instructions 80%, 90%, 95% Gas Furnaces & Accessories ACS, ACV, ADS, ADV, AMH, AMS, AMV, DCS, DDS, DHS, DMS, GCH, GCS, GDH, GDS, GCV, GHS, GKS, GME, GMH, GMS, GMV This manual is to be used by qualified, professionally trained HVAC technicians only. Goodman does not assume any responsibility for property damage or personal injury due to improper service procedures or services performed by an unqualified person. Copyright © 2006-2007 Goodman Manufacturing Company, L.P. www.goodmanmfg.com www.
TABLE OF CONTENTS IMPORTANT INFORMATION ........................... 2-3 POLARIZATION & PHASING ............................. 92 PRODUCT IDENTIFICATION ........................ 4-14 MAINTENANCE ............................................ 93-95 OPERATING INSTRUCTIONS .................... 20-22 SERVICING .................................................96-128 ACCESSORIES ........................................... 23-27 TROUBLESHOOTING .............................. 105-106 PRODUCT DESIGN ............
IMPORTANT INFORMATION Special Warning for Installation of Furnace or Air Handling Units in Enclosed Areas such as Garages, Utility Rooms or Parking Areas Carbon monoxide producing devices (such as an automobile, space heater, gas water heater, etc.) should not be operated in enclosed areas such as unventilated garages, utility rooms or parking areas because of the danger of carbon monoxide (CO) poisoning resulting from the exhaust emissions.
PRODUCT IDENTIFICATION The model and manufacturing number are used for positive identification of component parts used in manufacturing. Please use these numbers when requesting service or parts information.
PRODUCT IDENTIFICATION MODEL # MFG. # 80 % GAS FURNACES ADS8* ADS8*****AA Amana® Brand 80% Gas Furnace, 39" tall, Dedicated Downflow, Induced Draft, 39" 80% furnace redesign changes that include new two tone grey painted cabinet and front panels, PSC motor, standardized blower decks, and a Surestart Silicon Nitride Igniter. Left or right gas pipe entry.The furnaces also feature an integrated electronic ignition control and a Million-Air stainless steel tubular heat exchanger.
PRODUCT IDENTIFICATION 6 MODEL # MFG. # 80 % GAS FURNACES GHS8* GHS8*****AA GHS8*****BA GHS8*****BB GHS8*****BC GHS8*****BD Goodman® Brand 80% Gas Furnace, 39" tall, Upflow/Horizontal Left or Right, (High Air Flow Design), Induced Draft, new grey painted cabinet and front panels, PSC motor, standardized blower decks and a Carbide Mini-Igniter. Left or right gas pipe entry. The furnaces also feature an integrated electronic ignition control and aluminized steel tubular heat exchanger.
PRODUCT IDENTIFICATION MODEL # MFG. # DESCRIPTION ACS9* P1257001F through P1257006F Amana® Brand 90% Gas Furnace, Downflow/Horizontal Left and Right, 40" tall, Induced Draft, new two tone grey painted cabinet and front panels, PSC motor, standardized blower decks and a Surestart Silicon Nitride Igniter. Left or right gas pipe entry. The furnaces also feature an integrated electronic ignition control and a Million-Air stainless steel tubular heat exchanger. NOx Certified. Chassis sizes are now 17.
PRODUCT IDENTIFICATION MODEL # MFG. # DESCRIPTION Amana® Brand 95% Gas Furnace, Upflow/Horizontal Left or Right, 40" tall, Induced Draft, new AMH95 AMH95***AA two tone grey painted cabinet and front panels, standardized blower decks and a 120V Silicon AMH95***AB Nitride Igniter. Left or right gas pipe entry. The furnaces also feature an integrated electronic AMH95***AC ignition control and a Million-Air stainless steel tubular heat exchanger. NOx Certified. Chassis sizes are now 17.5", 21" and 24.
PRODUCT IDENTIFICATION MODEL # MFG. # DCS9* P1257102F, P1257104F, P1257106F Amana® Distinctions™ Brand 90% Gas Furnace, Downflow/Horizontal Left and Right, 40" tall, Induced Draft, furnace design changes that include new two tone grey painted cabinet and front panels, PSC motor, standardized blower decks and a Carbide Mini-Igniter. Left or right gas pipe entry. The furnaces also feature an integrated electronic ignition control and aluminized steel tubular heat exchanger. NOx Certified.
PRODUCT IDENTIFICATION MODEL # MFG. # DESCRIPTION GCS9* P1257201F, P1257202F P1257204F, P1257206F Goodman® Brand 90% Gas Furnace, Downflow/Horizontal Left and Right, 40" tall, Induced Draft, new grey painted cabinet and front panels, PSC motor, standardized blower decks and a Carbide Mini-Igniter. Left or right gas pipe entry. The furnaces also feature an integrated electronic ignition control and aluminized steel tubular heat exchanger. NOx Certified. Chassis sizes are now 17.5", 21" and 24.5" wide.
PRODUCT IDENTIFICATION MODEL # MFG. # DESCRIPTION GMV9* Goodman® Brand 90% Variable Speed - 2 stage heat Gas Furnace, Upflow/Horizontal Left or Right, 40" tall, 2-stage Induced Draft, new grey painted cabinet and front panels, standardized blower decks and a Carbide Mini-Igniter. Left or right gas pipe entry. The furnaces also feature an integrated electronic ignition control and aluminized steel tubular heat exchanger. NOx Certified. P1257610F - Chassis sizes of 17.5", 21" and 24.5" wide.
PRODUCT IDENTIFICATION MODEL # MFG # DESCRIPTION Fossil Fuel Kit. The AFE18-60A control is designed for use where the indoor coil is located above/downstream of a gas or fossil fuel furnace when used with a heat pump. It will operate with single and two stage heat pumps and single and two stage furnaces. The AFE18-60A control will turn the heat pump unit off when the furnace is turned on. An anti-short cycle feature initiates a 3 minute timed off delay when the compressor goes off.
PRODUCT IDENTIFICATION MODEL # DEHUM1 EFR01 FTK03A HA02 HALP10 HALP11 HALP13 MFG # DESCRIPTION P1227801F Dehumidistat. For use with Goodman® and Amana® Brand two-stage variable speed furnace models ADV8, AMV8, ACV9, AMV9, GMV8, GCV9, GMV9, GMV95. Wall mounted, 24 volt humidity control available as a Dehumidistat used to reduce the airflow in the air conditioning mode when necessary to lower the humidity in an occupied home to prevent dew build-up associated with high humidity levels.
PRODUCT IDENTIFICATION MODEL # MFG # DESCRIPTION P1210305F P1210306F High Altitude Natural Gas Kit. For use with Goodman® and Amana® Brand 90% furnace models ACS9, AMS9, DCS9, DMS9, GCS9 and GMS9. These kits are required when installing the furnaces above their maximum rated altitude. This kit contains natural gas orifices. The orifices in the kit have been selected with the American Gas Association.
ACCESSORIES LPM-03B LPT-00A SBT14 SBT17 SBT21 LPM-05 Propane Gas Conversion Kit Downflow Subbase 14" Downflow Subbase 17.
ACCESSORIES 16 LPM-03B LPT-00A SBT14 SBT17 SBT21 LPM-05 Propane Gas Conversion Kit Downflow Subbase 14" Downflow Subbase 17.
ACCESSORIES HAPS27 HAPS28 HAPS29 LPLP01 LPM-03B LPM-05 LPT-00A High Altitude Pressure Switch High Altitude Pressure Switch High Altitude Pressure Switch Propane Low Pressure Switch Propane Gas Conversion Kit Propane Gas Conversion Kit Propane Gas Conversion Kit HANG14 High Altitude Natural Gas Kit FTK03A HANG13 EFR01 External Filter Rack High Altitude Natural Gas Kit DEHUM1 Dehumidistat HANG12 DCVK-30 Concentric Vent Kit (3") High Altitude Natural Gas Kit DCVK-20 Concentric Vent Kit (
ACCESSORIES (5) (2) (3) (4) (2) X X GCH91155DXA X X X X X (5) (2) (3) (4) (2) X GCS90453BXA X X X X X X X (2) (1) (4) (2) X X X GCS90703BXA X X X X X X X (2) (3) (4) (2) X X X GCS90904CXA X X X X X X (2) (3) (4) (2) X X X GCS91155DXA X X X X X X (2) (3) (4) (2) X X X GKS90453BXA* X X X X X X X (3) (1) (2) X X GKS90703BXA* X X X X X X X (3) (1) (2) X X GKS90704CXA* X X X X X X X (3) (1) (2) X X GKS90904C
OPERATING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions explosion may result causing property damage, personal injury or loss of life. A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand. B. BEFORE OPERATING smell all around the appliance area for gas.
OPERATING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions explosion may result causing property damage, personal injury or loss of life. LIRE AVANT DE METTRE EN MARCHELIRE AVERTISSEMENT: Quiconque ne respecte pas á la lettre les instructions dans le présent manuel risque de déclecher un incendie ou une explosion entraînant des dammages matériels, des lésions corporelles ou la perte de vies humaines. A. This appliance does not have a pilot.
OPERATING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burners. Do not try to light the burners by hand. B. BEFORE OPERATING smell around the appliance area for gas.
OPERATING INSTRUCTIONS CONSIGNES DE SECURITE - LIRE AVANT D'ALLUMER L'APPAREIL INSTRUCTIONS DE SERVICE AVERTISSEMENT: Le non-respect des instructions qui suivent peut ^ entrainer un risque d'incendie ou d'explosion causant des dommages, des blessures ou la mort. A. Cet appareil comporte pas de veilleuse. Il est muni d'un mecanisme qui allume ^ ^ manuellement. automatiquement le bruleur. N'allumez paz le bruleur B. Sentir tout autour de l'appariel AVANT D'ALLUMER afin de deceler toute fuite de gaz.
ACCESSORIES EXTERNAL FILTER RACK KIT ( EFR01 ) SLOTS IN FILTER CLEAR SCREWS ON UNIT BLOWER DECK SCREWS UNIT SIDE PANEL FRONT OF UNIT FILTER RACK ASSEMBLY (FACE FILTER OPENING TOWARDS FRONT OF UNIT) BASE OF UNIT RETURN AIR CUTOUT AREA LOWER EDGE SCREW EFR01 EXTERNAL FILTER RACK KIT Used on Models 90% Upflow Model Furnaces 23
ACCESSORIES INTERNAL FILTER RETENTION KIT RF000180 RF000181 F ILT E R A CC E S S DOOR FILTER RAIL SCREW E LT R R ET U R N D UC T FI E SIDE PANEL R LT FI FILTER ANGLE SCREW FILTER ANGLE SCREW FIL T E R S UP P O RT B RA C KE T BASE FILTER RAIL SCREW FILTER RAILS (2) FILTER ANGLES (2) A IR F L O W RF000180 Quantity 20 20 10 80 1 Part # 10690301 20242801 20178501 M0211216 20512701 Quantity 10 20 1 Part # 10368501 M0211216 20512701 Description Filter Angle Filter Rail Filter Retainer Screw
ACCESSORIES CONCENTRIC VENT CONVERSION KIT ( DCVK-20 DCVK-30 ) Vent The DCVK-20 (2") or the DCVK30 (3") is a new concentric vent kit approved with furnaces listed in this manual. This concentric vent kit allows for vertical or horizontal vent termination. The illustrations give a brief view of the kit and its application. See the section in this manual under "Vent Flue and Combustion Air Pipe Terminations" for more information or consult the Installation and Operating Instructions (IO-619B).
PRODUCT IDENTIFICATION SIDE WALL VENT KIT (0170K00000S) Description This side wall only vent kit #0170K00000S is to be used with 2” or 3” vent systems. This kit is NOT intended for use with single pipe (indirect vent) installations. The vent kit must terminate outside the structure and may be installed with the intake and exhaust pipes located sideby-side or with one pipe above the other.
ACCESSORIES CONCENTRIC VENT CONVERSION KIT ( HCVK VCVK ) V e rtic a l (V C V K ) H o riz o n ta l (H C V K ) Combustion Air Intake Pipe Outside Connection for Fresh Air Intake Pipe to Furnace Vent/Flue Termination with Tee Vent/Flue Termination (Tee, Pipe, & 2" to 4" Reducer) Combustion Air Intake Pipe 12" Minimum Above Roof or Highest Anticipated Snow Level Tee Seal Penetration with Caulking Outside 12" Minimum Above Grade or Highest Anticipated Snow Level Seal Penetration with Flashing and C
PRODUCT DESIGN Safety Please adhere to the following warnings and cautions when installing, adjusting, altering, servicing, or operating the furnace. WARNING TO PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE, REFER TO THIS MANUAL. FOR ADDITIONAL ASSISTANCE OR INFORMATION, CONSULT A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.
PRODUCT DESIGN American National Standards Institute 1430 Broadway New York, NY 10018 National Fire Protection Association 1 Batterymarch Park Quincy, MA 02269 • CSA International 8501 East Pleasant Valley Cleveland, OH 44131 A copy of the CAN/CGA B149 Installation Codes can be obtained from: CSA International 178 Rexdale Boulevard Etobicoke, Ontario, Canada M9W, 1R3 The rated heating capacity of the furnace should be greater than or equal to the total heat loss of the area to be heated.
PRODUCT DESIGN • • • closed non-direct vent furnace has an adequate supply of combustion air, vent from a nearby uncontaminated room or from outdoors. Refer to the Combustion and Ventilation Air Requirements section in this manual or the installation instructions for details. If the furnace is used in connection with a cooling unit, install the furnace upstream or in parallel with the cooling unit coil. Premature heat exchanger failure will result if the cooling unit coil is placed ahead of the furnace.
NOTE: A single-stage thermostat with only one heating stage can be used to control a two-stage furnace. The application of a single-stage thermostat does not offer "true" thermostat driven two-stage operation, but provides a timed transition from low to high fire. The furnace will run on low stage for a fixed period of time before stepping up to high stage to satisfy the thermostat's call for heat.
PRODUCT DESIGN Consult the instructions packaged with the thermostat and dehumidistat for mounting instructions and further precautions. COMBUSTION AND VENTILATION AIR REQUIREMENTS WARNING POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH 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 BE SUPPLIED TO THE FURNACE AREA.
PRODUCT DESIGN Chimney or Gas Vent Chimney or Gas Vent NOTE: Each opening must have a free area of not less than one square inch per 1000 BTU of the total input rating of all equipment in the enclosure, but not less than 100 square inches. Ventilation louvers (each end of attic) NOTE: The inlet and outlet air openings must each have a free area of not less than one square inch per 4000 BTU of the total input rating of all equipment in the enclosure.
PRODUCT DESIGN 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. 9.3.7 Louvers, Grilles, and Screens. Chimney or Gas Vent Opening Furnace Water Heater Alternate Opening Location 9.3.7.1 Louvers and Grilles.
PRODUCT DESIGN Category I Venting (Vertical Venting) (80% Furnaces Only) WARNING TO PREVENT POSSIBLE PERSONAL INJURY OR DEATH DUE TO ASPHYXIATION, NON-CONDENSING GAS FIRED WARM AIR FURNACES MUST CATEGORY I VENTED. DO NOT VENT ANY OF THESE FURNACES USING CATEGORY III VENTING. BE Category I Venting is venting at a non-positive pressure. A furnace vented as Category I is considered a fan-assisted appliance and does not have to be "gas tight.
PRODUCT DESIGN Masonry Chimneys Proper Chimney Termination? (Check 1) No Line, terminate with listed vent cap (Fix 1) No Change venting arrangements (Fix 2) No Rebuild crown (Fix 3) and/or Reline (Fix 4) No Reline (Fix 4) No Reline (Fix 4) No Reline (Fix 4) Yes Chimney channel free of solid and liquid fuel appliances? (Check 2) Yes Crown in good condition (Check 3) Yes Crown Wash Roof Line Clay Tile Size Generally 12" x 12" (24" Length) Cleanout free of debris? (Check 4) Yes Clay Tile S
PRODUCT DESIGN 10' or Less 2' Min. 2' Min. 3' Min. Wall or Parapet Chimney 10' or Less 2' Min. Ridge 3' Min. Chimney Termination 10 Feet Or Less From Ridge, Wall or Parapet More than 10' 3' Min. Wall or Parapet NOTE: No Height above parapet required when distance from walls or parapet is more than 10 feet. Height above any roof surface within 10 feet horizontally. More than 10' Ridge Chimney 10' 2' Min. 3' Min.
PRODUCT DESIGN Flexible liners should be hung straight or nearly straight. If it is spiraled in the chimney and in good condition, it should be rehung. To do this, break the top seal; pull up and cut off the excess liner length, and refit the top seal. Use caution when doing this, as the cut edges of flexible liners may be sharp. The surfaces of the liner must be physically sound. If gaps or holes are present, the metal liner must be removed and replaced (Fix 4).
PRODUCT DESIGN Fix 4 - Relining. Relining options include B vent and flexible liners. If the chimney has diagonal offsets, B vent probably cannot be used. If B vent is to be used, it must be supported adequately. Supports (such as fire stops or thimbles) must be used to prevent the B vent from coming into direct contact with the tile liner or chimney walls. Direct contact would result in higher heat loss, with an increased possibility of poor venting system performance.
PRODUCT DESIGN Drain Trap and Lines (90% Furnaces Only) In horizontal applications the condensate drain trap is secured to the furnace side panel, suspending it below the furnace. A minimum clearance of 4 3/4" below the furnace must be provided for the drain trap. Additionally, the appropriate downward piping slope must be maintained from the drain trap to the drain location. Refer to Condensate Drain Trap and Lines section in this manual or the installation instructions for further details.
PRODUCT DESIGN Propane Gas and/or High Altitude Installations WARNING POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR IF THE APPROPRIATE KITS MUST BE APPLIED TO INSURE SAFE AND PROPER FURNACE OPERATION. ALL THE CORRECT CONVERSION KITS ARE NOT INSTALLED. CONVERSIONS MUST BE PERFORMED BY A QUALIFIED INSTALLER OR SERVICE AGENCY. This furnace is shipped from the factory configured for natural gas at standard altitude.
PRODUCT DESIGN As an alternative to PVC pipe, primer, solvent cement, and fittings, ABS materials which are in compliance with the following specifications may be used. Two or three inch ABS Schedule 40 pipe must meet ASTM D1527 and, if used in Canada, must be CSA listed. Solvent cement for ABS to ABS joints must meet ASTM D2235 and, if used in Canada, must be CSA listed. The solvent cement for the PVC to ABS transition joint must meet ASTM D3138.
PRODUCT DESIGN Canadian Venting Requirements (90% Furnaces Only) In Canada, venting must conform to the requirements of the current CAN/CGA-B149 Installation Code. Use only CSA listed two or three inch diameter PVC or ABS pipe, solvent cement, and fittings throughout. Carefully follow the manufacturers’ instructions for cutting, cleaning, and solvent cementing PVC and/or ABS.
PRODUCT DESIGN Alternate Combustion Air Intake Location (90% Furnaces Only) WARNING THE RUBBER ELBOW IS NOT DESIGNED TO SUPPORAT A LOAD. WHEN THE RUBBER ELBOW IS MOUNTED EXTERNALLY TO THE FURNACE CABINET, EXTREME CARE MUST BE TAKEN TO ADEQUATELY SUPPORT FIELD-SUPPLIED VENT/FLUE PIPING, AS DAMAGE CAN RESULT IN LEAKS CAUSING BODILY INJURY OR DEATH DUE TO EXPOSURE TO FLUE GASES, INCLUDING CARBON MONOXIDE.
PRODUCT DESIGN between the vent pipe and the chimney must be closed with a weather-tight, corrosion-resistant flashing. For details concerning connection of the vent/flue pipe to the furnace, refer to Vent/Flue Pipe and Combustion Air Pipe - Standard Furnace Connections or Alternate Furnace Connections section in this manual or the installation instructions for specific details.
PRODUCT DESIGN ACV9, AMV9, GCV9, GMV9, GMV95 TEE UPFLOW Non-Direct Vent (Single Pipe) Maximum Allowable Length of Vent/Flue Pipe (ft)(1)(2) Unit Input Pipe(4) (inch) Number of Elbows 12 " MINIMUM TO ROOF OR HIGHEST ANTICIPATED SNOW LEVEL (3)(5) 1 2 3 4 5 6 7 8 2 71 68 65 62 59 56 53 50 2 49 46 43 40 37 34 31 28 3 71 68 65 62 59 56 53 50 90,000 3 71 68 65 62 59 56 53 50 115,000 3 49 46 43 40 37 34 31 28 45,000 70,000 COUNTERFLOW Non-Direct Vent
PRODUCT DESIGN WALL INSIDE OUTSIDE TEE or ELBOW TURNED DOWN COUPLING MINIMUM 12" FROM WALL ELBOW OR COUPLING 12" TO GROUND OR HIGHEST ANTICIPATED SNOW LEVEL 90% Furnace Horizontal Termination (Single Pipe) 12" MINIMUM VENT/FLUE TEE OR 90° ELBOW TURNED DOWN 12" MINIMUM ABOVE HIGHEST ANTICIPATED SNOW LEVEL or the installation instructions for specific details on termination construction.
PRODUCT DESIGN If the combustion air intake pipe is to be installed above a finished ceiling or other area where dripping of condensate will be objectionable, insulation of the combustion air pipe may be required. Use 1/2” thick closed cell foam insulation such as Armaflex or Insultube where required.
PRODUCT DESIGN Vertical pipe terminations should be as shown in the following figure. Refer to Section IX, Vent/Flue Pipe and Combustion Pipe - Termination Locations for details concerning location restrictions. The penetrations through the roof must be sealed tight with proper flashing such as is used with a plastic plumbing vent.
PRODUCT DESIGN VENT/INTAKE TERMINATIONS FOR INSTALLATION OF MULTIPLE DIRECT VENT FURNACES 2. The vent termination must be located at least 12” above ground or normally expected snow accumulation levels. If more than one direct vent furnace is to be installed vertically through a common roof top, maintain the same minimum clearances between the exhaust vent and air intake terminations of adjacent units as with the exhaust vent and air intake terminations of a single unit.
PRODUCT DESIGN DCVK KITS WARNING S IN GLE ST A GE F UR N A C E M A X IM UM A LLOWA B LE LEN GT H OF VE N T A N D C OM B US T ION A IR P IP E F E ET GAS INP UT RATE (KBtu/hr) PIPE KIT NUM BER DIAM ETER 2 3 4 5 6 7 45 2" DCVK-20 55 52 49 46 43 40 70 2" DCVK-20 55' 50' 45' 40' NA NA 90 3" DCVK-30 54 115 3" DCVK-30 55' 50' 45' 40' NA NA 51 48 45 42 PIPE KIT NUM BER DIAM ETER Number o f Elbows 3 4 5 6 7 45 2" DCVK-20 55 52 49 46 43 40 70 2" DCVK-20 33 30 27
PRODUCT DESIGN Vent 1" Maximum (TYP.) Combustion Air Strap (Field Supplied) Combustion Air Vent Vent Flush to 1" maximum Combustion Air "A" 45 Elbow (Field Supplied) Vent Exhaust Dimension "A" is touching or 2" maximum separation. FIGURE 7 8. Install the rain cap and the small diameter pipe assembly in the Y concentric fitting and the large pipe assembly. Ensure that the small diameter pipe is bottomed out and securely cemented in the Y concentric fitting. 9.
PRODUCT DESIGN d. Terminal should be located where it will not be damaged or exposed to foreign objects such as stones, balls, etc. e. Terminal should be located where vent vapors are not objectionable. 2. Using the vent terminal base as a template, locate the pipe holes and the four mounting screw holes on the wall. Field-Supplied Reducing Couplings, if required Seal all holes through wall with sealant 2" or 3" Pipe 3. Cut two 3 7/8” diameter holes for the vent and intake pipes. 3" Pipe 4.
PRODUCT DESIGN • If the drain line is routed through an area which may see temperatures near or below freezing, precautions must be taken to prevent condensate from freezing within the drain line. If an air conditioning coil is installed with the furnace, a common drain may be used. An open tee must be installed in the drain line, near the cooling coil, to relieve positive air pressure from the coil’s plenum. This is necessary to prohibit any interference with the function of the furnace’s drain trap.
PRODUCT DESIGN 3. Attach PVC drain line to drain trap outlet with either a 90° elbow or coupling. NOTE: Ensure hoses and tubes maintain a downward slope for proper drainage and that they are not kinked or binding. INDUCED DRAFT BLOWER DRAIN PORT HOSE B Horizontal Installations RIGHT SIDE DOWN Horizontal installations with the right side down require that the drain hoses be connected to the right side front cover drain port and the rubber elbow drain port.
PRODUCT DESIGN CAUTION PROPANE GAS CONVERSION WARNING TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING. Inlet gas supply pressures must be maintained within the ranges specified below. The supply pressure must be constant and available with all other household gas fired appliances operating.
PRODUCT DESIGN When sizing a trunk line, be sure to include all appliances which will operate simultaneously when sizing a trunk line. The gas piping supplying the furnace must be properly sized based on the gas flow required, specific gravity of the gas, and length of the run. The gas line installation must comply with local codes, or in their absence, with the latest edition of the National Fuel Gas Code, NFPA 54/ANSI Z223.1.
PRODUCT DESIGN MANUAL SHUT OFF VALVE (UPSTREAM FROM GROUND JOINT PIPE UNION) GAS VALVE MANUAL SHUT OFF VALVE (UPSTREAM FROM GROUND JOINT PIPE UNION) ALTERNATE GAS LINE LOCATION PLUG IN ALTERNATE GAS LINE HOLE PLUG IN ALTERNATE GAS LINE HOLE GROMMET IN STANDARD GAS LINE HOLE * * GROUND JOINT PIPE UNION ALTERNATE GAS LINE LOCATION HEIGHT REQUIRED BY LOCAL CODE HEIGHT REQUIRED BY LOCAL CODE * BURNERS * MANIFOLD GAS VALVE GROMMET IN STAND ARD GAS LINE HOLE MANIFOLD DRIP LEG DRIP LEG COUNTERFL
PRODUCT DESIGN GAS PIPING CHECKS Before placing unit in operation, leak test the unit and gas connections. WARNING TO AVOID THE POSSIBLITY OF EXPLOSION OR FIRE, NEVER USE A MATCH OR OPEN FLAME TO TEST FOR LEAKS. Check for leaks using an approved chloride-free soap and water solution, an electronic combustible gas detector, or other approved testing methods. NOTE: Never exceed specified pressures for testing.
PRODUCT DESIGN WARNING IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE. – DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE. – WHAT TO DO IF YOU SMELL GAS: • DO NOT TRY TO LIGHT ANY APPLIANCE.
PRODUCT DESIGN Use a separate fused branch electrical circuit containing properly sized wire, and fuse or circuit breaker. The fuse or circuit breaker must be sized in accordance with the maximum overcurrent protection specified on the unit rating plate. An electrical disconnect must be provided at the furnace location. NOTE: Line polarity must be observed when making field connections. NOTE: Wire routing must not interfere with circulator blower operation, filter removal, or routine maintenance.
PRODUCT DESIGN OPTIONAL ACCESORIES ELECTRONIC AIR CLEANER 120 VAC HOT AND PARK TERMINALS NEUTRAL EAC-H HUM-H HUMIDIFIER 120 VAC NEUTRAL TERMINALS INTEGRATED CONTROL MODULE A 40 V.A. transformer and an integrated electronic control are built into the furnace to allow use with most cooling equipment. Consult the wiring diagram, located in the Technical Manual or on the blower door for further details of 115 Volt and 24 Volt wiring.
PRODUCT DESIGN ( W2 ) Thermostat Two-Stage Heating W1 W2 YLO W1 C Y C G R G R W1 W2 Furnace Integrated Control Module W1 YLO Two-Stage Heating Only W Y O YLO Y ( B/C G R G R ) Thermostat Single-Stage Heating with Single-Stage Cooling W1 W2 DEHUM Furnace Integrated Control Module NEU Y Dehumidistat [Optional] HOT C Remote Condensing Unit (Single-Stage Cooling) Single-Stage Heating with Single-Stage Cooling NOTE: To apply a single-stage heating thermostat, the ther
PRODUCT DESIGN Thermostat Wiring Reference Chart ( ADV8, AMV8, ACV9, AMV9, GMV8, GCV9, GMV9, GMV95 ) Two-Stage Variable Speed Furnace CONTINUOUS FAN COOLING HEATING GENERAL Mode Thermostat Connection Connection Options Furnace Circulator Blower Operation During Call From Thermostat 24 Volts HOT R From Room Thermostat To R On Two-Stage Integrated Control Module N/A 24 Volts COMMON C From Room Thermostat To C On Two-Stage Integrated Control Module N/A Low Stage Connection For "Two-Sta
PRODUCT DESIGN SINGLE STAGE THERMOSTAT APPLICATION ( ) Thermostat Single-Stage Heating with Single-Stage Cooling W Y O Y YLO B/C G R G R W1 W2 Furnace Integrated Control Module DEHUM TWIN NEU Y Dehumidistat [Optional] HOT C Remote Condensing Unit (Single-Stage Cooling) Single-Stage Heating with Single-Stage Cooling NOTE: To apply a single-stage heating thermostat, the thermostat selector jumper on the integrated Control module must be set on single stage.
PRODUCT DESIGN Fossil Fuel Applications The 80% & 90% Single-Stage and Two-Stage furnaces can be used in conjunction with a heat pump in a fossil fuel application. A fossil fuel application is where an outdoor temperature sensor determines the most cost efficient means of heating (heat pump, gas furnace, or both). A heat pump thermostat with two stages of heat is required to properly use the single-stage furnace with a heat pump.
PRODUCT DESIGN 8 7 6 5 Cooling Speed Tap A 8 7 6 5 Normal 8 7 6 5 Cooling Speed Tap B O F F 4 3 2 4 3 2 1 * O F F 1 O F F 8 7 6 5 4 O F F 3 2 1 + (Plus) Adjust 8 7 6 5 O O F N F 4 3 2 1 8 7 6 5 O O N F F 4 3 2 1 Cooling Speed Tap C Cooling Speed Tap D 4 3 2 1 O O F N F 8 7 6 5 4 3 2 1 • O O N F F (* indicates factory setting) 8 7 6 5 Cooling Speed Taps (* indicates factory setting) 1 min OFF 100% CFM 50% CFM 100% CFM 1/2 min Heating Speed Tap A Heating Speed Tap B Heating Speed
CIRCULATOR BLOWER TIMINGS 80% & 90% Furnaces NOTE: Items in this section refer to the air circulator blower fan, NOT to the induced draft blower. The induced draft blower timing sequence is not adjustable. The circulator blower fan timing is adjustable only on models with optional “heating fan OFF delay” adjustment pins or switches. It is NOT adjustable in any other circumstances. As shipped, the circulator blower fan will remain on for 150 seconds after the gas valve closes.
PRODUCT DESIGN COOLING AIRFLOW REQUIREMENT (CFM) 600 800 1000 1200 1400 1600 2000 0453_XA 376* 384 480 576 --- --- --- 0703_XA --- 564* 564* 564* 672 --- --- 0704_XA --- --- 564* 564* 672 768 --- 0904_XA --- --- 752* 752* 752* 768 --- 0905_XA --- --- --- 752* 752* 768 800 1155_XA --- --- --- 940* 940* 940* 800 *Minimum filter area dictated by heating airflow requirement.
PRODUCT DESIGN EXAMPLE: AMV9, ACV9, GMV9, GCV9, GMV95 Filter Size (in2) = Input__Airflow UPFLOW COOLING AIRFLOW REQUIREMENT (CFM) 600 800 1000 1200 1400 1600 2000 0453__XA 376* 384 480 576 --- --- --- 0704__XA --- --- 627* 627* 672 768 --- 0905__XA --- --- --- 836* 836* 836* 960 1155__XA --- --- --- 940* 940* 940* 960 Input Airflow COUNTERFLOW COOLING AIRFLOW REQUIREMENT (CFM) 600 800 1000 1200 1400 1600 2000 0704__XA --- --- 320* 320* 336 384 ---
PRODUCT DESIGN As an alternative a media air filter or electronic air cleaner can be used as the requested filter. Refer to the following minimum filter requirement charts for determination of the minimum filter area to ensure proper unit performance. The following figures show possible filter locations. NOTE: A ductwork access door must be used in counterflow applications to allow filter removal.
PRODUCT DESIGN NORMAL SEQUENCE OF OPERATION Goodman / Amana® Distinctions™ Brand Single-Stage 80% or 90% Furnaces White-Rodgers 50A55 Integrated Ignition Control POWER UP 1. 115 VAC power applied to furnace. 2. Integrated ignition control module performs internal checks. 3. Integrated ignition control module LED will light. 4. Integrated ignition control monitors safety circuits continuously. 5. Furnace awaits call from thermostat. NORMAL HEATING SEQUENCE 1.
PRODUCT DESIGN NORMAL SEQUENCE OF OPERATION Goodman Two-Stage 80% or 90% Furnaces White-Rodgers 50M56 Integrated Ignition Control 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 LED will light. Integrated control module monitors safety circuits continuously. • Furnace awaits call from thermostat. • R and W thermostat contacts close, initiating a call for heat.
PRODUCT DESIGN 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 Y thermostat contacts close, initiating a call for • R and G thermostat contacts close, initiating a call for cool. • Integrated control module performs safety circuit checks. • Outdoor fan and compressor are energized. • Circulator blower is energized on cool speed following a fixed five second on delay.
PRODUCT DESIGN NORMAL SEQUENCE OF OPERATION Goodman Two-Stage 80% or 90% Furnaces White-Rodgers 50V51 Integrated Ignition Control POWER UP The normal power up sequence is as follows: 1. 115 VAC power applied to furnace. 2. Integrated control module performs internal checks. 3. Integrated control module LED will light. 4. Integrated control module monitors safety circuits continuously. 5. Furnace awaits call from thermostat. HEATING MODE The normal operational sequence in heating mode is as follows: 1.
PRODUCT DESIGN FAN ONLY MODE DEHUMIDIFICATION MODE The normal operational sequence in fan only mode is as follows: The normal operational sequence in dehumidification mode is as follows: 1. R and YLO/G or Y/G thermostat contacts close, initiaing a call for cool. 1. R and G thermostat contacts close, initiating a call for fan. 2. Integrated control module performs safety circuit checks. 3.
PRODUCT DESIGN NORMAL SEQUENCE OF OPERATION COOLING MODE Amana® Bramd Single-Stage 80% or 90% Furnaces The normal operational sequence in cooling mode is as follows: 1. R and Y thermostat contacts close, initiating a call for cool. White-Rodgers 50A65 Integrated Ignition Control POWER UP 1. 115 VAC power applied to furnace. 2. Integrated ignition control performs internal checks. 3. Integrated ignition control module LED will light. 4. Integrated ignition control monitors safety circuits continuously.
PRODUCT DESIGN NORMAL SEQUENCE OF OPERATION Amana Brand Two-Stage 80% and 90% Furnaces ® White-Rodgers 50V61 Integrated Ignition Control POWER UP The normal power up sequence is as follows: 1. 115 VAC power applied to furnace. 2. Integrated control module performs internal checks. 3. Integrated control module LED will light. 4. Integrated control module monitors safety circuits continuously. 5. Furnace awaits call from thermostat.
PRODUCT DESIGN COOLING MODE The normal operational sequence in cooling mode is as follows: 1. R and YLO/G or Y/G thermostat contacts close, initiating a call for cool. 2. Integrated control module performs safety circuit checks. 3. Outdoor fan and compressor are energized to their appropriate speed. 4. Circulator blower is energized on the appropriate cool speed at the level and time determined by the selected ramping profile. Electronic air cleaner terminals are energized with circulator blower. 5.
SYSTEM OPERATION HEATING - Abnormal Operation (Amana® Brand 80% and 90% Single Stage Furnaces - White Rodgers 50A65 Ignition Control) The following presents the probable causes of questionable furnace operation and how to fix them. Look through the observation window in the blower access door and make a note of the number of flashes in sequence between pauses.
SYSTEM OPERATION HEATING - Abnormal Operation (Amana® Brand 80% & 90% Variable Speed Furnaces White Rodgers 50V61 Ignition Control) The following presents the probable causes of questionable furnace operation and how to fix them. Look through the observation window in the blower access door and make a note of the number of flashes in sequence between pauses.
SYSTEM OPERATION HEATING - Abnormal Operation (Goodman / Amana® Distinctions™ Brand 80% Furnaces - White Rodgers 50A55 Ignition Control) The following presents the probable causes of questionable furnace operation and how to fix them. Look through the observation window in the blower access door and make a note of the number of flashes in sequence between pauses.
SYSTEM OPERATION NORMAL SEQUENCE OF OPERATION Goodman 2-Stage Variable Speed Integrated Ignition Control Refer to Timing Charts for sequencing. 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 lights. • Integrated control module monitors safety circuits continuously. • Furnace awaits call from thermostat.
SYSTEM OPERATION CONSTANT FAN • • • • R and G thermostat contacts close, initiating a call for fan. Integrated control module performs safety circuit checks. Circulator blower is energized on continuous fan speed (56% of high stage cooling) following a five (5) second delay. Electronic air cleaner terminals are energized. Circulator blower runs, integrated control module monitors safety circuits continuously. R and G thermostat contacts open, completing the call for fan. Circulator blower is de-energized.
SYSTEM OPERATION HEATING - Abnormal Operation (Goodman 80% & 90% Variable Speed Furnaces - White Rodgers 50V51 Ignition Control) The following presents the probable causes of questionable furnace operation and how to fix them. Look through the observation window in the blower access door and make a note of the number of flashes in sequence between pauses.
SYSTEM OPERATION TROUBLESHOOTING CHART Symptoms of Abnormal Associated Operation LED Code2 • Furnace fails to operate. • Integrated control module diagnostic LED provides no signal. NONE Fault Description(s) AMH8, AMS8, ADS8, DDS8, DMS8, DHS8, GME8, GMH8, GMS8, GDS8, GHS8 Possible Causes • No 115 volt power • Manual disconnect switch to furnace, or no 24 OFF, door switch open, or 24 volt wires improperly volt power to connected or loose. integrated control module.
SYSTEM OPERATION TROUBLESHOOTING CHART Symptoms of Abnormal Operation • Circulator blower runs continuously. No furnace operation. • Integrated control module diagnostic LED is flashing FOUR (4) flashes. • Induced draft blower and circulator blower runs continuously. No furnace operation. Associated LED Code(2)(5) 4 Fault Description(s) • Primary limit circuit is open. 4 FLASHES 5 • Flame sensed with no call for heat.
SYSTEM OPERATION TROUBLESHOOTING CHART lt Description(s) Symptoms of Abnormal Operation Associated LED Code2 • Furnace fails to operate. NONE • Integrated control module diagnostic LED provides no signal. • LED is Steady On ON Fault Description(s) AMS9, ACS9, DMS9, DCS9, GMS9, GCS9, GKS9, AMS95, GMS95 Possible Causes • No 115 volt power • Manual disconnect to furnace, or no 24 switch OFF, door switch volt power to open, or 24 volt wires integrated control improperly connected or module. loose.
SYSTEM OPERATION TROUBLESHOOTING CHART Symptoms of Abnormal Operation • Circulator blower runs continuously. No furnace operation. • Integrated control module diagnostic LED is flashing FOUR (4) flashes. • Induced draft blower and circulation blower runs continuously. No furnace operation. • Integrated control module diagnostic LED is flashing FIVE (5) flashes. • Circulator blower runs continuously. No furnace operation. • Integrated control module diagnostic LED is flashing SIX (6) flashes.
SYSTEM OPERATION TROUBLESHOOTING CHART Symptoms of Abnormal Operation Associated LED Code Description(s) • Furnace fails to operate. NONE • No 115 volt power to furnace, or no 24 volt power to integrated control module. 2 • Integrated control module diagnostic LED provides no signal. ADV8, AMV8, ACV9, AMV9, GMV8, GCV9, GMV9 Fault • Blown fuse or circuit breaker.
SYSTEM OPERATION TROUBLESHOOTING CHART Symptoms of Abnormal Operation • Circulator blower runs continuously. No furnace operation. • Integrated control module diagnostic LED is flashing FOUR (4) flashes. • Integrated control module diagnostic LED is flashing FIVE (5) times. • Induced draft blower and circulator blower run continuously. No furnace operation. • Furnace fails to operate. • Integrated control module diagnostic LED is flashing continuously.
POLARIZATION AND PHASING As more and more electronic's are introduced to the Heating Trade, Polarization of incoming power and phasing of primary to secondary voltage on transformers becomes more important. INCOMING POWER METER READS METER READS 120 VOLTS 0 VOLTS Polarization has been apparent in the Appliance industry since the introduction of the three prong plug, however, the Heating Industry does not use a plug for incoming power, but is hard wired.
MAINTENANCE WARNING HIGH VOLTAGE DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. CAUTION IF YOU MUST HANDLE THE ITNITOR, HANDLE WITH CARE. T OUCHING THE IG NITOR BODY WITH BARE FINGERS, ROUG H HANDLING, OR VIBRATIO N COULD RESULT IN EARLY IGNITO R FAILURE. O NLY A Q UALIFIED SERVICER SHOULD EVER HANDLE THE IGNITO R.
MAINTENANCE CONDENSATE DRAINAGE SYSTEM (QUALIFIED SERVICER ONLY) The drain tubes, standpipe, and field supplied drain line must be checked annually and cleaned as often as necessary to ensure proper condensate drainage. FLUE PASSAGES (QUALIFIED SERVICER ONLY) At the start of each heating season, inspect and, if necessary, clean the furnace flue passages. CLEANING FLUE PASSAGES (QUALIFIED SERVICER ONLY) 1. Turn OFF the electrical power and gas supply to the furnace. 2.
MAINTENANCE HEATING PERFORMANCE TEST Before attempting to diagnose an operating fault, run a heating performance test and apply the results to the Service Problem Analysis Guide. To conduct a heating performance test, the BTU input to the furnace must be calculated. After the heating cycle has been in operation for at least fifteen minutes and with all other gas appliances turned off, the gas meter should be clocked.
SERVICING 1 1 CUBIC FEET One GAS RATE -- CUBIC FEET PER HOUR Seconds for One Revolution 1/4 cu/ft 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 90 82 75 69 64 60 56 53 50 47 45 43 41 39 37 36 34 33 32 31 30 -28 -26 -- 96 Size of Test Dial 1/2 1 2 cu/ft cu/ft cu/ft 5 cu/ft 180 164 150 138 129 120 113 106 100 95 90 86 82 78 75 72 69 67 64 62 60 -56 -53 -- 1800 1636 1500 1385 1286 1200 1125 1059 1000 947 900 857 818 783 750 720 692 667 643 621 600 581 563 545 529 514
SERVICING Power Failure Blown Fuse Loose Connection Shorted or Broken Wires No Low Voltage Faulty Thermostat Faulty Transformer • • • • • • • Faulty Flame Sensor Faulty Ignition Control Gas Valve or Gas Supply Shut Off Faulty Induced Draft Blower Faulty Blower Motor (PSC & ECM) Broken or Shorted Ignitor Dirty Flame Sensor, Low UA Stuck Gas Valve Faulty Gas Valve Open Auxiliary Limit Improper Air Flow or Distribution Cycling on Limit • • • • • • • • • • • • • • • • • • • • Flashback Gas Pressure • Cr
SERVICING SERVICE NUMBERS S-1 S-2 S-3 S-3A S-3B S-4 S-15 S-15A S-16A S-200 S-201 S-300 S-301 S-302 S-303 S-304 S-305 S-306 S-307 S-308 S-309 S-310 S-311 S-312 S-313 S-314 98 CHECKING VOLTAGE .............................................................................................................. 99 CHECKING WIRING ................................................................................................................. 99 CHECKING THERMOSTAT, WIRING, AND ANTICIPATOR ...........................
SERVICING S-1 CHECKING VOLTAGE WARNING HIGH VOLTAGE DISCONNECT ALL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE 3. If any wires must be replaced, replace with AWM, 105°C. 2/64 thick insulation of the same gauge or its equivalent. CHECKING THERMOSTAT, WIRING AND ANTICIPATOR S-3A THERMOSTAT AND WIRING PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. 1. Remove the burner door on 80% and 90% furnaces to gain entry to the Junction Box.
SERVICING The heating anticipator setting for furnaces covered in this manual is 0.70 Amps. If the anticipator current draw is unknown, then a current amp draw should be measured to determine the anticipator setting. Use an amprobe as shown in the following drawing. 10 TURNS OF THERMOSTAT WIRE (From "W" on thermostat) STATIONARY JAW OF AMPROBE WARNING LINE VOLTAGE NOW PRESENT 3. Use a voltmeter, check voltage across terminals R and C. Must read 24 VAC. 4.
SERVICING S-15 CHECKING CAPACITOR The direct drive motors are of the permanent split capacitor design. A run capacitor is wired across the auxiliary and a portion of the main windings. The capacitors primary function is to reduce the line current while greatly improving the torque characteristics of a motor.
SERVICING 3. High voltage is present at the motor all the time. Motor operation is controlled through the low voltage motor interface board that provides an output voltage to the motor end bell. This voltage output determines the CFM, which the motor wil provide. A Green LED light, located on the integrated ignition control, next to the fuse, indicates the airflow that the motor is supposed to be delivering.
SERVICING WARNING LINE VOLTAGE NOW PRESENT HIGH VOLTAGE ON CONTROL PINS WILL DESTROY MOTOR Check for line voltage on terminals 4 and 5. Verify terminal 3 is ground. Terminals 1 and 2 are jumpered in the harness for 120VAC operation.
SERVICING 6. The control module is now completely detached from the motor. Verify with a standard ohmmeter that the resistance from each motor lead (in the motor plug just removed) to the motor shell is greater than 100k ohms. (Measure resistance to unpainted motor end plate). If any motor lead fails this test do not proceed to install the control module. The motor is defective and must be replaced. Installing the new control module will cause it fail also. 7.
- Motor starts, but runs erratically. - Motor oscillates up & down while being tested off of blower. - Motor won't start. - Motor rocks slightly when starting. Symptoms of Abnormal Operation - Does removing panel or filter reduce "puffing"? - Check/replace filter. - Check/correct duct restrictions. - Adjust to correct blower speed setting. - Incorrect or dirty filter(s). - Incorrect supply or return ductwork. - Incorrect blower speed setting. - Varies up and down or intermittent.
- Turn power OFF prior to repair. - Turn power OFF prior to repair. - Check for loose blower housing, panels, etc. - Check for air whistling thru seams in ducts, cabinets or panels. - Check for cabinet/duct deformation. - Does removing panel or filter reduce "puffing"? - Check/replace filter. - Check/correct duct restrictions. - Adjust to correct blower speed setting. - Loose blower housing, panels, etc. - High static creating high blower speed. - Air leaks in ductwork, cabinets, or panels.
SERVICING VARIABLE SPEED (ECM) MOTOR TEST (Low Stage Heat Call) THERMOSTAT HEAT INPUT(S): R, W1 First, low voltage readings are measured with the 16-pin wire harness disconnected from the motor. A diagram of the harness and pin locations is provided below. Voltage measurement is AC or DC as specified in the chart below under the (Volts) column. Set your voltage meter to the proper AC or DC reading as requested below.
SERVICING VARIABLE SPEED (ECM) MOTOR TEST (High Stage Heat Call) THERMOSTAT HEAT INPUT(S): R, W1, W2 First, low voltage readings are measured with the 16-pin wire harness disconnected from the motor. A diagram of the harness and pin locations is provided below. Voltage measurement is AC or DC as specified in the chart below under the (Volts) column. Set your voltage meter to the proper AC or DC reading as requested below.
SERVICING VARIABLE SPEED (ECM) MOTOR TEST (Fan Only Call) THERMOSTAT CONTINUOUS FAN INPUT(S): R, G First, low voltage readings are measured with the 16-pin wire harness disconnected from the motor. A diagram of the harness and pin locations is provided below. Voltage measurement is AC or DC as specified in the chart below under the (Volts) column. Set your voltage meter to the proper AC or DC reading as requested below.
SERVICING VARIABLE SPEED (ECM) MOTOR TEST (Cooling Low-Stage Call) THERMOSTAT LOW INPUT(S): R, Y1, G First, low voltage readings are measured with the 16-pin wire harness disconnected from the motor. A diagram of the harness and pin locations is provided below. Voltage measurement is AC or DC as specified in the chart below under the (Volts) column. Set your voltage meter to the proper AC or DC reading as requested below.
SERVICING VARIABLE SPEED (ECM) MOTOR TEST (Cooling Two-Stage Call) THERMOSTAT HEAT INPUT(S): R, Y1, Y2, G First, low voltage readings are measured with the 16-pin wire harness disconnected from the motor. A diagram of the harness and pin locations is provided below. Voltage measurement is AC or DC as specified in the chart below under the (Volts) column. Set your voltage meter to the proper AC or DC reading as requested below.
SERVICING VARIABLE SPEED (ECM) MOTOR TEST (Heat Pump Cooling Single-Stage Call) THERMOSTAT HEAT INPUT(S): R, Y1, O, G First, low voltage readings are measured with the 16-pin wire harness disconnected from the motor. A diagram of the harness and pin locations is provided below. Voltage measurement is AC or DC as specified in the chart below under the (Volts) column. Set your voltage meter to the proper AC or DC reading as requested below.
SERVICING S-200 CHECKING DUCT STATIC S-201 The maximum and minimum allowable external static pressures are found in the specification section. These tables also show the amount of air being delivered at a given static by a given motor speed or pulley adjustment. The more air (CFM) being delivered through a given furnace, the less the rise will be; so the less air (CFM) being delivered, the greater the rise.
SERVICING S-300 CHECKING PRIMARY LIMIT CONTROL PRIMARY LIMIT CONTROL All 80% and 90% furnaces use a nonadjustable, automatic reset, bi-metal type limit control. Refer to the following drawing for the location of the primary limit. * * * * 2 * * * Location of Primary Limit Primary Limit Control Location (90% Upflow Furnace Shown, Counterflow Similar) The following drawing illustrates the style of limit switches used on the 90% furnaces.
SERVICING VOLT / OHM METER BLOWER HOUSING Testing Primary Limit Control (80% Furnaces) AUXILIARY LIMIT CONTROL Auxiliary Limit Control Location (All 80% Single-Stage Furnaces) All 90% single-stage upflow furnaces use one auxiliary limit switch for control of high temperatures within the furnace or duct work. This control is preset, nonadjustable and must be manually reset. The control is located in the blower compartment of the furnace on the blower deck, as shown in the following illustration.
SERVICING WARNING HIGH VOLTAGE DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY AUXILIARY LIMIT CONTROL DAMAGE, PERSONAL INJURY OR DEATH. BLOWER HOUSING AUXILIARY LIMIT CONTROL Auxiliary Limit Control Location (80 % and 90% Two-Stage Furnaces) The 80% two-stage furnaces auxiliary limit control (automatic reset) is connected in series with the gas valve and the integrated ignition control.
SERVICING To aid in identifying these controls, color coded labels are attached to the back of the controls. Refer to the Auxiliary Limit Charts in furnace Technical Manual for color codes and temperature settings. On two-stage 80% and 90% models the ignition control the diagnostic light will flash (4) four times indicating a trip of the rollout switch. These symptoms are identical to a trip of the primary limit control.
SERVICING S-303 INDUCED DRAFT BLOWER MOTOR WARNING HIGH VOLTAGE DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY S-305 CHECKING MAIN BURNERS The main burners are used to provide complete combustion of various fuels in a limited space, and transfer this heat of the burning process to the heat exchanger.
SERVICING A Gas Valve On/Off Selector Switch INLET GAS STREAM B Inlet Pressure Tap (Side of Valve) Pressure Regulator Adjustment (Under Cap Screw) The length of Dimension "A" determines the angle of Gas Stream "B". Gas Valve On/Off Selector Switch GAS STREAM B S-307 CHECKING GAS PRESSURE Gas Supply Pressure Measurement Outlet (Manifold) Pressure Tap White-Rodgers Model 36F22 DENT OR BURR A dent or burr will cause a severe deflection of the gas stream.
SERVICING Gas Manifold Pressure Measurement and Adjustment (80% & 90% Single-Stage Furnaces) GAS LINE GAS SHUTOFF VALVE CAUTION GAS LINE TO FURNACE TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT OPEN TO ATMOSPHERE DRIP LEG CAP WITH FITTING MANOMETER HOSE MANOMETER Measuring Inlet Gas Pressure (Alternate Method) RATING PLATE. ONLY MINOR ADJUSTMENTS SHOULD BE MADE BY ADJUSTING THE GAS VALVE PRESSURE REGULATOR.
SERVICING WARNING LINE VOLTAGE NOW PRESENT 2. Connect a calibrated water manometer (or appropriate gas pressure gauge) at the gas valve outlet pressure tap. Refer to previous Measuring Manifold Gas Pressure figure for proper connection. 3. Turn ON the gas and electrical power supply and operate the furnace. 4. Measure gas manifold pressure with burners firing. Adjust manifold pressure using the table below. Manifold Gas Pressure Natural Gas 3.5" w.c. Propane Gas 10.0" w.c.
SERVICING Propane Gas Adjustments WARNING HIGH VOLTAGE DISCONNECT ALL ELECTRICAL POWER AND SHUT OFF GAS SUPPLY BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. 1. After turning off gas to furnace at the manual gas shutoff valve external to the furnace, remove burner compartment door to gain access to the gas valve. 2.
SERVICING Amana® Brand - 80% and 90% furnaces: Should read approximately 1 to 3 amps. NOTE: Due to the "Adaptive Igniter Modulation Routine" of the integrated ignition control, the current reading will fluctuate when reading with a standard amp meter. Induced Draft Blower Pressure Switch Pressure Switch Hose 7. After checking and/or replacing of hot surface ignitor, reinstall burner compartment door and verify proper unit operation.
SERVICING S-311 HIGH ALTITUDE APPLICATION (USA) When these furnaces are installed at high altitude, the appropriate High Altitude Orifice or Pressure Switch 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 High Altitude Orifice Kit will provide the proper design certified input rate within the specified altitude range.
SERVICING Amana® brand 80% and 90% Single-Stage (ADS8, AMS8, ACS9, AMS9, AMS95) NOTE: The models above use White-Rodgers 50A65-289 ignition control board. 1. Check for 120 volts from Line 1 (Hot) to Line 2 (Neutral) at the ignition control. No voltage, check the door switch connections and wire harness for continuity. 2. Check for 24 volts from W to C terminal on the ignition control. No voltage. Check transformer, room thermostat, and wiring.
SERVICING b. The two-stage variable speed furnaces should have 120 Volts at the motor at all times, even without a call for cooling or heating. These motors receive their operational signals (24 Volts) through the 16-pin wiring harness, connected between the motor and integrated control board. NOTE: For complete troubleshooting information on units using the ECM/ICM blower motors, refer to the servicing section - Checking Air Circulator Blowers (S-16B and S-16C) in this service manual.
SERVICING 1. Check for 120 volts from Line 1 (Hot) to Line 2 (Neutral) at the ignition control. No voltage, check the door switch connections and wire harness for continuity. CFM 87654321 OFF S4 87654321 ON S3 CUT FOR DEHUM 2. Check for 24 volts from W1 to C terminal on the ignition control. No voltage. Check transformer, room thermostat, and wiring.
SERVICING 6. If proof of flame was established voltage will be provided to the air circulation blower following the heat on delay period. IGNITOR FLAME SENSOR 23/64" + 1/64" 3/16" + 1/16" DISTANCE OF IGNITOR TO BURNER DISTANCE OF SENSOR TO BURNER a. BEFORE replacing the ECM motor assembly or the end bell, first check the motor with a GE TECMate PRO tester. If the motor runs with the tester, the motor is good.
ACCESSORY WIRING DIAGRAMS HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
ACCESSORY WIRING DIAGRAMS HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. FLASH3 = BOTH T'Stat Connections Y88FA-3 WHT W1 W2 FOR SINGLE STAGE OPERATION: T'Stat Connections WHT WHT BLK RED REMOTE FAULT SIGNAL OUTPUT *Tape wire ends if not used. FURNACE TWINING KIT - FTK03A This wiring diagram is for reference only. Not all wiring is as shown above.
ACCESSORY WIRING DIAGRAMS HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. GREEN DE-HUMIDISTAT WHITE 70 80 60 50 40 ON 30 DEHUM INTEGRATED IGNITION CONTROL DE-HUMIDISTAT - DEHUM1 This wiring diagram is for reference only. Not all wiring is as shown above. Refer to the appropriate wiring diagram for the unit being serviced.
