Service Instructions TM 34.5" Chassis ACVC96/AMVC96 GCVC96/GMVC96 Gas Furnaces 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.
TABLE OF CONTENTS IMPORTANT INFORMATION ..................................... 2 - 6 PRODUCT IDENITIFICATION .................................. 7 - 11 SYSTEM OPERATION COMFORTNET™ ............ 53 - 59 ACCESSORIES .................................................... 12 - 15 MAINTENANCE ................................................... 79 - 80 INSTALLATION CONSIDERATIONS ...................... 16 - 41 ACCESSORY WIRING DIAGRAMS ...................... 81, 83 SYSTEM OPERATION .............................
IMPORTANT INFORMATION To locate an authorized servicer, please consult your telephone book or the dealer from whom you purchased this product. For further assistance, please contact: CONSUMER INFORMATION LINE GOODMAN® BRAND PRODUCTS TOLL FREE 1-877-254-4729 (U.S. only) email us at: customerservice@goodmanmfg.com fax us at: (731) 856-1821 (Not a technical assistance line for dealers.) CONSUMER INFORMATION LINE AMANA® BRAND PRODUCTS TOLL FREE 1-877-254-4729 (U.S. only) email us at: hac.consumer.
IMPORTANT INFORMATION CO can cause serious illness including permanent brain damage or death. B10259-216 Advertencia especial para la instalación de calentadores ó manejadoras de aire en áreas cerradas como estacionamientos ó cuartos de servicio. Las emisiones de monóxido de carbono pueden circular a través del aparato cuando se opera en cualquier modo. El monóxido de carbono puede causar enfermedades severas como daño cerebral permanente ó muerte.
IMPORTANT INFORMATION 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.
IMPORTANT INFORMATION 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.
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: GMVC96 REV AA MODEL: GCVC96 REV AA Equipment Type Goodman Brand Residential Gas Furnace Equipment Type Goodman Brand Residential Gas Furnace Heating Stages Two Heating Stages Two Cooling Stages Two Control Type ClimateTalk ™ or Conventional 24 Volt Cooling Stages Two Blower Motor Type 4 Wire Variable Speed ECM Control Type ClimateTalk ™ or Conventional 24 Volt Blower Motor Type 4 Wire Variable Speed ECM GMVC96 0403BN 0603BN 0803BN 0804CN 1005CN 100
PRODUCT IDENTIFICATION MODEL # MFG # AFE18-60A AMU1620 AMU1625 AMU2020 AMU2025 GMU1620 GMU1625 GMU2020 GMU2025 ASAS-10 ASAS-11 ASAS-12 ASAS-18 CFSB17 CFSB21 CFSB24 CTK01AA CTK01BA N/A P1251305F P1251306F P1251307F P1251308F N/A 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.
PRODUCT IDENTIFICATION MODEL # CTK02** CTK03AA CTK03AB CTK04 MFG # DESCRIPTION CTK02** Communicating Thermostat Kit- Di gi ta l l y communi ca ti ng thermos ta t. Des i gned for us e wi th compati bl e Ama na® Bra nd or Goodman® Bra nd Ai r Ha ndl ers or Furna ces and outdoor s pl i t AC or Hea t Pump units .
PRODUCT IDENTIFICATION MODEL # MFG # DESCRIPTION N/A External Filter Rack Kit. For us e wi th Goodma n® a nd Ama na ® Brand 90% upfl ow va ri a bl e s peed ga s furna ce model s . Thi s ki t i s i ntended to provi de a l oca ti on, externa l to the furna ce ca s i ng, for i ns ta l l a ti on of a perma nent fi l ter.
ACCESSORIES 96% Com Furnace Accessories Mo de l Numb e r AFE18 0 - 6 0 A AMU / G MU EFR0 2 AS AS / G S AS CFS B17 CF S B2 1 CFS B2 4 RF0 0 0 14 2 De sc rip tio n Fossil F ue l Kit Me d ia Air Cle a n e rs Exte rna l Filte r Ra c k Ele c tron ic Air Cle a ne r Downflow S u bb a se 17 . 5 " Do wn flow S ub ba se 2 1" Downflow S u bba se 24.
ACCESSORIES 96% Com Furnace Accessories Mode l Numbe r DEHUM1 LP M- 0 8 LP LP 0 3 HAS FK- 1 HAS FK- 1 HAS FK- 2 HAS FK- 2 HAS FK- 3 HAS FK- 3 De sc ription De humidista t L. P .
ACCESSORIES SLOTS IN FILTER CLEAR SCREWS ON UNIT EXTERNAL FILTER RACK (EFR02) BLOWER DECK SCREWS 96% Upflow Model Furnaces 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 SIDE WALL VENT KITS (0170K00000S) (0170K00001S) Description 0170K00000S This side wall only vent kit #0170K00000S is to be used with 2” - 3” vent systems.
ACCESSORIES CONCENTRIC VENT CONVERSION KIT The CVENT-2 (DCVK20) (2") or the CVENT-3 (DCVK-30) (3") is a 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-619*).
INSTALLATION CONSIDERATIONS 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 Application This product is designed for use as a residential home gas furnace.
INSTALLATION CONSIDERATIONS • National Fire Protection Association 1 Batterymarch Park Quincy, MA 02169-7471 The rated heating capacity of the furnace should be greater than or equal to the total heat loss of the area to be heated. The total heat loss should be calculated by an approved method or in accordance with “ASHRAE Guide” or “Manual J-Load Calculations” published by the Air Conditioning Contractors of America.
INSTALLATION CONSIDERATIONS • • 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 the furnace is installed horizontally, the furnace access doors must be vertical so that the burners fire horizontally into the heat exchanger. Do not install the unit with the access doors on the “up/top” or “down/ bottom” side of the furnace.
INSTALLATION CONSIDERATIONS 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 CSA B149 Installation Codes. Thermostat Requirements The optional CTK0*** thermostat kit may be used with ComfortNet™ compatable furnaces (ACVC, AMVC, GCVC, GMVC models). Refer to System Operation - ComfortNet™ System for details.
INSTALLATION CONSIDERATIONS Most homes will require outside air be supplied to the furnace area by means of ventilation grilles or ducts connecting directly to the outdoors or spaces open to the outdoors such as attics or crawl spaces. The following information on air for combustion and ventilation is reproduced from the National Fuel Gas Code NFPA 54/ANSI Z223.1 Section 9.3. 9.3* Air for Combustion and Ventilation.
INSTALLATION CONSIDERATIONS (1)*Where directly communicating with the outdoors or where communicating to the outdoors through vertical ducts, each opening shall have a minimum free area of 1 in.2/4000 Btu/hr (550 min2/kW) of total input rating of all appliances in the enclosure. [See Figure A.9.3.3.1(1)(a) and Figure A.9.3.3.1(1)(b).
INSTALLATION CONSIDERATIONS (c) The minimum size of outdoor opening(s) shall be the full size of outdoor opening(s) calculated in accordance with 9.3.3, multiplied by the reduction factor. The minimum dimension of air openings shall not be less than 3 in. (80 mm). 9.3.8.4 Ducts shall not serve both upper and lower combustion air openings where both such openings are used. The separation between ducts servicing upper and lower combustion air openings shall be maintained to the source of combustion air. 9.
Installation Positions *MVC96 models may be installed up flow or horizontally with left or right side down. *CVC96 models may be installed down flow or horizontally with left or right side down. Do not install any furnace on its back. Horizontal Installations 1. Horizontal installations require 5.5" under the furnace to accommodate the drain trap. 2. Horizontal furnaces must be installed with ¾” slope from back to front to permit condensate flow towards the front of the furnace.
INSTALLATION CONSIDERATIONS Alternate Electrical and Gas Line Connections The furnaces have provisions allowing for electrical and gas line connections through either side panel. In horizontal applications the connections can be made either through the “top” or “bottom” of the furnace. 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.
INSTALLATION CONSIDERATIONS NOTE: This provision does not apply to the combustion air intake termination of a direct vent application. • The vent termination of a non-direct vent application must terminate at least 4 feet below, 4 feet horizontally from, or 1 foot above any door, window, or gravity air inlet into any building.
INSTALLATION CONSIDERATIONS Horizontal vent/flue pipe terminations should be as shown in the following figure. Refer to Vent/Flue Pipe and Combustion Air Pipe - Termination Locations section in this manual or the installation instructions for details concerning location restrictions. A 2 3/8" diameter wall penetration is required for 2" diameter pipe while a 3 1/2" diameter hole is required for 3" diameter pipe.
INSTALLATION CONSIDERATIONS and outside of the wall. The wall penetration should be sealed with silicone caulking material. *MVC96/*CVC96 Direct Vent (2 - Pipe) and Non-Direct Vent (1- Pipe) 90° ELBOWS (6) M aximum Allowable Length of Vent/Flue Pipe MODEL *M V96C0403BN *M VC960603BN *M VC960803BN *M VC960804CN *M VC961005CN *M VC961005DN *M VC961205DN *CVC960403BN *CVC960603BN *CVC960804CN *CVC961005CN *CVC961205DN Pipe Size (4) (in.
INSTALLATION CONSIDERATIONS Condensate Drain Lines and Drain Trap A condensing gas furnace achieves its high level of efficiency by extracting heat from the products of combustion to the point where condensation takes place. The condensate must be collected in the furnace drain trap and routed to an appropriate drain location in compliance with local and national codes. 90° ELBOWS 3”-24” BETWEEN PIPES AIR INTAKE 12" MIN.
INSTALLATION CONSIDERATIONS 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. The minimum gas supply pressure must be maintained to prevent unreliable ignition. The maximum must not be exceeded to prevent unit overfiring. INLET GAS SUPPLY PRESSURE Natural Gas Minimum: 4.5" w.c. Maximum: 10.0" w.c. Propane Gas Minimum: 11.0" w.c. Maximum: 13.0" w.c.
INSTALLATION CONSIDERATIONS 4. Install a drip leg to trap dirt and moisture before it can enter the gas valve. The drip leg must be a minimum of three inches long. GAS PIPING CONNECTIONS CAUTION TO AVOID POSSIBLE UNSATISFACTORY OPERATION OR EQUIPMENT DAMAGE DUE TO UNDERFIRING OF EQUIPMENT, USE THE PROPER SIZE OF 5. Install a 1/8" NPT pipe plug fitting, accessible for test gage connection, immediately upstream of the gas supply connection to the furnace.
INSTALLATION CONSIDERATIONS 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.
INSTALLATION CONSIDERATIONS 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.
INSTALLATION CONSIDERATIONS 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.
HUM-IN NEUTRAL HUM-OUT INSTALLATION CONSIDERATIONS 24 VOLT HUMIDIFIER A 24 volt hum circuit may be powered off of the n/c side of the low fire pressure. If added in the field, the wiring must conform to all local and national codes. Connect the COM side of the humidifier to the C terminal on the furnace control board (or to the COM side of the 24 VAC transformer). Do not connect 115V humidifier to these terminals.
INSTALLATION CONSIDERATIONS Thermostat Wiring - Two-Stage Variable Speed ComfortNet™ Furnaces As a two-stage non-communicating furnace, the furnace integrated control module provides terminals for both “W1” and “W2”, and “Y1” and “Y2” thermostat connections. This allows the furnace to support the following system applications: ‘Two-Stage Heating Only’, ‘Two-Stage Heating with Single Stage Cooling’, and ‘Two-Stage Heating with TwoStage Cooling’.
INSTALLATION CONSIDERATIONS CFM CHART Model *MVC960403BN* *MVC960603BN* *MVC960803BN* *MVC960804CN* *MVC961005CN* *MVC961005DN* *MVC961205DN* *CVC960403BN* *CVC960603BN *CVC960803BN *CVC960804CN* *CVC961005CN* *CVC961205DN* Low Stage Cool High Stage Cool Low Stage Heat A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C D A B C 403 527 675 803 398 557 696 810 403 540 705 819 513 660 791 913 564 784 982 1259 597 852 1031 1282 547 831 1020 1278 449 569 716 854 433 541 686 8
INSTALLATION CONSIDERATIONS DIP SWITCHES - FURNACES EQUIPPED WITH PCBKF103, PCBKF104, or PCBKF105 Switch Bank S1 S3 S4 S5 Purpose Function 90 120 Heating Off Delay 150 180 2 Stage Stat Thermostat 2 Stage Stat Setup 1 Stg Stat 5 min delay 1 Stg Stat auto delay A B Cooling Airflow C D Add 5% Minus 5% Trim Add 10% Minus 10% A B Ramping Profile C D A B Heating Airflow C D Disabled Dehum Enabled Disabled Trim Enabled 25% 50% Continuous Fan 75% 100% 1 Off On Off On Off On Off On Off On Off On Dip Swit
INSTALLATION CONSIDERATIONS Single-Stage Thermostat Application A single-stage thermostat with only one heating stage may be used to control this furnace. The application of a singlestage thermostat does not offer “true” thermostat-driven twostage 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.
INSTALLATION CONSIDERATIONS 2. Determine the proper air flow for the cooling system. Most cooling systems are designed to work with air flows between 350 and 450 CFM per ton. Most manufacturers recommend an air flow of about 400 CFM per ton. Example: 2.5 tons X 400 CFM per ton = 1000 CFM The cooling system manufacturer’s instructions must be checked for required air flow.
INSTALLATION CONSIDERATIONS Model *MVC960403BN* *MVC960603BN* *MVC960803BN* *MVC960804CN* *MVC961005CN* *MVC961005DN* *MVC961205DN* Minimum Recommended Filter Size^ 1 - 16 X 25 Side or Bottom 1 - 16 X 25 Side or Bottom 1 - 16 X 25 Side or Bottom 1 - 16 X 25 Side or Bottom 1 - 20 X 25 Bottom / 2 - 16 X 25 Side Return 1 - 20 X 25 Bottom / 2 - 16 X 25 Side Return 1 - 20 X 25 Bottom / 2 - 16 X 25 Side Return *CVC960403BN* 2 - 10 X 20 or 1 - 16 X 25 Top Return *CVC960603BN* 2 - 10 X 20 or 1 - 16 X 25 Top Retur
INSTALLATION CONSIDERATIONS Horizontal Installations Filter(s) must be installed external to the furnace casing for horizotal installations. For most installations it is preferable to use a central return with filters installed in the duct behind the return air grill. In this way filter replacement is relatively simple by merely removing the grille, rather than going into the attic or crawl space.
SYSTEM OPERATION 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 displays 8 8 on dual 7-segment display LED’s. • Integrated control module monitors safety circuits continuously. • Furnace awaits call from thermostat. Dual 7-segment LED’s display ON while awaiting call from thermostat.
SYSTEM OPERATION FAN ONLY MODE The normal operational sequence in fan only mode is as follows: • 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 following a five (5) second delay. Electronic air cleaner terminal is energized. • Circulator blower runs, integrated control module monitors safety circuits continuously. • R and G thermostat contacts open, completing the call for fan.
SYSTEM OPERATION the gas valve will be de-energized and another purge will occur and a third ignitor warm up for an additional (2) seconds will occur. The control will cycle the gas valve a total of three (3) times before it determines it cannot establish measurable combustion and enters a locked out state. The diagnostic error code for this problem is E0.
SYSTEM OPERATION NOTE: Turn off power to the furnace prior to inserting memory card onto the control. With memory card inserted onto control, turn power to furnace on. Control has accepted memory card data once control displays ON on the dual, 7-segment display. Memory card may be left on control or removed and used on another furnace of the same model. Turn power off to furnace prior to removing memory card. 15. ECM Blower Motor Not Running.
SYSTEM OPERATION 22. Motor Parameters. This condition occurs if the motor does not receive all the information is requires to operate or an event occurs that prevents the motor from running, or the motor fails to start for (40) consecutive attempts. The diagnostic error code for the this condition is b7. Probable causes are intermittent wiring connection between the control and motor, an error with the furnace control, or any of the conditions described in 19, 20, or 21 above. 23. Low Indoor Airflow.
TROUBLESHOOTING Symptoms of Abnormal Diagnostic/ Status LED Operation (Legacy & Codes ComfortNet™ Thermostat) Fault Description • Furnace fails to operate • Integrated control module LED display provides no signal.
TROUBLESHOOTING Symptoms of Abnormal Operation (Legacy & ComfortNet™ Thermostat) Diagnostic/ Status LED Codes Fault Description ComfortNet™ Thermostat Only Message Code Possible Causes Corrective Actions Notes & Cautions • Induced draft blower runs continuously with no further furnace operation. • Integrated control module LED display provides E2 error code. • ComfortNet™ thermostat “Call for Service” icon illuminated. • ComfortNet™ thermostat scrolls “Check Furnace” message.
TROUBLESHOOTING Symptoms of Abnormal Operation (Legacy & ComfortNet™ Thermostat) Diagnostic/ Status LED Codes Fault Description ComfortNet™ Thermostat Only Possible Causes Message Code IGNITER FAULT E7 • Improperly connected igniter. • Shorted igniter. • Poor unit ground. • Igniter relay fault on integrated control module. Corrective Actions • Check and correct wiring from integrated control module to igniter. • Replace shorted igniter. • Check and correct unit ground wiring.
TROUBLESHOOTING Symptoms of Abnormal Diagnostic/ Operation (Legacy Status LED Fault Description & ComfortNet™ Codes Thermostat) ComfortNet™ Thermostat Only Message Code Possible Causes Corrective Actions Notes & Cautions • Verify shared data set is • Turn power OFF prior to repair correct for the specifc model. Re-populate data • Use memory card for using correct memory the specifc model. card if required. • Insert memory card BEFORE turning power ON.
TROUBLESHOOTING Symptoms of Abnormal Diagnostic/ Operation (Legacy Status LED Fault Description & ComfortNet™ Codes Thermostat) • Furnace fails to operate. • Integrated control module LED display provides b4 error code. • ComfortNet™ thermostat “Call for Service” icon illuminated. • ComfortNet™ thermostat scrolls “Check Furnace” message. b4 • Furnace fails to operate. • Integrated control module LED display provides b5 error code. • ComfortNet™ thermostat “Call for Service” icon illuminated.
TROUBLESHOOTING INTERNAL CONTROL FAULT/NO POWER O E E E n NORMAL OPERATION 0 1 2 LOCKOUT DUE TO EXCESSIVE RETRIES LOW STAGE PRESSURE SWITCH STUCK OPEN E 3 E 4 OPEN HIGH LIMIT SWITCH E 5 E 6 OPEN FUSE E 7 E 8 IGNITER FAULT OR IMPROPER GROUNDING E 9 E A HIGH STAGE PRESSURE SWITCH STUCK OPEN E F d 0 d 4 AUXILIARY SWITCH OPEN b b b b 0 1 2 FLAME DETECTED WHEN NO FLAME SHOULD BE PRESENT LOW FLAME SIGNAL HIGH STAGE PRESSURE SWITCH STUCK CLOSED AT START OF HEATING CYCLE REVERSED 115 VAC POLAR
SYSTEM OPERATION ComfortNet™ System OVERVIEW The ComfortNet system is a system that includes a ComfortNet compatible furnace and air conditioner or heat pump with a CTK0*** thermostat. A valid ComfortNet system could also be a compatible furnace, CTK0*** thermostat and non-communicating, single stage air conditioner. Any other system configurations are considered invalid ComfortNet systems and must be connected as a traditional (or legacy) system (see Electrical Connections for wiring connections).
ComfortNet™ System SYSTEM OPERATION If your communicating thermostat kit does not include a transformer, an accessory kit is available separately by ordering part TFK01.
SYSTEM OPERATION ComfortNet™ System FURNACE ADVANCED FEATURES MENUS DIAGNOSTICS Submenu Item Indication/User Modifiable Options Comments Fault 1 (FAULT #1) Most recent furnace fault For display only Fault 2 (FAULT #2) Next most recent furnace fault For display only Fault 3 (FAULT #3) Next most recent furnace fault For display only Fault 4 (FAULT #4) Next most recent furnace fault For display only Fault 5 (FAULT #5) Next most recent furnace fault For display only Fault 6 (FAULT #6) Least
SYSTEM OPERATION ComfortNet™ System NON-COMM (APPLIES ONLY TO A COMMUNICATING COMPATIBLE FURNACE MATCHED WITH A NON-COMMUNICATING COMPATIBLE SINGLE STAGE AIR CONDITIONER) Submenu Item User Modifiable Options Comments Cool Airflow (CL CFM) 18, 24, 30, 36, 42, 48, or 60, default is 18 Selects the airflow for the non-CT compatible single stage AC unit Cool Airflow Trim (CL TRM) -10% to +10% in 2% increments, default is 0% Cool Airflow Profile (CL PRFL) A, B, C, or D, default is A Cool ON Delay (CL
ComfortNet™ System SYSTEM OPERATION SYSTEM TROUBLESHOOTING NOTE: Refer to the instructions accompanying the ComfortNet compatible outdoor AC/HP unit for troubleshooting information. Refer to the Troubleshooting Chart for a listing of possible furnace error codes, possible causes and corrective actions.
SYSTEM OPERATION 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 control module from damage.
SYSTEM OPERATION ComfortNet™ System Venting The venting system should be planned and installed with the following in mind; • Should not be longer than necessary • Use 45°elbows rather than 90° elbows when possible • Must not sag or otherwise trap condensate • Use longest radius fittings possible • If using 3" venting, make the transition from 2" to 3" as close as practically possible • Make sure there is no flue gas recirculation into the combustion air pipe Condensate Drainage Furnace combustion can be a
SYSTEM OPERATION Some of the electronic boards being used today, with flame rectification, will not function properly and/or at all without polarization of incoming power. Some also require phasing between the primary and secondary sides of step-down transformers.
SYSTEM OPERATION 1 1 CUBIC FEET One GAS RATE -- CUBIC FEET PER HOUR Size of Test Dial Size of Test Dial 5 cu/ft Seconds for One Revolution 1/4 cu/ft 1/2 cu/ft 1 cu/ft 2 cu/ft 5 cu/ft 720 1800 36 25 50 100 200 500 327 655 1636 37 -- -- 97 195 486 300 600 1500 38 23 47 95 189 474 277 555 1385 39 -- -- 92 185 462 Seconds for One Revolution 1/4 cu/ft 1/2 cu/ft 1 cu/ft 2 cu/ft 10 90 180 360 11 82 164 12 75 150 13 69 138 14 64 129 257 514 1286
SYSTEM OPERATION Power Failure Blown Fuse Loose Connection Shorted or Broken Wires No Low Voltage Faulty Thermostat Faulty Transformer Poor or High Resistance Ground • • • • • • • Faulty Ignition Control Gas Valve or Gas Supply Shut Off Faulty Induced Draft Blower Faulty Blower Motor (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 Delayed Ignition • • • • • • • • • • • • • • • • • • • • •
SYSTEM OPERATION sERVICE NUMBERS S-1 CHECKING VOLTAGE ................................. 64 S-305 CHECKING MAIN BURNERS ....................... 72 S-2 CHECKING WIRING ................................... 64 S-306 CHECKING ORIFICES ................................. 72 CHECKING THERMOSTAT, WIRING S-307 CHECKING GAS PRESSURE ........................ 72 AND ANTICIPATOR ................................... 64 S-308 CHECKING S-3A THERMOSTAT AND WIRING ......................
SYSTEM OPERATION S-1 CHECKING VOLTAGE CHECKING THERMOSTAT, WIRING AND ANTICIPATOR 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 S-3A THERMOSTAT AND WIRING WARNING DISCONNECT ALL POWER BEFORE SERVICING. PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. 1. Remove the burner door. 2. Remove cover from the Junction Box and gain access to incoming power lines.
SYSTEM OPERATION S-4 CHECKING TRANSFORMER AND Control CIRCUIT A step-down transformer 120 volt primary to 24 volt secondary, 40 VA (Heating and Cooling Models) supplies ample capacity of power for either operation. 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 ECM control connections are made through the integrated ignition control. No other control connections are needed.
SYSTEM OPERATION 6. Ensure motor and wheel turn freely. Check for interference between wheel and housing or wheel and motor. Repair or replace as needed. 7. Check housing for cracks and/or corrosion. Repair or replace as needed. 8. Check motor mounting bracket. Ensure mouting bracket is tightly secured to the housing. Ensure bracket is not cracked or broken. UltraCheck-EZTM Diagnostic Tool The UltraCheck-EZTM diaganostic tool is the preferred method (part # UTT-01) to diagnose the ECM motor.
SYSTEM OPERATION Motor Control/End Bell Checks 5 AC Line Hot Connection 4 AC Line Neutral Connection 3 Gnd 2 } 1 Lines 1 and 2 will be connected for 120VAC Power Connector applications only POWER CONNECTOR (1/2 HP MOTORS) "Motor Half“ (Viewed from Plug End) inductor AC Line Hot Connection 5 4 AC Line Neutral Connection 3 Gnd 2 } 1 Lines 1 and 2 will be connected for 120VAC Power Connector applications only POWER CONNECTOR (3/4 & 1 HP MOTORS) "Motor Half“ (Viewed from Plug End) HIGH VOLT
SYSTEM OPERATION 7. Locate the 3-circuit connector in the control/end bell. Using an ohmmeter, check the resistance between each terminal in the connector. If the resistance is 100kΩ or greater, the control/end bell is functioning properly. Replace the control/end bell if the resistance is lower than 100kΩ. 8. Reassemble motor and control/end bell in reverse of disassembly. Replace blower assembly into the furnace.
SYSTEM OPERATION may result in condensing in or overheating of the heat exchanger. An airflow and temperature rise table is provided in the blower performance specification section. Determine and adjust temperature rise as follows: 1. Operate furnace with burners firing for approximately ten minutes. Check BTU input to furnace - do not exceed input rating stamped on rating plate. Ensure all registers are open and all duct dampers are in their final (fully or partially open) position. 2.
SYSTEM OPERATION Manual or Automatic Reset Auxiliary Limits Located in Blower Side WARNING VOLT / OHM METER 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. 1. Remove the wires from the auxiliary limit control terminals. COLOR IDENTIFYING TAB 2. Using an ohmmeter, test for continuity across the two terminals (only test when the auxiliary limit is at room temperature).
SYSTEM OPERATION FLAME ROLLOUT SWITCHES * * * * 2 * * * Flame Rollout Switch Location (90% Upflow Furnace Shown, Counterflow Similar) The control is designed to open should a flame roll out occur. An over firing condition or flame impingement on the heat shield may also cause the control to open. If the rollout control opens, the air circulation blower will run continuously. WARNING LINE VOLTAGE NOW PRESENT 1.
SYSTEM OPERATION 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. Proper ignition, combustion, and extinction are primarily due to burner design, orifice sizing, gas pressure, primary and secondary air, vent and proper seating of burners. BURNERS Burners have been redesigned for 34.5" chassis furnaces.
SYSTEM OPERATION WARNING WARNING DISCONNECT ELECTRICAL POWER AND SHUT OFF GAS SUPPLY. HIGH VOLTAGE DISCONNECT ALL ELECTRICAL POWER AND SHUT OFF GAS SUPPLY BEFORE SERVICING OR INSTALLING THIS UNIT. 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.
SYSTEM OPERATION WARNING WARNING LINE VOLTAGE HIGH VOLTAGE DISCONNECT ALL ELECTRICAL POWER NOW PRESENT 3. Turn ON the gas and electrical power supply and operate the furnace. 4. White-Rodgers 36J54 Valves: a. Back outlet pressure test screw (inlet/outlet pressure boss) out one turn (counterclockwise, not more than one turn). b. Attach a hose and manometer to the outlet pressure outlet pressure boss. c. Turn ON the gas supply. d.
SYSTEM OPERATION WARNING LINE VOLTAGE NOW PRESENT 6. Place unit in heating cycle, measure current draw of ignitor during preheat cycle. The steady state current at 120V is 0.37 to 0.68 amps. 7. After checking and/or replacing of hot surface ignitor, reinstall burner compartment door and verify proper unit operation. 4.
SYSTEM OPERATION S-312 CHECKING FOR DELAYED IGNITION Delayed ignition is a delay in lighting a combustible mixture of gas and air which has accumulated in the combustion chamber. When the mixture does ignite, it may explode and/or rollout causing burning in the burner venturi. If delayed ignition should occur, the following should be checked. Furnace design makes this extremely unlikely unless safety controls have been by-passed or tampered with. Never by-pass or alter furnace controls. 1.
SYSTEM OPERATION 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 through the 4-pin wiring harness, connected between the motor and integrated control board. NOTE: For complete troubleshooting information on units using the ECM blower motors, refer to the servicing section - Checking Air Circulator Blowers (S-16B) in this service manual.
SYSTEM OPERATION S-314 CHECKING FLAME SENSOR A flame sensing device is used in conjunction with the ignition control module to prove combustion. If proof of flame is not present the control will de-energize the gas valve and "retry" for ignition or lockout. 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. 1. Disconnect the flame sensor wire from the sensor. 2.
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, trap, and field supplied drain line must be checked annually and cleaned as often as necessary to ensure proper condensate drainage. FLAME SENSOR (QUALIFIED SERVICER ONLY) Under some conditions, the fuel or air supply can create a nearly invisible coating on the flame sensor. This coating acts as an insulator, causing a drop in the flame sensing signal.
MAINTENANCE 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. INTEGRATED IGNITION CONTROL 1 2 R C G W1 W2 Y1 Y2 O DE HUM WHITE BLACK GREEN 70 80 60 50 40 DE-HUMIDISTAT 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.
WIRING DIAGRAMS HI 3 C 2 PM 1 NO PU FLAME SENSOR C GY GY NO FRONT COVER PRESSURE SWITCH BL PU PK BK BL BK 11 12 OR WH/PU 9 5 6 1 2 3 HEAT OFF DLY T-STAT 24 VAC 115 VAC OR 8 DIAGNOSTIC LED'S FLAME SENSOR 115 VAC NEUTRAL 40 VA TRANSFORMER TH (4) 24 VAC AUTO RESET PRIMARY AUTO RESET AUXILIARY LIMIT LIMIT CONTROL CONTROLS HLO (10) Y1 PSO (7) W1 LOW FIRE PRESS. SWITCH C PS1 (2) NO W2 Y2 TO MICRO NO PS2 (12) C HIGH FIRE PRESS.
