Service Instructions TM Goodman® & Amana® Brand 80% Communicating Gas Furnaces GMVC8, AMVC8, ADVC8 & Accessories ® 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. The material in this manual does not supercede manufacturer’s installation and operation instructions.
TABLE OF CONTENTS IMPORTANT INFORMATION ......................... 2 - 4 SYSTEM OPERATION COMFORTNET™ ...59 - 64 PRODUCT IDENTIFICATION ...................... 5 - 10 POLARIZATION AND PHASING ........................ 65 ACCESSORIES ..........................................11 - 12 MAINTENANCE ........................................... 66 - 68 OPERATING INSTRUCTIONS ...................13 - 15 SERVICING ................................................. 69 - 86 PRODUCT DESIGN ...........................
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.
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.# DESCRIPTION GMVC8***AA GMVC80704B*AA Goodman® Brand 80% communicating capable furnace, 33 3/8" tall, upflow / horizontal installation GMVC80905C*AA positions, 2 stage gas heat, supports 2 stage cooling, induced draft. 4 wire serially communicating ECM GMVC81155C*AA motor. 120 volt silicon carbide hot surface ignition. Left or right gas pipe entry. Aluminized steel tubular heat exchanger. "X" models are low NOx. Available cabinet widths are 17.
PRODUCT IDENTIFICATION MODEL# AMVC8***AA AMVC8***AB MFG.# DESCRIPTION AMVC80704BXAA Amana® Brand 80% communicating capable furnace, 33 3/8" tall, upflow / horizontal installation AMVC80905CXAA positions, 2 stage gas heat, supports 2 stage cooling, induced draft. 4 wire serially communicating ECM AMVC81155CXAA motor. 120 volt silicon carbide hot surface ignition. Left or right gas pipe entry. Stainless steel tubular heat exchanger. Low NOx. Available cabinet widths are 17.
PRODUCT IDENTIFICATION MODEL# ADVC8***AA ADVC8***AB ADVC8***AA ADVC8***BA MFG.# DESCRIPTION ADVC80703BXAA ADVC80905CXAA ADVC81155CXAA Amana ® Brand 80% communicating capable furnace, 33 3/8" tall, dedicated down flow installation, 2 stage gas heat, supports 2 stage cooling, induced draft. 4 wire serially communicating ECM motor. 120 volt silicon carbide hot surface ignition. Left or right gas pipe entry. Stainless s teel tubular heat exchanger. Low NOx. Available cabinet widths are 17.
PRODUCT IDENTIFICATION MODEL # AFE18-60A CTK01AA CTK01BA CTK02** CTK03AA CTK03AB MFG # DESCRIPTION N/A 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.
PRODUCT IDENTIFICATION MODEL # MFG # DESCRIPTION DEHUM1 P1227801F Dehumidistat. Wall mou nted, 24 volt hu midity control available as a Dehumidistat used to reduce the airflow in th e air conditioning mode to lower the humidity in an occupied home. This control features a moisture-sen sitive nylon element and also provides positive On-Off settings for manual operatio n.
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 80% Upflow Model Furnaces 11
ACCESSORIES A/GMVC80604B** A/GMVC800805C** A/GMVC81005C** ADVC80603B** ADVC80805C** ADVC81005C** AMU / GMU ASASD / GSASD SBT17 SBT21 CTK0* LPM06 LPLP03 HA-02 Media Air Cleaner Electronic Air Cleaner Downflow Subbase 17.
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.
OPERATING INSTRUCTIONS ROBINET A GAZ MANUEL, EN POS "ON/MARCHE" GAS INLET ARRIVEE DU GAZ MANUAL GAS LEVER SHOWN IN "ON" POS 15
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 Application This product is designed for use as a residential home gas furnace.
PRODUCT DESIGN 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 A furnace installed in a confined space (i.e., a closet or utility room) must have two ventilation openings with a total minimum free area of 0.25 square inches per 1,000 BTU/hr of furnace input rating. One of the ventilation openings must be within 12 inches of the top; the other opening must be within 12 inches of the bottom of the confined space. In a typical construction, the clearance between the door and door frame is usually adequate to satisfy this ventilation requirement.
PRODUCT DESIGN reduce the speed of the circulator blower during operation in the cooling mode. To be compatible with these furnaces, a dehumidistat must operate on 24 VAC and utilize a switch which opens on humidity rise. Refer to Electrical Connections - 24 Volt Dehumidistat Wiring section in this manual or the installation instructions for correct installation procedure.
PRODUCT DESIGN 9.3.2.2* Known Air Infiltration Rate Method.
PRODUCT DESIGN (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). Chimney or Gas Vent Outlet air duct Furnace NOTE: The air duct openings must have a free area of not less than one square inch per 2000 BTU of the total input rating of all equipment in the enclosure*. 9.3.5 Engineered Installations.
PRODUCT DESIGN 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. 9.3.8.5 Ducts shall not be screened where terminating in an attic space. 9.3.8.6 Horizontal upper combustion air ducts shall not slope downward toward the source of combustion air. 9.3.8.
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 Si
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 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. It is not acceptable to vent one appliance inside the B vent and other appliances outside.
PRODUCT DESIGN This furnace is shipped from the factory configured for natural gas at standard altitude. Propane gas installations require an orifice change to compensate for the energy content difference between natural and propane gas. High altitude installations may require both a pressure switch and an orifice change. These changes are necessary to compensate for the natural reduction in the density of both the gas fuel and the combustion air at higher altitude.
PRODUCT DESIGN GAS VALVE This unit is equipped with a 24 volt gas valve controlled during furnace operation by the integrated control module. As shipped, the valve is configured for natural gas. The valve is field convertible for use with propane gas by using the appropriate propane gas conversion kit. Taps for measuring the gas supply pressure and manifold pressure are provided on the valve.
PRODUCT DESIGN DIRECT/STANDARD INLET PIPING When gas piping enters directly to the gas valve through the standard inlet hole (upflow through the right side panel), the installer must supply straight pipe with a ground joint union to reach the exterior of the furnace. NOTE: The rigid pipe must be long enough to reach the outside of the cabinet. A semi-rigid connector to the gas piping can be used outside the cabinet per local codes.
PRODUCT DESIGN ELECTRICAL CONNECTIONS WARNING AN UNDETECTED GAS LEAK WILL CREATE A DANGER OF EXPLOSION OR FIRE. IF THE PRESENCE OF GAS IS SUSPECTED, FOLLOW THE INSTRUCTIONS ON THE COVER OF THIS MANUAL. FAILURE TO DO SO COULD RESULT IN SERIOUS PERSONAL INJURY OR DEATH. WARNING TO AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO THE UNIT MUST BE PROPERLY POLARIZED AND GROUNDED.
PRODUCT DESIGN CAUTION OPTIONAL ACCESORIES ELECTRONIC AIR CLEANER EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES A PRECAUTION 120 VAC HOT AND PARK TERMINALS WARNING TO AVOID THE RISK OF ELECTRICAL SHOCK, INJURY, OR DEATH, THE FURNACE MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH LOCAL HUM-H EAC-H NOTE: Wire routing must not interfere with circulator blower operation, filter removal, or routine maintenance. NEUTRAL HUMIDIFIER WHEN REMOVING HOLE PLUGS.
PRODUCT DESIGN Options for control: With the CTK02 thermostat. From the Main Menu > Clock & Display > Hum Display > (On). Enter the Advanced menu by pressing left and right arrows for three seconds > Com Devices > Furnace > Setup > Humidity > (On or Independent) If “On” is selected, the HUM IN – HUM OUT contacts will close during a call for heat if the room humidty is below the humidity set point selected on the CTK02**.
PRODUCT DESIGN 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.
PRODUCT DESIGN Models Equipped with PCBKF101 or PCBKF102 Control Board Speed Selection Dip Switches Cool Selection Switches Adjust Selection Switches Profile Selection Switches TAP 1 2 3 4 A OFF OFF OFF OFF OFF B ON C OFF D ON Profiles 5 Model Heat Selection Switches 6 *DVC80603B*** 7 8 OFF OFF OFF OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON ON ON ON ON ON ON ON Tap *DVC80805C*** Pre-Run Short-Run OFF Delay A ------- -------- 60 sec/100% B ---
PRODUCT DESIGN 24 Volt Dehumidistat Wiring The optional usage of a dehumidistat allows the furnace’s circulator blower to operate at a slightly lower speed (85% of desired speed) during a combined thermostat call for cooling and dehumidistat call for dehumidification. This can be done through an independent dehumidistat or through a thermostat’s DEHUM terminal (if available). This lower blower speed enhances dehumidification of the conditioned air as it passes through the AC coil.
PRODUCT DESIGN CONTINUOUS FAN OPERATION The two stage furnace control will energize ECM blower motor when the fan switch on the thermostat is turned to the "ON" position. Continuous fan speed will be of the furnaces maximum airflow capability. 25%, 50%, 75%, or 100% selectable by DIP switch setting or communicating thermostat. Example: If the furnace’s maximum airflow capability is 2000 CFM, the continuous fan speed will be 0.30 x 2000 CFM = 600 CFM.
PRODUCT DESIGN Select the desired “adjust” tap by positioning switches 3 and 4 appropriately. To enable adjustments and select -5, 5, -10 or 10% trim, you must set dipswitch S52 to ON. If S5-2 is in the OFF position, you will receive 0% trim. Refer to the following figure for switch positions and their corresponding taps. Verify CFM by noting the number displayed on the dual 7-segment LED display. 6. The multi-speed circulator blower also offers several custom ON/OFF ramping profiles.
PRODUCT DESIGN S5 Trim Enable SWITCH 2 DISABLE ENABLE OFF ON •Profile D ramps up to 50% of the demand for 1/2 minute, then ramps to 85% of the full cooling demand airflow and operates there for approximately 7 1/2 minutes. The motor then steps up to the full demand airflow. Profile D has a 1/2 minute at 50% airflow OFF delay. OFF OFF CIRCULATING AIR AND FILTERS DUCTWORK - AIRFLOW Duct systems and register sizes must be properly designed for the C.F.M. and external static pressure rating of the furnace.
PRODUCT DESIGN Air cleaner installation location Maximum Heating Airflow Filter (Media) Dimensions Air Cleaner Family Part Number Side or bottom return 1200 CFM 16 in X 20 in x 5¼" AM11-1620-5 Side or bottom return 1600 CFM 16 in X 25 in x 5¼" AM11-1625-5 Side or bottom return 1600 CFM 20 in X 20 in x 5¼" AM11-2020-5 Side or bottom return 2000 CFM 20 in X 25 in x 5¼" AM11-2025-5 Side return (for 2 separate returns) Side return (Right angle) 2 X 1600 CFM 2, 16 in X 25 in x 5¼" AM11-32
PRODUCT DESIGN cally require less frequent replacement intervals. Avoid using highly restrictive 1" filters which produce static pressure loss greater than .25" W.C. In some installations the minimum filter size required (consult filter sizing chart ) will not lend itself to a filter installation on the side of the furnace. The installation of a centrally installed air cleaner cabinet or a return duct filter installation may offer more practicality.
PRODUCT DESIGN DIP SWITCHES - FURNACES EQUIPPED WITH PCBKF103 AND HIGHER 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 Switch 2 3 Off Off On On On On
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 0P or 0N while awaiting call from thermostat.
SYSTEM OPERATION FAN ONLY MODE HEATING - Abnormal Operation 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 (25, 50, 75, 100% of the furnace’s maximum airflow capability) following a five (5) second delay. Electronic air cleaner terminal is de-energized.
SYSTEM OPERATION 2. System Lockout. If a flame is not sensed during the first seven (4) seconds after the gas valve is energized, the control turns off the gas. There will then be a 30 second delay while the induced draft blower is energized to purge the heat exchanger. The ignitor will again be energized and preheated for an additional (1) second. The gas valve will then be energized.
SYSTEM OPERATION 14. Invalid Memory Card Data. This condition occurs if the control rejects the shared data set on a memory card. Memory cards are model specific. The diagnostic error code for this condition is d4. 15. ECM Blower Motor Not Running. This condition occurs if the control fails to detect the ECM blower motor running when it should be running. The furnace will not operate if the control detects the blower motor is not running when it should be 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 • No 115 power to furnace or no 24 volt power to integrated control module • Blown fuse or circuit breaker • Integrated control module has an internal fault PCBKF103 / PCBKF104 / PCBKF105 ComfortNet™ Thermostat Only Message Code INTERNAL FAULT EE Possible Causes Corrective Actions Notes & Cautions • Manual disconnect switch OFF, door switch open or 24 volt wire improperly
PCBKF103 / PCBKF104 / PCBKF105 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.
TROUBLESHOOTING Symptoms of Abnormal Operation (Legacy & ComfortNet™ Thermostat) Diagnostic/ Status LED Codes Fault Description PCBKF103 / PCBKF104 / PCBKF105 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.
TROUBLESHOOTING Symptoms of Abnormal Diagnostic/ Operation (Legacy Status LED Fault Description & ComfortNet™ Codes Thermostat) PCBKF103 / PCBKF104 / PCBKF105 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.
OP E0 x LED display indicates OP x Low stage pressure switch circuit is closed at start of heating cycle. x Low stage pressure switch circuit is not closed. E1 E2 x Induced draft blower runs continuously with no further furnace operation. x Integrated control module LED display provides E2 error code. x ComfortNet™ thermostat “Call for Service” icon illuminated. x ComfortNet™ thermostat scrolls “Check Furnace” message.
EA d0 REVERSED PLTY NO NET DATA x Polarity of 115 volt AC is reversed x Data not yet on network. EA d0 E9 x Furnace fails to operate. x Integrated control module LED display provides EA error code. x ComfortNet™ thermostat “Call for Service” icon illuminated. x ComfortNet™ thermostat scrolls “Check Furnace” message. x Furnace fails to operate. x Integrated control module LED display provides d0 error code. x ComfortNet™ thermostat “Call for Service” icon illuminated.
x Flame sensed with no call for heat. x Open Fuse x Flame sense micro amp signal is low x Problem with igniter circuit. E4 E5 E6 E7 x Induced draft blower and circulator blower runs continuously. No furnace operation. x Integrated control module LED display provides E4 error code. x ComfortNet™ thermostat “Call for Service” icon illuminated. x ComfortNet™ thermostat scrolls “Check Furnace” message. x No furnace operation. x Integrated control module LED display provides E5 error code.
d4 b0 b1 b2 b3 x Furnace fails to operate. x Integrated control module LED display provides b0 error code. x ComfortNet™ thermostat “Call for Service” icon illuminated. x ComfortNet™ thermostat scrolls “Check Furnace” message. x Furnace fails to operate. x Integrated control module LED display provides b1 error code. x ComfortNet™ thermostat “Call for Service” icon illuminated. x ComfortNet™ thermostat scrolls “Check Furnace” message. x Furnace fails to operate.
b6 b7 b9 MOTOR VOLTS MOTOR PARAMS LOW ID AIRFLOW x Circulator blower motor shuts down for over or under voltage condition. x Circulator blower motor shuts down due to over temperature condition on power module. x Circulator blower motor does not have enough information to operate properly. x Motor fails to start 40 consecutive times. x Airflow is lower than demanded. b6 b7 b9 x Furnace fails to operate. x Integrated control module LED display provides b7 error code.
TROUBLESHOOTING PCBKF103 / PCBKF104 / PCBKF105 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 CLOSED AT START OF HEATING CYCLE 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
PCBKF101 / 2 TROUBLESHOOTING INTERNAL CONTROL FAULT/NO POWER 58 O n NORMAL OPERATION (PCBBF102) O P NORMAL OPERATION (PCBKF101) E E E E E E E E E E E d d b b b b b b b b b C C LOCKOUT DUE TO EXCESSIVE RETRIES 0 1 2 3 4 5 6 7 8 9 A 0 4 0 1 2 3 4 5 6 7 9 1 2 LOW STAGE PRESSURE SWITCH STUCK CLOSED AT START OF HEATING CYCLE LOW STAGE PRESSURE SWITCH STUCK OPEN OPEN HIGH LIMIT SWITCH FLAME DETECTED WHEN NO FLAME SHOULD BE PRESENT OPEN FUSE LOW FLAME SIGNAL IGNITER FAULT OR IMPROPER GROUNDING HIGH STAGE
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-compatible, 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 NOTE: Use of an accessory transformer is recommended if installing a dual fuel system. Failure to use the transformer in the outdoor unit could result in over loading of the furnace transformer. SYSTEM WIRING BETWEEN FURNACE AND NONCOMFORTNET COMPATIBLE SINGLE STAGE AIR CONDITIONER COMFORTNET SYSTEM ADVANCED FEATURES If your communicating thermostat kit does not include a transformer, an accessory kit is available 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) Leas
SYSTEM OPERATION ComfortNet™ System STATUS Submenu Item Indication (for Display Only; not User Modifiable) Mode (MODE) Displays the current furnace operating mode CFM (CFM) Displays the airflow for the current operating mode The integrated furnace control has some on-board tools that may be used to trouble-shoot the network. These tools are; red communications LED, green receive (Rx) LED, and learn button. • Red communications LED – Indicates the status of the network.
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.
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 C .o d e )sINSTALLING 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 FLUE PASSAGES (QUALIFIED SERVICER ONLY) At the start of each heating season, inspect and, if necessary, clean the furnace flue passages. 4. Inclined Manometer - to measure static pressure, pressure drop across coils, filters, and draft. 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 To adjust the pressure regulator on the gas valve, turn down (clockwise) to increase pressure and input, and out (counterclockwise) to decrease pressure and input. Since normally propane gas is not installed with a gas meter, clocking will be virtually impossible. The gas orifices used with propane are calculated for 2500 BTU per cubic foot gas and with proper inlet pressures and correct piping size, full capacity will be obtained.
SERVICING TABLE OF CONTENTS S-1 CHECKING VOLTAGE ............................................................................................................................................. 72 S-2 CHECKING WIRING ............................................................................................................................................... 72 S-3A THERMOSTAT AND WIRING .......................................................................................................................
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 -- 70 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 Poor or High Resistance Ground • • • • • • • • 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 Delayed Ignition • • • • • • • • • • • • • • • • • • •
SERVICING 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 to gain entry to the Junction Box. 2. Remove cover from the Junction Box and gain access to incoming power lines.
SERVICING 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 3. Use a voltmeter, check voltage across terminals R and C. Must read 24 VAC. 4. No voltage indicates faulty transformer, open fuse, bad wiring, bad splice, or open door interlock switch. 5.
SERVICING Checking ECM Motors ECM motors connect directly to the AC Line Voltage. DO NOT insert contactors in series with the ECM Motor AC Line. The control is powered continuously to insure reliable start-up. The connector plug is polarized, verify and reverify correct connector orientation before applying power. DO NOT force plug into motor and make sure power is off before inserting power connector. DO NOT apply voltage to terminals 1 or 2. General Checks/Considerations 1.
SERVICING Electrical Checks - High Voltage Power Circuits HIGH VOLTAGE! Disconnect ALL power before servicing or installing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death. 1. Disconnect power to the furnace. 2. Disconnect the 5-circuit power connector to the ECM motor. 3. Turn on power to the furnace. WARNING 7. If no voltage is present, check supply voltage to the furnace. See section S-1. 8. Disconnect power to the furnace.
SERVICING 6. Inspect the large capacitors inside the control/end bell (see figure below). Replace the control/end bell if any of the capacitors are bulging or swollen. 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.
SERVICING SUPPLY AIR CUTAWAY OF DUCTWORK TO EXPOSE COIL SUPPLY AIR INCLINED MANOMETER Amana Elec tronic Ai r Cleaner Ca ution High Voltage To a void per sonal in u j ry, wait 15 secon ds afte r de -ene rgizing u nit b efore touch n i g unit n i terior .
SERVICING Style 1 drawing illustrates the Primary Limit used on the 80% furnaces. S-301 CHECKING AUXILIARY LIMIT CONTROL Auxiliary Limit Control Location Style 1 WARNING The 80% two-stage furnaces use an auxiliary limit (automatic reset) control connected in series with the primary limit control and rollout limit controls connected to the integrated ignition control. If its temperature should be exceeded, it will open, interrupting the voltage to the gas valve causing it to close.
SERVICING On two-stage 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. To aid in identifying these controls, color coded labels have been affixed to the back of these controls. Refer to the Rollout Limit Charts in furnace Technical Manual for temperature settings and color codes.
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 .023" - .027" DAMAGE, PERSONAL INJURY OR DEATH. 1. Remove burner compartment door to gain access to the induced draft blower motor. 2. Disconnect the motor wire leads from its connection point at the induced draft motor. 3. Using a ohmmeter, test for continuity between each of the motor leads. 4.
SERVICING NOTE: At either location, a hose fitting must be installed prior to making the hose connection. NOTE: Use adapter kit #0151K00000S to measure gas pressure on White-Rodgers 36G22 and 36G54 gas valves. A GAS STREAM B installed. GAS LINE GAS SHUTOFF VALVE The length of Dimension "A" determines the angle of Gas Stream "B". GAS LINE TO FURNACE DENT OR BURR GAS STREAM B OPEN TO ATMOSPHERE DRIP LEG CAP WITH FITTING A dent or burr will cause a severe deflection of the gas stream.
SERVICING 8. Turn on electrical power and verify proper unit operation. 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. Gas Manifold Pressure Measurement and Adjustment Natural Gas Adjustments WARNING HIGH VOLTAGE D ISCONNECT ALL ELECTRICAL POWER AND SHUT OFF GAS SUPPLY BEFORE SERVICING OR INSTALLING.
SERVICING Regulator Vent High Fire Regulator Adjust WARNING HIGH VOLTAGE DISCONNECT ALL ELECTRICAL POWER AND SHUT OFF GAS SUPPLY BEFORE SERVICING OR INSTALLING. Gas Valve On/Off Selector Switch Low Fire Regulator Adjust Honeywell Model VR9205 (Two-Stage) Measuring Gas Pressure: Two-Stage Valves Cont'd Manometer Hose Open to Atmosphere 7. Turn on gas to furnace and check for leaks. If leaks are found, repair and then reinstall burner compartment door. 8.
SERVICING 2. Ignitor cool - approximately 70 - 77°F. 3. Disconnect the ignitor from the Ignition Control. 4. Using an ohmmeter measure the resistance of the ignitor: 120 Volt Silicon Nitride : 120V Nitride Igniter should read between 37 to 68 ohms. 5. Reconnect ignitor. WARNING 2. Remove wires from the pressure switch(es) electrical terminals. 3. Using a VOM check from common terminal to NC (Normally Closed) - should read open. If switch reads as above proceed to Step 4, otherwise replace control. 4.
SERVICING S-311 HIGH ALTITUDE APPLICATION (USA) The furnace as shipped requires no change to run between 0 - 4500 feet. Do not attempt to increase the firing rate by changing orifices or increasing the manifold pressure below 4500 feet. This can cause poor combustion and equipment failure. High altitude installations above 4500 feet may require both a pressure switch and an orifice change.
SERVICING 2. Check for 24 volts from W1 to C terminal on the ignition control. No voltage. Check transformer, room thermostat, and wiring. If you have 24 volts coming off the transformer but receive approximately 13 volts on the terminal board between (C) and (R), check for blown fuse. 3. Check for 120 volts to the induced draft blower (lowstage) by measuring voltage between Pin 3 and Pin 4 (on the 5-pin connector) located on circuit board.
SERVICING PRESSURE SWITCH CHART *MVC8 / ADVC8 Pressure Switch Trip Points And Usage Chart Low Fire Low Fire High Fire High Fire Low / High Set Point on Pressure Fall (PF) W.C. Max Make Pressure On Rise W.C. Set Point on Pressure Fall (PF) W.C. Max Make Pressure On Rise W.C. Pressure Switch Assembly Part # *MVC80604B*AA - 0.35 ± .05 - 0.54 - 0.65 ± .05 - 0.84 0130F00049 *MVC80805C*AA - 0.30 ± .05 - 0.49 - 060 ± .05 - 0.79 0130F00050 *MVC80805C*BA / BB - 0.35 ± .05 - 0.54 - 0.65 ± .
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.
SCHEMATICS 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 CONTROL MODULE 1 2 R C G W 1 W 2 Y1 Y2 O DE HUM 1 2 R C G W 1 W2 Y1 Y2 O DEHUM 1 2 R C G W1 W2 Y1 Y2 O DEHUM 3 1 6 4 7 9 12 10 13 15 ANSI Z21.20 AUTOMATIC IGNITION SYSTEM 24VAC 60Hz 0.8 A. MAX. ST5 GND TX RX 12V FS ST4 BK IGN-N R WH IND-N 59-4715 REV.
SCHEMATICS 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. TYPICAL SCHEMATIC ADVC8/AMVC8/GMVC8_____X* MODEL FURNACES PCBKF103 This schematic is for reference only. Not all wiring is as shown above. Refer to the appropriate wiring diagram for the unit being serviced.
*MVC8, *DVC8 WIRING DIAGRAMS TO 115 VAC/ 1 Ø /60 HZ POWER SUPPLY WITH OVERCURRENT PROTECTION DEVICE GND BK 2 PM 1 WH DISCONNECT NO TO 115VAC/ 1 Ø /60 HZ POWER SUPPLY WITH OVERCURRENT PROTECTION DEVICE HIGH FIRE PRESSURE SWITCH FLAME SENSOR YL WARNING: DISCONNECT POWER BEFORE SERVICING. WIRING TO UNIT MUST BE PROPERLY POLARIZED AND GROUNDED.
