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 ............................... 3 SYSTEM OPERATION COMFORTNET™ ... 57 - 62 PRODUCT IDENTIFICATION ........................ 4 - 9 POLARIZATION AND PHASING ......................... 63 ACCESSORIES ..........................................10 - 11 MAINTENANCE ........................................... 64 - 66 OPERATING INSTRUCTIONS .................... 12 -14 SERVICING .................................................67 - 84 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.# 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 Ama na® 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 moto r. 120 volt silicon carbide hot surface ignition. L eft 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 cooli ng, 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 -60 A CTK01 AA CTK01 BA CTK02** CTK03 AA CTK03 AB 8 MFG # DESCRIPTION N/A Foss il Fue l Kit. Th e AFE18 -60 A co ntrol is d es igned fo r us e w here the in door co il is located above /dow ns tream o f a g as or fos s il fue l furnace w hen us e d w ith a h eat pum p. It w ill operate with s ingle a nd tw o s tage he at pum ps and s ingle and tw o s tag e furnaces .
PRODUCT IDENTIFICATION MODEL # MFG # DESCRIPTION DEHUM1 P1227801F Dehumidistat. Wall mou nted, 24 volt humidity 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-sensitive nylon element and also provides positive On-Off settings for manual operation.
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 10
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 14
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 ELECTRO NIC AIR C LEANER EDGES OF SHEET METAL HOLES MAY BE SHARP. USE GLOVES A PRECAUTION WHEN REMOVING HOLE PLUGS. WARNING 120 VAC NEUTR AL TERMINALS TO AVOID THE RISK OF ELECTRICAL SHOCK, INJURY, OR DEATH, THE FURNACE MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH LOCAL NEUTRAL 120 VAC HO T AND PARK TERMINALS HUM-H NOTE: Wire routing must not interfere with circulator blower operation, filter removal, or routine maintenance.
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 TAP 1 A OFF OFF OFF OFF OFF B ON C OFF D ON Profiles 2 3 Profile Selection Switches 4 5 Model Heat Selection Switches 6 OFF OFF *DVC80603B*** 7 8 OFF OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON ON ON ON ON ON ON ON Tap Pre-Run Short-Run OFF Delay A - ---- -- - -- - -- -- 60 sec/100% B - -- -- -- 30
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 Example: If the furnace’s maximum airflow capability is 2000 CFM, the continuous fan speed will be 0.30 x 2000 CFM = 600 CFM. For the PCBKF103 and PCBKF104, continuous fan speeds that provide 25, 50, 75 and 100% of the furnace’s maximum airflow capability are selectable via dip switches S5- 3, 4. Example: If the furnace’s maximum airflow capability is 2000 CFM and 25% continuous fan speed is selected, the continuous fan speed will be 0.25 x 2000 CFM = 500 CFM.
PRODUCT DESIGN 6. The multi-speed circulator blower also offers several custom ON/OFF ramping profiles. These profiles may be used to enhance cooling performance and increase comfort level. The ramping profiles are selected using DIP switches S4- 1, 2. Refer to the following figure for switch positions and their corresponding taps. Refer to the bullet points below for a description of each ramping profile. Verify CFM by noting the number displayed on the dual 7-segment LED display.
PRODUCT DESIGN 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. Ductwork should be designed in accordance with the recommended methods of "Air Condition Contractors of America" manual D.
PRODUCT DESIGN UPRIGHT FILTER INSTALLATIONS Depending on the installation and/or customer preference, differing filter arrangements can be applied. Filters can be installed in the central return register and a side panel external filter rack kit (upflow filter kit # EFR01). 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.
PRODUCT DESIGN DIP SWITCHES - FURNACES EQUIPPED WITH PCBFK103 / PCBKF104 Dip Switch Switch Bank Purpose Function 1 2 3 90 Off Off 120 On Off Heating Off Delay 150 Off On 180 On On S1 2 Stage Stat On Thermostat 2 Stage Stat On Setup 1 Stg Stat 5 min delay Off 1 Stg Stat auto delay Off A Off Off B On Off Cooling Airflow C Off On D On On S3 Add 5% Off Minus 5% On Trim Add 10% Off Minus 10% On A Off Off B On Off Ramping Profile C Off On D On On S4 A Off B On Heating Airflow C Off D On Disabled Off Dehum Enabled
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 • • Electronic air cleaner terminal and circulator blower are de-energized. Furnace awaits next call from thermostat. 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 (25, 50, 75, 100% of the furnace’s maximum airflow capability) following a five (5) second delay.
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. 44 23. Low Indoor Airflow.
TROUBLESHOOTING Symptoms of Abnormal Diagnostic/ Operation (Legacy & Status LED ComfortNet™ Thermostat) Codes Fault Description PCBKF103 ComfortNet™ Thermostat Only Message Code INTERNAL FAULT EE Possible Causes AND PCBKF104 Corrective Actions • Furnace fails to operate • Integrated control module LED display provides no signal.
PCBKF103 TROUBLESHOOTING Symptoms of Abnormal Operation (Legacy & ComfortNet™ Thermostat) Diagnostic/ Status LED Codes Fault Description ComfortNet™ Thermostat Only Message Code AND PCBKF104 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.
PCBKF103 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. AND PCBKF104 Corrective Actions • Check and correct wiring from integrated control module to igniter. • Replace shorted igniter.
PCBKF103 TROUBLESHOOTING Symptoms of Abnormal Diagnostic/ Operation (Legacy Status LED Fault Description & ComfortNet™ Codes Thermostat) ComfortNet™ Thermostat Only Message Code Possible Causes AND PCBKF104 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.
PCBKF103 TROUBLESHOOTING AND PCBKF104 INTERNAL CONTROL FAULT/NO POWER O n E 0 E 1 NORMAL OPERATION E 2 LOW STAGE PRESSURE SWI TCH STUCK OPEN E 3 E 4 OPEN HIGH LIMIT SWITCH E 5 OPEN FUSE E 6 LOW FLAME SIGNAL E 7 IGNITER FAULT OR IMPROPER GROUNDING E 8 HIGH STAGE PRESSURE SWITCH STUCK CLOSED AT START OF HEATING CYCLE E 9 E A E F d 0 d 4 HIGH STAGE PRESSURE SWITCH STUCK OPEN b b b b 0 1 2 3 b 4 b 5 b 6 LOCKOUT DUE TO EXCESSIVE RETRIES LOW STAGE PRESSURE SWITCH STUCK CLOSED AT START OF H
PCBKF101/2 TROUBLESHOOTING INTERNAL CONTROL FAULT/NO POWER 56 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 P
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. 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 CONFIGURATION Submenu Item Indication (for Display Only; not User Modifiable) Number of Heat Stages (HT STG) Displays the number of furnace heating stages Input Rate (BTU/HR) Displays the furnace input rate in kBtu/hr Motor HP (1/2, ¾, or 1 MTR HP) Displays the furnace indoor blower motor horsepower DIAGNOSTICS Submenu Item Indication/User Modifiable Options Comments Fault 1 (FAULT #1) Most recent furnace fault For display on
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.
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 IGNITOR BODY WITH BARE FINGERS, ROUGH HANDLING, OR VIBRATION COULD RESULT IN EARLY IGNITOR FAILURE. O NLY A QUALIFIED SERVICER SHOULD EVER HANDLE THE IGNITOR.
MAINTENANCE FLUE PASSAGES (QUALIFIED SERVICER ONLY) At the start of each heating season, inspect and, if necessary, clean the furnace flue passages. 3. Volt-Ohm Meter - testing continuity, capacitors, and motor windings. 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 CAUTION ALWAYS CONNECT A MONOMETER TO THE OUTLET TAP AT THE GAS VALVE BEFORE ADJUSTING THE PRESSURE REGULATOR. IN NO CASE SHOULD THE FINAL MANIFOLD PRESSURE VARY MORE THAN PLUS OR MINUS .3 INCHES WATER COLUMN FROM 3.5 INCHES WATER COLUMN FOR NATURAL GAS OR 10 INCHES WATER COLUMN FOR PROPANE GAS. 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.
SERVICING TABLE OF CONTENTS S-1 CHECKING VOLTAGE ............................................................................................................................................. 69 S-2 CHECKING WIRING ............................................................................................................................................... 69 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 -- 68 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 D ISCONNECT 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 installed. GAS STREAM B 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 Open to Atmosphere Manometer Hose 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 For installations above 4500 feet, please refer to your distributor for required kit(s). Contact the distributor for a tabular listing of appropriate manufacturer’s kits for propane gas and/or high altitude installations. The indicated kits must be used to insure safe and proper furnace operation. All conversions must be performed by a qualified installer, or service agency. In some areas the gas supplier may artificially derate the gas in an effort to compensate for the effects of altitude.
SERVICING 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.
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.
