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Service Manual - East Coast Metal Distributors

1. 106 212 529 103 514 10 Thousand 1 Thousand CUBIC FEET 185 180 176 172 157 19 153 164 160 H 124 310 122 CR 41 SERVICING 42 Service Problem POSSIBLE CAUSE DOTS IN ANALYSIS GUIDE INDICATE POSSIBLE CAUSE Power Failure Blown Fuse Loose Connection Shorted or Broken Wires No Low Voltage Faulty Thermostat Faulty Transformer Poor or High Resistance Ground Improper Heat Anticipator Setting Improper Thermostat Location Faulty Flame Sensor SYMPTOM No Heat Burner Won t Ignite System Will Not Start Burner Ignites Locks Out Unsatisfactory Heat Test Method Remedy Short Cycles Long Cycles Soot and or Fumes Too Much Heat Not Enough Heat l Check wiring LET LL dL Gg L gd dg 41 Check Transformer e 00 Check Thermostat le Measure Ground Resistance _ lee ee Adjust Heat Anticipator Setting Relocate Thermostat L e MONA Test Control Test Flame Sensor See Service Procedure Reference S 3B S 316 S 300 S 302 S 314 Faulty Ignition Control Gas Valve or Gas Supply Shut Off Faulty Induced Draft Blower Faulty Blower Motor PSC Broken or Shorted Ignitor Test Control EEEREN Turn Valves to On Position Test Induced Draft Motor e J Test Blower Motor PSC Test Ignitor S 313
2. 0411 ed 191113 BUS 93 e t d I CSS961005CNAA CSS961206DNAA ACCESSORY WIRE DIAGRAMS HIGH VOLTAGE WARNING 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 ALL FUEL SYSTEM CONTROL BOARD AFE1860A co POWER SUPPLY INPUT FURNACE DEMAND OUTPUT lt BLOWER FAN DEMAND lt OUTPUT POWER SUPPLY INPUT COMMON SECOND STAGE FURNACE DEMAND OUTPUT COMPRESSOR OUTPUT lt POWER SUPPLY W1 FURN W2 HP hi E o N lt gt 2 Ko SECOND STAGE COMPRESSOR OUTPUT REVERSING VALVE OUTPUT r u Y2 HP 2 Y2 STAT Y2 FURN N MAN POWER SUPPLY OUT TO THERMOSTAT CALL FOR REVERSING VALVE CALL FOR COMPRESSOR CALL FOR EMERGENCY HEAT CALL FOR BLOWER FAN CALL FOR FURNACE HEAT POWER SUPPLY COMMON OUT TO THERMOSTAT CALL FOR 2ND STAGE FURNACE HEAT CALL FOR 2ND STAGE COMPRESSOR Y STAT Y FURN Y HP Ico om lt oj 45VDC X Y 5 99999
3. Pressure 0 5 psig or less and pressure drop of 0 3 W C Based on 0 60 Specific Gravity Gas BTUH Furnace Input eating Value of Gas BTU Cubic Foot To connect the furnace to the building s gas piping the in staller must supply a ground joint union drip leg manual shutoff valve and line and fittings to connect to gas valve In some cases the installer may also need to supply a transition piece from 1 2 pipe to a larger pipe size The following stipulations apply when connecting gas pip ing Refer to the following figures for typical gas line con nections to the furnace 1 Use black iron or steel pipe and fittings for the build ing piping 2 Use pipe joint compound on male threads only Pipe joint compound must be resistant to the action of the fuel used 3 Use ground joint unions 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 5 Install a 1 8 NPT pipe plug fitting accessible for test gage connection immediately upstream of the gas supply connection to the furnace 6 Use two pipe wrenches when making connection to the gas valve to keep it from turning The orientation of the gas valve on the manifold must be maintained as shipped from the factory 7 Install a manual shutoff valve between the gas meter and unit within six feet of the unit If a union is in stalled the union mus
4. A Initial Release 1st Revision A Amana G Goodman M Upflow Horizontal C Downflow Horizontal K Dedicated Upflow D Dedicated Downflow A Initial Release B 1st Revision N Natural Gas X Low Nox C Variable Speed ComfortNet E High Efficiency S Single Speed 14 17 5 M Modulating C 21 V 2 Stage D 24 5 Convertible 2 Stage S Single Stage 3 1200 4 1600 5 2000 CFM 97 97 AFUE 80 80 AFUE 040 40 000 060 60 000 080 80 000 100 100 000 120 120 000 PRODUCT IDENTIFICATION MODEL GMSS920402BNAA GMSS920603BNAA GMSS920803BNAA GMSS920804CNAA GMSS920805CNAA GMSS921004CNAA GMSS921005CNAA GMSS921205DNAA GCSS920402BNAA GCSS920603BNAA GCSS920804CNAA GCSS921005CNAA GMSS960402BNAA GMSS960603BNAA GMSS960803BNAA GMSS960804CNAA GMSS960805CNAA GMSS961005CNAA GMSS961205DNAA GCSS960402BNAA GCSS960603BNAA GCSS960804CNAA GCSS961005CNAA GCSS961205DNAA DESCRIPTION Goodman Brand 92 Single Stage Gas Furnace 34 5 tall Upflow Horizontal Installation 1 stage gas valve induced draft PSC motor 120 volt silicon carbide 17 second hot surface ignition Left or right gas pipe entry The furnace also features an aluminized steel tubular heat exchanger Available cabinet widths are 17 5 21 and 24 5 wide Goodman Brand 92 Single Stage Gas Furnace 34 5 tall Downflow Horizontal Installatio
5. Figure 9 3 3 2 Combustion Air From Outdoors through Single Combustion Air Opening 9 3 4 Combination Indoor and Outdoor Combustion Air The use of a combination of indoor and outdoor combustion air shall be in accor dance with 1 through 3 see example calculation in Annex J 1 Indoor Openings Where used openings connecting the interior spaces shall comply with 9 3 2 3 2 Outdoor Opening s Location Outdoor opening s shall be located in accordance with 9 3 3 3 Outdoor Opening s Size The outdoor opening s size shall be calculated in accordance with the following a The ratio of the interior spaces shall be the available volume of all communicating spaces divided by the required volume b The outdoor size reduction factor shall be 1 minus the ratio of interior spaces 18 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 5 Engineered Installations Engineered combustion air installa tions shall provide an adequate supply of combustion ventilation and dilution air and shall be approved by the authority having jurisdiction 9 3 6 Mechanical Combustion Air Supply Where all combustion air is provided by a mechanical air supply system the combustion air shall be supplied form outdoors at the minimum rate of
6. 55920805 55921004 55921005 MSS921205DNAA MSS960402BNAA MSS960603BNAA MSS960803BNAA 55960804 55960805 55961005 MSS961205DNAA The down flow horizontal 34 5 single stage furnace is avail able in the following models CSS920402BNAA CSS920603BNAA CSS920804CNAA CSS921005CNAA CSS960402BNAA CSS960603BNAA CSS960804CNAA CSS961005CNAA CSS961205CNAA 19 INSTALLATION CONSIDERATIONS AIR DISCHARGE Side Return Side Return Duct Connectio Connectio UPFLOW UPRIGHT Bottom Return Duct FEES Bottom Ret 2 Connection DISCHARGE COUNTERFLOW HORIZONTAL RIGHT AIR DISCHARGE UPFLOW HORIZONTAL LEFT AIR DISCHARGE NS NN COUNTERFLOW HORIZONTAL LEFT AIR DISCHARGE Bottom Return Duct AIR DISCHARGE UPFLOW HORIZONTAL RIGHT AIR DISCHARGE 90 Furnace Recommended Installation Positions NOTE Alternate vertical piping connections can not be used when an upflow 90 furnace is installed with supply air discharging to the right or when a counterflow furnace is installed with supply discharging to the left In this case use the standard flue and combustion air piping connec tions Alternate Electrical and Gas Line Connections Furnaces have provisions allowing for electrical and gas line connections through either side panel In horizontal applica tions the connections can be mad
7. 99999999 co o ES L mnoo zuiumcirzH N Y MICROPROCESSOR ko POWER SUPPLY OUT lt TO HP CONTROL HP CALL FOR FURNACE DURING DEFROST REVERSING VALVE OUTPUT lt COMPRESSOR lt CONTACTOR OUTPUT POWER SUPPLY COMMON OUT TO HP CONTRO 2 ioo ka KA o ODT OUTDOOR THERMOSTAT 2ND STAGE COMPRESSOR DEMAND OUTPUT lt ALL FUEL SYSTEM CONTROL BOARD AFE18 60A 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 For use with Heat Pumps in conjunction with 80 or 90 Single Stage or Two Stage Furnaces 38 SERVICING S 1 S 2 S 3A S 3B S 10B S 15 S 15A S 16A S 200 S 201 S 300 S 302 S 303 S 304 S 305 S 306 S 307 S 308 S 309 S 310 S 311 S 312 S 313 S 314 SERVICE NUMBERS CHECKING VOLTAGE mm 45 CHECKING WIRING tt 45 TAERMOSTAT AND WIRING 2 rte rtr ala 45 HEATING ANTIGIPATOR dg 45 CHECKING TRANSFORMER AND CONTROL CIRCUIT ins 46 CAPACITANCE CHECK iia daa 46 CHECKING APACITOR mE 46 RESISTANCE GHEC K miii liada idad 48 CHECKING AIR CIRCULATOR BLOWER MOTOR PSC ii 47 CHECKING DUCTSTA ME ss ttes tac 47 CHECKING TEMPERATURE
8. CONTINUOUS RAPID FLASH Fault Description s Primary or auxiliary limit circuit is open Flame sensed with no call for heat Rollout limit circuit is open Control board fuse open Flame sense microamp signal is low Polarity of 115 or 24 volt power is reversed Possible Causes Faulty primary or auxiliary limit switch Insufficient conditioned air over the heat exchanger Blocked filters restrictive ductwork improper circulator blower speed or failed circulator blower Loose or improperly connected wiring Short to ground in flame sense circuit Flame rollout Misaligned burners blocked flue and or air inlet pipe or failed induced draft blower Loose or improperly connected wiring Faulty rollout limit Short in thermostat wiring Control board fuse Flame sensor is coated oxidized Flame sensor incorrectly positioned in burner flame Lazy burner flame due to improper gas pressure or combustion air Polarity of 115 volt AC power to furnace or integrated control module is reversed Orange and gray wires to transformer are reversed Poor unit ground Corrective Action Check primary auxiliary limit Replace if necessary Check filters and ductwork for blockage Clean filters or remove obstruction Check circulator blower speed and performance Correct speed or replace blower if necessary Tighten or correct w
9. The internal vent pipe and elbow may be removed from the furnace to permit the vent to exit the top original side of the furnace If this option is used an RF000142 Vent Drain cou pling must be used to keep condensate from collecting in the inducer assembly To install the drain refer to the following instructions and illustration 1 Remove screws from vent flange 2 Removeinternal elbow and vent pipe 3 OCutpipe 2 1 2 from flange 4 Remove cabinet plug adjacent to inducer outlet and in stall an original cabinet vent hole e Install RF000142 coupling on inducer outlet 6 Install flanged vent section removed in step 2 and se cure with clamps 7 Secureflange to cabinet using screws removed in step 1 Insert flange Cut 2 long RF000142 25 INSTALLATION CONSIDERATIONS FLANGE f A Qa Ww N poro f M Wy AMA 23 M E Ill 9 1 Jl JP 1 LS 2 GAS SUPPLY AND PIPING The furnace rating plate includes the approved furnace gas input rating and gas types The furnace must be equipped to operate on the type of gas applied This includes any con version kits required for alternate fuels and or high altitude PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE THE INLET GAS SUPPLY
10. Combustion air intake pipe system where applicable Check for blockage and or leakage Check the out side termination and the connection at the furnace e Heat exchanger Check for corrosion and or buildup within the heat exchanger passageways Burners Check for proper ignition burner flame and flame sense e Drainage system Check for blockage and or leakage Check hose connections at and internal to furnace e Wiring Check electrical connections for tightness and or corrosion Check wires for damage Filters AIR FILTER NEVER OPERATE FURNACE WIHTOUT A FILTER INSTALLED AS DUST AND LINT WILL BUILD UP ON INTERNAL PARTS RESULTING IN LOSS OF EFFICIENCY EQUIPMENT DAMAMGE AND POSSIBLE FIRE Filters must be used with this furnace Filters do not ship with these furnaces but must be provided by the installer for proper furnace operation Remember that dirty filters are the most common cause of inadequate heating or cooling performance 56 warning HIGH VOLTAGE DISCONNECT ALL POWER BEFORE SERVICING REMOVING THE FILTER OR PREFORING ANY OTHER MAINTENEACE MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH Maintenance Improper filter maintenance is the most common cause of inadequate heating or cooling performance Filters should be cleaned permanent or replaced disposable every two months or as required It is the owner s responsibility to
11. PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK THE FURNACE MUST BE LOCATED TO PROTECT THE ELECTRICAL COMPONENTS FROM WATER Charge ESD Precautions NOTE Discharge body s static electricity before touching unit An electrostatic discharge can adversely affect electri cal components Use the following precautions during furnace installation and servicing to protect the integrated control module from dam age By putting the furnace the control and the person at the same electrostatic potential these steps will help avoid exposing the integrated control module to electrostatic dis charge This procedure is applicable to both installed and uninstalled ungrounded furnaces 1 Disconnect all power to the furnace Do not touch the integrated control module or any wire connected to the control prior to discharging your body s electrostatic charge to ground 2 Firmly touch a clean unpainted metal surface of the furnace near the control Any tools held in a person s hand during grounding will be discharged 3 Service integrated control module or connecting wiring following the discharge process in Step 2 Use caution not to recharge your body with static electricity i e do not move or shuffle your feet do not touch ungrounded objects etc If you come in contact with an ungrounded object repeat Step 2 before touching control or wires 4 Discharge any static electricity from your body to ground before removing a n
12. REVIEW ALL SERVICE INFORMATION IN THE APPROPRIATE SERVICE MANUAL BEFORE BEGINNING REPAIRS IMPORTANT NOTICES FOR CONSUMERS AND SERVICERS Ah RECOGNIZE SAFETY SYMBOLS WORDS AND LABELS THIS UNIT SHOULD NOT BE CONNECTED TO OR USED IN CONJUNCTION WITH ANY DEVICES THAT ARE NOT DESIGN CERTIFIED FOR USE WITH THIS UNIT OR HAVE NOT BEEN TESTED AND APPROVED BY GOODMAN SERIOUS PROPERTY DAMAGE OR PERSONAL INJURY REDUCED UNIT PERFORMANCE AND OR HAZARDOUS CONDITIONS MAY RESULT FROM THE USE OF DEVICES THAT HAVE NOT BEEN APPROVED OR CERTIFED BY GOODMAN INSTALLATION AND REPAIR OF THIS UNIT SHOULD BE PERFORMED ONLY BY INDIVIDUALS MEETING THE REQUIREMENTS OF AN ENTRY LEVEL TECHNICIAN AT A MINIMUM AS SPECIFIED BY THE AIR To PREVENT THE RISK OF PROPERTY DAMAGE PERSONAL INJURY OR DEATH CONDITIONING HEATING AND REFRIGERATION INSTITUTE AHRI DO NOT STORE COMBUSTIBLE MATERIALS OR USE GASOLINE OR OTHER ATTEMPTING TO INSTALL OR REPAIR THIS UNIT WITHOUT SUCH FLAMMABLE LIQUIDS OR VAPORS IN THE VICINITY OF THIS APPLIANCE BACKGROUND MAY RESULT IN PRODUCT DAMAGE PERSONAL INJURY OR DEATH GOODMAN WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES IF YOU INSTALL OR PERFORM SERVICE ON THIS UNIT YOU ASSUME RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROPERTY DAMAGE WHICH MAY RESULT MANY JURISDICTIONS REQUIRE A LICENSE TO INSTALL OR SERVICE HEATING AND AIR CONDITIONING EQUIPMENT warninc HIGH VOLT
13. fonctionner ces appareils dans un endroit clos assures vous qu il y ait une ventilation directe provenant de l exterier Cette ventilation est n cessaire pour viter le danger d intoxication au CO pouvant survenir si un appareil produisant du monoxyde de carbone continue de fonctionner au sein de la zone confin e Les missions de monoxyde de carbone peuvent etre recircules dans les endroits clos si l appareil de chauffage ou de traitement d air sont en marche Le monoxyde de carbone peut causer des maladies graves telles que des dommages permanents au cerveau et meme la mort B10259 216 Amana is a registered trademark of Maytag Corporation or its related companies and is used under license All rights reserved IMPORTANT INFORMATION Ir ws FOR YOUR SAFETY LIRE AVANT DE METTRE Ea READ BEFORE OPERATING EN MARCHELIRE WARNING If you do not follow these instructions AVERTISSEMENT Quiconque ne respecte pas 4 explosion may result causing property damage la lettre les instructions dans le pr sent manuel personal injury or loss of life risque de d clecher un incendie ou une explosion entra nant des dammages mat riels des l sions A This appliance does not have a pilot It is equipped corporelles ou la perte de vies humaines with an ignition device which automatically lights the burner Do nat try to light the burner by hand A Cet appareil ne comporte pas de veilleuse Il est muni d un dispositif d
14. instructions 9 3 1 3 Appliances shall be located so as not to interfere with proper circulation of combustion ventilation and dilution air 9 3 1 4 Where used a draft hood or a barometric draft regulator shall be installed in the same room or enclosure as the appliance served so as to prevent any difference in pressure between the hood or regulator and the combustion air supply 9 3 1 5 Makeup air requirements for the operation of exhaust fans kitchen ventilation systems clothes dryers and fireplaces shall be considered in determining the adequacy of a space to provide combustion air require ments 9 3 2 Indoor Combustion Air The required volume of indoor air shall be determined in accordance with the method in 9 3 2 1 or 9 3 2 2 ex cept that where the air infiltration rate is known to be less than 0 40 ACH the method in 9 3 2 2 shall be used The total required volume shall be the sum of the required volume calculated for all appliances located within the space Rooms communicating directly with the space in which the appliances are installed through openings not furnished with doors and through combustion air openings sized and located in accordance with 9 3 2 3 are considered a part of the required volume 9 3 2 1 Standard Method The minimum required volume shall be 50 ft per 1 000 Btu hour 4 8m kW 9 3 2 2 Known Air Infiltration Rate Method Where the air infiltra tion rate of a structure is known the minimum req
15. required clearances to combustible materials a minimum of 24 inches service clearance must be available in front of the unit 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 ofthe 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 re quirement Furnace Suspension If suspending the furnace from rafters or joist use 3 8 threaded rod and 2 x2 x1 8 angle iron as shown in the fol lowing figure If the furnace is installed in a crawl space it must also be suspended from the floor joist or supported by a concrete pad Never install the furnace on the ground or allow itto be exposed to water The length of rod will depend on the application and the clearances necessary PROVIDE 8 MINMUM CLEARANCE BETWEEN CENTER ROD AND FURNACE CABINET TO ALLOW FOR CIRCULATOR BLOWER REMOVAL 3 8 DIAMETER THREADED ROD 6 PLACES ASSURE FURNACE IS LEVEL FROM END TO END ON 90 FURNACES MAKE SURE UNIT HAS A SLIGHT FORWARD TILT WITH THE FRONT OF THE FURNACE 0 3 4 BELOW THE BACK OF THE FURNACE ALTERNATE GAS PIPING NUTS SUPPORT VAN CONDENSATE DRAIN GA
16. system and a single stage heating single stage cooling system Refer to the following figures for proper connec tions to the integrated control module Heating Heating Cooling Room Room Thermostat Thermostat 9 9 c w Remote w Condensing Fumace Furnace Unit Control Control Typical Field Wiring 24 VAC Control Circuit CIRCULATING AIR AND FILTERS DUCTWORK AIR FLOW 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 Conditioning Contrac tors of America manual D A duct system should be installed in accordance with Stan dards of the National Board of Fire Underwriters for the In stallation of Air Conditioning Warm Air Heating and Venti lating Systems Pamphlets No 90A and 90B A return air filter is not supplied with the furnace The in staller must supply a means of filtering all of the return air Filter s shall comply with UL900 or CAN ULC S111 Stan dards Upflow furnaces with air delivery of less than 1800 CFM Use one side return or one bottom return ductwork connec tion Upflow furnaces with air delivery of 1800 CFM or higher Use two side returns or one side return and one bottom return connection Guide dimples locate the side and bottom return cutout locations Use a straight edge to scribe lines connecting the dimp
17. 0 35 ft min per 1000 Btu hr 0 034 m min per kW for all appliances located within the space 9 3 6 1 Where exhaust fans are installed additional air shall be provided to replace the exhausted air 9 3 6 2 Each of the appliances served shall be interlocked to the me chanical air supply system to prevent main burner operation where the mechanical air supply system is not in operation 9 3 6 3 Where combustion air is provided by the building s mechanical ventilation system the system shall provide the specified combustion air rate in addition to the required ventilation air 9 3 7 Louvers Grilles and Screens 9 3 7 1 Louvers and Grilles The required size of openings for com bustion ventilation and dilution air shall be based on the net free area of each opening Where the free area through a design of louver or grille or screen is known it shall be used in calculating the size opening required to provide the free area specified Where the louver and grille design and free area are not known it shall be assumed that wood louvers will have 25 percent free area and metal louvers and grilles will have 75 percent free area Nonmotorized louvers and grilles shall be fixed in the open position 9 3 7 2 Minimum Scree Mesh Size Screens shall not be smaller than 1 4 in mesh 9 3 7 3 Motorized Louvers Motorized louvers shall be interlocked with the appliance so they are proven in the full open position prior to main burner ignitio
18. DiscoNNEcr ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT MULTIPLE POWER SOURCES MAY Y BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS WIRING ERRORS CAN COUSE IMPROPER AND DANGEROUS OPERATION VERIFY PROPER OPERATION AFTER SERVICING WIRING HARNESS The wiring harness is an integral part of this furnace Field alteration to comply with electrical codes should not be re quired Wires are color coded for identification purposes Refer to the wiring diagram for wire routings If any of the original wire as supplied with the furnace must be replaced it must be replaced with wiring material having a tempera ture rating of at least 105 C Any replacement wiring must be copper conductor 115 VOLT LINE VOLTAGE CONNECTION OF ACCESSORIES HUMIDIFIER AND ELECTRONIC AIR CLEANER 96 MODELS ONLY The furnace integrated control module is equipped with line volt age accessory terminals for controlling power to an optional field supplied humidifier and or electronic air cleaner The accessory load specifications are as follows Turn OFF power to the furnace before installing any accesso ries Follow the humidifier or air cleaner manufacturers instruc tions for locating mounting grounding and controlling these accessories Accessory wiring connections are to be made through the 1 4 quick connect terminals provided on the fur nac
19. 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 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 Con tractors of America Location Requirements and Considerations To PREVENT POSSIBLE EQUIPMENT DAMAGE PROPERTY DAMAGE PERSONAL INJURY OR DEATH THE FOLLOWING BULLET POINTS MUST BE OBSERVED WHEN INSTALLING THE UNIT Follow the instructions listed below when selecting a fur nace location Refer also to the guidelines provided in the Combustion and Ventilation Air Requirements section in this manual or the installation instructions for details e Centrally locate the furnace with respect to the pro posed or existing air distribution system e Ensure the temperature of the return air entering the furnace is between 55 F and 100 F when the furnace is heating Ifthe furnace is installed in an application where the typical operating sound level of a furnace is deemed objectionable an optional sound reduction kit is avail able Consult your local distributor for more details Provide provisions for venting combustion products outdoors through a proper venting system Special consideration should be given to vent flue pipe routing and combustion air intake pipe when applicable 90 Furnaces Refe
20. IDENTIFYING TAB Testing Primary Limit Control 90 Furnaces 4 After completing check and or replacement of primary limit control reinstall burner compartment door 5 Turnon electrical power and verify proper unit operation To aid in identifying these controls refer to the Primary Limit Charts in furnace Technical Manual for part number tem perature setting and color s code Manual Reset Auxiliary Limit Located in Blower Deck The 90 single stage upflow furnaces use two auxiliary limit switch for control of high temperatures within the furnace or duct work This control is preset nonadjustable and auto reset The control is located in the blower compartment of the furnace on the blower deck as shown in the following illustration warnine 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 To AVOID POSSIBLE FIRE ONLY RESET THE AUXILIARY LIMIT CONTROL ONCE IF IT SHOULD OPEN A SECOND TIME A QUALIFIED SERVICER MUST DETERMINE WHY THE AUXILIARY LIMIT OPENED BEFORE RESETTING AGAIN To aid in identifying these controls color coded labels are attached to the back of the controls Refer to the Auxiliary Limit Charts in furnace Technical Manual for color codes and temperature settings S 302 CHECKING FLAME ROLLOUT CONTROL A temperature activated manual reset control is mounte
21. INJURY OR DEATH DUE TO EXPOSURE TO FLUE GASES INCLUDING CARBON MONOXIDE caution BE SURE NOT TO DAMAGE INTERNAL WIRING OR OTHER COMPONENTS WHEN REINSTALLING COUPLING AND SCREWS Vent Flue Pipe Lengths and Diameters Refer to the following tables for applicable length elbows and pipe diameter for construction of the vent flue pipe sys tem of a non direct vent installation In addition to the vent flue pipe a single 90 elbow must be secured to the com bustion air intake to prevent inadvertent blockage The tee or elbows used in the vent flue termination must be included when determining the number of elbows in the piping sys tem 21 INSTALLATION CONSIDERATIONS MSS9 CSS9 Direct Vent 2 Pipe Non Direct Vent 1 Pipe 9 Maximum Allowable Length of Vent FLue Pipe Number of Elbows 3 5 PIPE MODEL 1 2 3 4 5 6 7 8 SIZE MSS920402BN 2 165 160 155 150 145 140 135 130 3 168 161 154 147 140 133 126 119 2 20 MSS920603BN 3 78 2 N A MSS920803BN 3 23 2 MSS920804CN 3 23 2 5 MSS920805CN 3 23 2 25 MSS921004CN 3 119 2 N A MSS921005CN 3 64 2 A N A MSS921205DN 3 51 16 2 65 CSS920402BN 3 88 2 25 CSS920603BN 3 78 2 N A CSS920804CN 3 111 2 N A CSS921005CN 3 78 MODEL 8 SIZE MSS960402BN 2 00 95 90 85 80 75 70 65 3 168 161 154 147 140 133 126 119 2 45 40 35 30 25 20 1
22. To determine proper air movement proceed as follows 1 With clean filters in the furnace use a draft gauge in clined manometer to measure the static pressure of the return duct at the inlet of the furnace Negative Pressure 2 Measure the static pressure of the supply duct Posi tive Pressure 3 Addthe two 2 readings together for total external static pressure NOTE Both readings may be taken simultaneously and read directly on the manometer if so desired If an air con ditioner coil or Electronic Air Cleaner is used in conjunc tion with the furnace the readings must also include the ses components as shown in the following drawing 4 Consult proper tables for the quantity of air If the total external static pressure exceeds the minimum or maximum allowable statics check for closed dampers registers undersized and or oversized poorly laid out duct Work SUPPLY AIR Ly CUTAWAY OF DUCTWORK EXPOSE COIL INCLINED MANOMETER RETURN AIR Checking Static Pressure S 201 CHECKING TEMPERATURE RISE The more air CFM being delivered through a given fur nace the less the rise will be so the less air CFM being delivered the greater the rise The temperature rise should be adjusted in accordance to a given furnace specifica tions and its external static pressure An incorrect tem perature rise may result in condensing in or overh
23. a portion of the main windings The capacitors primary func tion is to reduce the line current while greatly improving the torque characteristics of a motor This is accomplished by using the 90 phase relationship between the capacitor cur rent and voltage in conjunction with the motor windings so thatthe motor will give two phase operation when connected to a single phase circuit The capacitor also reduces the line current to the motor by improving the power factor to the load A WARNING DISCHARGE CAPACITOR THROUGH A 20 TO 30 OHM RESISTOR BEFORE HANDLING Two quick ways to test a capacitor are a resistance anda capacitance check Refer to the next two figures for proper meter connections for the resistance and capacitance test ing of the capacitor S 15A RESISTANCE CHECK Ah 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 w 1 Remove blower compartment door to gain access to capacitor 2 Discharge capacitor and remove wire leads 3 Set an ohmmeter on its highest ohm scale and connect the leads to the capacitor a Good Condition indicator swings to zero and slowly returns toward infinity b Shorted indicator swings to zero and stops there replace Open no reading replace Reverse leads Check again no reading replace d Reverseleads and rech
24. allumage qui allume BEFORE OPERATING smell all around the appliance automatiquement le br leur Ne pas tenter area for gas Be sure to smell next tothe floor d allumer le br leur manuellement because some gas is heavier than air and will B AVANT DE LE FAIRE FONCTIONNER settle on the floor renifler tout autour de l appariel pour d celer une odeur de gaz Renifler pr s du plancher car certains gaz sont plus lourds que l air et peuvent s accumuler au niveau du so l WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building QUE FAIRE S IL Y AUNE ODEUR DE GAZ Immediately call your gas supplier from a neighbor s Ne pas tenter d allumer l appariel phone Follow the gas supplier s instructions Ne toucher aucun interrupteur lectrique If you cannot reach your gas supplier n utiliser aucun t l phone dans le b timent call the fire department Appeler imm diatement le fournisseur de gaz en employant le t l phone d n voisin Respecter la lettre les instructions du C Use only your hand to push in or turn the gas control lever fournisseur de gaz Never use tools If the lever will not push in or turn by Si personne ne r pond appeler le service des hand don t try to repair it call a qualified service incendies technician Force or attempted repair may result in a fire C Ne pousser ou tourner le levier d admission du gaz or explosi
25. an to 1 maximum DCVK Horizontal Installation 35 GOODMAN and AMANA BRAND MSS9 CSS9 Model Furance Accessories 92 Single Stage ACCESSORIES EE EERE 3 EL omen HET UOISISAUOY sen ouedoid 6 E LN3AO 0E HA9Q jy quen 9inueouo9 Z LNAAO 02 HA9Q iy quan 50000040210 1U9A JUNOW usni4 IEM PIS 2 IEM PIS 2 Jouea 2 sere amem c Dll sewsoavemon yoey 191114 JEUJO X3 443 77 Required above 7 000 Ft altitude T 36 ACCESSORIES GOODMAN and AMANA BRAND MSS9 CSS9 Model Furance Accessories 96 Single Stage 9 445 20 dl UV c 5 445 se5 dl UV H11SVH 20 dl UV cv L000 H Burjdno V09 9134V eng HO MUS 0d1d1 ainssald MO d1 9559 seg Umoq 12 95549 eseg wo 4 Umoq 21 9539 seg UA UOISISAUOY LOWd1 sen euedoid E E LN3AO 0E HA9Q py 9inueouo9 2 LN3A9 0Z HA9Q py Sinueouo9 50000040210 JUNOW usni4 IeM PIS 21 9PIS 2 e 5 59 SVSV red above 7 000 F altitude NWY CIPON
26. area of not less than one square inch per 2000 BTU of the total input _ rating of all equipment the 3 Outlet air duct enclosure Water urnace Heater Inlet air duct Figure A 9 3 3 1 2 All Combustion Air From Outdoors through Horizontal Ducts 9 3 3 2 One Permanent Opening Method One permanent open ings commencing within 12 in 300 mm of the top of the enclosure shall be provided The appliance shall have clearances of at least 1 in 25 mm from the sides and back and 6 in 150 mm from the front of the appliance The opening shall directly communicate with the out doors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors see Figure A 9 3 3 2 and shall have a minimum free area of the following 1 1 in 3000 Btu hr 700 mm per kW of the total input rating of all appliances located in the enclosure and 2 Not less than the sum of the areas of all vent connectors in the space NOTE The single opening must have a free area of not less than one square inch per 3000 BTU of the total input rating of all equip ment in the enclosure but not less than the sum of the areas of all vent connectors in the confined space lt Chimney or Gas Vent TS 1 Alternate water Opening Location V z 8
27. differing filter arrangements can be applied Filters can be installed in the central return register and a side panel ex ternal filter rack kit upflow filter kit EFRO2 As an alter native a media air filter or electronic air cleaner can be used as the requested filter Refer to the following minimum filter requirement charts for determination of the minimum filter area to ensure proper unit performance The following figures show possible filter locations NOTE A ductwork access door must be used in counterflow applications to allow filter removal If the filter rack is used the side of the plenum must be at least as tall as dimension A shown the following illustration For dimension of A refer to the following chart Refer to Minimum Filter Area tables to determine filter area requirement NOTE Filters can also be installed elsewhere in the duct system such as a central return Horizontal Installations Filter s must be installed external to the furnace casing for horizontal installations For most installations it is prefer able 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 ADDITIONAL FILTERING ACCESSORIES External Filter Rack Kit EFRO2 The external filter rack kit is intended to provide a location external to the furnace casing for installation
28. from the Ignition Control 4 Using an ohmmeter measure the resistance of the igni tor at room temperature a normal reading will be 37 68 ohms 5 Reconnectignitor LINE VOLTAGE NOW PRESENT 6 Placeunitin heating cycle measure current draw of ig nitor during preheat cycle S 309 CHECKING FOR FLASHBACK Flashback will also cause burning in the burner venturi but is caused by the burning speed being greater than the gas air flow velocity coming from a burner port Flashback may occur at the moment of ignition after a burner heats up or when the burner turns off The latter is known as extinction pop Since the end results of flashback and delayed ignition can be the same burning in the burner venturi a definite attempt should be made to determine which has occurred If flashback should occur check for the following 1 Improper gas pressure adjust to proper pressure See S 307 CHECKING GAS PRESSURE 2 Check burner for proper alignment and or replace burner 3 Improper orifice size check orifice for obstruction S 310 CHECKING PRESSURE SWITCH The pressure control is a safety device to prevent the com bustion cycle from occurring with inadequate venting caused by a restricted or blocked vent pipe 53 SERVICING 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 D
29. inlet pressures and correct piping size full capacity will be obtained With propane gas no unit gas valve regulator is used how ever the second stage supply line pressure regulator should be adjusted to give 10 water column with all other gas con suming appliances running The dissipation of the heat transferred to the heat exchanger is now controlled by the amount of air circulated over its surface The amount CFM of air circulated is governed by the exter nal static pressure in inches of water column of duct work cooling coil registers etc applied externally to the unit versus the motor speed tap direct drive or pulley adjust ments of the motor and blower belt drive A properly operating unit must have the BTU per hour input and CFM of air within the limits shown to prevent short cy cling of the equipment As the external static pressure goes up the temperature rise will also increase Consult the proper tables for temperature rise limitation WIRING DIAGRAMS MSS92 CSS92 MSS96 CSS96 24 VAC OR BLOWER _ HUMIDIFIER INTEGRATED HUMIDIFIER GY MET 1 gt il CONTROL MODULE 24 VAC OPEN WHEN D 24V THERMOSTAT PVA GAS CONNECTIONS 115 VAC VALVE E N E C CLASS 2 WIRE E RWY L mes ID BLOWE
30. keep air filters clean When replacing a filter it must be replaced with a filter of the same type and size Filter Removal Depending on the installation differing filter arrangements can be applied Filters can be installed in the central return register the bottom of the blower compartment upflow only a side panel external filter rack kit upflow only or the duct work above a counterflow furnace A media air filter or elec tronic air cleaner can be used as an alternate filter The filter sizes given in the Product Design section of this manual or the product Specification Sheet must be followed to en sure proper unit performance Refer to the following infor mation for removal and installation of filters FILTER REMOVAL PROCEDURE Media Air Filter or Electronic Air Cleaner Removal Follow the manufacturer s directions for service Horizontal Unit Filter Removal Filters in horizontal installations are located in the central return register INDUCED DRAFT AND CIRCULATION BLOWERS The bearings in the induced draft blower and circulator blower motors are permanently lubricated by the manufacturer No further lubrication is required Check motor windings for ac cumulation of dust which may cause overheating Clean as necessary MAINTENANCE CONDENSATE DRAINAGE SYSTEM QUALIFIED SERVICER ONLY The drain tubes standpipe and field supplied drain line must be checked annually and cleaned as often as neces sary to ensure p
31. measured with the burners operating To mea sure and adjust the manifold pressure use the following procedure HIGH VOLTAGE Disconnect ALL ELECTRICAL POWER AND SHUT OFF GAS SUPPLY BEFORE SERVICING OR INSTALLING 1 After turning off gas to furnace at the manual gas shutoff valve external to the furnace remove burner compart ment door to gain access to the gas valve 2 Connect a calibrated water manometer or appropriate gas pressure gauge at the gas valve outlet pressure tap Refer to Measuring Gas Pressure Single Stage Valves figure for single stage valve outlet pressure tap connections 52 LINE VOLTAGE NOW PRESENT 3 Turn ON the gas and electrical power supply and oper ate the furnace 4 Measure gas manifold pressure with burners firing Ad just manifold pressure using the table below The final manifold pressure must not vary more than 0 3 w c from the above specified pressures Any necessary major changes in gas flow rate should be made by changing the size of the burner orifice 5 White Rodgers 36J22 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 Turn on power and close thermostat R and W1 contacts to provide a call for heat e Measure the gas manifold pressure with burners fir ing Ad
32. motor starts and the condensing unit runs then the trouble is in the thermostat or wir ing Repair or replace as necessary 10 After completing check and or repair of wiring and check and or replacement of thermostat reinstall blower compartment door 11 Turn on electrical power and verify proper unit opera tion S 3B HEATING ANTICIPATOR On older thermostats the heating anticipator is a wire wound adjustable heater which is energized during the ON cycle to help prevent overheating of the conditioned space The anticipator is a part of the thermostat and if it should fail for any reason the thermostat must be replaced Modern thermostats do not have this type of heat anticipator Many have a selector switch to adjust the number of cycles per hour 45 SERVICING Cooling Anticipator The cooling anticipator is a small heater resistor in the thermostat During the OFF cycle it heats the bimetal element helping the thermostat call for the next cooling cycle This prevents the room temperature from rising too high be fore the system is restarted properly sized anticipator should maintain room temperature within 1 1 2 to 2 degrees The anticipator is fixed in the subbase and is not to be replaced If the anticipator should fail for any reason the subbase must be changed S 4 CHECKING TRANSFORMER AND CONTROL CIRCUIT A step down transformer 120 volt primary to 24 volt second ary 40 VA Heating and Cooling Models
33. of a perma nent filter on upflow model furnaces The rack is designed to mount over the indoor blower compartment area of either side panel and provide filter retention as well as a location for attaching return air ductwork Electronic Air Cleaner ASAS and GSAS or Media Air Cleaner AMU and GMU The electronic air cleaner and media air cleaner are multi positional high efficiency air filtration devices that can be installed in any position except with the access door fac ing down The best location for the air cleaner is in the INSTALLATION CONSIDERATIONS return air duct next to the blower compartment Before in stalling the air cleaner consider the application The elec tronic air cleaner must be readily accessible for periodic inspection and cleaning of the pre filters and electronic cells while the media air cleaner must be readily accessible for periodic inspection and replacement of the Media Air Cleaner AMU and GMU filter cartridge 3 per carton MO 1056 M1 1056 M2 1056 M8 1056 to maintain maximum effi ciency and trouble free operation Carbon Filters 1156 3 and 1856 3 set of 3 are also available See Product Cata log for exact filter for your model NORMAL SEQUENCE OF OPERATION Power Up 1 115 VAC power applied to furnace 2 Integrated ignition control module performs internal checks 3 Integrated ignition control module LED will light 4 Integrated ignition control monitors safety circuits con ti
34. other gas appliances such as a water heater ensure there is an adequate supply of combustion and ven tilation air for the other appliances Refer to the latest edi tion of the National Fuel Gas Code NFPA 54 ANSI Z223 1 16 Section 9 3 or CAN CGA B149 Installation Codes Sec tions 7 2 7 3 or 7 4 or applicable provisions of the local building codes for determining the combustion air require ments for the appliances Most homes will require outside air be supplied to the fur nace area by means of ventilation grilles or ducts connect ing 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 7223 1 Section 9 3 9 3 Air for Combustion and Ventilation 9 3 1 General 9 3 1 1 Air for combustion ventilation and dilution of flue gases for appliances installed in buildings shall be obtained by application of one of the methods covered in 9 3 2 through 9 3 6 Where the requirements of 9 3 2 are not met outdoor air shall be introduced in accordance with methods covered in 9 3 3 through 9 3 6 Exception No 1 This provision shall not apply to direct vent appliances 9 3 1 2 Appliances of other than natural draft design and other than Category 1 vented appliances shall be provided with combustion ven tilation and dilution air in accordance with the appliance manufacturer s
35. technician or gas company IN ON POSITION Bo TURN OFF GAS TO APPLIANCE MIN POUR COUPER L ADMISSION NNI DE GAZ DE L APPAREIL 1 Set the thermostat to lowest setting 1 R gler le thermostat la temp rature la plus basse 2 Turn off all electric power to the appliance 2 Couper l alimentation lectrique de l appareil s il if service is to be performed faut proc der des op rations d entretien 3 Push the gas control lever to OFF Position 3 Pousse le levier du contr le du gaz OFF ARRET Do not force position 4 Replace control access panel Ne pas forcer 4 Remettre en place le panneau d acc s 11072712 IMPORTANT INFORMATION LIRE AVANT DE METTRE EN MARCHELIRE VARNI NG 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 burner Do not tryto light the burner by hand B BEFOREOPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building o Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions o If you ca
36. the burners and heat exchangers causing flame impingement Make sure the field installed gas line is not binding and causing distortion of burner assembly If the furnace is installed as a one pipe system make sure the surrounding area and structure are adequate to provide combustion air Make sure there are no cabinet air leaks allowing sup ply air to affect combustion If heat exchanger integrity is uncertain follow proce dures in Service Bulletin SF 041 33 ACCESSORIES EXTERNAL FILTER RACK 02 SLOTS IN FILTER CLEAR SCREWS ON UNIT Used on Models 90 Upflow Model Furnaces UNIT SIDE PANEL 0 FRONT OF UNIT OF UNIT RETURN AIR CUTOUT AREA BLOWER DECK FILTER RACK ASSEMBLY FACE FILTER OPENING TOWARDS FRONT OF UNIT LOWER EDGE SCREW SIDE WALL VENT KIT 0170K00000S 0170K00001S SIDE WALL VENT KIT 0170K00000S This side wall only vent kit 0170K000008 is to be used with 2 3 vent systems This kit is NOT intended for use with single pipe indirect vent installations The vent kit must terminate outside the structure and may be installed with the intake and exhaust pipes located side by side or with one pipe above the other See the section in this manual under Vent Flue and Com bustion Air Pipe Terminations for more information or con sult the Installation Instructions 10 635 SIDE WALL VENT KIT 0170K00001S This side wal
37. to be performed 3 Remove control access panel 4 Move the gas control switch or knob to OFF Do not force 5 Replace control access panel WARNING Improper installation adjustment alteration service or maintenance can cause injury or property damage Refer to the user s information manual provided with this furnace For assistance or additional information consult a qualified installer service agency or the gas supplier This furnace must be installed in accordance with the manufacturers instructions and local codes In the absence of local codes follow the National Fuel Gas Code ANSI Z223 1 WARNING If not installed operated and maintained in accordance with the manufacturer s instructions this product could expose you to substances in fuel combustion which can cause death or serious illness and which are known to the State of California to cause cancer birth defects or other reproductive harm This product contains fiberglass insulation Fiberglass insulation contains a chemical known by the State of California to cause cancer FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance 0140F00688 Rev A 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
38. 5 Push the gas control lever to OFF Position 5 Pousse le levier du contr le du gaz OFF ARRET Do not force position 6 Wait five 5 minutes to clear out any gas Then 6 Attendre cing 5 minutes pour laisser echapper tout le smell for gas including near the floor If you gaz Renifler tout autour de l appareil y compris pr s du then smell gas STOP Follow ROBINET A GAZ plancher pour d celer une odeur de gaz Si c est le cas in the safety information above MANUEL EN POS ARRETER Passer l tape B des instructions de s curiti on this label if you don t smell ON MARCHE Sur la portion sup rieure de cette tiquette gas go to next step S il n y a pas d odeur de gaz passer l tape suivant 7 Push gas control lever RED amp DH 7 Pousse le levier du contr le du gaz ON MARCHE to ON mm position 8 Replace access panel gt O 3 8 Remettre en place le panneau d acc s 9 Turn on all electric ARRIVEE DE LA 5 9 Mettre l appareil sous tension power to the appliance DU GAZ 10 R gler le thermostat la temp rature desir e 10 Set thermostat to desired setting 11 Si l appareil ne se met pas en marche suiyre les instructions intitul es Comment coupler l admission da appliance will not operate de gaz de l appereil et appeler un technicien follow the instructions To Turn Off Gas To Appliance and call your qualifi ou le fourrnisseur de gaz service
39. 5 10 MSS960603BN 3 68 161 154 147 140 133 126 119 MSS960803BN 2 35 30 25 20 15 10 5 N A 3 68 161 154 147 140 133 126 119 MSS960804BN 2 60 55 50 45 40 35 30 25 3 113 106 99 92 85 78 71 64 MSS960805CN 2 45 40 35 30 25 20 15 10 3 20 113 106 99 92 85 78 71 MSS961005CN 2 2 3 102 MSS961205DN WA 3 109 65 88 10 CSS960402BN N w A a B o w a N m Ui CSS960603BN 3 68 161 154 147 140 133 126 119 CSS960804CN 2 40 35 30 25 20 15 10 5 3 120 113 106 99 92 85 78 71 CSS961005CN 2 N A N A 3 13 106 99 92 85 78 71 64 CSS961205DN 2 N A N A N A N A N A N A N A 3 10 103 96 89 82 75 68 61 1 Maximum allowable limits listed on individual lengths for inlet and flue and NOT a combination 2 Minimum requirement for each vent pipe is five 5 feet in length and one elbow tee 3 Tee used in the vent flue termination must be included when determining the number of elbows in the piping system 4 21 2 or 3 diameter pipe can be used in place of 2 diameter pipe 5 Increased Clearance Configurations using 2 45 deg Long Sweep elbows should be considered equivalent to one 90 deg elbow 6 One 90 elbow should be secured to the combustion air intake connection Vent Flue and Combustion Air Pipe Lengths and Diam eters Refer to the preceding table for applicable length elbows and pipe diameter for
40. AGE 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 IMPORTANT INFORMATION IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY AFIRE OREXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE PERSONAL INJURY ORLOSS OF LIFE DONOTSTORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE WHATTODOIF YOU SMELL GAS e DO NOT TRY TO LIGHT ANY APPLIANCE DONOT TOUCH ANY ELECTRICAL SWITCH DO NOT USE ANY PHONE IN YOUR BUILDING IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR S PHONE FOLLOW THE GAS SUPPLIER S INSTRUCTIONS e IF YOU CANNOT REACH YOUR GAS SUPPLIER CALL THE FIRE DEPARTMENT INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER SERVICE AGENCY OR THE GAS SUPPLIER SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF TURN OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE FURNACE BEFORE TURNING OFF THE ELECTRICAL SUPPLY 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 CONSUMER INFORMATION LINE GOODMAN BRAND PRODUCTS AMANA BRAND PRODUCTS TOLL FREE TOLL FREE 1 877 254 4729 U S only 1 877 254 4729 U S only email us at email us at customerservice goodma
41. CTRIC CODE 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 PROPERTY DAMAGE PERSONAL INJURY OR DEATH 24 VOLT HUMIDIFIER 24 volt humidifier can be connected to the normally open terminal of the main pressure switch The humidifier com mon would then be connected to C on the control board low voltage terminal strip If it is necessary for the installer to supply additional line voltage wiring to the inside of the furnace the wiring must conform to all local codes and have a minimum tempera ture rating of 105 C All line voltage wire splices must be made inside the furnace junction box 24 VOLT THERMOSTAT WIRING NOTE Low voltage connections can be made through ei ther the right or left side panel Wire routing must not inter fere with circulator blower operation filter removal or routine maintenance A 40 V A transformer and an integrated electronic control are built into the furnace to allow use with most cooling equip ment Consult the wiring diagram located in the Technical Manual or on the blower door for further details of 115 Volt and 24 Volt wiring THERMOSTAT WIRING The single stage furnace will have W terminal and will use a single stage thermostat The following drawing illus trates the typical field wiring for a heat only single stage 29 INSTALLATION CONSIDERATIONS
42. DENTIFYING TAB Checking Flame Rollout Switch a If no voltage is measured on either side of control it indicates ignition control or wiring to control prob lem b If voltage is measured on one side of the control and not the other it indicates the control is open If voltage is measured on both sides of the control the wiring to gas valve or valve is at fault 3 After check and or replacement of rollout switch rein stall burner compartment door and verify proper unit op eration 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 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 Touch one probe of the ohmmeter to the motor frame ground and the other probe in turn to each lead If the windings do not test continuous or a reading is obtained to ground replace the motor 5 Ifthe windings have a continuity reading reconnect wires Turn power on to the furnace and turn the thermostat on in the heating mode Check voltage for 115V at the induced draft motor terminals during the trial for ignition If you have 115V and the motor do
43. Dialtype thermometers or thermocouple meter op tional to measure dry bulb temperature 2 Amprobe to measure amperage and voltage 3 Volt Ohm Meter testing continuity capacitors and motor windings 4 Inclined Manometer to measure static pressure pressure drop across coils filters and draft 5 Water Manometer 12 to test gas inlet and mani fold pressure Other recording type instruments can be essential in solv ing abnormal problems however in many instances they may be rented from local sources Proper equipment promotes faster more efficient service and accurate repairs resulting in fewer call backs HEATING PERFORMANCE TEST Before attempting to diagnose an operating fault run a heat ing performance test and apply the results to the Service Problem Analysis Guide To conduct a heating performance test the input to the furnace must be calculated After the heating cycle has been in operation for at least fifteen minutes and with all other gas appliances turned off the gas meter should be clocked To find the BTU input multiply the number of cubic feet of gas consumed per hour by the heating value of the gas be ing used The calorific value of the gas being used is found by contacting your local utility EXAMPLE It is found by the gas meter that it takes forty 40 seconds for the hand on the cubic foot dial to make one complete revolution with all appliances off except the fur na
44. EATH 1 Remove burner compartment door to gain access to pres sure switch es 2 Remove wires from the pressure switch es electrical terminals 3 Remove the pressure control hose from the control and interconnect with an inclined manometer as shown in the following figures With a call for heat and the inducer running check across the pressure switch contacts with an ohm meter If the contacts are not closed compare the negative reading on the inclined manometer with the rating on the pressure switch to determine whether the switch is defective or if the nega tive pressure is inadequate to close the switch INDUCED DRAFT BLOWER a PRESSURE SWITCH EX AO T PRESSURE SWITCH 2 HOSE OPEN TO ATMOSPHERE OY 9 1 4 TEE COIL COVER E PRESSURE SWITCH H i LE I J INCLINED MANOMETER INDUCED HOSE TO INDUCED DRAFT Co DRAFT BLOWER TAP Blower Pressure Switch Negative Pressure Measurement S 311 HIGH ALTITUDE APPLICATION USA A high altitude kit is required for installationsabove 7 000 ft Refer to the accessory matrix in this manual to determine the proper natural gas and LP gas high altitude kit for your furnace 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 Furnace de
45. ING These tests must be completed within a given time frame due to the operation of the ignition control The ignition control is capable of diagnosing many furnace failures to help in troubleshooting The trial for ignition pe riod is 4 seconds The indicator light display may be viewed by looking through the sight glass in the blower compartment door If the blower compartment door is removed failure to hold the door switch closed while removing the blower compartment door will result in the loss of the stored failure code In most cases recycling the ignition control will result in the same failure code originally displayed A WARNING These tests must be completed within a given time frame due to the operation of the ignition control 1 Check for 120 volts from Line 1 Hot to Line 2 Neutral at the ignition control No voltage check the door switch connections and wire harness for continuity 2 Check for 24 volts from W to C terminal on the ignition control No voltage Check transformer room thermo SERVICING stat and wiring If you have 24 volts coming off the transformer but re ceive approximately 13 volts on the terminal board be tween C and R check for blown fuse Check for 120 volts to the induced draft blower by mea suring voltage between Pin 1 on the 2 pin connector and Line Neutral on the control board No voltage re place ignition control If voltage is present in Steps 1 through 3 and t
46. NUFACTUR S SPECIFIED REPLACEMENT PARTS MUST BE USED WHEN SERVICING 3 IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE FURNACE MUST BE REPLACED IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A TEMPERATURE RATING OF AT LEAST 105 C USE COPPER CONDUCTORS ONLY 4 BLOWER SPEEDS SHOULD BE ADJUSTED BY INSTALLER TO MATCH THE INSTALLATION REQUIREMENTS SO AS TO PROVIDE THE CORRECT HEATING TEMPERATURE RISE AND THE CORRECT COOLING CFM 5 UNIT MUST BE PERMANENTLY GROUNDED AND CONFORM TON E C AND LOCAL CODES Wiring is subject to change Always refer to the wiring diagram on the unit for the most up to date wiring 59
47. O DE CARBONO Advertencia especial para la instalaci n de calentadores manejadoras de aire en reas cerradas como estacionamientos cuartos de servicio Los equipos aparatos que producen mon xido de carbono tal como autom vil calentador de gas calentador de agua por medio de gas etc no deben ser operados en reas cerradas debido al riesgo de envenenamiento por mon xido de carbono CO que resulta de las emisiones de gases de combusti n Si el equipo aparato se opera en dichas reas debe existir una adecuada ventilaci n directa al exterior Esta ventilaci n es necesaria para evitar el peligro de envenenamiento por CO que puede ocurrir si un dispositivo que produce mon xido de carbono sigue operando en el lugar cerrado Las emisiones de mon xido de carbono pueden circular a trav s del aparato cuando se opera en cualquier modo El mon xido de carbono puede causar enfermedades severas como da o cerebral permanente muerte B10259 216 RISQUE D EM POISONNEM ENT AU MONOXYDE DE CARBONE Avertissement special au sujet de l installation d appareils de chauffage ou de traitement d air dans des endroits clos tets les garages les locaux d entretien et les stationnements Evitez de mettre en marche les appareils produisant du monoxyde de carbone tels que les automobile les appareils de chauffage autonome etc dans des endroits non ventil s tels que les d empoisonnement au monoxyde de carbone Si vous devez faire
48. OPERATING Gas inlet and manifold pressures should be checked and adjusted in accordance to the type of fuel being consumed The line pressure supplied to the gas valve must be within the range specified below The supply pressure can be mea sured at the gas valve inlet pressure tap or at a hose fitting installed in the gas piping drip leg The supply pressure must be measured with the burners operating To measure the gas supply pressure use the following procedure DISCONNECT ELECTRICAL POWER AND SHUT OFF GAS SUPPLY 1 After turning off gas to furnace at the manual gas shut off valve external to the furnace remove burner com partment door to gain access to the gas valve 2 Connect a calibrated water manometer or appropriate gas pressure gauge at either the gas valve inlet pres sure tap or the gas piping drip leg as shown in the fol lowing figures NOTE At either location a hose fitting must be installed prior to making the hose connection NOTE Use adapter kit 0151 000005 to measure gas pressure on White Rodgers 36G22 gas valves GAS LINE GAS SHUTOFF VALVE OPEN TO ATMOSPHERE DRIP LEG CAP EE WITH FITTING MANOMETER HOSE MANOMETER Measuring Inlet Gas Pressure Alternate Method 3 Turn ON the gas and electrical power supply and oper ate the furnace and all other gas consuming appliances on the same gas supply line 4 Measure furnace gas supply pressure with burners fir i
49. PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING Inlet gas supply pressures must be maintained within the ranges specified below The supply pressure must be con stant and available with all other household gas fired appli ances 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 Maximum 10 0 5 E W C 10 0 w c Minimum 11 0 Maximum 13 0 w c HIGH ALTITUDE DERATE When this furnace is installed at high altitude the appropri ate High Altitude orifice kit must be applied This is required due to the natural reduction in the density of both the gas fuel and combustion air as altitude increases The kit will provide the proper design certified input rate within the speci fied altitude range High altitude kits are purchased according to the installa tion altitude and usage of either natural or propane gas Refer to the product Specification Sheet or the Accessory Matrix in this Manual for a tabular listing of appropriate altitude ranges and corresponding manufacturer s high altitude Natu ral Propane gas and or Pressure Switch kits Do not derate the furnace by adjusting the manifold pres sure to a lower pressure than specified on the furnace rating plate The combination of the lower air density and a lower manifold pressure wil
50. Pipe section for piping details See rating plate for proper gas pressure Turn power OFF prior to repair SERVICING S 1 CHECKING VOLTAGE warning HIGH VOLTAGE DISCONNECT ALL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH 1 Remove the burner door on furnaces to gain entry tothe Junction Box 2 Remove cover from the Junction Box and gain access to incoming power lines With Power ON LINE VOLTAGE NOW PRESENT 3 Using a voltmeter measure the voltage across the hot and neutral connections NOTE To energize the furnace the Door Interlock Switch must be engaged at this point 4 No reading indicates open wiring open fuse no power or faulty Door Interlock Switch from unit to fused disconnect service Repair as needed 5 With ample voltage at line voltage connectors ener gize the furnace blower motor by jumpering terminals R to G on the integrated ignition control 6 With the blower motor in operation the voltage should be 115 volts 10 percent 7 Ifthe reading falls below the minimum voltage check the line wire size Long runs of undersized wire can cause low voltage If wire size is adequate notify the local power company of the condition 8 After completing check and or repair replace Junction Box cover and reinstall the service panel doors 9 Turn
51. R lt x WH i FRONT COVER RESSURE 2 ul ES 5 PRESSURE SWITCH SWITCH o a CRE PS 10 NO E rc ci PSO 4 To o FUSE El 2 7 MICRO 25 gt 20 2 JC INTEGRATED 8 CONTROL AUXILIARY AUTORESET d 42 MODULE LIMIT CONTROLS 2 3 RO2 11 LIMIT D 2 Cp CD CONTROL A TRO 5 25 1 2 z lt D MANUAL RESET ROLLOUT LIMIT CONTROL S z H 5 SINGLE CONTROL ON 40K BTU A THO 24 VAC oro 2 40 VA za E 3 TRANSFORMER o ER us 115 VAG gt t 5 Ez FLAME SENSOR gt LU DIAGNOSTIC 5 z 20 LED gt WH A lt Hvac Hor an PARK TERMINALS HOT SURFACE n IGNITER Y HEATH E m GND E z W 3 z 5 ES El mon BK HI RD E 5 L MED a ale on a R MED LOW ES 8 2 LL cc RD LOW 3 zu dE gt BR Dir m 3 CIRCULATOR 8 BR S e 20w L AUXILIARY 0 fh aay CONTROLS duS CAPACITOR 9 utig ELO BLOWER COMPARTMENT TELECTRONIC g H AIR CLEANER B 4 URNER COMPARTMENT 2 JUNCTION BOX gt O DOOR ra I E o BK SWITCH a z o d I WH Li INDUCED DRAFT WARNING BLOWER DISCONNECT POWER BEFORE SERVICING AUTO RESET WIRING TO UNIT O PRIMARY LIMIT PU MUST BE CONTROL PROPERLY BL POLARIZED AND GROUNDED Z NET on TO 115VAC 1 60 HZ POWER SUPPL
52. S PIPING 2 x2 x1 8 ANGLE IRON 3 PLACES TILT OUTWARD TO ALLOW FOR DOOR AND CIRCULATOR BLOWER REMOVAL POSITION AS CLOSE AS POSSIBLE TO BLOWER DECK TO ALLOW FOR CIRCULATOR BLOWER REMVOAL 90 Suspended Furnace Shown FURNACE REMOVAL NOTE When an existing furnace is removed from a venting system serving other appliances the venting system may be too large to properly vent the remaining attached appli ances The following vent testing procedure is reproduced from the American National Standard National Standard of Canada for Gas Fired Central Furnaces ANSI Z21 47 latest edition CSA 2 3b latest edition Section 1 23 1 The following steps shall be followed with each appliance connected to the venting system placed in operation while any other appliances connected to the venting system are not in operation a Seal any unused openings in the venting system b Inspect the venting system for proper size and horizontal pitch as required by the National Fuel Gas Code ANSI Z223 1 or the CSA B149 Installation Codes and these instructions Determine that there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition Insofaras practical close all building doors and windows and all doors between the space in which the appliance s connected to the venting system are located and other spaces of the building Turn on clothes dryers and any applian
53. S 317 S 303 S 16A S 308 Dirty Flame Sensor Low UA Stuck Gas Valve Faulty Gas Valve Open Auxiliary Limit Improper Air Flow or Distribution Cycling on Limit Delayed Ignition Flashback Orifice Size Gas Pressure Cracked Heat Exchanger Clean Flame Sensor eoe Replace Gas Valve Replace Gas Valve Reset Control 4 Check Duct Static eo Check Controls amp Temperature Rise e Test for Delayed Ignition Test for Flashback ore eoo0 Check Gas Pressure Check Burner Flames S 314 S 304 S 304 S 201 S 300 S 309 S 311 S 306 S 311 S 307 S 305 Furnace Undersized Furnace Oversized Faulty Pressure Switch Blocked or Restricted Flue Replace with Proper Size Furnace lel Replace with Proper Size Furnace e Test Pressure Switch Check Flue Drawdown Pressure S 318 S 318 S 310 S 310 Open Roll Out Switch Bouncing On Pressure Switch Test Flame Roll Out Control e Test Negative Pressure S 302 S 310 TROUBLESHOOTING Associated LED Code NONE CONTINUOUS ON Fault Description s Symptoms of Abnormal Operation Furnace fails to operate Integrated control module diagnostic LED provides no signal No 115 volt power to furnace or no 24 volt power to integrated control module Blown fuse or circuit breaker Integrated control module has an internal f
54. Service Instructions GMSS9 GCSS9 AMSS9 ACSS9 Single Stage Gas Furnaces and 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 RS661201 2r2 Amana is a registered trademark of Maytag Corporation or its related companies and is used under license March 2015 All rights reserved Copyright 2014 2015 Goodman Company L P TABLEOF CONTENTS IMPORTANT INFORMATION 2 7 SERVICING TABLE OF CONTENTS 39 PRODUCT IDENTIFICATION S712 TROUBLESHOOTING 22 25 45 43 44 INSTALLATION CONSIDERATIONS 13 31 SERVICING emt 45 55 SYSTEM OPERATION neee 32 33 MAINTENANCE nan items 56 58 ACCESSORIES name 24 30 WIRINGDIAGIRAMS none 59 IMPORTANT INFORMATION Pride and workmanship go into every product to provide our customers with quality products It is possible however that during its lifetime a product may require service Products should be serviced only by a qualified service technician who is familiar with the safety procedures required in the repair and who is equipped with the proper tools parts testing instruments and the appropriate service manual
55. VENT INTAKE FACING DOWN M 12 MIN TO ROOF OR HIGHEST ANTICIPATED SNOW LEVEL VENT PIPE TERMINATION OPTIONS ELBOWS STRAIGH Horizontal vent flue pipe terminations should be as shown in the following figure Refer to Vent Flue Pipe and Combus tion Air Pipe Termination Locations section in this manual or the installation instructions for details concerning loca tion restrictions A 2 3 8 diameter wall penetration is re quired for 2 diameter pipe while a 3 1 2 diameter hole is required for 3 diameter pipe To secure the pipe passing through the wall and prohibit damage to piping connections a coupling should be installed on either side of the wall and INSTALLATION CONSIDERATIONS solvent cemented to a length of pipe connecting the two couplings The length of pipe should be the wall thickness plus the depth of the socket fittings to be installed on the 90 inside and outside of the wall The wall penetration should eee ad AND be sealed with silicone caulking material TURNED DOWN or ah 90 ELBOW TURNED gt DOWN Les gt 12 MIN ABOVE 12 MIN ABOVE pc Je HIGHEST ANTICIPATED HIGHEST ANTICIPATED M SNOW LEVEL SNOW LEVEL L Combustion Air Intake may also be snorkeled to obtain 12 min ground clearance Alternate Vent Termination Above Anticipated Snow Level Dual Pipe Y 3 24 EEN PIPES VENT FLUE TEE OPTIONAL zu 45 ELBOW sm Horiz
56. Y WITH o OVERCURRENT PROTECTION DEVICE WH Fe AX WARNING DISCONNECT POWER BEFORE ID BLOWER MANUAL RESET ROLLOUT LIMIT CONTROL S JUNCTION SERVICING WIRING TO UNIT MUST BE PRESSURE 2 VAC SINGLE CONTROL ON 40K BTU BL BO PROPERLY POLARIZED AND GROUNDED SWITCH HUMIDIFIER GND 2 TA I 2 CIRCUIT c2 was E N 885 CONNECTOR E lt eno MI Kay _ L a IGNITER FRONT COVER FLAME 3 t DISCONNECT s GAS VALVE PRESSURE SWITCH SENSOR STEADY NORMAL OPERATION LOW VOLTAGE 24V EQUIPMENT GND 777 OFF CONTROL FAILURE LOW VOLTAGE FIELD FIELDEND 1 FLASH SYSTEM LOCKOUT RETRIES EXCEEDED 2 FLASHES PRESSURE SWITCH STUCK CLOSED HEVOLTAGEASV FIELD SPLICE 3 FLASHES PRESSURE SWITCH STUCK OPEN HI VOLTAGE FIELD SWITCH TEMP 4 FLASHES OPEN HIGH LIMIT Junction 5 FLASHES FLAME SENSE WITHOUT GAS VALVE TERMINAL O IGNITER 6 FLASHES OPEN ROLLOUT OPEN CONTROL FUSE INTERNAL TO SWITCH PRESS ogo 7 FLASHES 7 FLASHES LOW FLAME SIGNAL INTEGRATED CONTROL OVERCURRENT y 8 FLASHES 8 FLASHES CHECK IGNITER OR IMPROPER GROUNDING PLUG CONNECTION LH PROT DEVICE CONTINUOUS RAPID FLASHES REVERSED 115 VAC POLARITY COLOR CODES PK PINK YL YELLOW BR BROWN OR ORANGE WH WHITE PU PURPLE BL BLUE GN GREEN GY GRAY BK BLACK RD RED 0140F02015 A NOTES 1 SET HEAT ANTICIPATOR ON ROOM THERMOSTAT AT 0 7 AMPS 2 MA
57. a cooling unit install the furnace upstream or in parallel with the cooling unit coil Premature heat exchanger fail ure will result if the cooling unit coil is placed ahead of the furnace Ifthe furnace is installed in a residential garage posi tion the furnace so thatthe burners and ignition source are located not less than 18 inches 457 mm above the floor Protect the furnace from physical damage by vehicles fthefurnace is installed horizontally the furnace ac cess 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 Clearances and Accessibility Installations must adhere to the clearances to combustible materials to which this furnace has been design certified The minimum clearance information for this furnace is pro vided on the unit s clearance label These clearances must be permanently maintained Refer to Specification Sheet for minimum clearances to combustible materials Clearances must also accommodate an installation s gas electrical and drain trap and drain line connections If the alternate combustion air intake or vent flue connections are used on a 90 furnace additional clearances must be provided to accommodate these connections Refer to Vent Flue Pipe and Combustion Air Pipe section in this manual or the in stallation instructions for details NOTE In addition to the
58. a tabular listing of appropriate manufacturer s kits for propane gas and or high altitude in stallations The indicated kits must be used to insure safe and proper furnace operation All conversions must be per formed by a qualified installer or service agency VENT FLUE PIPE AND COMBUSTION AIR PIPE FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN BODILY INJURY OR DEATH CAREFULLY READ AND FOLLOW ALL INSTRUCTIONS GIVEN IN THIS SECTION UPON COMPLETION OF THE FURNACE INSTALLATION CAREFULLY INSPECT THE ENTIRE FLUE SYSTEM BOTH INSIDE AND OUTSIDE THE FURNACE TO ASSURE IT IS PROPERLY SEALED LEAKS IN THE FLUE SYSTEM CAN RESULT IN SERIOUS PERSONAL INJURY OR DEATH DUE TO EXPOSURE TO FLUE PRODUCTS INCLUDING CARBON MONOXIDE A condensing gas furnace achieves its high level of efficiency by extracting almost all of the heat from the products of combustion and cooling them to the point where condensa tion takes place Because ofthe relatively low flue gas tem perature and water condensation requirements PVC pipe is used as venting material This furnace must not be connected to Type B BW or L vent or vent connector and must not be vented into any portion of a factory built or masonry chimney except when used as a pathway for PVC as described later in this sec tion Never common vent this appliance with another appli ance or use a vent which is used by a solid fuel appliance It is the responsibility of the installer to follow the m
59. aining 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 Uselongest radius fittings possible e If using 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 affected if a furnace is holding condensate Check for proper connections of drain hoses make sure furnace condensate trap is clean Make sure SYSTEM OPERATION furnace is not improperly sloped Make sure air condition ing coil drain is not interfering with furnace drain Other Causes 1 Manifold Gas Pressure must be set for the gas being used Natural or L P high and low firing rates If con verted to L P gas check size of all orifices Remove Draft Inducer Check the integrity of the gasket between the inducer and the collector box cover any air leak here will have a negative effect on combustion Check the orifice hole in the collector box it must be free of burrs on both sides Make sure burners are clean not out of position and line up correctly with exchanger tubes including the heat exchanger orifice plate between the burners and the heat exchanger tubes make sure it is not loose missing a screw or hanging down between
60. air Exception Direct vent appliances designed for installation in a solid fuel burning fireplace where installed in accordance with the manufacture s installation instructions 9 3 8 8 Combustion air intake openings located on the exterior of the building shall have the lowest side of the combustion air intake openings located at least 12 in 300 mm vertically from the adjoining grade level Horizontal Applications and Considerations Horizontal applications in particular may dictate many of the installation s specifics such as airflow direction duct work connections flue and or combustion air pipe connec tions etc The basic application of this furnace as a hori zontal furnace differs only slightly from an upright installa tion When installing a furnace horizontally additional con sideration must be given to the following Drain Trap and Lines In horizontal applications the condensate drain trap is se cured to the furnace side panel suspending it below the furnace A minimum clearance of 5 5 below the furnace must be provided for the drain trap Additionally the appro priate downward piping slope must be maintained from the drain trap to the drain location Refer to Condensate Drain Trap and Lines section in this manual or the installation instructions for further details If the drain trap and drain line will be exposed to temperatures near or below freezing ad equate measures must be taken to prevent condensate f
61. anufac turers recommendations and to verify that all vent flue pip ing and connectors are compatible with furnace flue prod ucts Additionally it is the responsibility of the installer to INSTALLATION CONSIDERATIONS ensure that all piping and connections possess adequate structural integrity and support to prevent flue pipe separa tion shifting or sagging during furnace operation Dual Certification Non Direct Direct Vent 90 Furnaces Only The 90 furnace is dual certified and may be installed as a non direct vent single pipe or direct vent dual pipe appli ance A non direct vent installation requires only a vent flue pipe A direct vent installation requires both a vent flue pipe and a combustion air intake pipe Refer to the ap propriate section for details concerning piping size length number of elbows furnace connections and terminations To AVOID BODILY INJURY FIRE OR EXPLOSION SOLVENT CEMENTS MUST BE KEPT AWAY FROM ALL IGNITION SOURCES SPARKS OPEN FLAMES AND EXCESSIVE HEAT AS THEY ARE COMBUSTIBLE LIQUIDS AVOID BREATHING CEMENT VAPORS OR CONTACT WITH SKIN AND OR EYES Precautions should be taken to prevent condensate from freezing inside the vent flue pipe and or at the vent flue pipe termination It is our recommendation that all vent flue piping exposed to temperatures below 35 F for extended periods of time should be insulated with 1 2 thick closed cell foam Also all vent flue piping exp
62. as 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 mea suring the gas supply pressure and manifold pressure are provided on the valve NOTE The gas supply pressure on White Rodgers J model gas valve used on single stage furnaces can be checked with a gas pressure test kit Part 0151K00000S available through our authorized dis tributors The gas valve has a manual ON OFF control located on the valve itself This control may be set only to the ON or OFF position Refer to the Lighting Instructions Label or the Putting the Furnace Into Operation section of this manual or the installation instructions for use of this con trol during start up and shut down periods GAS PIPING CONNECTIONS To AVOID POSSIBLE UNSATISFACTORY OPERATION OR EQUIPMENT DAMAGE DUE TO UNDERFIRING OF EQUIPMENT USE THE PROPER SIZE OF NATURAL PROPANE GAS PIPING NEEDED WHEN RUNNING PIPE FROM THE METER TANK TO THE FURNACE The gas piping supplying the furnace must be properly sized based on the gas flow required specific gravity ofthe gas INSTALLATION CONSIDERATIONS and length of the run The gas line installation must comply with local codes or in their absence with the latest edition of the National Fuel Gas Code NFPA 54 ANSI Z223 1
63. ault LED is Steady On Normal Operation Furnace lockout due to an exces sive number of ignition retries 3 total Furnace fails to operate Integrated control module diagnostic LED is flashing ONE 1 flash Pressure switch circuit is closed Induced draft blower is not operating Furnace fails to operate Integrated control module diagnostic LED is flashing TWO 2 flashes Pressure switch circuit not closed Induced draft blower is operating Induced draft blower runs continuously with no further furnace operation Integrated control module diagnostic LED is flashing THREE 3 flashes Possible Causes Manual disconnect switch OFF door Switch open or 24 volt wires improperly connected or loose Blown fuse or circuit breaker Integrated control module has an internal fault Normal Operation Failure to establish flame Cause may be no gas to burners front cover pressure switch stuck open bad igniter or igniter alignment improper orifices or coated oxidized or improperly connected flame sensor Loss of flame after establishment Cause may be interrupted gas supply lazy burner flames improper gas pressure or restriction in flue and or combustion air piping front cover pressure Switch opening or improper induced draft blower performance Induced draft blower pressure switch contacts sticking Shorts in pressure switch
64. cated above downstream of a gas or fossil fuel furnace when used with a heat pump AFE18 60A N A It will operate with single and two stage heat pumps and single and two stage furnaces The AFE18 60A control will turn the heat pump unit off when the furnace is turned on An anti short cycle feature initiates a 3 minute timed off delay when the compressor goes off AMU1620 P1251305F AMU1625 P1251306F Media Air Cleaner Ahigh efficiency air filtration device designed to remove dirt dust AMU2020 P1251307F pollen and other microscopic particles from the air passing through it Flexible AMU2025 P1251308F performance range up to 2 000 CFMcapacity The air cleaner should be installed in the system so that all the system air is circulated through the air cleaner The air cleaner GMU1620 will only remove the airborne contaminants delivered to it Maximum performance is GMU1625 obtained when the system blower is set for continuous operation Carbon filters GMU2020 optional are available GMU2025 Electronic Air Cleaner The High Efficiency Electronic Air Cleaner is designed to remove air contaminants down to 01 microns Carbon filters optional remove odors Dual indicator lights show unit operation ata glance Electronic proving switch cycles the air cleaner On Off with the system fan Durable powder coat paint finish resists corrosion P1251301F P1251302F P1251303F P1251304F Counterflow Subbase Kit For use with 34 5 down flow furnac
65. ce Take this information and locate it on the gas rate chart Observe the forty 40 seconds locate and read across to the one 1 cubic foot dial column There we find the num ber 90 which shows that ninety 90 cubic feet of gas will be consumed in one 1 hour Let s assume the local gas utility has stated that the calo rific value of the gas is 1 025 BTU per cubic foot o7 MAINTENANCE Multiplying the ninety 90 cubic feet by 1 025 BTU per cu bic foot gives us an input of 92 250 BTUH Checking the BTU input on the rating plate of the furnace being tested EXAMPLE INPUT 92 000 BTU HR OUTPUT CAP 84 000 Should the figure you calculated not fall within five 5 per cent of the nameplate rating of the unit adjust the gas valve pressure regulator or resize orifices 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 coun terclockwise to decrease pressure and input 58 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
66. ce for a minimum of 5 seconds NOTE The control board will automatically reset one hour after lockout occurs If the furnace frequently has to be reset it means that a problem exists that should be cor rected Refer to Troubleshooting Chart on the following pages for aid in determining the cause 3 Pressure Switch Stuck Closed If the control senses the pressure switch is closed when the induced draft blower is off it waits until the fault is corrected The diagnostic light code for this problem is 2 flashes The probable cause is either a faulty pressure switch or wiring 4 Pressure Switch Stuck Open If after the induced draft blower is energized the pressure switch does not close within 5 minutes the control will go into a 1 hour lockout The control will automatically reset from lock out and restart the ignition sequence The diagnostic light code for this problem is three short flashes fol lowed by a pause The probable causes are either dis connected hose to the pressure switch faulty pres sure switch or wiring or restricted air intake or flue pip ing 32 5 Open Primary or Auxiliary Limit If the limit control opens the air circulator blower will be turned on until the limit closes The induced draft blower will turn off for 5 seconds then turn off The diagnostic light code for this problem is four short flashes followed by a pause The probable cause is either low conditioned air flow due to dirty filter or resi
67. ce not connected to the venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they shall operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers d Follow the lighting instructions Place the appliance being in spected in operation Adjust thermostat so appliance shall oper ate continuously e Test for draft hood equipped spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle f Afterit has been determined that each appliance connected to the venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous conditions of use g Ifimproper venting is observed during any of the above tests the common venting system must be corrected 15 INSTALLATION CONSIDERATIONS Corrections must be in accordance with the latest edition of the National Fuel Gas Code NFPA 54 ANSI Z223 1 and or CSA B149 Installation Codes 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 2223 1 and or CSA B149 Installation Codes Thermostat Requirements A high quality single stage thermostat with a C terminal is recommended to control the G SS9 and A SS9 furnace Thermostat Location In an area having good air circulat
68. circuit Pressure switch hose blocked pinched or connected improperly Blocked flue and or inlet air pipe blocked drain System or weak induced draft blower Incorrect pressure switch setpoint or malfunctioning Switch contacts Loose or improperly connected wiring Integrated control module will automatically attempt to reset from lockout after one hour LED Flash code will cease if power to the control module is interrupted through the disconnect or door switch Corrective Action Assure 115 and 24 volt power to furnace integrated control module Check integrated control module fuse 3A Replace if necessary Check for possible shorts in 115 and 24 volt circuits Repair as necessary Replace bad integrated control module Locate and correct gas interruption Check front cover pressure switch operation hose wiring contact operation Correct if necessary Replace or realign igniter Check flame sense signal Clean sensor if coated and or oxidized Check flue piping for blockage proper length elbows and termination Verify proper induced draft blower perfor mance Replace induced draft blower pressure switch Repair short e Inspect pressure switch hose Repair if necessary e Inspect flue and or inlet air piping for blockage proper length elbows and termination Check drain system Correct as necessary e Correct pressure switch setpoi
69. construction of the vent flue and com bustion air intake pipe systems of a non direct vent single pipe installation The number of elbows tabulated repre 22 sents the number of elbows and or tees in each Vent Flue amp Combustion Air Intake pipe Elbows and or tees used in the terminations must be included when determining the num ber of elbows in the piping systems If the combustion air intake pipe is to be installed above a finished ceiling or other area where dripping of condensate will be objectionable insulation of the combustion air pipe may be required Use 1 2 thick closed cell foam insulation such as Armaflex or Insultube where required Vent Flue Pipe Terminations The vent flue pipe may terminate vertically as through a roof or horizontally as through an outside wall Vertical vent flue pipe termination should be as shown in the following figures Refer to Vent Flue Pipe and Combustion Air Pipe Termination Locations section in this manual or the installation instructions for details concerning location restrictions The penetration of the vent through the roof must be sealed tight with proper flashing such as is used with a plastic plumbing vent NOTE Terminate both pipes in the same pressure zone same side of roof no major obstacles between pipes etc TEE OPTIONAL COMBUSTION AIR INTAKE NA MIN OPTIONAL HEIGHT DIFFEREN Not required for BETWEEN single pipe installation INTAKE AND
70. d to the manifold assembly on 90 furnaces as shown in the following illustrations Should read continuous unless heat exchanger tempera ture is above limit control setting If not as above replace the control FLAME ROLLOUT SWITCHES Flame Rollout Switch Location The control is designed to open should a flame roll out oc control opens the air circulation blower will run continu ously On single stage models the ignition control diagnostic light will flash 6 six times indicating a trip of the rollout switch or an open control board fuse To aid in iderntifying 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 tem perature settings and color codes LINE VOLTAGE NOW PRESENT 1 Remove the burner compartment door to gain access to the rollout switch es mounted to burner bracket The servicer should reset the ignition control by opening and closing the thermostat circuit Then look for the ignitor glowing which indicates there is power to the ignition con trol Measure the voltage between each side of the rollout control and ground while the ignition control tries to power the gas valve 2 Measure the voltage between each side of the rollout control and ground during the ignition attempt Refer to the following figure 49 SERVICING VOLT OHM METER 9 o RESET BUTTON COLOR I
71. dates 47 CHECKING PRIMARY LIMIT CONTROL Ett Ge ert Ge E 48 CHECKING FLAME ROLLOUT CONTERBOL itcr cd dd 49 INDUCED DRAFT BLOWER MOTOR 8 nt te tte nd lid 50 CHECKING GAS VALVE 50 CHECKING MAIN BURNERS ipe ter neve een terne ft tomate anne ennemie 50 CHECKING ORIFICES ra M 50 CHECKING GAS PRESSURE oda las 51 CHECKING HOT SURFACE IGNITOR 22 cott de ac dicta 53 CHECKING FOR FLASHBACK coccion dre 53 CHECKING PRESSURE 53 HIGH ALTITUDE APPLICATION USA essen 54 CHECKING FOR DELAYED IGNITION tinea tute na t Pet v uua Cen eau 54 CHECKING INTEGRATED IGNITION CONTROL BOARDS iii 54 CHECKING FLAME SENSOR date rates daret etr epe etes nn Ra to 55 39 SERVICING As more and more electronic s are introduced to the Heat ing Trade Polarization of incoming power and phasing of primary to secondary voltage on transformers becomes more important 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 Some ofthe electronic boards being used today with flame rectification will not function properly and or at all without polarization of incoming power Some also require phas ing betw
72. e Gas Installation IF THE GAS FURNACE IS INSTALLED IN A BASEMENT AN EXCAVATED AREA OR A CONFINED SPACE IT IS STRONGLY RECOMMENDED TO CONTACT A PROPANE SUPPLIER TO INSTALL A GAS DETECTING WARNING DEVICE IN CASE OF A GAS LEAK SINCE PROPANE GAS IS HEAVIER THAN AIR ANY LEAKING GAS SETTLE IN ANY LOW AREAS OR CONFINED SPACES PROPANE GAS ODORANT MAY FADE MAKING THE GAS UNDETECTABLE EXCEPT WITH A WARNING DEVICE ANUNDETECTED GAS LEAK WILL CREATE A DANGER OF EXPLOSION ORFIRE IF THE PRESENCE OF GAS IS SUSPECTED FOLLOW THE INSTRUCTIONS ON THE COVER OF THIS MANUAL FAILURE TODO SO COULD RESULTIN SERIOUS PERSONAL INJURY OR DEATH 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 Nor 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 Do NOT TOUCH ANY ELECTRICAL SWITCH DO NOT USE ANY PHONE IN YOUR BUILDING IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR S PHONE FOLLOW THE GAS SUPPLIER S INSTRUCTIONS F YOU CANNOT REACH YOUR GAS SUPPLIER CALL THE FIRE DEPARTMENT INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER SERVICE AGENCY OR THE GAS SUPPLIER 28 Sizing Between First and Second Stage Regulator Maximum Propane Capacities listed are based on 2 psig
73. e either through the top or bottom of the furnace Drain Pan A drain pan must be provided if the furnace is installed above aconditioned area The drain pan must cover the entire area under the furnace and air conditioning coil if applicable Freeze Protection If the drain trap and drain line will be exposed to tempera tures near or below freezing adequate measures must be taken to prevent condensate from freezing NOTE The use of insulation and or heat tape is recommended Failure to provide proper condensate drainage can result in property damage 20 Propane Gas and or High Altitude Installations POSSIBLE PROPERTY DAMAGE PERSONAL INJURY OR DEATH MAY OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INSTALLED THE APPROPRIATE KITS MUST BE APPLIED TO INSURE SAFE AND PROPER FURNACE OPERATION ALL CONVERSIONS MUST BE PERFORMED BY A QUALIFIED INSTALLER OR SERVICE AGENCY This furnace is shipped from the factory configured for natu ral gas at standard altitude Propane gas installations re quire an orifice change to compensate for the energy con tent difference between natural and propane gas High altitude installations may require both a pressure switch and an orifice change These changes are necessary to com pensate for the natural reduction in the density of both the gas fuel and the combustion air at higher altitude Refer to the Accessories Charts in this manual or product Specification Sheet for
74. e integrated control module The humidifier and electronic air cleaner hot terminals are identified as HUM and EAC The humidifier and electronic air cleaner neutral terminals are identi fied as NEUTRAL All field wiring must conform to applicable codes Connections should be made as shown See Figure 28 If it is necessary for the installer to supply additional line voltage wiring to the inside of the furnace the wiring must conform to all local codes and have a minimum temperature rating of 105 C All line voltage wire splices must be made inside the furnace junction box The integrated control module single humidifier terminal HUM is energized with 115 volts whenever the induced draft blower is energized This terminal can also be used to provide 115 volt power to a humidifier transformer The remaining primary transformer wire would be connected to the Line N on the control board The integrated control module electronic air cleaner terminals EAC are energized with 115 volts whenever the circulator blower is energized NOTE Wire routing must not to interfere with circulator blower operation filter removal or routine maintenance CAUTION EDGES OF SHEET METAL HOLES MAY BE SHARP USE GLOVES AS PRECAUTION WHEN REMOVING HOLE PLUGS To AVOID THE RISK OF ELECTRICAL SHOCK INJURY OR DEATH THE FURNACE MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH LOCAL CODES OR IN THEIR ABSENCE WITH THE LATEST EDITION OF THE NATIONAL ELE
75. e models These kits are available for the following furnace widths 17 5 wide CFSB17 21 wide CFSB21 and 24 5 wide CFSB24 The kits must be used to prevent excessive temperature from reaching combustible materials if the furnace is installed on a combustible floor This subbase effectively separated the furnace base and plenum from combustible materials To ensure safe installation do not install the counterflow floor base directly on carpeting tile or other combustible material other than wood flooring 11 PRODUCT IDENTIFICATION MODEL mes DESCRIPTION DCVK 20 CVENT 2 Conceniric Vent Kit This kitis designed to allow terminations of a direct vent furnace to be concentrically vented through a wall or roof This kit allows a single penetration DCVK 30 to support terminations for both the vent flue and the combustion air intak CVENT 3 External Filter Rack Kit For use with 34 5 up flow gas furnaces This kit is intended to provide a location external to the furnace casing for installation of a permanent filter The rack is mounted over the indoor air blower compartment area of either Side Wall Only Concentric Vent Kit This kit is to be used with 2 3 vent systems 0170K00000S The vent kit mustterminate outside the structure This kitis NOT intended for use with single pipe indirect vent installations Side Wall Only Concentric Vent Kit This kitis to be used with 2 vent systems The 0170K00001S vent ki
76. eating of the heat exchanger An airflow and temperature rise table is provided in the blower performance specification sec tion Determine and adjust temperature rise as follows 1 Operate furnace with burners firing for approximately ten minutes Check BTU input to furnace do not ex ceed 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 Place thermometers in the return and supply ducts as close to the furnace as possible Thermometers must not be influenced by radiant heat by being able to see the heat exchanger 47 SERVICING CROSS HATCHED AREA SUBJECTED TO RADIANT HEAT DO NOT MEASURE SUPPLY AIR TEMPERATURE IN THIS AREA pe SE AIR T SUPPLY CHO RISE T SUPPLY T RETURN RL i T RETURN e 55 3 6 SS 2 5 2 QS 55 oS D 55 gt eS 5 1 5255 0000600000 505 RLL 500 n 5 E MEASURE HERE Checking Temperature Rise 3 Subtract the return air temperature from the supply air temperature to determine the air temperature rise Al low adequate time for thermometer readings to stabi lize 4 Adjust temperature rise by adjusting the circulator blower speed Increase blower speed to reduce temperature rise Decrease blower speed to increase temperature rise Refer to Circulator Blower Speed section in the Pr
77. eck SERVICING S 16A CHECKING AIR CIRCULATOR BLOWER MOTOR PSC Disconnect ALL POWER BEFORE SERVICING 1 Remove blower compartment door to gain access to the circulator blower motor and integrated ignition con trol 2 Discharge the capacitor on PSC motors Disconnect the motor wire leads from its connection point at the integrated ignition control module and capacitor if ap plicable 3 Using aohmmeter test for continuity between each of the motor leads 4 Touch one probe of the ohmmeter to the motor frame ground and the other probe in turn to each lead If the windings do not test continuous or a reading is ob tained to ground replace the motor 5 After completing check and or replacement of circula tor blower motor or induced draft blower motor reinstall blower compartment door 6 Turn on electrical power and verify proper unit opera tion S 200 CHECKING DUCT STATIC The maximum and minimum allowable external static pres sures are found in the specification section These tables also show the amount of air being delivered at a given static by a given motor speed or pulley adjustment The furnace motor cannot deliver proper air quantities CFM against statics other than those listed Too great of an external static pressure will result in insuf ficient air that can cause excessive temperature rise re sulting in limit tripping etc Whereas not enough static may result in motor overloading
78. een the primary and secondary sides of step down transformers We recommend that these two items be checked during normal installation and or service calls See as follows INCOMING POWER METER READS METER READS 120 VOLTS 0 VOLT VOLT OHM VOLT OHM METER o METER Q G THIS IS L1 OR THE THIS IS THE COMMON HOT POWER LEG OR NEUTRAL LEG These then should be wired to the furnace accordingly Some transformers will display phasing symbols as shown CHECKING FOR PHASING PRIMARY TO SECONDARY OF UNMARKED TRANSFORMERS METER READS METER READS 24 VOLTS VOLT OHM METER TRANSFORMER INE VOLTAGE NEUTRAL LINE VOLTAGE L1 HOT VOLT OHM METER 120 VOLTS VOLT OHM METER VOLT OHM METER READS 144 VOLTS OUT OF PHASE If meter reads approximately 96 volts the primary to secondary are in phase if reads approximately 144 volts out of phase reverse low voltage wires NOTE For flame rectification the common side of the secondary voltage 24 V is cabinet grounded If you were to bench test a transformer the primary neutral and secondary common must be connected together for testing purposes V Cx NEUTRAL 1 24V 120 V d on E oso PHASING SYMBOL 40 in the illustration to the left to assist in determining proper transformer phasing Checking for polarization and phasing should become a habit in servicing Let s start now SERVICING 1 Million 100 Thousand
79. es not run replace the induced draft motor 6 After completing check and or replacement of in duced draft motor reinstall burner compartment door 7 Turn on electrical power and verify proper unit opera tion 50 S 304 CHECKING GAS VALVE REDUNDANT Acombination redundant operator type gas valve which pro vides all manual and automatic control functions required for gas fired heating equipment is used The valve provides control of main burner gas flow pressure regulation and 100 percent safety shut off Disconnect ALL POWER BEFORE SERVICING Single stage gas valves should be tested on the furnace with 24 VAC connected to the gas valve and manometers reading supply line and manifold pressures 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 have been redesigned for 34 5 chassis furnaces Overall length and width dimensions remain the same as 40 model burners The burners used 34 5 models have burner head insert with larger diameter center hole and a larger number of surrounding holes 025 002 CARRYOVER SLOT WIDTH 12X 9 125 16X 125 x 030 MIN SLOT Beckett Bu
80. ew control from its container Follow Steps 1 through 3 if installing the control on a furnace Return any old or new controls to their containers before touching any ungrounded object Product Application This product is designed for use as a residential home gas furnace Itis not designed or certified for use in mobile home trailer or recreational vehicle applications This furnace can be used in the following non industrial commercial applications Schools Office buildings Churches Retail stores Nursing homes Hotels motels Common or office areas In all applications the furnace must be installed per the installation instructions Goodman brand G SS9 and Amana brand A SS9 fur naces are ETL certified All furnaces are built for use with Natural gas but can be converted for use with LP gas NOTE If using propane gas a propane conversion kit is required Goodman brand G SS9 and Amana brand A SS9 high efficiency furnaces are dual certified Dual certification means that the combustion air inlet pipe is optional and the furnace can be vented as a Non direct vent single pipe central forced air furnace in which combustion air is taken from the installation area or from air ducted from the outside or Direct vent dual pipe central forced air furnace in which all combustion air supplied directly to the furnace burn ers through a special air intake system outlined in this manual and the installation instruction
81. follow the instructions ToTurn Off Gas ToAppliance and call your service technician or gas company MANUAL GAS LEVER SHOWN IN ON POS OPERATING INSTRUCTIONS MI VISEEN MARCHE EI 1 ARRETEZ Lisez les instructions de s curit dans la _ Section sup rieure de cette tiquette 2 R gler le thermostat la temp rature la plus basse 3 Couper l alimentation lectrique de l appareil 4 Cet appareil menager etant dote d un systeme d allumage automatique ne pas essayer allumer le br leur manuellement 5 Pousse le levier du contr le du gaz a OFF ARRET position 6 Attendre cinq 5 minutes pour laisser echapper tout le gaz Renifler tout autour de l appareil y comprispr s du plancher pour d celer une odeur de gaz Si c est le cas ARR TEZ Passer l etape B des instructions de securite sur la portion superieure de cette etiquette S il n y a pas d odeur de gaz passer l et pe suivante 7 Pousse le levier du contr le du gaz ON MARCHE position 8 Remettre en place le panneau d acc s 9 Mettre l appareil sous tension 10 R gler le thermostat la temp rature d sir e 11 Si l appareil ne se met pas en marche suivre les instructions intitul es Comment couper l admission de gaz de l appareil et appeler un technicien qualifi ou le fournisseur de gaz 1 Set the thermostat to lowest setting 2 Turn off all electric power to the appliance if service is to be performed 3 Push the gas contro
82. he in duced draft blower is operating check for 120 volts to the ignitor during the preheat cycle Measure voltage between Pin 2 on the 2 pin connector and Line Neu tral on the control board No voltage check pressure switch After the ignitor warm up time begin checking for 24 volts to the gas valve Voltage will be present for seven seconds only if proof of flame has been established S 314 CHECKING FLAME SENSOR A flame sensing device is used in conjunction with the igni tion 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 1 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 Connect a micro amp meter in series with this wire and the sensor terminal 2 Be sure the positive side of the meter is to the sensor depending on the model and the negative side of the meter is to sensor terminal LINE VOLTAGE NOW PRESENT 3 Place the unit into a heating cycle 4 As soon as flame is established a micro amp reading should be evident once proof of flame micro amp read ing is established the hot surface ignitor will be de energized 5 The Integrated Ignition controls will have 1 to 4 micro amps If the micro amp reading is less than the mini mum specified c
83. heck for high resistance wiring con nections sensor to burner gap dirty flame sensor or poor grounding 6 Ifabsolutely no reading check for continuity on all com ponents and if good replace ignition control module NOTE Contaminated fuel or combustion air can create a nearly invisible coating on the flame sensor This coating works as an insulator causing a loss in the flame sense signal If this situation occurs the flame sensor must be cleaned with steel wool 55 MAINTENANCE d warnin 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 IF YOU MUST HANDLE THE ITNITOR HANDLE WITH CARE TOUCHING THE IGNITOR BODY WITH BARE FINGERS ROUGH HANDLING OR VIBRATION COULD RESULT IN EARLY IGNITOR FAILURE ONLY A QUALIFIED SERVICER SHOULD EVER HANDLE THE IGNITOR ANNUAL INSPECTION The furnace should be inspected by a qualified installer or service agency at least once per year This check should be performed at the beginning of the heating season This will ensure that all furnace components are in proper working order and that the heating system functions appropriately Pay particular attention to the following items Repair or service as necessary e Flue pipe system Check for blockage and or leak age Check the outside termination and the connec tions at and internal to the furnace e
84. information in this section for a description of the problem 1 Internal Control Failure with Integrated Ignition Control Check for voltage to the furnace and low volt age at the control board Check for blown fuse on the control board If the control determines it has an inter nal fault it enters a locked out state Any of the situa tions mentioned will cause the diagnostic LED to pro vide no signal The control board should only be re placed after all other checks from the Troubleshooting Charthave been verified 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 ener gized to purge the heat exchanger The ignitor will next be energized and preheated The gas valve will then be energized If flame is not sensed in seven 4 seconds the gas valve will be de energized and another purge 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 light code for this problem is one short flash followed by a longer pause The control can be reset and brought out of lockout mode by turning the thermostat off for more than 5 seconds and less than 20 seconds and then back on It can also be reset by turning off the electrical disconnect switch to the fur na
85. ion locate the thermostat about five feet high on a vibration free inside wall Do not install the thermostat where it may be influenced by any of the following Drafts or dead spots behind doors in corners or un der cabinets Hotor cold air from registers e Radiant heat from the sun Lightfixtures or other appliances e Radiant heatfrom a fireplace e Concealed hot or cold water pipes or chimneys Unconditioned areas behind the thermostat and de humidistat such as an outside wall COMBUSTION AND VENTILATION AIR REQUIREMENTS POSSIBLE PROPERTY DAMAGE PERSONAL INJURY OR DEATH MAY OCCUR IF THE FURNACE IS NOT PROVIDED WITH ENOUGH FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF FLUE GASES MOST HOMES REQUIRE OUTSIDE AIR BE SUPPLIED TO THE FURNACE AREA Improved construction and additional insulation in buildings have reduced heat loss by reducing air infiltration and es cape around doors and windows These changes have helped in reducing heating cooling costs but have created a prob lem supplying combustion and ventilation air for gas fired and other fuel burning appliances Appliances that pull air out of the house clothes dryers exhaust fans fireplaces etc increase the problem by starving appliances for air When the furnace is installed as a direct vent 2 pipe fur nace no special provisions for air for combustion are re quired However if this furnace is to be installed in the same space with
86. iring connection Correct short at flame sensor or in flame sensor wiring Check burners for proper alignment Check flue and air inlet piping for blockage proper length elbows and termination Correct as necessary Check rollout limit Replace if necessary Check induced draft blower for proper performance Replace if necessary Tighten or correct wiring connection Clean flame sensor if coated oxidized Inspect for proper sensor alignment Check inlet air piping for blockage proper length elbows and termination Compare current gas pressure to rating plate info Adjust as needed Review wiring diagram to correct polarity Reverse orange and gray wires going to transformer Verify proper ground Correct if necessary LED Flash code will cease if power to the control module is interrupted through the disconnect or door switch 44 Cautions and Notes Turn power OFF prior to repair Replace primary auxiliary limit with proper replace ment part Replace blower with correct replacement part Turn power OFF prior to repair Turn power OFF prior to repair See Vent Flue Pipe section for piping details Replace rollout limit with correct replacement part Replace induced draft blower with correct replace ment part Replace control board fuse Turn power OFF prior to repair Clean flame sensor See Vent Flue
87. ith a high quality thread sealer Aywarnine 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 7 Turn on gas to furnace and check for leaks If leaks are found repair and then reinstall burner compartment door 8 Turn on electrical power and verify proper unit opera tion Gas Valve On Off Selector Switch OUTLET 25 E oor I Pressure Regulator Outlet Pressure Tap Adjustment Under Cap Screw Inlet Pressure Tap White Rodgers Model 36J22 Single Stage Pressure Regulator under cap screw Inlet Pressure Outlet Tap Pressure 9 Tap LS INLET Honeywel i OUTLET ON F Id Gas Valve On Off Selector Switch Honeywell Model VR8215 High Stage 9 7 to 10 3 w c 10 0 w c Low Stage 5 7 to 6 3 w c 6 0 w c S 308 CHECKING HOT SURFACE IGNITOR Single stage furnaces use a 115 volt silicon carbide igniter p n 0130F00008 with 17 second warm up time WARNING Disconnect ALL POWER BEFORE SERVICING 1 Remove burner compartment door to gain access to the ignitor 2 Ignitor cool approximately 70 77 F 3 Disconnect the ignitor
88. just manifold pressure using the Manifold Gas Pressure table shown below f Remove regulator cover screw from the outlet pres sure regulator adjust tower and turn screw clockwise to increase pressure or counterclockwise to decrease pressure Replace regulator cover screw i Turn off all electrical power and gas supply to the sys tem j Remove the manometer hose from the hose barb fit ting or outlet pressure boss k Turn outlet pressure test screw in to seal pressure port clockwise 7 in Ib minimum 6 Honeywell VR8215 Valve a Remove the outlet pressure boss plug Install an 1 8 NPT hose barb fitting into the outlet pressure tap b Attach a hose and manometer to the outlet pressure barb fitting c Turn ON the gas supply d Turn on power and close thermostat R and W1 contacts to provide a call for low stage heat e Measure the gas manifold pressure with burners fir ing Adjust manifold pressure using the Manifold Gas Pressuretable shown SERVICING f Remove regulator cover screw from the outlet pres sure regulator adjust tower and turn screw clock wise to increase pressure or counterclockwise to decrease pressure Replace regulator cover screw i Turn off all electrical power and gas supply to the system j Remove the manometer hose from the hose barb fitting or outlet pressure boss k Remove the 1 8 NPT hose barb fitting from the out let pressure tap Replace the outlet pressure boss plug and seal w
89. l lever to FF Position Do not force 4 Replace control access panel TOTURNOFFGASTOAPPLIANCE MW POUR COUPER L ADMISSIO E DE GAZ DE L APPAREIL 1 R gler le thermostat la temp rature la plus bass 2 Couper l alimentation lectrique de l appareil s il faut proc der des operations d entretien 3 Pousse le levier du contr le du gaz OFF ARRET position Ne pas forcer 4 Remettre en place le panneau d acc s 0140F00681 REVA IMPORTANT INFORMATION FOR YOUR SAFETY READ BEFORE OPERATING WARNING W 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 Be sure to smell next to the floor because some gas E heavier than air and will settle on the oor WHAT TO DO IF YOU SMELL GAS not try to light any appliance Do not touch any electric switch do not use any telephone in your building e Immediately call your supplier from a neighbor s phone Follow the gas suppliers instructions If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life If you cannot reach your gas supplier call the fire department C Use only your hand to move the gas control switch or knob Never use tools If the gas control switch or knob will not
90. l only vent kit 0170K00001S is to be used with 2 vent systems This kit is NOT intended for use with single pipe indirect vent installations The vent kit must terminate outside the structure and may be installed with the intake and exhaust pipes located side by side or with one pipe above the other See the section in this manual under Vent Flue and Com bustion Air Pipe Terminations for more information or con sult the Installation Instructions IO 805 34 o e Vertical Installation ACCESSORIES CONCENTRIC VENT CONVERSION KIT CVENT 2 DCVK 20 CVENT 3 DCVK 30 Vent The CVENT 2 DCVK 20 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 termina tion 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 Installa tion and Operating Instructions IO 619 Vent Combustion Air aw Elbow Field Supplied Maintain 12 18 for Canada minimum clearance above highest anticipated snow level Maximum of 24 above roof Combustion Air Roof Boot Flashing Field Supplied Support Field Supplied 45 Elbow lt _ Field Supplied DCVK Combustion Air Strap Field Supplied Vent
91. l prohibit the burner orifice from draw ing the proper amount of air into the burner This may cause incomplete combustion flashback and possible yellow tip ping In some areas the gas supplier may artificially derate the gas in an effort to compensate for the effects of altitude If 26 the gas is artificially derated the appropriate orifice size must be determined based upon the BTU ft content of the derated gas and the altitude Refer to the National Fuel Gas Code NFPA 54 ANSI Z223 1 and information pro vided by the gas supplier to determine the proper orifice size A different pressure switch may be required at high altitude regardless of the BTU ft content of the fuel used Refer to the product Specification Sheet or Technical Manual for a tabular listing of appropriate altitude ranges and correspond ing manufacturer s pressure switch kits PROPANE GAS CONVERSION POSSIBLE PROPERTY DAMAGE PERSONAL INJURY OR DEATH MAY OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INSTALLED THE APPROPRIATE KITS MUST BE APPLIED TO INSURE SAFE AND PROPER FURNACE OPERATION ALL CONVERSIONS MUST BE PERFORMED BY A QUALIFIED INSTALLER OR SERVICE AGENCY This unit is configured for natural gas The appropriate manufacturer s propane gas conversion kit must be ap plied for propane gas installations SS9 models using a White Rodgers 36J22 single stage valve use LPM 07 LP Conversion Kit GAS VALVE This unit is equipped with a 24 volt g
92. les Cut out the opening on these lines An under sized opening will cause reduced airflow For bottom return connection remove the bottom of the cabinet before set ting the furnace on the raised platform or return air duct closed return duct system must be used with the return duct connected to the furnace NOTE Ductwork must never be attached to the back of the furnace Supply and return connections to the furnace may be made with flexible joints to reduce noise transmission if desired If a central return is used a connecting duct must be installed between the unit and the utility room wall so the blower will not interfere with combustion air or draft The room closet or alcove 30 must not be used as a return air chamber When the furnace is used in connection with a cooling unit the furnace should be installed in parallel with or on the upstream side of the cooling unit to avoid condensation in the heating element With a parallel flow arrangement the dampers or other means used to control the flow of air must be adequate to prevent chilled air from entering the furnace and if manually operated must be equipped with means to prevent operation of either unit unless the damper is in the full heat or cool position When the furnace is heating the temperature of the return air entering the furnace must be between 55 F and 100 F UPRIGHT FILTER INSTALLATIONS Depending on the installation and or customer preference
93. min 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 lt Chimney or Gas Vent Ventilation louvers each end of attic NOTE The inlet and outlet air openings must each have a free area of not less than one square inch per 4000 BTU of the total input rating of all equipment in the enclosure Outlet Air Inlet Air Alternate air inlet Ventilation louvers for unheated crawl space Figure A 9 3 3 1 1 a All Combustion Air From Outdoors Inlet Air from Ventilated Crawl Space and Outlet Air to Ventilated Attic lt Chimney or Gas Vent Ventilation louvers each end of attic NOTE The inlet and outlet air openings must each have a free area of not less than one square inch per 4000 BTU of the total input rating of all equipment in the enclosure Outlet Air Inlet air duct ends 1 ft 300 mm above floor Enn Figure A 9 3 3 1 1 b Combustion Air From Outdoors through Ventilated Attic 2 Where communicating with the outdoors through horizontal ducts each opening shall have a minimum free area of 1 in 2000 Btu hr 1100 min kW of total input rating of all appliances in the enclo sure See Figure A 9 3 3 1 2 17 INSTALLATION CONSIDERATIONS lt Chimney or Gas Vent NOTE The air duct openings must have a free
94. n 1 stage gas valve induced draft PSC motor 120 volt silicon carbide 17 second hot surface ignition Left or right gas pipe entry The furnace also features an aluminized steel tubular heat exchanger Available cabinet widths are 17 5 21 wide Goodman Brand 96 Single Stage Gas Furnace 34 5 tall Upflow Horizontal Installation 1 stage gas valve induced draft PSC motor 120 volt silicon carbide 17 second hot surface ignition Left or right gas pipe entry The furnace also features an aluminized steel tubular heat exchanger Available cabinet widths are 17 5 21 and 24 5 wide Goodman Brand 96 Single Stage Gas Furnace 34 5 tall Downflow Horizontal Installation 1 stage gas valve induced draft PSC motor 120 volt silicon carbide 17 second hot surface ignition Left or right gas pipe entry The furnace also features an aluminized steel tubular heat exchanger Available cabinet widths are 17 5 21 and 24 5 wide PRODUCT IDENTIFICATION MODEL ACSS92 ACSS96 10 AMSS920402BNAA AMSS920603BNAA AMSS920803BNAA AMSS920804CNAA AMSS920805CNAA AMSS921004CNAA AMSS921005CNAA AMSS921205DNAA ACSS920402BNAA ACSS920603BNAA ACSS920804CNAA ACSS921005CNAA AMSS960402BNAA AMSS960603BNAA AMSS960803BNAA AMSS960804CNAA AMSS960805CNAA AMSS961005CNAA AMSS961205DNAA ACSS960402BNAA ACSS960603BNAA ACSS960804CNAA ACSS961005CNAA ACSS961205DNAA DESCRIPTION Amana Brand 92 Single Stage Gas Furnace Upflow H
95. n and during main burner operation Means shall be provided to prevent the main burner form igniting should the louver fail to open during burner startup and to shut down the main burner if the louvers close during burner operation 9 3 8 Combustion Air Ducts Combustion air ducts shall comply with 9 3 8 1 through 9 3 8 8 9 3 8 1 Ducts shall be constructed of galvanized steel or a material having equivalent corrosion resistance strength and rigidity Exception Within dwellings units unobstructed stud and joist spaces shall not be prohibited from conveying combustion air provided that not more than one fireblock is removed 9 3 8 2 Ducts shall terminate in an unobstructed space allowing free movement of combustion air to the appliances 9 3 8 3 Ducts shall serve a single space INSTALLATION CONSIDERATIONS 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 main tained 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 down ward toward the source of combustion air 9 3 8 7 The remaining space surrounding a chimney liner gas vent spe cial gas vent or plastic piping installed within a masonry metal or factory built chimney shall not be used to supply combustion
96. ndre le fournisseur de gaz appelez le service des incendies C Ne pousser ou tourner la manette d admission du gaz qu la main Ne jamais emploer d outil cette fin Si la manette reste coinc e ne tenter pas de la r parer appelez un technicien qualifi Quiconque tente de forcer la manette ou de la r parer peut provoquer uneexplosion ou un incendie D Ne pas se servir de cet appareil s il a t plong dans l eau m me partiellement Faire inspecter l appareil par un technicien qualifi et remplacer toutr partie du syst me de contr le et toute commande qui ont t plong es dans l eau 1 STOP Read the safety information above on this label 2 Set the thermostat to lowest setting 3 Turn off all electric power to the appliance 4 This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand 5 Push the gas control lever to OFF Do not force 6 Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you then smell gas STOP Follow B in the safety information above on this label if you don t smell Position ROBINETAGAZ MANUEL ENPOS ON MARCHE gas go to next step 7 Push gas control lever to ON gt 8 Replace access panel ARRIVEE 9 Turn on all electric DUGAZ power to the appliance 10 Setthermostattodesiredsetting 11 If the appliance will not operate
97. ne Re fer to Vent Flue and Combustion Air Pipe Termination Lo cations or Concentric Vent Termination section in this manual or the installation instructions for specific details on termi nation construction Concentric Vent Kits DCVK Application The DCVK 20 and DCVK 30 kit is designed to allow the terminations of a direct vent furnace to be concentrically vented through a wall or roof This kit allows a single pen etration to support terminations for both the vent flue pipe and the combustion air intake pipe DCVK Vent Termination Clearances 1 Determine termination locations based on clearances specified in furnace installation instructions and following steps as shown in Figures 1 3 6 7 8 and 9 Direct Vent Terminal 50 000 Btuh orless Direct Vent Terminal More than 50 000 Btuh FIGURE 1 2 The vent termination must be located at least 12 above ground or normally expected snow accumulation levels 3 Do NOT terminate over public walkways Avoid areas where condensate may cause problems such as above planters patios or adjacent to windows where steam may cause fogging 4 The vent termination shall be located at least 4 horizontally from any electric meter gas meter regulator and any relief equipment These distances apply ONLY to U S Installations 5 The vent termination shall be located at least 3 above any forced air inlet located within 10 and at least 10 from acombustion ai
98. ng Supply pressure must be within the range speci fied in the following table INLET GAS SUPPLY PRESSURE Maximum 100 W C Maximum 13 0 w c W C Minimum 11 0 w c If supply pressure differs from above make necessary ad justments to pressure regulator gas piping size etc and or consult with local gas utility 51 SERVICING 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 5 Disconnect manometer after turning off gas at manual shutoff valve Reinstall plug before turning on gas to fur nace 6 Turn OFF any unnecessary gas appliances started in step 3 7 Turn on gas to furnace and check for leaks If leaks are found repair and then reinstall burner compartment door 8 Turnon electrical power and verify proper unit opera tion Gas Manifold Pressure Measurement and Adjust ment To PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE THE GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE ONLY MINOR ADJUSTMENTS SHOULD BE MADE BY ADJUSTING THE GAS VALVE PRESSURE REGULATOR NOTE Use adapter kit 0151 KO0000S to measure gas pres sure on White Rodgers 36J22 gas valves Only small variations in gas pressure should be made by adjusting the gas valve pressure regulator The manifold pres sure must be
99. nmfg com hac consumer affairs amanahvac com fax us at 731 856 1821 fax us at 731 856 1821 Not a technical assistance line for dealers Not a technical assistance line for dealers Outside the U S call 1 713 861 2500 Not a technical assistance line for dealers Your telephone company will bill you for the call IMPORTANT INFORMATION DANGER PELIGRO CARBON MONOXIDE POISONING HAZARD 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 If a furnace or air handler is installed in an enclosed area such as a garage utility room or parking area and a carbon monoxide producing device is operated therein there must be adequate direct outside ventilation This ventilation is necessary to avoid the danger of CO poisoning which can occur if a carbon monoxide producing device continues to operate in the enclosed area Carbon monoxide emissions can be re circulated throughout the structure if the furnace or air handler is operating in any mode CO can cause serious illness including permanent brain damage or death B10259 216 RIESGO DE INTOXICACION POR MONOXID
100. nnot reach your gas supplier call the fire department C Use only your hand to push in or turn the gas control lever Never use tools If the lever will not push in or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion D Do not use this appliance if any part has been underwater Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been underwater AVERTISSEMENT Quiconque ne respecte pas la lettre les instructions dans le pres nt manuel risque de d clencher un incendie ou une explosion entrainant des dommages mat riels des lesions corporelles ou la perte de vies humaines A Cet appareil ne comporte pas de veilleuse llest muni d undispositif d allumage qui allume automatiquement le br leur Ne pas tenter d allumer le br leur manuellement B AVANT DE LE FAIRE FONCTIONNER renifler tout autour del appariel pour dec ler une odeur de gaz Renifler pr s du plancher car certains gaz sont plus lourds que l airet peuvent s accumuler au niveau du sol QUEFAIRE S IL Y A UNE ODEUR DE GAZ o Ne pas tenter d allumer d appareils o Ne toucher aucun interrupteur ne pas vous servir des t l phones dans le b timent Appelez imm diatement votre fournisseur de gaz depuis un voisin Suivez les instructions du fournisseur de gaz Sivous ne pouvez rejoi
101. nt or contact motion e Tighten or correct wiring connection Cautions and Notes e Turn power OFF prior to repair Replace inte grated control module fuse with 3A automotive fuse Read precautions in Electrostatic Discharge section of manual Turn power OFF prior to repair gniter is fragile handle with care Clean flame sensor See Vent Flue Pipe section for piping details Turn power OFF prior to repair Replace pressure switch with proper replace ment part Turn power OFF prior to repair Replace pressure switch with proper replacement part 43 TROUBLESHOOTING Symptoms of Abnormal Associated Operation Circulator blower runs continuously No furnace operation Integrated control module diagnostic LED is flashing FOUR 4 flashes Induced draft blower and circulation blower runs continuously No furnace operation Integrated control module diagnostic LED is flashing FIVE 5 Circulator blower runs continuously No furnace operation Integrated control module diagnostic LED is flashing SIX 6 flashes Normal furnace operation Integrated control module diagnostic LED is flashing SEVEN 7 flashes e Furnace fails to operate Integrated control module diagnostic LED is flashing continu ously Integrated control module will automatically attempt to reset from lockout after one hour LED Code
102. nuously 5 Furnace awaits call from thermostat Norma HEATING SEQUENCE 1 Rand W thermostat contacts close initiating a call for heat 2 Integrated control module performs safety circuit checks 3 The induced draft blower is energized causing pres sure switch contacts to close Induced draft blower remains energized for pre purge period 4 lgnitor warm up begins after pre purge is completed The ignition control has a WARM UP PERIOD OF 17 SECONDS 5 Gas valve opens at end of ignitor warm up period deliv ering gas to burners to establish flame 6 The control checks for a signal from the flame sensor within seven 4 seconds after the gas valve is ener gized Gas will only continue to flow if a flame signal is present 7 Circulator blower is energized on heat speed following a fixed thirty 30 second blower on delay 8 Furnace runs integrated control module monitors safety circuits continuously 9 Rand W thermostat contacts open allowing the gas valve to cycle off 10 Induced draft blower is de energized following a fifteen 15 second post purge 11 Circulator blower is de energized following heat off de lay period 12 Furnace awaits next call from thermostat Cooling Mode The normal operational sequence in cooling mode is as follows 1 R and Y thermostat contacts close initiating a call for cool 2 Integrated control module performs safety circuit checks 3 Outdoor fan and compress
103. o the terminal from foreign ob jects c Wind effects that may cause recirculation of flue products debris or light snow d Visible vent vapors Vent Maintain 12 18 for Canada minimum clearance above highest anticipated snow level Maximum of Combustion Air 24 above roof Tusc ME t Field Supplied Roof Boot Flashing A _ po 2 o i Field Supplied 45 Elbow a Field Supplied Vent gt 4 combustion Air Le FIGURE 3 INSTALLATION CONSIDERATIONS Do NOT OPERATE THE FURNACE WITH THE RAIN CAP REMOVED AS RECIRUCLATION OF THE FLUE GASES MAY OCCUR WATER MAY ALSO COLLECT INSIDE THE LARGER COMBUSTIN AIR PIPE AND FLOW TO THE BURNER ENCLOSURE FAILURE TO FOLLOW THIS WARNING CAN RESULT IN PROPERTY DAMAGE EQUIPMENT DAMAGE PERSONAL INJURY OR DEATH Concentric Sidewall Vent Kit 0170K00000S This sidewall only vent kit is to be used with 2 3 vent Systems The vent kit must terminate outside the structure and may be installed with the intake and exhaust pipes lo cated side by side or with one pipe above the other This kit is NOT intended for use with single pipe non direct vent installations Re No e NN y 0 Condensate Drain Lines Drain A condensing gas furnace achieves its high level of efficiency by extracting almost all of the heat from the products of combustion and cooling them to the point where condensa tion takes place The conden
104. oduct Design section of this manual for speed chang ing details Temperature rise is related to the BTUH out put of the furnace and the amount of air CFM circu lated over the heat exchanger Measure motor current draw to determine that the motor is not overloaded dur ing adjustments S 300 CHECKING PRIMARY LIMIT CONTROL Primary limit controls are nonadjustable automatic reset bi metal type limit control Refer to the following drawing for the location of the primary limit PRIMARY LIMIT CONTROL Primary Limit Control Location 48 The following drawing illustrates the style of limit switches used on the 90 furnaces ENCLOSED DISK 4 FRONT VIEW SIDE VIEW Primary Limit Control Style 90 Furnaces A warninc HIGH VOLTAGE Disconnect ALL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH 1 Remove burner compartment door to gain access to the primary limit 2 Remove low voltage wires at limit control terminals 3 With an ohmmeter test between these two terminals as shown in the following drawing The ohmmeter should read continuous unless heat exchanger tem perature is above limit control setting If not as above replace the control VOLT OHM METER Testing Primary Limit Control SERVICING VOLT OHM METER COLOR
105. on qu la main ne jamais emploer d outil cet effet Si la manette reste coinc e ne pas tenter de la D Do not use this appliance if any part has been underwater r parer appeler un technicien qualifi Quiconque Immediately call a qualified service technician to inspect tente de forcer la manette ou de la reparer peut the appliance and to replace any part of the control d clencher une explosion ou un incendie system and any gas control which has been underwater D Ne pas se servir de cet appareil s il a t plong dans l eau compl tement ou en partie Appeler un technicien qualifi pour inspecter l appareil et remplacer tout partie du syst me de contr le et toute commande qui ont t plong s dans l eau B oreraTincG INSTRUCTIONS RM Miseen MARCHE STOP Read the safety information above on ARRET R Lisez les instructions de s curit sur this label la portion sup rieure de cette tiquette R gler le thermostat la temp rature la plus basse 2 Set the thermostat to lowest setting ae 3 Turn off all power to the appliance 3 Couper l alimentation lectrique de l appareil 4 This appliance is equipped with an ignition 4 Cet appareil menager tant dot d un syst me device which automatically lights the burner d allumage automatique ne pas essayer Do not try to light the burner by hand allumer le br leur manuellement
106. on electrical power and verify proper unit opera tion S 2 CHECKING WIRING Disconnect ALL POWER BEFORE SERVICING 1 Check wiring visually for signs of overheating damaged insulation and loose connections 2 Use anohmmeter to check continuity of any suspected open wires 3 If any wires must be replaced replace with AWM 105 C 2 64 thick insulation of the same gauge or its equivalent CHECKING THERMOSTAT WIRING AND ANTICIPATOR S 3A THERMOSTAT AND WIRING Disconnect ALL POWER BEFORE SERVICING 1 Remove the blower compartment door to gain access to the thermostat low voltage wires located at the furnace integrated control module terminals 2 Remove the thermostat low voltage wires at the furnace control panel terminal board 3 Jumper terminals R to W or W1 and W2 for two stage models on the integrated ignition control With Power On and Door Interlock Switch closed LINE VOLTAGE NOW PRESENT 4 Induced Draft Motor must run and pull in pressure Switch 5 Ifthe hot surface ignitor heats and at the end of the ig nitor warm up period the gas valve opens and the burners ignite the trouble is in the thermostat or wir ing 6 With power off check the continuity of the thermostat and wiring Repair or replace as necessary If checking the furnace in the air conditioning mode pro ceed as follows 7 With power off Jumper terminals R to Y to G 8 Turnonthe power 9 Ifthe furnace blower
107. ontal Termination Single Pipe Above Highest Anticipated Snow Level 4 12 MINIMUM VENT FLUE TEE 90 ELBOW TURNED DOWN 12 MINIMUM ABOVE HIGHEST ANTICIPATED SNOW LEVEL om n NA KA VENT FLUE PIPE OPTIONAL 0 OR 45 ELBOW AR vidi gt 12 MIN TO GRADE OR 2 Jet yd 90 Furnace Horizontal Termination Single Pipe Above Highest Anticipated Snow Level In a basement installation the vent flue pipe can be run be tween joist spaces If the vent pipe must go below a joist and then up into the last joist space to penetrate the header two 45 elbows should be used to reach the header rather than two 90 elbows Direct Vent Dual Pipe Piping Direct vent installations require both a combustion air in take and a vent flue pipe The pipes may be run horizontally and exit through the side of the building or run vertically and w IS 12 MIN ABOVE HIGHEST ANTICIPATED LA SNOW LEVEL Alternate Horizontal Vent Termination Dual Pipe 23 INSTALLATION CONSIDERATIONS exit through the roof of the building The pipes may be run through an existing unused chimney however they must extend a minimum of 12 inches above the top of the chim ney The space between the pipes and the chimney must be closed with a weather tight corrosion resistant flashing Both the combustion air intake and a vent flue pipe termina tions must be in the same atmospheric pressure zo
108. operate don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion D Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS 1 STOP Read the safety information above on this label 2 Set the thermostat to lowest setting 3 Turn off all electric power to the appliance 4 This appliance is equipped with an automatic ignition system which automatically lights the burners Do not try to light the burners by hand 5 Remove control access panel 6 Move the gas control switch or knob GAS CONTROL SWITCH SHOWN IN ON POSITION 7 Wait five 5 minutes to clear out any gas If you then smell gas STOP Follow B in the safety information above on this label If you don t smell gas go to the next step 8 Move the gas control switch or knob to ON 9 Replace control access panel 10 Turn on all electric power to the appliance 11 Set the thermostat to the desired setting 12 If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier TO TURN OFF GAS TO APPLIANCE 1 Set the thermostat to its lowest setting 2 Turn off all electric power to the appliance if service is
109. or are energized 4 Circulator blower is energized on cool speed following a fixed five 5 second on delay 5 Furnace circulator blower and outdoor cooling unit run integrated control module monitors safety circuits con tinuously 6 Rand Y thermostat contacts open completing the call for cool 7 Outdoor fan and compressor are de energized 8 Circulator blower is de energized following a fixed forty five 45 second cool off delay period 9 Furnace awaits next call from thermostat Fan Only Mode The normal operational sequence in fan only mode is as follows 1 R and G thermostat contacts close initiating a call for fan 2 Integrated control module performs safety circuit checks 3 Circulator blower is energized on heat speed Elec tronic air cleaner terminals are energized 4 Circulator blower runs integrated control module moni tors safety circuits continuously 5 Rand G thermostat contacts open completing the call for fan 6 Furnace awaits next call from thermostat 7 Furnace awaits next call from thermostat 31 SYSTEM OPERATION HEATING Abnormal Operation The following presents the probable causes of question able furnace operation and how to fix them Look through the observation window in the blower access door and make a note of the number of flashes in sequence between pauses Next refer to the Troubleshooting Chart on the following pages for an interpretation of the LED signals and to the
110. orizontal Installation 34 5 tall 1 stage gas valve induced draft PSC motor 120 volt silicon carbide 17 second hot surface ignition Left or right gas pipe entry The furnace also features a stainless steel tubular heat exchanger Available cabinet widths are 17 5 21 and 24 5 wide Amana Brand 92 Single Stage Gas Furnace Downflow Horizontal Installation 34 5 tall 1 stage gas valve induced draft PSC motor 120 volt silicon carbide 17 second hot surface ignition Left or right gas pipe entry The furnace also features a stainless steel tubular heat exchanger Available cabinet widths are 17 5 and 21 wide Amana Brand 96 Single Stage Gas Furnace Upflow Horizontal Installation 34 5 tall 1 stage gas valve induced draft PSC motor 120 volt silicon carbide 17 second hot surface ignition Left or right gas pipe entry The furnace also features a stainless steel tubular heat exchanger Available cabinet widths are 17 5 21 amp 24 5 wide Amana Brand 96 Single Stage Gas Furnace Downflow Horizontal Installation 34 5 tall 1 stage gas valve induced draft PSC motor 120 volt silicon carbide 17 second hot surface ignition Left or right gas pipe entry The furnace also features a stainless steel tubular heat exchanger Available cabinet widths are 17 5 21 and 24 5 wide PRODUCT IDENTIFICATION MODEL DESCRIPTION Fossil Fuel Kit The AFE18 60A control is designed for use where the indoor coil is lo
111. osed outdoors in excess of the terminations shown in this manual or in unheated areas should be insulated with 1 2 thick closed cell foam Inspect piping for leaks prior to installing insulation The following bullets and diagram describe the restrictions concerning the appropriate location of vent flue pipe and com bustion air intake pipe when applicable terminations Re fer to the installation instructions for specific details on ter mination construction All terminations must be located at least 12 inches above ground level or the anticipated snow level Ventterminations must terminate at least feet above any forced air inlet located within 10 feet NOTE This provision does not apply to the combus tion 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 horizon tally from or 1 foot above any door window or gravity air inlet into any building Theventtermination of a direct vent application must terminate at least 12 inches from any opening through which flue gases may enter a building door window or gravity air inlet Theventtermination of vent pipe run vertically through a roof must terminate at least 12 inches above the roof line orthe anticipated snow level and be at least 12inches from any vertical wall including any antici pated snow build up e Aventtermination shall not terminate over p
112. pressure drop at 10 psig setting Capacities in 1 000 BTU Rour To convert to capacitiesat 15 psig settings multiply by 1 130 To convert capacities at 5 psig settings multiply by 0 879 Sizing Between Second or Second Stage Regulator amp Appliance Maximum Propane Capacities listed are based on 1 2 W C pressure drop at 11 W C setting Capacities in 1 000 BTU hour 79 72 90 78 162 307 630 48 ps pie je psp sc pe ps p 200 19 39 66 100 54 112 209 439 250 8 v 36 Data in accordance with NFPA pamphlet No 54 Propane Gas Piping Charts When installing a propane storage tank the contractor must consider proper tank sizing safety efficiency ground char acteristics and aesthetics For a residential customer the size may range from 100 1 000 gallons depending on house hold use Typically a 500 gallon tank is ample for an aver age four bedroom home However it is best to consult your local propane supplier to ensure the proper sizing for pro pane storage requirements Determining the correct tank size for each household is a function of demand economy efficiency and convenience It is a process that requires cooperation between the propane supplier and customer ELECTRICAL CONNECTIONS To AVOID THE RISK OF ELECTRICAL SHOCK WIRING TO THE UNIT MUST BE PROPERLY POLARIZED AND GROUNDED INSTALLATION CONSIDERATIONS warnine HIGH VOLTAGE
113. r 1000 BTU of the total input rating of all equip ment in the enclosure but not less than 100 square inches 1 lt Opening 1 Water Furnace Heater n Opening Figure A 9 2 3 3 1 All Combustion Air from Adjacent Indoor Spaces through Indoor Combustion Air Openings 2 Combining spaces in different stories The volumes of spaces in different stories shall be considered as communicating spaces where such spaces are connected by one or more openings in doors or floors having a total minimum free area of 2 in 1000 Btu hr 4400 mm kW of total input rating of all appliances 9 3 3 Outdoor Combustion Air Outdoor combustion air shall be pro vided through opening s to the outdoors in accordance with the meth ods in 9 3 3 1 or 9 3 3 2 The minimum dimension of air openings shall not be less than 3 in 80 mm 9 3 3 1 Two Permanent Openings Method Two permanent open ings one commencing within 12 in 300 mm of the top and one com mencing within 12 in 300 mm of the bottom of the enclosure shall be provided The openings shall communicate directly or by ducts with the outdoors or spaces that freely communicate with the outdoors as follows 1 Where directly communicating with the outdoors or where commu nicating to the outdoors through vertical ducts each opening shall have a minimum free area of 1 2 4000 Btu hr 550
114. r intake of another appliance except another direct vent furnace intake 6 In Canada the Canadian Fuel Gas Code takes precedence over the preceding termination instructions 24 2 or 2 1 2 Diameter SDR 26 eg 3 or 4 Diameter SDR 26 Pipe 7 n 2 or 3 Diameter Y Concentric Fitting FIGURE 2 A 2 or 3 Diameter Rain Cap These kits are for vertical or horizontal termination of the combustion air inlet and the exhaust vent pipes on Category IV gas fired condensing furnaces The DCVK 30 kit can be used for 3 diameter pipe systems The DCVK 20 kit can be used for the 2 diameter pipe system For the correct pipe size for the furnace Both the combustion air inlet and the exhaust vent pipes must attach to the termination kit The termination kit must terminate outside the structure and must be installed per the instructions outlined below for vertical or horizontal termination Vertical termination is preferred Field supplied pipe and fittings are required to complete the installation 1 Determine the best location for the termination kit Roof termination is preferred since it is less susceptible to damage has reduced intake contaminants and less vis ible vent vapors For side termination consideration should be given to a Possible damage from the vapors to plants shrubs other equipment and building materials b Possible damage t
115. r to the Vent Flue Pipe and Com bustion Air Pipe Termination Locations section in this manual or the installation instructions for appropriate termination locations Also for 90 furnaces refer to the Vent Flue Pipe and Combustion Air Pipe Termi 14 nation Locations section in this manual or the instal lation instructions to determine if the piping system from furnace to termination can be accomplished within the guidelines given NOTE The length of flue and or combustion air piping can be a limiting factor in the location of the furnace Locate the 90 furnace so that the condensate can be piped at a downward slope away from the furnace to the drain Do not locate the furnace or its conden sate drainage system in any area subject to below freezing temperatures without proper freeze protec tion Refer to the Condensate Drain Lines and Trap section in this manual or the installation instructions for further details Set the 90 furnace on a level floor to enable proper condensate drainage If the floor becomes wet or damp at times place the furnace above the floor on a con crete base sized approximately 1 1 2 larger than the base of the furnace Refer to the Horizontal Applica tions and Considerations section in this manual or the installation instructions for leveling of horizontal furnaces Ensure upflow or horizontal furnaces are not installed directly on carpeting or any other combustible mate rial The only combustible ma
116. rely on your sense of smell Contact a local propane gas supplier about installing a gas detecting warning system If the presence of gas is suspected follow the instructions on this page All propane gas equipment must conform to the safety stan dards of the National Board of Fire Underwriters NBFU Manual 58 For satisfactory operation propane gas pressure must be 10 inch WC at the furnace manifold with all gas appliances in operation Maintaining proper gas pressure depends on three main factors 1 Vaporization rate depending on temperature of the liq uid and wetted surface area of the container or con tainers 2 Proper pressure regulation Two stage regulation is rec ommended for both cost and efficiency 3 Pressure drop in lines between regulators and between second stage regulator and the appliance Pipe size will depend on length of pipe run and total load of all appli ances Complete information regarding tank sizing for vaporization recommended regulator settings and pipe sizing is avail able from most regulator manufacturers and propane gas suppliers Use pipe dope approved for use with L P gas 27 INSTALLATION CONSIDERATIONS Refer to the following illustration for typical propane gas in stallations and piping 5 to 15 PSIG 20 PSIG Max First Stage Regulator Continuous 11 W C 200 PSIG Second Stage Maximum Regulato NNNNNNNNNNNNNNNNNNNNNNNNNNANNNT Typical Propan
117. rner Disconnect ALL Gas AND ELECTRICAL POWER SUPPLY In checking main burners look for signs of rust oversized and undersized carry over ports restricted with foreign ma terial etc refer to previous drawing Burner cross over slots should not be altered in size S 306 CHECKING ORIFICES Single stage furnaces are factory equipped with 45 gas orifices SERVICING Orifices should be treated with care in order to prevent dam age They should be removed and installed with a box end wrench in order to prevent distortion In no instance should an orifice be peened over and redrilled This will change the angle or deflection of the vacuum effect or entraining of pri mary air which will make it difficult to adjust the flame prop erly WARNING Disconnect ALL Gas AND ELECTRICAL POWER SUPPLY 1 Check orifice visually for distortion and or burrs 2 Check orifice size with orifice sizing drills 3 Ifresizing is required a new orifice of the same physical size and angle with proper drill size opening should be installed GAS STREAM The length of Dimension A determines the angle of Gas Stream B A dent or burr will cause a severe deflection of the gas stream S 307 CHECKING GAS PRESSURE Gas Supply Pressure Measurement To PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE THE INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES
118. rom freezing NOTE The use of insulation and or heat tape is recommended Failure to provide proper condensate drain age can result in property damage Leveling Leveling ensures proper condensate drainage from the heat exchanger and induced draft blower For proper flue pipe drainage the furnace must be level lengthwise from end to end The furnace should also be level from back to front or have a slight tilt with the access doors downhill approxi mately 3 4 from the back panel The slight tilt allows the heat exchanger condensate generated in the recuperator coil to flow forward to the recuperator coil front cover In horizontal installations with the furnace laying on the left hand side the alternate vent connection may be used In this configuration the internal elbow is removed The stan dard piping connections may also be used in these posi tions Refer to Vent Flue Pipe and Combustion Air Pipe section in the installation instructions for details concerning the conversion to the alternate vent flue and combustion air connections on the 90 furnace The 34 5 single stage furnace is one of the products in our newly redesigned line of shorter chassis furnaces It is avail able in 92 96 AFUE up flow horizontal model and a down flow horizontal model The up flow horizontal 34 5 single stage furnace is avail able in the following models MSS920402BNAA MSS920603BNAA 55950803 55920804
119. roper 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 If this occurs a qualified servicer must carefully clean the flame sensor with steel wool After cleaning the flame sensor output should be as listed on the specifica tion sheet BURNERS warnine HIGH VOLTAGE ELECTRICAL COMPONENTS ARE CONTAINED IN BOTH COMPARTMENTS TO AVOID ELECTRICAL SHOCK INJURY OR DEATH DO NOT REMOVE ANY INTERNAL COMPARTMENT Y OR ATTEMPT ANY ADJUSTMENT CONTACT A QUALIFIED SERVICE AGENT AT ONCE IF AN ABNORMAL FLAME APPEARANCE SHOULD DEVELOP Periodically during the heating season make a visual check of the burner flames Turn the furnace on at the thermostat Wait a few minutes since any dislodged dust will alter the normal flame appearance Flames should be stable quiet soft and blue with slightly orange tips They should not be yellow They should extend directly outward from the burner ports without curling downward floating or lifting off the ports Check the burner flames for 1 Stable soft and blue Burner Flame 2 Not curling floating or lifting off TEST EQUIPMENT Proper test equipment for accurate diagnosis is as essen tial as regular hand tools The following is a must for every service technician and ser vice shop 1
120. s To ensure proper installation operation and servicing thor oughly read the installation and service manuals for specif ics pertaining to the installation servicing and application of this product POSSIBLE PROPERTY DAMAGE PERSONAL INJURY OR DEATH DUE TO FIRE EXPLOSION SMOKE SOOT CONDENSTAION ELECTRICAL SHOCK OR CARBON MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION REPAIR OPERATION OR MAINTENANCE OF THIS PRODUCT TO PREVENT PROPERTY DAMAGE PERSONAL INJURY OR DEATH DUE TO FIRE DO NOT INSTALL THIS FURNACE IN A MOBILE HOME TRAILER OR RECREATIONAL VEHICLE To ensure proper furnace operation install operate main tain and service the furnace in accordance with the installa tion operation and service instructions all local building codes and ordinances In their absence follow the latest edition of the National Fuel Gas Code NFPA 54 ANSI Z223 1 and or CAN CGA B149 Installation Codes local plumbing or waste water codes and other applicable codes A copy of the National Fuel Gas Code NFPA 54 ANSI Z223 1 can be obtained from any of the following 13 INSTALLATION CONSIDERATIONS American National Standards Institute 1430 Broadway New York NY 10018 National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 CSA International 8501 East Pleasant Valley Cleveland OH 44131 copy of the CAN CGA B149 Installation Codes can be obtained from CSA International 178 Rexdale Boulevard
121. sate which is generated must be piped to an appropriate drain location IN UPRIGHT UPFLOW INSTALLATIONS THE DRAIN TRAP MUST BE MOUNTED ON THE OPPOSITE SIDE OF THE UNIT FROM THE JUNCTION BOX THIS WILL REDUCE THE RISK OF WATER REACHING THE JUNCTION BOX IN THE EVENT OF A BLOCKED DRAIN CONDITION FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN POSSIBLE PROPERTY DAMAGE PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK e Ifthe drain line is routed through an area which see temperatures near or below freezing precau tions must be taken to prevent condensate from freezing within the drain line e lfanair conditioning coil is installed with the furnace a common drain may be used An open tee must be installed in the drain line near the cooling coil to relieve positive air pressure from the coil s plenum This is necessary to prohibit any interference with the function of the furnace s drain trap Drain Information for Horizontal Installations NOTE Horizontal installations require 5 5 under the fur nace to accommodate the drain trap The horizontal furnace must be installed with 34 slope from back to front to permit condensate flow towards the front of the furnace When installing a MSS9 horizontally with the left side down there are two options for connecting the vent pipe to the furnace Option 1 Venting may be connected to the furnace vent pipe fitting on the original top now the end of the furnace Option 2
122. sign makes this extremely unlikely unless safety controls have been by passed or tampered with Never by pass or alter furnace controls If delayed ignition should occur the following should be checked 1 Improper gas pressure adjust to proper pressure See S 307 CHECKING GAS PRESSURE 2 Improper burner positioning burners should be in locat ing slots level front to rear and left to right 54 3 Carry over lighter tube or cross lighter obstructed clean 4 Main burner orifice s deformed or out of alignment to burner replace S 313 CHECKING INTEGRATED IGNITION CONTROL BOARDS NOTE Failure to earth ground the furnace reversing the neutral and hot wire connection to the line polarity or a high resistance connection in the neutral line may cause the control to lockout due to failure to sense flame To AVOID THE RISK OF ELECTRICAL SHOCK WIRING TO THE UNIT MUST BE PROPERLY POLARIZED AND GROUNDED DISCONNECT POWER BEFORE PERFORMING SERVICE LISTED BELOW The ground wire must run from the furnace all the way back to the electrical panel Proper grounding can be confirmed by disconnecting the electrical power and measuring re sistance between the neutral white connection and the burner closest to the flame sensor Resistance should be less than 2 ohms The ignition control is a combination electronic and elec tromechanical device and is not field repairable Complete unit must be replaced WARN
123. stance in duct work faulty limit faulty blower or blower speed set to low 6 Flame Sensed with No Call for Heat If the control senses a flame when the gas valve is de energized it will run the air circulation blower and the induced draft blower continuously with no further furnace operation The diagnostic flash code for this is a five flashes The probable causes are either a short to ground in flame sense circuit miswiring lingering burner flame or a slow closing gas valve 7 Open Rollout Limit Open Control Board Fuse If the rollout control opens the air circulator blower will be en ergized all the time The diagnostic light code for this problem is six flashes followed by a pause The prob able cause is either restricted flue piping or improper air requirements 8 Low Flame Sense Signal If the furnace continues to operate and the micro amp signal from the flame sensor falls below specified level the diagnostic light code for this problem will be seven flashes followed by a pause The probable cause is either a coated oxidized sensor incorrectly positioned sensor in burner flame or lazy burner flame due to improper gas pressure or combus tion air 9 Igniter circuit or poor ground Improperly connected igniter bad igniter or poor ground to the equipment The diagnostic light code for this problem is eight flashes Combustion Quality Combustion quality can be affected by several factors Major factors are venting and dr
124. supplies ample capacity of power for either operation A 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 PROPERTY DAMAGE PERSONAL INJURY OR DEATH 1 Remove blower compartment door to gain access to the thermostat low voltage wires located at the furnace integrated control module 2 Remove the thermostat low voltage wires at the furnace integrated control module terminals With Power On and Door Interlock Switch closed LINE VOLTAGE NOW PRESENT 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 Checktransformer primary voltage at incoming line voltage connections fuse splices and blower door interlock switch 6 voltage is available to the primary side of trans former and not at secondary side the transformer is inoperative Replace 7 After completing check and or replacement of trans former and check and or repair of control circuit rein stall blower compartment door 8 Turnon electrical power and verify proper unit opera tion 46 S 10B CAPACITANCE CHECK LINE VOLTAGE NOW PRESENT S 15 CHECKING CAPACITOR The direct drive motors are of the permanent split capacitor design A run capacitor is wired across the auxiliary and
125. t be downstream of the manual shutoff valve between the shutoff valve and the fur nace 8 Tighten all joints securely GAS PIPING CHECKS Before placing unit in operation leak test the unit and gas connections 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 Higher pressure may damage the gas valve and cause subsequent overfiring resulting in heat exchanger failure Disconnect this unit and shutoff valve from the gas supply piping sys tem before pressure testing the supply piping system with pressures in excess of 1 2 psig 3 48 kPa Isolate this unit from the gas supply piping system by closing its external manual gas shutoff valve before pressure testing supply pip ing system with test pressures equal to or less than 1 2 psig 3 48 kPa PROPANE GAS TANKS AND PIPING PROPANE GAS IS HEAVIER THAN AIR AND ANY LEAKING GAS CAN SETTLE IN ANY LOW AREAS OR CONFINED SPACES TO PREVENT PROPERTY DAMAGE PERSONAL INJURY OR DEATH DUE TO FIRE OR EXPLOSION CAUSED BY A PROPANE GAS LEAK INSTALL A GAS DETECTION WARNING DEVICE A gas detecting warning system is the only reliable way to detect a propane gas leak Iron oxide rust can reduce the level of odorant in propane gas Do not
126. t must terminate outside the structure This kitis NOT intended for use with single pipe indirect vent installation LP Gas Low Pressure Kit Designed for use with furnaces converted to LP gas The kit LPLPOS3 monitors gas line pressure with a pressure switch and will open the circuit to the gas valve if the LP tank pressure gets low LP Conversion Kit Converts a 34 5 single stage furnace to operate on L P gas The LPM 07 A A kit contains an L P gas valve and a set of six L P orifices Drain Coupling Kit For use when the drain vent elbow has been removed in a RF000142 horizontal left installation This kit prevents condensate from getting in the inducer and routes the condensate to a drain This kit can also be used on the furnace combustion air inlet to catch condensate 12 INSTALLATION CONSIDERATIONS Safety Please adhere to the following warnings and cautions when installing adjusting altering servicing or operating the fur nace 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 THIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS WHICH MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE KNOWN TO THE STATE CALIFORNIA TO CAUSE CANCER BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM To PREVENT POSSIBLE PROPERTY DAMAGE
127. terial allowed is wood A special accessory subbase must be used for up right counterflow unit installations over any combus tible material including wood Refer to subbase in structions for installation details NOTE A subbase will not be required if an air conditioning coil is located beneath the furnace between the supply air opening and the combustible floor Exposure to contaminated combustion air will result in safety and performance related problems Do not install the furnace where the combustion air is ex posed to the following substances chlorinated waxes or cleaners chlorine based swimming pool chemicals water softening chemicals deicing salts or chemicals carbon tetrachloride halogen type refrigerants cleaning solutions such as perchloroethylene printing inks paint removers varnishes hydrochloric acid cements and glues antistatic fabric softeners for clothes dryers and masonry acid washing materials Isolate a nondirect furnace from an area contaminated by any of the above substances This protects the non direct ventfurnace from airborne contaminants INSTALLATION CONSIDERATIONS To ensure that the enclosed non direct ventfurnace has an adequate supply of combustion air vent from anearby uncontaminated room or from outdoors Re fer to the Combustion and Ventilation Air Require ments section in this manual or the installation in structions for details e Ifthe furnace is used in connection with
128. ublic walk ways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators relief valves or other equipment Thecombustion air intake termination of a direct vent application should not terminate in an area which is frequently dusty or dirty NOTE In Canada the B149 Fuel Gas Code takes prece dence over the preceding termination restrictions Direct Vent Installations On upflow units secure the combustion air intake pipe di rectly to the air intake coupling On counterflow units se cure the combustion air intake pipe to the air intake cou pling using the rubber coupling and worm gear hose clamps provided with the unit The counterflow rubber coupling al lows service removal of air intake piping internal to the fur nace blower compartment The combustion air intake pipe can also be secured directly to the counterflow unit air in take pipe coupling Non Direct Vent Installations A minimum of one 90 elbow must be installed on the com bustion air intake coupling to guard against inadvertent blockage caution EDGES OF SHEET METAL HOLES MAY BE SHARP USE GLOVES AS PRECAUTION WHEN REMOVING HOLE PLUGS THE RUBBER ELBOW IS NOT DESIGNED TO SUPPORAT LOAD WHEN THE RUBBER ELBOW IS MOUNTED EXTERNALLY TO THE FURNACE CABINET EXTREME CARE MUST BE TAKEN TO ADEQUATELY SUPPORT FIELD SUPPLIED VENT FLUE PIPING AS DAMAGE CAN RESULT IN LEAKS CAUSING BODILY
129. uired volume shall be determined as follows INSTALLATION CONSIDERATIONS 1 For appliances other than fan assisted calculate using the following equation 21 fe 1 ACH 1000 2 For fan assisted appliances calculate using the following equation Required Volume gt other 3 Required Volume gt Bu 1 jon 1000 Btu hr where om all appliances other than fan assisted input in Btu per hour fan assisted appliances input in Btu per hour ACH airchange per hour percent of volume of space exchanged per hour expressed as a decimal 3 For purposes of this calculation an infiltration rate greater than 0 60 ACH shall not be used in the equations in 9 3 2 2 1 and 9 3 2 2 2 9 3 2 3 Indoor Opening Size and Location Openings used to connect indoor spaces shall be sized and located in accordance with the follow ing 1 Combining spaces on the same story Each opening shall have a minimum free area of 1 in 1000Btu hr 2200 mm kW of the total input rating of all appliances in the space but not less than 100 in 0 60m One opening shall commence within 12 in 300 mm of the top and one opening shall commence within 12 in 300 mm of the bottom of the enclosure see Figure A 9 3 2 3 1 The mini mum dimension of air openings shall be not less than 3 in 80 mm Chimney or Gas Vent NOTE Each opening must have a free area of notless than one square inch pe

Service Manual - East Coast Metal Distributors

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