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Goodman GMEC96 Service Instructions

1. c us e 9 G 9 CHO wow FO s T EIL Ts e Eg o e l9 E PN 02 ve ES ras PCBBF133 Control Board 4 After the ignitor warmup time begin checking for 24 volts to the gas valve Voltage will be present for four seconds only if proof of flame has been established 5 If proof of flame was established voltage will be provided to the air circulation blower following the heat on delay period 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 56 LINE VOLTAGE NOW PRESENT 3 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 The Integrated Ignition controls will have 1 to 4 micro amps If the micro amp reading is less than the mini mum specified check for high resistance wiring con nections sensor to burner gap dirty flame sensor or poor grounding If absolutely 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
2. d 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 Flame current can be measured in two ways 1 2 Putting a D C microamp meter in series with the flame rod Putting a D C volt meter across the two solder pads in the flame current section of the control board 1 D C volt 1 microamp Flame Current Solder Pads m CAUTION 20V NEUTRAL S E d 8 r Em o mur q sts ff B zi Ne Bago A 9 b 20 O PO T 660 _ Os gt 2007 s pi cem 9 o HO 0 Macr my nes 0 o o A 9 JA O s e 9 69 cs ZS 3 x EMIERSONLe re E Climate Technologies R578 ra 5 om e HE 2880800889 e 2 cm R580 T K5 amp E S Y ber Pim 5 00 2 e CL 9 e i ambe ROT EOS P E Som S v gt or 7 OFF OH FO 5 00 SES s B z STO 5 pem m gon CH ws O e enm 5 a e d 5G ere 3 e E E Q o e m 59 ur z IS D Cu Es Po ARA G 6 eo amp G o YIO Y w1 w2 R G TWIN ey
3. Using a single stage thermostat the options for high fire Duty Cycle delay are 10 minutes 20 minutes or auto The automatic second stage logic is a method of en ergizing the second stage valve based on the recent 38 50 average of the heating duty cycle During a typical 50 62 heating day there will be at least one call for heat 62 75 within a 3 hour period and usually much more often During this mode the low to high stage delay is deter fron mined by using the average calculated duty cycle from 88 100 the table below Once the specified delay time has expired the second stage valve will be energized On the heating cycle following a period of 3 hours or gt Purpose _ silkscreen Function greater in which there is no call for heat the second MM stage valve will energize based on the average calcu di Delay s 150 seconds Of lated duty cycle prior to the three hour no call for heat s Bp seconds ON If the average calculated duty cycle is less than 50 then the low to high stage delay will be determined from the table below In this case an assumption is made that the outside temperature is fairly mild and the long time between calls for heat was due to a low thermal loss in the building Going quickly to second stage heat is not required in this instance Heat Mode Blower Off Delay Timing 32 SYSTEM OPERATION COOLING MO
4. INSTALLATION CONSIDERATIONS Vent Maintain 12 18 for Canada a minimum clearance above highest anticipated snow level Maximum of Combustion Air Roof Boot Flashing Field Supplied Support Field Supplied 45 Elbow L Field Supplied Vent Combustion Air V Condensate Drain Lines and Drain Trap 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 condensate 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 If the drain line is routed through an area which may 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 i
5. 547 547 778 547 313 547 586 N A TI8 586 TI8 586 N A SYSTEM OPERATION MEC960603BN All DIP Switch Positions All DIP Switch Positions FACTORY uda All DIP Switch Positions OFF OFF OFF ON OFF OFF ON ON OFF OFF ON OFF OFF OFF ON OFF ON ON ON OFF ON ON ON ON MEC960803BN All DIP Switch Positions FACTORY All DIP Switch Positions SETTING All DIP Switch Positions OFF OFF OFF ON OFF OFF ON ON OFF OFF ON OFF OFF OFF ON OFF ON ON ON OFF ON ON ON ON W2 Ylo Ylo Ylo Ylo Ylo Ylo Ylo Ylo W1 W2 Ylo Ylo Ylo Ylo Ylo Ylo Ylo Ylo DIP SWITCH SETTING 0 1 0 2 0 3 0 4 0 5 06 07 08 CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM CFM CFM 894 846 780 720 660 603 554 505 894 42 846 44 780 48 720 52 660 57 603 554 505 1328 40 1287 41 1249 43 1215 44 1170 46 1131 1085 1046 782 629 547 469 396 333 N A N A 1236 1189 1149 1101 1066 1017 969 928 782 629 547 469 396 333 N A N A 1149 1104 1057 1017 963 918 865 822 1149 1104 1057 1017 963 918 865 822 1236 1189 1149 1101 1066 1017 969 928 1149 1104 1057 1017 963 918 865 822 894 846 780 720 660 603 554 505 1149 1104 1057 1017 963 918 865 822 1328 1287 1249 1215 1170 1131 1085 1046 782 629 547 469 396 333 N A N A 1236 1189 1149 1101 1066 1017 969 928 1328 1287 1249 1215 1170 1131 1085 1046 1236 1189 1149 1101 1066 1017 969 928 1328 1287 1249 1215 1170 1131 1085 1046 782 629 547 469 396 333 N A N A DIP SWITCH SETTING
6. 0 1 0 2 0 3 0 4 0 5 06 07 08 CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM CFM CFM 1221 1172 1128 1087 1049 1005 959 2922 1221 41 1172 42 1128 44 1087 46 1049 47 1005 959 922 1311 54 1293 55 1249 57 1203 59 1172 61 1122 1088 1041 750 644 569 507 442 388 328 1111 1068 1025 984 941 885 N A 801 750 644 569 507 442 388 328 NA 894 842 784 726 682 618 562 519 894 842 784 726 682 618 562 519 1111 1068 1025 984 941 885 801 894 842 784 726 682 618 562 519 1221 1172 1128 1087 1049 1005 959 922 894 842 784 726 682 618 562 519 1311 1293 1249 1203 1172 1122 1088 1041 750 644 569 507 442 388 328 1111 1068 1025 984 941 885 801 1311 1293 1249 1203 1172 1122 1088 1041 1111 1068 1025 984 941 885 801 1311 1293 1249 1203 1172 1122 1088 1041 750 644 569 507 442 388 328 NA 29 SYSTEM OPERATION 30 MEC961004CN All DIP Switch Positions All DIP Switch Positions FACTORY All DIP Switch Positions SETTING OFF OFF OFF ON OFF OFF ON ON OFF OFF ON OFF OFF OFF ON OFF ON ON ON OFF ON ON ON ON MEC961205DN All DIP Switch Positions All DIP Switch Positions FACTORY All DIP Switch Positions SETTING OFF OFF OFF ON OFF OFF ON ON OFF OFF ON OFF OFF OFF ON OFF ON ON ON OFF ON ON ON ON 1 w2 Ylo Ylo Ylo Ylo Ylo Ylo Ylo Ylo W1 w2 Ylo Ylo Ylo Ylo Ylo Ylo Ylo Ylo DIP SWITCH SETTING 0 1 0 2 0 3 0 4 0 5 0 6 CFM Rise CFM Rise CFM Rise CF
7. 6 9 001 11 000 ft altitude 34 ACCESSORIES EXTERNAL FILTER RACK KIT 90 Upflow Model Furnaces FRONT OF UNIT BASE OF UNIT EFRO2 UNIT SIDE PANEL 0 RETURN AIR CUTOUT AREA SLOTS IN FILTER CLEAR SCREWS ON UNIT N BLOWER DECK SCREWS N FILTER RACK ASSEMBLY FACE FILTER OPENING TOWARDS FRONT OF UNIT LOWER EDGE SCREW SIDE WALL VENT KIT 0170K00000S 0170K00001S Description This side wall only vent kit 0170 000008 is to be used with 2 3 vent systems The 0170K00001S is a side wall vent kit that is to used with 2 vent systems ONLY This kit is NOT intended for use with single pipe indi rect vent installations The vent kit must terminate outside the struc ture 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 Combustion Air Pipe Terminations for more information or consult the Installation Instructions IO 635 Horizontal Installation Vertical Installation 35 ACCESSORIES 36 CONCENTRIC VENT CONVERSION KIT DCVK 20 DCVK 30 CVENT 2 CVENT 3 Vent The DCVK 20 2 or the DCVK m s aintain 12 for Canada 30 3 is a concentric vent kit minimum clearance above highest approved with furnaces listed in anticipated snow level Maximum of this manual Combust
8. 110 105 100 95 90 85 or2 2 60 000 90 85 80 75 70 65 60 or21 2 80 000 B 2 or 2 1 2 65 60 55 50 45 40 80 000 B 193 186 179 172 165 158 151 80 000 C NEN or 21 2 15 10 5 80 000 C Lr pepe 186 179 172 165 158 151 100 000 20 21 2 20 15 10 5 100 000 3 200 193 186 179 172 165 158 151 120000 2 or 21 2 35 30 25 20 15 10 120 000 3 95 90 85 80 75 70 65 60 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 2 1 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 consid ered equivalent to one 90 deg elbow 6 One 90 elbow should be secured to the combustion air intake connection VENT FLUE TEE OR 90 ELBOW TURNED DOWN 12 MINIMUM ABOVE HIGHEST ANTICIPATED SNOW LEVEL 90 Furnace Horizontal Termination Single Pipe Above Highest Anticipated Snow Level INSTALLATION CONSIDERATIONS NOTE Terminate both pipes in the same pressure zone same side of roof no major obstacles between pipes etc TEE OPTIONAL COMBUSTION AIR INTAKE OPTIONAL Not required for single pip
9. 980 1340 980 1478 980 1984 605 1340 1984 1340 1984 605 0 8 CFM 1101 1101 1504 406 1399 406 820 820 1399 820 1101 820 1504 406 1399 1504 1399 1504 406 0 8 CFM 1425 1425 1942 N A 1276 N A 913 913 1276 913 1425 913 1942 N A 1276 1942 1276 1942 N A SYSTEM OPERATION UPRIGHT FILTER INSTALLATIONS Depending on the installation and or customer preference differing filter arrangements can be applied Filters can be installed in the central return register and a side panel exter nal filter rack kit upflow filter kit EFRO2 As an alternative a media air filter or electronic air cleaner can be used as the requested filter Refer to the following minimum filter require ment charts for determination of the minimum filter area to ensure proper unit performance The following figures show possible filter locations 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 FI
10. Adjust Heat Anticipator Setting 598 Relocate Thermostat S 316 Faulty Limit or Roll Out Switch Test Control S 300 S 302 Faulty Flame Sensor Faulty Ignition Control S 314 S 313 Test Flame Sensor Test Control Gas Valve or Gas Supply Shut Off Turn Valves to On Position S 317 Faulty Induced Draft Blower Test Induced Draft Motor S 303 Faulty Blower Motor PSC Test Blower Motor PSC S 16A B C Broken or Shorted Ignitor Dirty Flame Sensor Low UA S 308 S 314 Test Ignitor Clean Flame Sensor Stuck Gas Valve Replace Gas Valve S 304 Faulty Gas Valve S 304 S 301 Replace Gas Valve Open Auxiliary Limit Improper Air Flow or Distribution Cycling on Limit Reset Control Check Duct Static S 200 S 201 S 300 Delayed Ignition Hashback Check Controls amp Temperature Rise Test for Delayed Ignition Test for Flashback S 312 S 309 S 311 Orifice Size Check Orifices S 306 S 311 Gas Pressure Check Gas Pressure S 307 Cracked Heat Exchanger Furnace Undersized Check Burner Flames S 305 Replace with Proper Size Furnace Furnace Oversized Replace with Proper Size Furnace Faulty Pressure Switch Test Pressure Switch Blocked or Restricted Flue Open Roll Out Switch Check Flue Drawdown Pressure Bouncing On Pressure Switch CM NES Test Flame Roll Out Control S 302 Test Ne
11. 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 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 3 Check 120 volt outputs on the 5 pin harness Pin 1 HSI Hot Pin 2 Inducer High Pin 3 Inducer Low Pin 4 Inducer N Pin 5 HSIN 55 SERVICING
12. Switch 5 f the switch will not close after manually resetting it must be replaced 6 Measure the voltage between each side of the rollout control and ground during the ignition attempt If a roll out switch has tripped it is important to find out why Possible causes could be flame impingement orifice plate out of position burners with excessive cross over slot dimension over firing improper orifices improper gas pressure air leaking from around the heat exchanger into the burner compartment air leaking through the heat exchanger itself 50 7 After check and or replacement of rollout switch rein stall burner compartment door and verify proper unit op eration 5 303 INDUCED DRAFT BLOWER Motor Awarnine 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 ofthe motor leads 4 Touchone 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
13. gas water heater etc Should not be operated in enclosed areas such as unventilated garages or utility rooms 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 and a carbon monoxide producing device is operated therein there must be adequate direct outside ventilation 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 N DANGER RISQUE D EMPOISONNEMENT 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 fonctionner ces appareils dans un endroit clos assures vous qu il y ait une ventilation directe provenant de l exterie 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 N PE
14. lt Chimney or Gas Vent NOTE Each opening must have a free area of not less than one square inch per 1000 BTU of the total input rating of all equip ment in the enclosure but not less than 100 square inches Opening m 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 provided through opening s to the outdoors in accordance with the methods 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 13 INSTALLATION CONSIDERATIONS 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
15. minals 3 Using an ohmmeter test for continuity across the two terminals VOLT OHM METER RED RESET BUTTON COLOR IDENTIFYING TAB Testing Auxiliary Limit Control TO AVOID POSSIBLE FIRE ONLY RESET THE AUXILIARY LIMIT CONTRO ONCE IF IT SHOULD OPEN A SECOND TIME A QUALIFIED SERVICER MUST DETERMINE WHY THE AUXILIARY LIMIT OPENED BEFORE RESETTING AGAIN 49 SERVICING 302 CHECKING FLAME ROLLOUT CONTROL A temperature activated manual reset control is mounted to the manifold assembly as shown in the following illustration FLAME ROLLOUT SWITCHES Flame Rollout Switch Location 90 Upflow Furnace Shown The control is designed to open should a flame roll out oc cur An over firing condition or flame impingement on the heat shield may also cause the control to open If the rollout control opens the air circulation blower will run continuously LINE VOLTAGE NOW PRESENT 1 Remove the burner compartment door to gain access to the rollout switch es mounted to burner bracket 2 Reset the manual roll out switch 3 Remove wires from roll out switch 4 Using an ohmmeter check for continuity across the
16. 115 voltsto condition before flashes on control board flashes p y ground amp neutral Neutral wire proceeding with repairs should measure 0 volts to ground Verify gas valve is not Confirm electrical and Furnace does not Ten bs me Gas valve current detected receiving voltage from an gas safe conditions operate ten Red flashes None None repeating a F with no call for heat electrical short If valve wiring before proceeding with on control board flashes is correct replace control board repairs doesnot Eleven Confirm electrically safe operate eleven Red Open limit switch circuit for Re set main power and check s y None None repeating condition before flashes on control board more than 5 minutes indoor blower operation flashes proceeding with repairs inducer running Furnace does not Twelve Confirm electrically safe 2 Control board igniter relay as operate twelve Red None None repeating QE Replace control board condition before not energizing igniter y flashes on control board flashes proceeding with repairs Furnace does not Confirm electrically safe operate control board None Solid ON Control board internal fault Replace control board condition before Red LED on solid proceeding with repairs Furnace does not Confirm electrically safe operate control board None Rapid Flash Twinning error Correct twinning wiring condition be
17. DEATH THE FURNACE MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH LOCAL CODES OR IN THEIR ABSENCE WITH THE LATEST EDITION OF THE Nationa ELECTRIC CODE 115 VOLT LINE CONNECTION OF ACCESSORIES ELECTRONIC AIRCLEANER 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 ACCESSORY LOAD SPECIFICATIONS Electronic 1 0 120 VA Air Cleaner 0 Amp maximum at 120 VAC 1 0 Amp maximum at 120 VAC Turn OFF power to the furnace before installing any acces sories Follow the humidifier or air cleaner manufacturers instructions for locating mounting grounding and control ling these accessories 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 The integrated control module electronic air cleaner termi nals EAC are energized with 115 volts whenever the circu lator blower is energized 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
18. GAS TO APPLIANCE DEI 1 Set the thermostat to its lowest setting 2 Turn off all electric power to the appliance if service is to be performed 3 Remove control access panel 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 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 7 Wait five 5 minutes to clear out any ae If you then smell gas STOP ollow 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 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 proper
19. W1 flash 9 proceeding with work Normal operation with Two EON Confirm electrically safe Normal operation with high i high or single stage call None repeating None None Required condition before or single stage call for heat for heat flashes proceeding with work Furnace does not Three Confirm electrically safe operate three Amber None repeating None W2 call present without W1 9 condition before improperly connected flashes on control board flashes f proceeding with repairs thermostat wires Furnace does not Four Faulty Confirm electrically safe Ylo or Y call present without thermostat wiring or operate four Amber None repeating None G comectad condition before flashes on control board flashes propery proceeding with repairs thermostat wires Clean flame rod with steel wool Confirm electrically safe condition before proceeding with repairs Dirty coated flame rod poor flame improper gas pressure poor flame sense wire or connections Furnace does not operate rapid Amber Rapid None Low flame sense current flashes on control board Confirm electrical and gas safe conditions before proceeding with repairs Furnace does not Gas valve stuck open Flame sensed when no x operate one Red flash None repeating improper wiringto gas valve flame should be present e on control board flash shorted
20. WIRING Disconnect ALL POWER BEFORE SERVICING 1 Check wiring visually for signs of overheating damaged insulation and loose connections 2 Use an ohmmeter 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 equiva lent 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 fur nace 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 d WARNING 4 Induced Draft Motor must run and pull in pressure Switch 5 Ifthe hot surface ignitor heats and at the end of the ignitor 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 thermo stat 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 8 Turn onthe power 9 Ifthe furnace blower motor starts and the condensing unit runs then the trouble is in the thermostat or wi
21. Wi J Ypresentwith no G Y1 present with no G call Rapid j Lowflamesensecurent 2 2 Soid _ Standby Normal Speraton wih cat forte Normal Operation with call for Low stage cool Normal Operation with call for High stage cool or single stage cooling Y G DiAGNOSTIC CHART Referto the Troubleshooting Chartin the back of this manual for assistance in determining the source of unit operational prob lems External Lockout control lockout resulting from an external fault sensed by the control such as an unsuccessful re cycle or retry period or a limit trip Once in External Lockout the control will shut down for a period of one hour before attempting another trial for ignition Internal Lockout A Afailure internal to the control board RECALL Retrieving Fault Codes To retrieve fault codes push and release the LAST ER ROR button for more than 1 5 second and less than 5 sec onds the LED will indicate this period by solid GREEN for 1 5 second to 5 seconds The LED will flash up to five stored fault codes beginning with the most recent If there are no fault codes in memory the LED will flash two green flashes The control will flash the most recent error first and the old est error last If multiple faults exist there will be 2 seconds between codes Solid LED error codes will not be
22. 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 BT U 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 nace 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 Multiplying the ninety 90 cubic feet by 1 025 BTU per cu bic foot give
23. 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 ensure proper unit performance Refer to the following information for removal and installation of fil ters 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 57 MAINTENANCE CONDENSATE DRAINAGE SYSTEM QUALIFIED SERVICER ONLY The drain tubes standpipe and field supplied drain line must be checked annually and cleaned as often as necessary to ensure proper condensate drainage 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 specification sheet BURNERS HI
24. air supply system the combustion air shall be supplied form outdoors at the minimum rate of 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 wi
25. allumez paz le br leur manuellement B Sentir tout autour de l appariel AVANT D ALLUMER afin de deceler toute fuite de gaz Assurez vous de sentir tout pres du plancher car certains gaz sont plus lourds que l air et se d poseront sur le plancher SI VOUS SENTEZ UNE ODEUR DE GAZ Ne tentez d allumer aucun appariel Ne touchez pas aux interrupteurs lectriques n utiliser aucun t l phone dans l difice o vous vous trouvez Appelez imm diatement votre fournisseur de gaz en utilisant le telephone d un voisin et suivez les instructions du fournisseur Appelez les pompiers si vous ne parvenez pas rejoindre votre fournisseur de gaz C N utiliser que votre main pour pousser ou tourner le commande du gaz N utilisez jamais d outils Si vous ne parvenez pas pousser ou tourner la commande ne tentez pas de la r parer appelez un r parateur qualifi Forcer la commande ou essayer de la r parer peut entrainer un risque d incendie ou d explosion D N utilisez pas cet appareil si l une de ses parties a t dans l eau Si cela se produit demandez imm diatement un r parateur qualifi d inspecter l appareil et de remplacer toute pi ce du systeme de contr le et toute commande de gaz ayant t dans l eau 0140F00002P E INSTRUCTIONS DE SERVICE MI UN INSTANT Lisez d abord les consignes de s curit ci dessus R glez le thermostat son point le plus bas Coupez l alimentation lectrique de l appare
26. appli ance It is the responsibility of the installer to follow the manufac 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 ensure that all piping and connections possess adequate structural integrity and support to prevent flue pipe separa tion shifting or sagging during furnace operation Materials and Joining Methods AVOID BODILY INJURY FIRE OR EXPLOSION SOLVENT CEMENTS MUST KEPT AWAY FROM ALL IGNITION SOURCES LE 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 exposed 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 combustion air intake pipe when applicable terminations Refer to or the installation instructi
27. 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 MAINTENANCE d w RNiNG 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 pipe system Check for blockage and or leak age Check the outside termination and the connec tions at and internal to the furnace e 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 Drainage s
28. condensing in or overheating of the heat exchanger An airflow and temperature rise table is provided in the blower performance specification section Determine and adjust temperature rise as follows 1 Operate furnace with burners firing for approximately ten minutes Check BTU input to furnace do not exceed input rating stamped on rating plate Ensure all registers are open and all duct dampers are in their final fully or partially open position 2 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 CROSS HATCHED AREA SUBJECTED TO RADIANT HEAT DO NOT MEASURE SUPPLY AIR TEMPERATURE IN THIS AREA lt gt SUPPLY gt AIR Ce gt LQ T SUPPLY RISE T SUPPLY T RETURN lt gt i T RETURN RETURN AIR 92 9 XX 52 2 25 55 0 oS 2 55 95 552 2 Rx 76 z eS 559 555 KS 550 09500 25 55 25 5 2 SS 5 c 5 2 5 SS LX 5 1 Q poo 5 0509 555 DNA MEASURE HERE Checking Temperature Rise 3 Subtract the return air temperature from the supply air temperature to determine the air temperature rise Allow adequate time for thermometer readings to stabilize 4 Adjust temperature rise by adjusting the circulator blower speed Increase blower speed to
29. flame rod or wire Furnace does not Faulty pressure switch operate two Red Two Confirm electrically safe pressure switch wires shorted am flashes on control board eNone None repeating Pressure switch stuck closed condition before nen control board inducer relay 4 a possible inducer flashes proceeding with repairs stuck dosed operation Faulty pressure switch pressure switch or tubing or Furnace does not Three 5 Confirm electrically safe Low fire pressure switch wiring connection control ui operate three Red None None repeating condition before stuck open board inducer relay failed vent flashes on control board flashes proceeding with repairs pipe restriction excessive elbowsor length 42 TROUBLESHOOTING double flashes Switch Green Amber Red mptom Fault Description Furnace does not Four Open limit circuit main rise static Confirm electrically safe 5 pe gas pressure burner alignment as operate four Red None None repeating limit aux limit or roll out m 2 es condition before a orifice plate position wiring to flashes on control board flashes switch all limits proceeding with repairs Control board fuse Furnace does not Five Limit amp rolloutcircuitopen Temperature rise duct static Confirm electrically safe operate five Red None None repeating for 15 mi
30. 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 96 furnace has W1 8 W2 terminals for connec tion of a two stage heating thermostat If desired a thermo stat with only one stage of heat may be used As shipped the furnace S1 1 switch is OFF S1 2 switch is ON This is the correct position to use a single stage heating thermo stat with auto timing transition to high fire OOOO Furnace Integrated Control Module Remote Condensing Unit Single Stage Cooling Thermostat Single Stage Heating with Single Stage Cooling NOTE To apply a single stage Heating Thermostat the thermostat selector switch on the Integrated Control Module must be set on single stage OO 9 amp 3 990 06 6 OO Remote Condensing Unit Single Stage Cooling Furnace Integrated Control Module Thermostat Two Stage Heating with Single Stage Cooling 25 INSTALLATION CONSIDERATIONS Ko 09 0909096 000 Remote Condensing Unit Two Stage Cooling Furnace Integrated Control Module Thermostat Two Stage Heating with Two Stage Cooling Thermostat Wiring Diagrams SINGLE STAGE HEATING THERMOSTAT APPLICATION A single stage thermostat with only one heating stage may be used to co
31. is installed in horizontal left position and the internal elbow is removed INSTALLATION CONSIDERATIONS Introduction This is a Category IV furnace This furnace uses a pressur ized venting system and must be installed per National and local codes requirements and the installation manual that was shipped with the furnace The MEC96 34 5 furnace is one of the products in our newly redesigned line of shorter chassis furnaces It is avail able in the following sizes and suitable for up flow horizon tal installation MEC960302BNAA MEC960402BNAA MEC960603BNAA MEC960803BNAA MEC961004CNAA MEC961205DNAA Safety Please adhere to the following warnings and cautions when installing adjusting altering servicing or operating the fur nace 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 OF CALIFORNIA TO CAUSE CANCER BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM To PREVENT POSSIBLE PROPERTY DAMAGE 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 bef
32. 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 025 002 CARRYOVER SLOT WIDTH b 1 J AX fe 16X 12X 125 125X 030 MIN SLOT d SEE NOTE 1 562 34 5 Burner 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 burner cross over slots should not be altered in size S 306 CHECKING ORIFICES MEC96 model furnaces have factory installed 45 natural gas orifices except MEC96030 which has 50 The only time resizing is required is when a reduction in firing rate is required for an increase in altitude or a furnace is being converted for use with LP gas 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 adjustthe flame prop erly This same problem can occur if an orifice spud of a different length is substit
33. nace no special provisions for air for combustion are re quired However if this furnace is to be installed in the same INSTALLATION CONSIDERATIONS space with 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 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 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
34. positioning burners should be in lo cating slots level front to rear and left to right 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 neu tral and hot wire connection to the line polarity or a high resistance connection in the neutral line may cause the con trol 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 resis tance 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 electro mechanical device and is not field repairable Complete unit must be replaced LINE VOLTAGE NOW PRESENT 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 period is 4 seconds Goodman Brand and Amana Brand Two Stage MEC96 1
35. quality thermostat with a C terminal is used to operate the furnace Thermostat Location In an area having good air circulation 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 Radiant heat from the sun Light fixtures or other appliances Radiantheat from a fireplace e Concealed hot or cold water pipes or chimneys Unconditioned areas behind the thermostat 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 ven 2 pipe fur
36. 00 600 1500 138 277 555 1385 129 257 514 1286 120 240 480 1200 113 225 22 200 189 106 180 5 10 138 277 692 31 62 124 248 621 30 60 120 240 600 e 232 581 19 28 55 Lo 1 2 514 90 as RENE 6 64 60 56 EN 424 50 400 477 Rs 45 90 180 439 CHEN 327 818 318 783 37 300 750 36 END WEA 108 100 es 86 82 164 EST TN 64 10 Thousand 1 Thousand CUBIC FEET O SERVICING Service Problem No Heat Unsatisfactory Heat POSSIBLE CAUSE DOTS IN ANALYSIS GUIDE INDICATE POSSIBLE CAUSE SYMPTOM Power Failure System Will Not Start Burner Won t Ignite Bumer Ignites Locks Out Burner Shuts Off prior to T Stat being Satisfied Short Cycles Long Cycles Soot and or Fumes Too Much Heat Not Enough Heat Test Method Remedy See Service Procedure Reference Test Voltage Blown Fuse Test Voltage Loose Connection Check Wiring Shorted or Broken Wires No Low Voltage Check Wiring Check Transformer Faulty Thermostat Check Thermostat Faulty Transformer Check Transformer Poor or High Resistance Ground Improper Heat Anticipator Setting Improper Thermostat Location Measure Ground Resistance
37. 48 34 469 40 413 45 349 885 30 821 32 755 35 684 39 621 43 557 874 697 612 533 470 414 1146 1097 1049 1002 941 895 874 697 612 533 470 414 928 868 810 743 670 614 928 868 810 743 670 614 1146 1097 1049 1002 941 895 928 868 810 743 670 614 870 658 548 469 413 349 928 868 810 743 670 614 885 821 755 684 621 557 874 697 612 533 470 414 1146 1097 1049 1002 941 895 885 821 755 684 621 557 1146 1097 1049 1002 941 895 885 821 755 684 621 557 874 697 612 533 470 414 DIP SWITCH SETTING 0 1 0 2 0 3 0 4 0 5 0 6 CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM 847 694 611 535 471 415 847 29 694 36 61 41 535 47 471 53 415 989 36 932 38 882 40 819 43 773 46 695 856 667 546 466 413 357 1143 1095 1046 996 946 890 856 667 546 466 413 357 960 898 840 780 711 659 960 898 840 780 711 659 1143 1095 1046 996 946 890 960 898 840 780 711 659 847 694 611 535 471 415 960 898 840 780 711 659 989 932 882 819 695 856 667 546 466 413 357 1143 1095 1046 996 946 890 989 932 882 819 695 1143 1095 1046 996 946 890 989 932 882 819 773 695 856 667 546 466 413 357 0 7 CFM 293 293 508 361 846 361 560 560 846 560 293 560 508 361 846 508 846 508 361 0 7 CFM 357 357 650 302 834 302 596 596 834 596 357 596 650 302 834 650 834 650 302 0 8 CFM N A N A 461 303 787 303 505 505 787 505 N A 505 461 303 787 461 787 461 303 0 8 CFM 313 313 586 N A 718
38. CES m HOLD DOWN NUTS j SUPPORT NUTS CONDENSATE DRAN GAS PIPING y 2 x2 x1 8 ANGLE IRON A FS RAGES POSITION AS CLOSE AS POSSIBLE TO BLOWER DECK TO ALLOW FOR CIRCULATOR BLOWER REMOVAL Pd TILT OUTWARD TO ALLOW FOR DOOR AND CIRCULATOR BLOWER REMOVAL 90 Suspended Furnace Shown ExISTING 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 c In so far as practical close all building doors and windows and all doors between the space in which the appliance s connected to the venting sys
39. DE MANUAL FAN ON LOW STAGE COOLING MODE SEQUENCE On a call for Fan the G thermostat contacts close On a call for lo cool the Ylo and G thermostat con tacts close signaling the control module The LED will display a GREEN 1 flash The compressor and condenser fan are energized The compressor is connected to the Ylo terminal of the control module The circulator fan is energized at lo cool speed after a cool on delay The electronic air cleaner will also be energized After the thermostat is satisfied the compressor is de energized Following the 60 second Cool Mode Fan Off Delay period the cool circulator and air cleaner relay are de energized When the call for Ylo and G are presented simulta neously the control will honor the Cool On delay and keep the circulator de energized After the Cool On delay the circulator fan and air cleaner relays are energized The circulator fan is energized at the cool speed If a call for G is present prior to a call for Ylo the circulator will remain at the FAN circulator speed during the Cool On delay SINGLE COOLING STAGE THERMOSTAT OR 2ND STAGE COOLING MODE SEQUENCE On a call for cool the Y and G thermostat contacts close signaling the control module The LED will display a GREEN 2 flash The compressor and condenser fan are energized The compressor is connected to the Y terminal of the con trol module The circulator fan is energized at cool speed a
40. E INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING High Fire Regulator Regulator Vent Adjust DNA O Gas Valve On Off T Selector Switch ow Fire Regulator Adjust Honeywell Model VR9205 Two Stage Measuring Gas Pressure Two Stage Valves Cont d Common Terminal C High Fire Coil Terminal HI Low Fire Coil Terminal LO Open to Manometer Atmosphere Hose Inlet Pressure Tap 1 8 NPT Manometer GS Outlet Pressure Tap b d 1 8 NPT Honeywell Model VR9205 Connected to Manometer 1 Removeregulator cover screw from the low LO outlet pressure regulator adjust tower and turn screw clock wise to increase pressure or counterclockwise to de crease pressure Replace regulator cover screw a Close thermostat R and W contacts to provide a call for heat b Remove regulator cover screw from the high HI out let pressure regulator adjust tower and turn screw clockwise to increase pressure or counterclockwise to decrease pressure Replace regulator cover screw c Turn off all electrical power and gas supply to the system d Remove the manometer hose from the outlet pres sure boss 53 SERVICING e Remove the 1 8 NPT hose b
41. E COMPRESSOR MICROPROCESSOR POWER SUPPLY OUT TO HP CONTROL HP CALL FOR FURNACE DURING DEFROST REVERSING VALVE OUTPUT COMPRESSOR CONTACTOR OUTPUT POWER SUPPLY COMMON OUT TO HP CONTROL ODT OUTDOOR THERMOSTAT 2ND STAGE COMPRESSOR DEMAND OUTPUT BREAK FOR ODT 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 8096 or 9096 Single Stage or Two Stage Furnaces 37 SERVICING 5 1 5 2 5 S 3B S 4 S 16A S 200 S 201 S 300 S 301 S 302 S 303 S 304 S 305 S 306 S 307 S 308 S 309 5 310 S 311 5 312 5 313 5 314 38 SERVICE NUMBERS eue dlerieBpiccfe 45 CHECKING WIRING 55256 ETE 45 THERMOSTATAND WIRING dicta neve uode ieee eames 45 HEATINGAN aelu ol A M 45 CHECKING TRANSFORMER AND CONTROL CIRCUIT iii 46 CHECKING AIR CIRCULATOR BLOWER MOTOR 46 CHECKING DUG T STATIG ist ipa tone cae mot ada 46 CHECKING TEMPERATURE nere nenne 45 CHECKING PRIMARY LIMIT a 45 tt que rutru ea metr d ve tante avt ede ut E rarae nee 48 CHECKING FLAME ROLLO
42. GH VOLTAGE ELECTRICAL COMPONENTS ARE CONTAINED IN BOTH COMPARTMENTS TO AVOID ELECTRICAL SHOCK INJURY OR DEATH DO NOT REMOVE ANY INTERNAL COMPARTMENT COVERS 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 2 Not curling floating or lifting off Burner Flame 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 Dial type thermometers or thermocouple meter op tional to measure dry bulb temperature 2 Amprobe to measure amperage and voltage 58 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
43. 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 applied for propane gas installations Refer to the specification sheet for the model you are servic ing Refer to the propane gas and or High Altitude Installa tions section for details GAS VALVE This unit is equipped with a 24 volt gas valve controlled dur ing 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 ap propriate propane gas conversion kit Taps for measuring the gas supply pressure and manifold pressure are provided on the valve NOTE The gas supply pressure on White Rodgers G J model gas valve can be checked with a gas pressure test kit Part 0151 000005 available through our authorized distributors 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 Put ting the Furnace Into Operation section of this manual or the installation instructions for use of this control during start up and shut down periods GASPIPING CONNECTIONS To AVOID POSSIBLE UNSATISFACTORY OPERATION OR EQUIPMENT DAMAGE DUE TO UNDERFIRING OF EQUIPMENT U
44. KS 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 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 please refer to the warning 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 lig 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 dropin 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 sizin
45. L SHOCK OR CARBON MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION REPAIR OPERATION OR MAINTENANCE OF THIS PRODUCT INSTALLATION CONSIDERATION 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 American National Standards Institute 1430 Broadway New York NY 10018 National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 CSA International 8501 East Pleasant Valley Cleveland OH 44131 A copy of the CAN CGA B149 Installation Codes can be obtained from CSA International 178 Rexdale Boulevard Etobicoke Ontario Canada M9W 1R3 The rated heating capacity of the furnace should be greater than or equal to the total heat loss of the area to be heated 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 Conditi
46. LE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH This furnace is equipped with a multi speed ECM motor Two wiring harnesses connect the motor to the integrated control board and furnace power supply The line voltage 115 VAC power supply to the motor is constant and not switched by the control board Motor operation is also de pendent on a 24 VDC signal on one of the four speed taps on the motor The airflow tables for heating and cooling speeds show the relationship between airflow CFM and external static pressure for each size furnace WARNING To AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK TURN OFF POWER TO THE FURNACE BEFORE CHANGING SPEED TAPS Circulator Blower Speed Facts 1 Motor speed Tap wiring must remain in factory posi tion on the control board and motor 2 There are 4 speed Tap wires to the motor T1 T2 T3 T4 3 There are 5 speeds available depending on DIP switch settings and found in air flow table for each size fur nace 4 T1 terminal is always energized for Low Heat Con stant Fan speed 5 T2terminal is always energized for High Heat speed 6 T3 terminal is always energized in Low Cooling 7 T4terminal is always energized in High Cooling SYSTEM OPERATION 8 Heating input W1 W2 always has priority over all other thermostat input 9 Cooling input YLo Y has priority over continuous fan input 10 Continuous f
47. LIGRO RIESGO DE INTOXICACI N POR MON XIDO DE CARBONO Advertencia especial para la instalaci n de calentadores 6 maneja oras de aire en reas cerradas como estacionamientos 6 cuartos de servicio Los equipos 6 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 ventilac n directa al exterior 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 dafio cerebral permanente muerte 0140M00020 D 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 goodmanmfg 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 N
48. LTERING ACCESSORIES External Filter Rack Kit 2 The external filter rack kit is intended to provide a location external to the furnace casing for installation 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 facing down The best location for the air cleaner is in the return air duct next to the blower compartment Before installing the air cleaner consider the application The electronic air cleaner must be readily accessible for periodic inspection and clean ing 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 efficiency and trouble free operation Carbon Filters 1156 3 and 1856 3 set of 3 are also available See Product Catalog for exact filter for your model A full line of air filtration and indoor air quality prod ucts are available and can be seen at www goodmanmfg com SEQUENCE OF OPERATIO
49. M Rise CFM Rise CFM 1522 1464 1402 1338 1280 1230 1522 41 1464 43 1402 44 1338 47 1280 49 1230 1861 48 1803 49 1749 51 1698 52 1653 54 1594 1004 890 805 710 620 553 1772 1713 1662 1609 1540 1498 1004 890 805 710 620 553 1312 1235 1170 1101 1037 962 1312 1235 1170 1101 1037 962 1772 1713 1662 1609 1540 1498 1312 1235 1170 1101 1037 962 1522 1464 1402 1338 1280 1230 1312 1235 1170 1101 1037 962 1861 1803 1749 1698 1653 1594 1004 890 805 710 620 553 1772 1713 1662 1609 1540 1498 1861 1803 1749 1698 1653 1594 1772 1713 1662 1609 1540 1498 1861 1803 1749 1698 1653 1594 1004 890 805 710 620 553 DIP SWITCH SETTING 0 1 0 2 0 3 0 4 0 5 0 6 CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM 1796 1753 1697 1645 1589 1536 1796 42 1753 43 1697 44 1645 45 1589 47 1536 2211 48 2162 49 2122 50 2076 51 2029 53 1986 1106 1017 946 855 764 681 1683 1628 1565 1511 1445 1387 1106 1017 946 855 764 681 1399 1327 1259 1185 1118 1051 1399 1327 1259 1185 1118 1051 1683 1628 1565 1511 1445 1387 1399 1327 1259 1185 1118 1051 1796 1753 1697 1645 1589 1536 1399 1327 1259 1185 1118 1051 2211 2162 2122 2076 2029 1986 1106 1017 946 855 764 681 1683 1628 1565 1511 1445 1387 2211 2162 2122 2076 2029 1986 1683 1628 1565 1511 1445 1387 2211 2162 2122 2076 2029 1986 1106 1017 946 855 764 681 0 7 CFM 1167 1167 1549 474 1452 474 880 880 1452 880 1167 880 1549 474 1452 1549 1452 1549 474 0 7 CFM 1478 1478 1984 605 1340 605 980
50. N POWER UP When power is supplied the control will energize the Red LED microcomputer runs its self check routine The control will check the status of the gas valve cir cuitry Line polarity is checked The control then enters standby waiting for a call for heat or cool The Furnace status LED will display a slow green flash signaling standby mode HEAT MODE Call For 1st Stage Heat On a call for first stage heat the thermostat contacts close signaling the control module The microcomputer runs its self check routine The Amber LED will display a slow flash signaling normal heat operation The control module checks the high limit and or aux iliary limit switch es for normally closed contacts The control checks the low pressure switch for a shorted condition The gas valve relay status is checked for proper op eration Once the low pressure switch is detected open the inducer blower is energized at high speed and the humidifier is enabled The low pressure switch is checked for closure Once the low pressure switch is closed the pre purge period begins The inducer will be energized at high speed for the pre purge period Following the completion of pre purge the inducer switches to low speed and the igniter warm up period begins After completion of the igniter warm up period Trial for ignition begins The first stage of the gas valve is energized The igniter is de energized when flame is sensed or at the c
51. NG THIS UNIT MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH 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 CONDITIONING HEATING AND REFRIGERATION INSTITUTE AHRI ATTEMPTING TO INSTALL OR REPAIR THIS UNIT WITHOUT SUCH BACKGROUND MAY RESULT IN PRODUCT DAMAGE PERSONAL INJURY OR DEATH IF THEINFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY AFIRE OR EXPLOSION 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 ORANY OTHER APPLIANCE WHAT TODO IF YOU SMELL GAS e DO NOT TRY TO LIGHT ANY APPLIANCE e DO NOT TOUCH ANY ELECTRICAL SWITCH DO NOT USE ANY PHONE IN YOUR BUILDING e IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR 5 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 IMPORTANT INFORMATION N DANGER Lm CARBON MONOXIDE POISONING HAZARD Special warning for installation of furnaces or air handling units in enclosed area such as garages utility rooms or parking areas Carbon monoxide producing devices such as automobile space heater
52. OPERTY 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 Limit FAULT CopEs If the control detects the high limit circuit open the RED LED will flash FOUR times and energize the inducer and indoor blower 48 If the limit circuit opens five times within a single call for heat the furnace will go into lockout for one hour The RED LED will display a FOUR flash code during this time The control board can be reset by cycling 115 volt power to the furnace If the limit circuit opens and does not close within five min utes the control assumes the blower has failed the RED LED will flash ELEVEN times If the limit circuit opens and does not close within fifteen minutes the control assumes the manual rollout or fuse has opened and the RED LED will flash FIVE times The control will enter a one hour lockout and the inducer will run continuously In an open limit condition the red LED will flash as described above but the error code will not be stored in memory until the limit resets or until 15 minutes has elapsed So if the limit resets in less than 5 minutes a four flash code will be st
53. S PHONE FOLLOW THE GAS SUPPLIER S INSTRUCTIONS 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 Sizing Between First and Second Stage Regulator Maximum Propane Capacities listed are based 2 psig pressure drop at 10 psig setting Capacities in 1 000 BTU hour 70 0 300 so 260 610 1200 1 900 2 900 1 200 2 600 Dur zoo T uono 125 200 2300 900 2 100 200 To convert to capacities at 15 psig settings multiply by 1 130 To convert to 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 WC setting Capacities in 1 000 BTU hour 60 16 35 72 pu rm pepe pese pe 100 78 O 250 7 ss eo os 48 100 185 300 590 Data in accordance with NFPA pamphlet No 54 Propane Gas Piping Charts 24 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
54. SE 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 of the gas and length of the run The gas line installation must comply with local codes or in their absence with the latest edition ofthe National Fuel Gas Code NFPA 54 ANSI Z223 1 22 Pressure 0 5 psig or less and pressure drop of 0 3 W C Based 0 60 Specific Gravity Gas BTUH Fumace Input Bezing Value of Gas ETU CubIc Fool 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 transi tion 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 connec tions 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 Useground joint unions 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 im
55. SENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH 1 Remove burner compartment door to gain access to pres sure switch es 2 Remove wires from the pressure switch es electrical ter minals 3 Remove the pressure control hose from the control and interconnect with an inclined manometer as shown in the following figures 4 With an ohm meter connected across the pressure switch terminals with the inducer running the switch should close and the ohm meter should show a complete circuit across the pressure switch If the switch is not closed compare the negative pressuretothe closing point specified for the particular switch Either the switch is defective or the inducer venting system is inadequate SERVICING INDUCED DRAFT BLOWER PRESSURE SWITCH T PRESSURE SWITCH HOSE OPEN TO ATMOSPHERE COIL COVER PRESSURE SWITCH INCLINED MANOMETER HOSE TO INDUCED DRAFT BLOWER TAP BLOWER Blower Pressure Switch Negative Pressure Measurement S 311 HIGH ALTITUDE APPLICATION USA The furnace as shipped requires no change to run between 0 7500 feet Do not attempt to increase the firing rate by changing orifices or increasing the manifold pressure below 7500 feet feet This can causepoor combustion and equip ment failure High altitude installations above 7500 feet feet may require both a pressure s
56. Service Instructions Goodman Brand GMEC96 amp Amana Brand AMEC96 Two Stage Furnace with multi speed ECM Motor 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 manufacturers installation and operation instructions Amana is a registered trademark of Maytag Corporation or its related companies and RS6612013 is used under license to Goodman Company L P Houston TX USA All rights reserved August 2014 Copyright 2014 Goodman Company L P TABLE OF CONTENTS IMPORTANT INFORMATION 2 PRODUGTIBENTIFIGATION rs 7 8 INSTALLATION CONSIDERATIONS 9 26 SYSTEM OPERATION eren 27 33 IMPORTANT INFORMATION ACCESSORIES Lana 34 37 SERVICING TABLE OF CONTENTS 38 Sb VIGIBNI 39 56 MAINTENANCE ceto itt art 57 58 Pride and workmanship go into every product to provide our customers with quality products Itis possible however that during its lifetime a product may require service Products should be serviced only by aqualified service technician whois familiar with the safety procedures required i
57. UT CONTROL dt ebd ga ce Y a uec uu 50 INDUCED DRAFT BLOWER MOTOR cesses rictu ice eter wee ean dao 50 CHECKING GAS VALVE 50 CHECKING MAIN BURNERS itte rhone carte Po anions eos 51 CHECKING ORIFICES m 51 CHECKING GAS PRESSURE tette dis 51 CHECKING HOT SURFACE IGNIMOR v nantais 54 CHECKING FOR FLASHBACK ca ceto yep te ta a gu Oven E aer dud 54 CHECKING PRESSURE CONTROL sirenita annn a e a aeina 54 HIGH ALTITUDE APPLICATION USA itcr neto erp eret talit eh rite eee 55 CHECKING FOR DELAYED IGNITION iii 55 CHECKING INTEGRATED IGNITION CONTROL BOARDS 55 CHECKING FLAME SENSOR rtr ert metn rie o er 56 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 phasing between the primary and secondary sides of step dow
58. 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 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 of the ventilation openings must be within 12 inches of the top the other opening must be within 12 inches of the bottom of the confined space In a typical construction the clearance between the door and door frame is usually adequate to satisfy this ventilation requir
59. ace Figure A 9 3 3 2 All 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 accordance 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 lo cated 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 Theratio 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 INSTALLATION CONSIDERATIONS c Theminimum 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
60. an input G has lowest priority The blower speed wiring connections must remain in factory position 1 Refer to the air flow table for your specific model furnace 2 Ifa cooling or heat pump condensing unit is being used in conjunction with this furnace the three DIP switches in S2 are used to select the proper cooling speeds to match the outdoor unit size Typical CFM requirements are 400 CFM Ton 1 Turn OFF power to the furnace 2 Selectthe heating and cooling blower speeds that match the installation requirements from the airflow table in this manual or the Service Manual If factory cooling speeds do not match the installation requirements the dip switch settings must be changed from factory posi tion 3 Turn ON power to furnace 4 Verify proper temperature rise in heat modes and CFM in cooling modes In general lower heating speeds will reduce electrical consump tion lower operating sound levels of the blower and increase the outlet air temperature delivered to the home The speeds available allow the blower performance to be optimized for the particular homeowner s needs 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 i
61. ana Brand A Initial Release Goodman Brand B 1st Revision Configuration M Upflow Horizontal Major Revision C Downflow Horizontal A Initial Release B 1st Revision Motor V Variable Speed ECM ComfortNet NOx E Multi Speed ECM N Low NOx S Single Speed Cabinet Width Gas Valve A 14 M Modulating 17 5 C 2 Stage 21 S Single Stage D 24 5 AFUE Maximum CFM 97 97 AFUE 2 800CFM 92 9296 AFUE 3 1200 CFM 4 1600 CFM MBTU h 5 2000 CFM 040 40 000 BTU h 060 60 000 BTU h 120 120 000 BTU h AMECO60302BNAA AMEC960402BNAA AMECO60603BNAA AMEC960803BNAA AMEC961004CNAA AMEC961205DNAA Amana Brand 96 Two Stage Heating Two Stage Cooling Gas Furnace Up flow Horizontal Left and Right 34 5 tall Induced Draft Nidec multi speed ECM motor Stainless Steel tubular heat exchanger 115 volt silicon nitride igniter Left or right gas ent GMECO60302BNAA GMEC960402BNAA GMECO60603BNAA GMEC960803BNAA GMEC961004CNAA GMEC961205DNAA Goodman Brand 96 Two Stage Heating Two Stage Cooling Gas Furnace Up flow Horizontal Left and Right 34 5 tall Induced Draft Nidec multi speed ECM motor Aluminized Steel tubular heat exchanger 115 volt silicon nitride igniter Left or right gas PRODUCT IDENTIFICATION Fossil Fuel Kit The AFE18 60A control is designed for use where the indoor coil is located above downstream of a gas or fossil fuel furnace when u
62. and other than Category 1 vented appliances shall be provided with combustion ven tilation and dilution air in accordance with the appliance manufacturer s 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 f
63. arb fitting from the outlet pressure tap Replace the outlet pressure boss plug and seal with a high quality thread sealer HIGH VOLTAGE Disconnect ALL ELECTRICAL POWER AND SHUT OFF GAS SUPPLY BEFORE SERVICING OR INSTALLING 2 Turn on gas to furnace and check for leaks If leaks are found repair and then reinstall burner compartment door 3 Turnon electrical power and verify proper unit operation Make sure furnace operates at the proper manifold pres sure at both high and low stage outputs High Stage 3 2 to 3 8 w c Low Stage 1 6 to 2 2 w c d varie 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 HIGH VOLTAGE Disconnect ALL ELECTRICAL POWER AND SHUT OFF GAS SUPPLY BEFORE SERVICING OR INSTALLING High Stage 9 7 to 10 3 w c S 308 CHECKING HOT SURFACE IGNITOR 120V Silicon Nitride Igniter MEC96 furnaces use a 120V silicon nitride igniter for ignition The normal operating tem perature is approximately 2156 F 2678 F At room tem perature the igniter ohm reading should be from 37 68 ohms 7 Placeunitin heating cycle measure current draw of ig nitor during preheat cycle 54 The steady state current at 120V is 0 37 to 0 68 amps 8 After checking and or replacing of hot surface ignitor re install burner compartme
64. ard Red wire connected to the COM terminal which is a female spade connection next to the T1 T4 wires on the control board Green ground wire connected to cabinet ground The control harness has Blue wire connected to T1 on the control board Red wire connected to T2 on the control board Orange wire connected to T3 on the control board Black wire connected to T4 on the control board The multi speed ECM motor requires a line voltage power supply black connected to CIRC H and white connected to neutral on the control board as well as a signal on one of the speed taps T1 T4 The speed tap voltage is D C and can vary depending on S2 DIP switch selection The voltage reading from any one of the speed taps is referenced between the female COM terminal next to the speed taps on the con trol board From COM to T1 or T2 6 7 VDC when ener gized From COM to T3 13 14 VDC when energized From COM to T4 6 7 or 13 14 VDC depending on S2 settings 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 insuffi cient air that can cause excessive temperature rise result ing in limi
65. ation This product is designed for use as a residential home gas furnace It is 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 such applications the furnace must be installed with the installation instructions The MEC96 furnaces ETL certified appliances and are appropriate for use with natural or propane gas NOTE If using propane gas a propane conversion kit is required MEC96 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 instructions 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 ELECTRICA
66. aust vent and air intake terminations of adjacent units as with the exhaust vent and air intake terminations of a single unit If more than one direct vent furnace is to be installed hori zontally through a common side wall maintain the clear ances as in the following figure Always terminate all ex haust vent outlets at the same elevation and always termi nate all air intakes at the same elevation nt cdi uM m 12 MIN SEPARATION e OPTIONAL pre INTAKE q SCREENS 4 MIN TO GRADE OR HIGHEST y lt ANTICIPATED SNOW LEVEL Termination of Multiple Direct Vent Furnaces Direct Vent Terminal 50 000 Btuh orless Direct Vent Terminal More than 50 000 Btuh FIGURE 1 DCVK Vent Termination Clearances 1 The venttermination must be located at least 12 above ground or normally expected snow accumulation levels 20 2 DoNOT 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 3 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 4 The venttermination shall be located at least 3 above any forced air inlet located within 10 and at least 10 from a combustion air intake of another appliance except another direct vent furnace intake 5 In Ca
67. az Renifler pr s du plancher car certains gaz sont plus lourds que l air et peuvent s accumuler au niveau du sol QUE FAIRE S IL Y A UNE ODEUR DE GAZ O Ne pas tenter d allumer d appareils oNe toucher aucun interrupteur ne pas vous servir des t l phones dans le b timent o Appelez imm diatement votre fournisseur de gaz depuis un voisin Suivez les instructions du fournisseur de gaz Si vous ne pouvez rejoindre 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 Sila manette reste coinc e ne tenter pas de la r parer appelez un technicien qualifi Quiconque tente de forcer la manete ou de la r parer peut provoquer une explosion ou un incendie D Ne pas se servir de cet appareil sil 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 gt plong es dans l eau D 15 En arc 1 ARRETEZ Lisez les instructions de s curit dans la Section sup rieure de celle 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 OFF ARRET posit
68. displayed Fault Code Reset To clear the fault code memory push and hold the LAST ERROR button for more than 5 seconds and less than 10 seconds the LED will indicate this period by RAPID GREEN FLASH for 5 seconds to 10 seconds The LED will flash three green flashes when the memory has been cleared The ignition control is equipped with a momentary push but ton switch that can be used to display on the diagnostic LED the last five faults detected by the control The control must be in Standby Mode no thermostat inputs to use the feature Depress the push button switch for approximately 2 sec onds Release the switch when the LED is turned off The diagnostic LED will then display the flash codes associated with the last five detected faults The order of display is the most recent fault to the least recent fault RESETTING From Lockout Furnace lockout results when a furnace is unable to achieve ignition after three attempts during a single call for heat It is characterized by a non functioning furnace and a one flash diagnostic LED code If the furnace is in lockout it can be reset in any of the following ways 1 Automatic reset The integrated control module will automatically reset itself and attempt to resume normal operations following a one hour lockout period 2 Manual power interruption Interrupt 115 volt power to the furnace for 1 20 seconds 3 Manual thermostat cycle Lower the thermostat so that th
69. e installation 12 MIN HEIGHT DIFFERENCE BETWEEN _ INTAKE AND VENT INTAKE FACING DOWN INTAKE SCREEN OPTIONAL 12 MIN TO ROOF HIGHEST ANTICIPATED SNOW LEVEL VENT PIPE TERMINATION OPTIONS ELBOWS STRAIGH 12 MIN VENT FLUE TEE OPTIONAL or 45 ELBOW TURNED DOWN or 90 ELBOW TURNED DOWN 12 MIN ABOVE P HIGHEST ANTICIPATED Le SNOW LEVEL Ju Horizontal Termination Single Pipe Above Highest Anticipated Snow Level VENT FLUE PIPE TEE OPTIONAL SCR EN _ OPTIONAL P y prs Standard Horizontal Terminations Dual Pipe 12 MIN TO GRADE OR HIGHEST ANTICIPATED SNOW LEVEL 90 VENT ELBOW HW pe sme VENT OPTIONAL a A 12 MIN ABOVE m Eo Ws HIGHEST ANTICIPATED SNOW LEVEL Alternate Horizontal Vent Termination Dual Pipe VENT 90 ELBOWS 3h gt 3 82 esl ES 4 3 24 EEN PIPES d A INTAKE MN 12 MIN ABOVE ab Combustion Air Intake may also be snorkeled to obtain 12 min ground clearance Alternate Vent Termination Above Anticipated Snow Level DualPipe INSTALLATION CONSIDERATIONS VENT INTAKE TERMINATIONS FOR INSTALLATION or MuL TIPLE DIRECT VENT FURNACES If more than one direct vent furnace is to be installed verti cally through a common roof top maintain the same mini mum clearances between the exh
70. ece dence over the preceding termination restrictions OTHER THAN COMBUSTION AIR TERMINATION ou NON DIRECT VENT VENT FLUE TERMINATION NO TERMINATIONS ABOVE WALKWAY GRADE OR HIGHEST ANTICIPATED SNOW LEVEL FORCED AIR INLET DIRECT VENT VENT FLUE TERMINATION THE RUBBER ELBOW IS NOT DESIGNED TO SUPPORAT A LOAD WHEN THE RUBBER ELBOW IS MOUNTED EXTERNALLY TO THE FURNACE CABINET EXTREME CARE MUST BE TAKEN TO ADEQUATELY SUPPORT FIELD SUPPLIED VENT FLUE PIPING AS DAMAGE CAN RESULT IN LEAKS CAUSING BODILY INJURY OR DEATH DUE TO EXPOSURE TO FLUE GASES INCLUDING CARBON MONOXIDE BE SURE NOT TO DAMAGE INTERNAL WIRING OR OTHER COMPONENTS WHEN REINSTALLING COUPLING AND SCREWS 18 Vent Flue Pipe Lengths Non Direct Vent and Diam eters 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 MEC96 Direct Vent 2 Pipe and Non Direct Vent 1 Pipe e Maximum Allowable Length of Vent Flue Pipe amp Combustion Air Pipe ft 02 2 Number of Elbows 5 Unit Input Pipe Size Btu in 3141516 7 40 000 115
71. ement MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS SES WEAR FRONT FLUE _ Upflow 1 1 Horizontal 1 4 if placed on combustible floor the floor MUST be wood ONL Y ig servicing or cleaning a 24 front clearance is recommended Unit connections electrical flue and drain may necessitate greater clearances than the minimum clearances listed above In all case accessibility clearance must take precedence over from the enclosure where accessitility clearances are greater Approved forline contact in the horizontal position 11 INSTALLATION CONSIDERATIONS 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 it to be exposed to water The length of rod will de pend on the application and the clearances necessary PROVIDE 8 MINIMUM CLEARANCE BETWEEN CENTER ROD AND FURNACE N TO ALLOW FOR CIRCULATOR BLOWER REMOVAL N ASSURE FURNACE IS LEVEL FROM END TO END 90 FURNACES MAKE SURE THE UNIT HAS SLIGHT FORWARD TILT WITH THE FRONT OF THE FURNACE 07 34 jj BELOW THE BACK OF THE FURNACE ALTERNATE GAS PIPING 3 8 DIAMETER THREADED ROD 6 PLA
72. ere is no longer a call for heat then reset to previ ous setting Interrupt thermostat signal to the furnace for 1 20 seconds SERVICING S 1 CHECKING VOLTAGE warnine 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 cover from the Junction Box and gain access to incoming power lines With Power ON LINE VOLTAGE NOW PRESENT 2 Using a voltmeter measure the voltage across the hot and neutral connections NOTE Toenergize the furnace the Door Interlock Switch must be engaged at this point 3 Noreading indicates open wiring open fuse no power or faulty Door Interlock Switch from unit to fused disconnect service Repair as needed 4 With ample voltage at line voltage connectors ener gize the furnace blower motor by jumpering terminals R to G on the integrated ignition control 5 With the blower motor in operation the voltage should be 115 volts 10 percent 6 Ifthereading 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 7 After completing check and or repair replace Junc tion Box cover and reinstall the service panel doors 8 Turn on electrical power and verify proper unit opera tion S 2 CHECKING
73. fore Red LED rapid flash proceeding with repairs Verify pressure switch Furnace does not 2 Three function amp tubing verify Confirm electrically safe operate control board Second stage pressure None None double inducer operating and pulling condition before Red LED with three switch stuck open a flashes enough vacuum to engage proceeding with repairs 43 Green Red LED Flash LED Flash ___ 1 Flame sensed when no flame should be present DL eC 2 Pressure Switch Stuck Closed Inducer Error 3 1st stage Pressure Switch Stuck Open Inducer Error Ll 1 4 Open limit switch Pp 5 Bj OpenRoloutOpenFuseDetect O o DL 1 6 Pressure switch cycle lockout n amp o 7 Extemallockout reties Pp 1 8 Extemal lockout recycles 3 9 Grounding or Reversed polari ___ 10 Gas flow with no call for heat 2 O D CC Limit switch open blower failure Cd DL A 12 ignitor Relay Failure 2 Solid internal GV Error Micro and Frequency Check j Twiningeror 3 double 2nd stage Pressure Switch Stuck Open Inducer Error ____ 1 Normal Operation with call for first stage heat W1 L 2 Normal Operation with call for second stage heat W2 ___ 3 W2 present with no
74. fter a cool on delay The electronic air cleaner will also be energized After the thermostat is satisfied the compressor is de energized and the Cool Mode FanOff Delay period begins Following the 60 second Cool Mode Fan Off Delay period the cool circulator and air cleaner relay are de energized signaling the control module The LED will display a solid GREEN When a call for is received the control will energize the circulator in low heat speed after the fan on delay time expires The electronic air cleaner will also be energized at this time When the thermostat fan switch is moved to the ON position the circulator blower is energized at low heat speed and the electronic air cleaner is also energized When the thermostat fan switch is moved back to the AUTO position the circulator fan and air cleaner relay are de energized and the control awaits a thermostat call for heat or cool Exception During the Cool On delay the control will not respond to the fan input If the fan was called prior to the call for cool the circulator will remain ener gized during the Cool On delay If the fan is called prior to a call for heat the circulator will remain energized during the entire call for heat sequence 33 ACCESSORIES GME95 amp AMEH96 FURNACE ACCESSORIES Approved Accessory for this model 2 eve 519 valve 4 7 000 11 000 ft altitude Not Approved for this model
75. g is avail able from most regulator manufacturers and propane gas suppliers Refer to the following illustration for typical propane gas in stallations and piping 5 to 15 PSIG First Stage 20 PSIG Max Regulator Continuous 11 W C 200 PSIG Second Stage Maximum Regulato 2 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 CAN SETTLE IN ANY LOW AREAS OR CONFINED SPACES PROPANE GAS ODORANT MAY FADE MAKING THE GAS UNDETECTABLE EXCEPT WITH A WARNING DEVICE AN UNDETECTED GAS LEAK WILL CREATE A DANGER OF EXPLOSION OR FIRE IF THE PRESENCE OF GAS IS SUSPECTED FOLLOW THE INSTRUCTIONS ON THE COVER OF THIS MANUAL FAILURE TO DO SO COULDRESULTINSERIOUS PERSONAL INJURY ORDEATH 23 INSTALLATION CONSIDERATIONS 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 Nor TRY TO LIGHT ANY APPLIANCE Do Nor TOUCH ANY ELECTRICAL SWITCH DO NOT USE ANY PHONE IN YOUR BUILDING IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR
76. g salts or chemicals carbon tetrachloride halogen type refrigerants INSTALLATION CONSIDERATIONS 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 solate a non direct vent furnace if it is installed near an area frequently contaminated by any of the above substances This protects the non direct ventfurnace from airborne contaminants To ensure that the en closed non direct ventfurnace has an adequate sup ply of combustion air vent from a nearby uncontami nated room or from outdoors Refer to the Combus tion and Ventilation Air Requirements section in this manual or the installation instructions for details e If the furnace is used in connection with a cooling unit install the furnace upstream or in parallel with the cooling unit coil Premature heat exchanger fail ure will result if the cooling unit coil is placed in the return air of the furnace Ifthe furnace is installed in a residential garage po sition the furnace so that the burners and ignition source are located not less than 18 inches 457 mm above the floor Protect the furnace from physical damage by vehicles Ifthe furnace 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
77. gative Pressure S 310 41 TROUBLESHOOTING Green Amber Red CREE Detective disconnect switch Determine cause and restore Confirm electrically safe Furnace fails to operate defective door switch No y Control board LED is off None None None 115 volt power 24 volt proper high and low volt power condition before supply proceeding with repairs power Confirm electrically safe None Required condition before proceeding with work Solid ON Nana pues not receiving a Confirm electrically safe Furnace fan only is Furnace is receiving a call for Rapid Flash None None None Required condition before running fan 24 volts on Gterminal proceeding with work Normal operation with One Confirm electrically safe 4 Normal operation with low n low stage call for cooling repeating None None stage call for cooling Ylo amp G None Required condition before amp G flash i 9 proceeding with work Normal operation with Two Normal operation with high Confirm electrically safe high orsingle stage call repeating None None or single stage call for cooling Required condition before for cooling Y amp G flashes Y amp G proceeding with work Normal operation with One 7 electrically safe 5 Normal operation with low a low stage call forheat repeating None stage call for heat W1 None Required condition before
78. heck 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 in terlock 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 LINE VOLTAGE NOW PRESENT d w RNiNG 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 46 S 16A CHECKING AIR CIRCULATOR BLOWER MOTOR MULTI SPEED ECM MOTOR Disconnect ALL POWER BEFORE SERVICING Remove blower compartment door to gain access to the circulator blower motor and integrated ignition control 2 Check for any obstruction that would keep the fan wheel fan motor from turning 3 Check wiring the motor has two wiring harnesses a main harness and a control harness The main pin har ness has White neutral wire connected to the Neutral terminal on the control board Black wire connected to the CIRC H terminal on the con trol bo
79. ical Manual for a tabular listing of appropriate altitude ranges and corre sponding manufacturer s high altitude Natural 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 rat ing plate The combination of the lower air density and a lower manifold pressure will prohibit the burner orifice from drawing the proper amount of air into the burner This may cause incomplete combustion flashback and possible yel low tipping In some areas the gas supplier may artificially derate the gas in an effort to compensate for the effects of altitude If 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 provided 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 Maximum 13 0 w c 21 INSTALLATION CONSIDERATIONS 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
80. ies Charts in this manual or product Specification Sheet for 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 of the 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 ap pliance or use a vent which is used by a solid fuel
81. il Cet appareil est muni d un m canisme qui allume automatiquement le br leur Ne tentez pas d allumer le br leur manuellement Retirez le panneau d acc s de la commande Mettez la commande de gaz la position ARR T OFF 7 Attendez cinq 5 minutes afin de permettre tout gaz pr sent d tre vacu Si vous sentez une odeur de gaz ce moment ARRET Z et suivez les consignes de s curit donn es au paragraphe B ci dessus Si vous ne sentez pas de gaz passez l tape suivante 8 Mettez la commande de gaz la position MARCHE ON 9 Remettez la panneau d acc s de la commande en place 10 R tablissez l alimenation lectrique de l appareil 11 R glez le thermostat le temp rature d sir e 12 Si l appareil ne fonctionne pas suivez les instructions intitule s Arr t du gaz et appelez un r parateur qualifie ou votre fournisseur de gaz EE Ar Er 00 R glez le thermostat son point le plus bas Coupez l alimentation lectrique de l appareil si vous devez effectuer un entretien Retirez le panneau d acc s de la commande Mettez la commande de gaz la position ARR T OFF Remettez le panneau d acc s de la commande en place BONS on gA JE Commande de gaz en position MARCHE IMPORTANT INFORMATION FOR YOUR SAFETY READ BEFORE OPERATING WARNING i f you do not follow these instructions exactly a fire or exp
82. ion 6 Attendre cing 5 minutes pour laisser echapper tout le gaz Renifier tout autour de l appareil y compris pr s du plancher pour d celer une odeur de gaz Si c est le cas ROBINET A GAZ ARR TEZ Passer letape B des instructions de securite MANUEL EN POS sur la portion superieure de cette etiquette ON MARCHE Sil 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 LEVER SHOWN IN ON POS POUR COUPER L ADMISSION 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 0140F00596 REVA 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 i M E C 96 060 3 B N A A 1 2 3 4 56 789 10 11 12 14 Minor Revision A Am
83. ion Air 24 above roof This concentric vent kit allows for vertical or horizontal vent termin oof Boot Flashing tion The illustrations give a briefF e Supplied view of the kit and its application See the section in this manual under Vent Flue and Combustion 7 7 Air Pipe Terminations for more information or consult the Installa tion and Operating Instructions IO 619 45 Elbow Field Supplied DCVK Strap Yj Combustion Air Vent Field Supplied nas to 1 Y maximum 2 Combustion Air Field Supplied 7 DCVK Horizontal Installation ACCESSORY WIRING 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 POWER SUPPLY INPUT POWER FURNACE DEMAND SUPPLY W1 FURN OUTPUT W2 HP BLOWER FAN DEMAND OUTPUT POWER SUPPLY INPUT COMMON SECOND STAGE FURNACE DEMAND OUTPUT COMPRESSOR OUTPUT SECOND STAGE COMPRESSOR OUTPUT Y2 HP REVERSING VALVE OUTPUT Y2 STAT Y2 FURN POWER SUPPLY OUT TO THERMOSTAT Y STAT CALL Y FURN OR REVERSING VALVE CALL FOR Y HP COMPRESSOR CALL FOR EMERGENC Y HEAT CALL FOR BLOWER FAN CALL FOR FURNACE HEAT POWER SUPPLY COMMON OUT TO THERMOSTAT CALL FOR 2ND STAGE FURNACE HEAT CALL FOR 2ND STAG
84. 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 co operation between the propane supplier and customer ELECTRICAL CONNECTIONS AVOID THE RISK OF ELECTRICAL SHOCK WIRING TO THE UNIT MUST BE PROPERLY POLARIZED AND GROUNDED A warninc 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 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 115VOLT LINE CONNECTIONS Before proceeding with electrical connections ensure that the supply voltage frequency and phase correspond to that specified on the unit rating plate Power supply
85. liances stated in step 3 Gas MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT Only small variations in gas pressure should be made by adjust ing the gas valve pressure regulator The manifold pressure must be measured with the burners operating To measure and adjust the manifold pressure use the following procedure Gas Line Gas Shutoff Valve Gas Line To Furnace Open To Atmosphere Drip Leg Cap With Fitting Manometer Hose Manometer Measuring Inlet Gas Pressure Alt Method caution TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAM AGE 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 1 Turn OFF gas to furnace at the manual gas shutoff valve external to the furnace 2 Turn off all electrical power to the system 3 Outlet pressure tap connections White Rodgers 36J54 valve Back outlet pressure test screw inlet outlet pressure tap out one turn counter clockwise not more than one turn 4 Attach a hose and manometer to the outlet pressure tap White Rodgers valve 5 Turn ON the gas supply SERVICING 6 Turn on power and close thermostat R W1 contacts to provide a call for low stage heat 7 Measure the gas manifold pressure with burners fir ing Adjust manifold pressure using the Manifold Gas Pressuretable shown below 8 Remove regula
86. losion may result causing property damage personal injury or loss of life A This appliance does not have a pilot Itis equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand B BEFORE OPERATING smell all around the appliance area for gas 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 o 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 olf you cannot 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 OPERATING INSTRUCTIONS 1 STOP Rea this label 2 Set the thermostat to lowest setting 3 Tum 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 bu
87. mediately upstream of the gas supply connection to the furnace 6 Usetwo 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 must be downstream of the manual shutoff valve between the shutoff valve and the fur nace 8 Tighten all joints securely INSTALLATION CONSIDERATIONS GAS PIPING CHECKS Before placing unit in operation leak test the unit and gas connections A WARNING TO AVOID THE POSSIBLITY OF EXPLOSION OR FIRE NEVER USE A MATCH OR OPEN FLAME TO TEST FOR LEAKS Check for leaks using an approved chloride free soap and water solution an electronic combustible gas detector or other approved testing methods NOTE Never exceed specified pressures for testing 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 system before pressure testing the supply piping system with pres sures 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 piping sys tem with test pressures equal to or less than 1 2 psig 3 48 kPa PROPANE GAS TAN
88. n transformers INCOMING POWER METER READS METER READS 120 VOLTS 0 VOLTS VOLT OHM VOLT OHM METER gt METER 0 G 0 THIS IS L1 OR THE THIS IS THE COMMON HOT POWER LEG OR NEUTRAL LEG These then should be wired to the furnace accordingly CHECKING FOR PHASING PRIMARY TO SECONDARY OF UNMARKED TRANSFORMERS METER READS 24 VOLTS VOLT OHM LINE VOLTAGE TRANSFORMER NEUTRAL LINE VOLTAGE VOLT OHM METER METER READS 120 VOLTS VOLT OHM METER VOLT OHM TI 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 NEUTRAL cee PHASING SYMBOL Some transformers will display phasing symbols as shown 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 NOTE Newer integrated ignition controls have a diagnos tic flash code for reversed polarity Refer to Troubleshoot ing Diagnostic Chartfor LED Codes 39 SERVICING 40 1 Million 100 Thousand 720 327 655 1636 150 3
89. n 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 S1 11 Stan dards If the furnace is installed without filters the warranty will be voided 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 lo cations Use a straight edge to scribe lines connecting the dimples Cut out the opening on these lines An undersized opening will cause reduced airflow For bottom return con nection remove the bottom of the cabinet before setting the furnace on the raised platform or return air duct A 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 in
90. n the repair and who is equipped with the proper tools parts testing instruments and the appropriate service manual REVIEW ALL SERVICE INFORMATION IN THE APPROPRIATE SERVICE MANUAL BEFORE BEGINNING REPAIRS IMPORTANT NOTICES FOR CONSUMERS AND SERVICERS 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 TO PREVENT THE RISK OF PROPERTY DAMAGE PERSONAL INJURY OR DEATH DO NOT STORE COMBUSTIBLE MATERIALS OR USE GASOLINE OR OTHER FLAMMABLE LIQUIDS OR VAPORS IN THE VICINITY OF THIS APPLIANCE 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 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 HIGH VOLTAGE Disconnect ALL POWER BEFORE SERVICING OR INSTALLI
91. nada the Canadian Fuel Gas Code takes precedence over the preceding termination instructions 3 or 4 Diameter 2 or2 1 2 Diameter SDR 26 Pipe 7 SDR 26 2 la Ml 2 or 3 Diameter 2 or 3 Diameter Rain Cap Y Concentric Fitting 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 CVENT 3 kit can be used for 3 diameter pipe systems The DCVK 20 CVENT 2 kit can be used for the 2 diameter pipe system 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 visible vent vapors For side termination consideration should be given to a Possible damage from the vapors to plants shurbs other equipment and building materials b Possible damage to the terminal from foreign ob jects c Wind effects that may cause recirculation of flue products debris or light snow d Visible vent vapors
92. ney or Gas Vent NOTE The air duct openings must have a free area of not less than one square inch per 2000 BTU of the total input rating of all equipment in the Outlet air duct enclosure Water Furnace 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 DP a 4 Wat 1 Alternate mor Opening heater Location Opening Furn
93. nt door and verify proper unit operation 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 PHESSURE 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 In addition to the in ducer pressure switch this furnace has a front cover pres sure switch wired in series with the gas valve This pressure switch keeps the gas valve from opening in the event of con densate backing up in the secondary heat exchanger This could occur from improperly connected drains or a plugged drain tube d warninc HIGH VOLTAGE DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT MULTIPLE POWER SOURCES M BE PRE
94. nterference with the function of the furnace s drain trap 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 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 Natural Gas Maximum 10 0 w c Minimum 11 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 re quired 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 specified altitude range High altitude kits are purchased according to the installa tion altitude and usage of either natural or propane gas Referto the product Specification Sheet or Techn
95. ntrol this furnace The application of a single stage thermostat offers a timed transition from low to high fire The furnace will run on low stage for a fixed period of time before stepping up to high stage to satisfy the thermostat s call for heat The delay period prior to step ping up can be set at either a fixed 10 or 20 minute time delay or aload based variable time between 1 and 12 min utes AUTO mode If the AUTO mode is selected the con trol averages the cycle times of the previous three cycles and uses the average to determine the time to transition from low stage to high stage Staging DIP Switches 51 1 51 2 OFF OFF ON OFF OFF ON ON ON no high fire without W2 call DIP Switch Heat Staging 2 Stage Stat 10 min delay AUTO 20 min delay factory setting TWINNING Using the TWIN terminals and proper wiring enables two MEC96 furnaces of the same model and size to be twinned Twinning allows simultaneous operation of two furnaces and forces the indoor blower motors of each furnace to operate synchronously into a common duct system Using the twin ning function will require only field installed wiring with no external kits or parts The staging DIP switches and speed tap DIP switches must be set the same on both furnaces 26 Furnace 1 Furnace 2 Room Thermostat pet T CIRCULATOR BLOWER SPEED ADJUSTMENT warninG HIGH VOLTAGE Disconnect ALL POWER BEFOR CHANGING SPEED TAPS MULTIP
96. nutes Open control gas pressure burner alignment condition before flashes on control board flashes board fuse or rollout switch lorifice plate position wiringto proceeding with repairs all limits Furnace does not Six Presence switch cyding i nes Confirm electrically safe lockout pressure switch has Excessive venting restriction operate six Red flashes None repeating gt condition before opened 5 same leaking pressure switch tubing on control board flashes proceeding with repairs Furnace does not Seven Lockout excessive retries pressure gas valve front UE electrical ang gas safe conditions operate seven Red None None repeating from flame not being proven cover pressure switch flame rit before proceeding with flashes on control board flashes duringtrial for ignition rod repairs Confirm electrical and Furnace does not Eight Lockout excessive recycles Gas pressure gas valve front un gas safe conditions operate eight Red None None repeating from flame proving being lost cover pressure switch flame before proceeding with flashes on control board flashes after being proven rod repairs 115 volt hot amp neutral supply to furnace reversed hot wire Furnace does not Nine a door switch amp L1 on control Confirm electrically safe operate nine Red None None repeating ing Wie 9 board must read
97. oaxial Coil Terminal HI Terminal M On Off Switch Common Terminal C White Rodgers Model 36J54 Connected to Manometer 1 Turn OFF gas to furnace at the manual gas shutoff valve external to the furnace 2 Connectacalibrated water manometer or appropri ate gas pressure gauge at either the gas valve inlet pressure tap or the gas piping drip leg See White Rodgers 36J54 gas valve figure for location of inlet pressure tap INLET GAS SUPPLY PRESSURE Natural Gas Minimum 4 5 w c Maximum 10 0 w c Minimum 11 0 w c Maximum 13 0 w c NOTE If measuring gas pressure atthe drip leg a field supplied hose barb fitting must be installed prior to making the hose connection If using the inlet pres sure tap on the White Rodgers 3654 gas valve then use the 36G J Valve Pressure Check Kit Part No 0151 000008 3 Turn ON the gas supply and operate the furnace and all other gas consuming appliances on the same gas supply line 4 Measure furnace gas supply pressure with burners firing Supply pressure must be within the range specified in the nlet Gas Supply Pressuretable 52 If supply pressure differs from table make the necessary adjustments to pressure regulator gas piping size etc and or consult with local gas utility 5 Turn OFF gas to furnace at the manual shutoff valve and disconnect manometer Reinstall plug before turning on gas to furnace 6 Turn OFF any unnecessary gas app
98. onclusion of the ignition activation period IAP whichever comes first When flame is sensed the delay to heat on period begins timing Retry counter is zeroed if after 10 seconds the flame is sensed Control enters normal operating loop where all inputs are continuously checked After the delay to heat on period the circulator fan is energized at the low heat speed The air cleaner will be energized with the circulator If the call for heat is lost while the control is in the trial for ignition period without flame being detected the control will turn off the gas valve and igniter The con trol then enters the post purge routine The post purge time will be increased to 60 seconds After complet ing the post purge the control resumes normal op eration 31 SYSTEM OPERATION CALL FOR 2ND STAGE AFTER FIRST STAGE The inducer motor is enabled at high speed The pressure switches are checked for closure Clo sure of the second stage pressure switch will ener gize the high fire stage of the gas valve The high speed circulator output is energized NOTE A call for 2nd stage without a call for 1st stage will be ignored and a three amber flash code will be displayed on the LED This error code will only be stored in memory once during a single power cycle 2ND STAGE SATISFIED FIRST STAGE STILL CALLED When the second stage of the thermostat is satisfied the inducer blower is reduced to low speed which de energizes the
99. oning 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 Centrally locate the furnace with respect to the pro posed or existing air distribution system Ensurethe temperature of the return air entering the furnace is between 55 F and 100 F when the furnace is heating 10 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 Refer 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 nation Locations section in this manual or the instal lation instructi
100. ons for specific details on termination construction All terminations must be located at least 12 inches above ground level or the anticipated snow level Vent terminations must terminate at least 3 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 applica tion Theventtermination 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 grav ity 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 win dow or gravity air inlet T INSTALLATION CONSIDERATIONS The vent termination of vent pipe run vertically through a roof must terminate at least 12 inches above the roof line or the anticipated snow level and be at least 12 inches from any vertical wall including any antici pated snow build up Aventtermination shall not terminate over public 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 pr
101. ons 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 Setthe 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 material allowed is wood 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 deicin
102. ore 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 new 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 Applic
103. ored If the limit resets in more than 5 but less than 15 minutes an eleven flash code will be stored If the limit is still open after 15 minutes a five flash code will be stored VOLT OHM METER COLOR IDENTIFYING TAB Testing Primary Limit Control 4 After completing check and or replacement of primary limit control reinstall burner compartment door 5 Turnon electrical power and verify proper unit opera tion S 301 CHECKING AUXILIARY LIMIT CONTROL The auxiliary limit control is designed to prevent furnace operation in case of main blower failure in horizontal instal lations It may also open if the power supply is interrupted while the furnace is firing The auxiliary limit control is suitable for both horizontal right and horizontal left installations Regardless of airflow direc tion it does not need to be relocated The 2 two auxiliary limits are located on the blower housing one on each side as shown in the following illustration SERVICING r N NS AUXILIARY LIMIT CONTROL M lane LIMIT CONTROL Auxiliary Limit Control Location A warninc 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 blower compartment door to gain access to the auxiliary 2 Remove the wires from the auxiliary limit control ter
104. ot a technical assistance line for dealers Your telephone company will bill you for the call IMPORTANT INFORMATION For YOUR SAFETY READ BEFORE OPERATING BEI 9 If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance does not have a pilot It is equipped with an ignition device which automatically lights the burners Do not try to light the burners by hand B BEFORE OPERATING smell around the appliance area for gas 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 telephone in your building Immediately call your supplier from a neighbor s phone Follow the gas suppliers instructions OPERATING INSTRUCTIONS BEEN 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 to OFF OY gt NAS e 6 uo E E EE GAS CONTROL SWITCH SHOWN IN ON POSITION EN TO TURN OFF
105. p 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 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 drain age can result in property damage 16 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 AIR DISCHARGE Side Return Duct Connectio Bottom Return Duct Connectio WY UPFLOW UPRIGHT ER UPFLOW HORIZONTAL LEFT AIR DISCHARGE TAN 1 Bottom Return D gt Duct AIR 4 DISCHARGE UPFLOW HORIZONTAL RIGHT AIR DISCHARGE Bottom Return Duct Connection 90 Furnace Recommended Installation Positions Alternate Electrical and Gas Line Connections The furnaces have provisions allowing for electrical and gas line connections through either side panel In horizon
106. r 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 The heating anticipator on older thermostats 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 Mod ern thermostats do not have this type of heat anticipator Many have a selector switch to adjust the number of cycles per hour 45 SERVICING S 4 CHECKING TRANSFORMER AND Control CIR CUIT A step down transformer 120 volt primary to 24 volt second ary 40 VA Heating and Cooling Models supplies ample capacity of power for either operation 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 blower compartment door to gain access to the thermostat low voltage wires located at the furnace inte grated 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 Useavoltmeter c
107. reduce temperature rise Decrease blower speed to increase temperature rise Refer to Circulator Blower Speed section in the Product Design section of this manual for speed changing de tails Temperature rise is related to the BTUH output of the furnace and the amount of air CFM circulated over the heat exchanger Measure motor current draw to de termine that the motor is not overloaded during adjust ments S 300 CHECKING PRIMARY LIMIT CONTROL All primary limit controls are nonadjustable automatic re set bi metal type limit control Refer to the following draw ing for the location of the primary limit 47 SERVICING PRIMARY LIMIT CONTROL 4 Primary Limit Control Location 90 Upflow Furnace Shown The following drawing illustrates the style of limit switches used on the 9096 furnaces ENCLOSED DISK T FRONT VIEW SIDE VIEW Primary Limit Control Style 90 Furnaces A warnine HIGH VOLTAGE Disconnect ALL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PR
108. rner by hand 5 Push the gas control lever to Position 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 gas go to next step 7 Push gas control lever to ON 8 Replace access panel 9 Turn on all electric power to the appliance 10 Set thermostat to desired setting 11 Ifthe appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas company TO TURN OFF GAS TO APPLIANCE 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 control lever to OFF Position Do not force the safely infrmation above on ARRIVEE DU GAZ 4 Replace control access panel LIRE AVANT DE METTRE EE EN MARCHELIRE 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 comporte pas de veilleuse Il est muni d un dispositif 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 de l appariel pour dec ler une odeur de g
109. ry built chimney shall not be used to supply combustion 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 open ings 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 Horizontal Installations 1 Horizontal installations require 5 5 under the furnace to accommodate the drain trap 2 Horizontal furnaces must be installed with 34 slope from back to front to permit condensate flow towards the front of the furnace When installing a MEC96 horizontally with the left side down there are two options for connecting the vent pipe to the furnace 1 Venting may be connected to the furnace vent pipe fit ting on the original top now the end of the furnace 2 Theinternal 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 u
110. s 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
111. second stage of the gas valve After the high heat off delay expires the circulator is reduced to low heat speed SIMULTANEOUS CALL FOR LOW AND HIGH HEAT A call for both stages of heat will establish low fire before going to high fire Operation Using a Single Stage Heating Thermostat If the average calculated duty cycle is 50 or greater then the heating cycle will be treated as if high stage is needed and the transition from low to high stage delay will happen quickly In this case an assumption is made that the outside temperature is cold and that the thermostat is likely coming out of setback Since assumptions are being made during this heating cycle the duty cycle for this heat cycle will not be used in the average calculated duty cycle formula for future heating cycles The duty cycle is calculated every cycle and used during the next cycle The equation for the duty cycle is calculated as follows Duty Cycle Time the ap propriate stage is ON Time of the complete cycle The average calculated duty cycle is determined by averaging the previous average calculated duty cycle with the duty cycle from the previous cycle This places a large emphasis on the previous cycle but allows a large variation in any one duty cycle to be averaged out after just a few complete heating cycles If there is no load activity for 24 hours or more then set the Duty Cycle 100 The initial default average calculated duty cycle 5096
112. sed an RF000142 Vent Drain coupling must be used to keep condensate from collecting in the inducer assembly Refer to the following instructions and illustration 15 INSTALLATION CONSIDERATIONS Insert flange Cut 2 long RF000142 yh 4 o PS po f 1005802 20 K wee o O gt gt H FLANGE A ASE RE INN X 2 W A T yi A ty aa Vent Flue Pipe Cuts 1 Remove screws from the vent flange 2 Remove the internal elbow and vent pipe 3 Cut 2 1 2 from the flange 4 Remove cabinet plug adjacent to inducer outlet and install an original cabinet vent hole 5 Install RF000142 coupling on inducer outlet 6 Install flanged vent section removed in step 2 and se cure with clamps 7 Secure flange to cabinet using screws removed in step1 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 tra
113. sed with a heat pump It will operate with single and two stage heat pumps and single and two stage furnaces The AFE18 60A control will turn the heat pump unit off when the furnace is turned on An anti short cycle feature initiates a 3 minute timed off delay when the compressor goes off Media Air Cleaner The Amana AMU and Goodman GMU Media Air Cleaner is a high efficiency air filtration device designed to remove dirt dust pollen and other microscopic particles from the air passing through it Flexible performance range up to 2 000 CFM capacity The air cleaner should be installed in the system so that all the system air is circulated through the air cleaner The air cleaner will only remove the airborne contaminants delivered to it Maximum performance is obtained when the system blower is setfor continuous operation Carbon filters optional are available 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 Concentric Vent Kit For use with Amana Brand high efficiency furnace models This kit is designed to allow terminations of a direct vent furnace to be concentrically vented through a wall or roof This kit allows a single penetration to s
114. t 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 required volume shall be determined as follows 1 For appliances other than fan assisted calculate using the following equation 3 Required Volume gt in T aer ACH 1000 Btu hr 2 For fan assisted appliances calculate using the following equation 3 Required Volume gt En ACH 1000 Btu hr where om appliances other than fan assisted input in Btu per hour m 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 con nect indoor spaces shall be sized and located in accordance with the following 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
115. t tripping etc Whereas not enough static may result in motor overloading SERVICING 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 Pres sure 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 condi tioner coil or Electronic Air Cleaner is used in conjunction with the furnace the readings must also include theses com ponents 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 reg isters undersized and or oversized poorly laid out duct work SUPPLY AIR CUTAWAY OF DUCTWORK TO EXPOSE COIL INCLINED MANOMETER RETURN AIR Checking Static Pressure S 201 CHECKING TEMPERATURE RISE The more air CFM being delivered through a given furnace the less the rise will be so the less air CFM being deliv ered the greater the rise The temperature rise should be adjusted in accordance to a given furnace specifications and its external static pressure An incorrect temperature rise may result in
116. tal ap plications the connections can be made 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 INSTALLATION CONSIDERATIONS 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 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 andan 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 Accessor
117. tem are located and other spaces of the building Turn on clothes dryers and any appliance 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 operate 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 12 f Afterithas 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 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 ofthe National Fuel Gas Code ANSI Z223 1 and or CSA B149 Installation Codes Thermostat Requirements Atwo stage heat cool thermostat is recommended A single stage heating thermostat may be used It is recommended that a high
118. terfere with combustion air or draft The room closet or alcove 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 27 SYSTEM OPERATION 28 MEC960302BN All DIP Switch Positions All DIP Switch Positions FACTORY All DIP Switch Positions SETTING OFF OFF OFF ON OFF OFF ON ON OFF OFF ON OFF OFF OFF ON OFF ON ON ON OFF ON ON ON ON MEC960402BN All DIP Switch Positions All DIP Switch Positions All DIP Switch Positions FACTORY SETTING OFF OFF OFF ON OFF OFF ON ON OFF OFF ON OFF OFF OFF ON OFF ON ON ON OFF ON ON ON ON W1 w2 Ylo Ylo Ylo Ylo Ylo Ylo Ylo Ylo W1 w2 Ylo Ylo Ylo Ylo Ylo Ylo Ylo Ylo DIP SWITCH SETTING 0 1 0 2 0 3 0 4 0 5 0 6 CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM 870 658 548 469 413 349 870 21 658 28 5
119. th the appliance so they are proven in the full open position prior to main burner ignition 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 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 special gas vent or plastic piping installed within a masonry metal or facto
120. to the fur nace must be N E C Class 1 and must comply with all applicable codes The furnace must be electrically grounded in accordance with local codes or in their absence with the latest edition of The National Electric Code ANSI NFPA 70 and or The Canadian Electric Code CSA C22 1 INSTALLATION CONSIDERATIONS Use a separate fused branch electrical circuit containing properly sized wire and fuse or circuit breaker The fuse or circuit breaker must be sized in accordance with the maxi mum overcurrent protection specified on the unit rating plate An electrical disconnect must be provided at the furnace location NOTE Line polarity must be observed when making field connections IN 90 FURNACE 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 Connect hot neutral and ground wires as shown in the wir ing diagram located on the unit s blower door Line polarity must be observed when making field connections Line volt age connections can be made through either the right or left side panel caution EDGES OF SHEET METAL HOLES MAY BE SHARP USE GLOVES AS PRECAUTION WHEN REMOVING HOLE PLUGS NOTE Wire routing must not interfere with circulator blower operation filter removal or routine maintenance To AVOID THE RISK OF ELECTRICAL SHOCK INJURY OR
121. to the furnace and turn the ther mostat 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 does 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 S 304 CHECKING GAS VALVE Redundant A combination 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 SERVICING DISCONNECT ALL POWER BEFORE SERVICING Two stage gas valves always require 24 volts between com mon and low fire main coil to open Also the furnace front cover pressure switch is wired in series with the low main solenoid of the gas valve In the event of a non functioning gas valve always check the front cover pressure switch Also see section S 307 on Checking Gas Pressure and section S 310 on Checking Pressure Switches S 305 CHECKING MAIN BURNERS 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 The
122. tor cover screw from the low LO out let pressure regulator adjust tower and turn screw clockwise to increase pressure or counterclockwise to decrease pressure Replace regulator cover Screw 9 Close thermostat R W1 and W2 contacts to pro vide a call for high stage heat 10 Remove regulator cover screw from the high HI out let pressure regulator adjust tower and turn screw clockwise to increase pressure or counterclockwise to decrease pressure Replace regulator cover Screw 11 Turn off all electrical power and gas supply to the system 12 Remove the manometer hose from the hose barb fit ting or outlet pressure tap 13 Replace outlet pressure tap White Rodgers 36J54 valve Turn outlet pressure test screw in to seal pressure port clockwise 7 in lb minimum 14 Turn on electrical power and gas supply to the sys tem 15 Close thermostat contacts R and W1 W2 to ener gize the valve Manifold Gas Pressure Gas Range Nominal Natura Low Stage Stage B2 38 wc 359 wc Low Stage 57 63 we 60we Hen Stage pr 103 w c Using a leak detection solution or soap suds check for leaks at outlet pressure tap plug Honeywell valve or screw White Rodg ers valve Bubbles forming indicate a leak SHUT OFF GAS AND REPAIR ALL LEAKS IMMEDIATELY NOTE For gas to gas conversion consult your dealer for ap propriate conversion To PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE TH
123. ty 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 For indoor installation PGB amp PGJ For outdoor installation only 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 0140F00001P IMPORTANT INFORMATION CONSIGNES D SECURIT LIRE AVANT D ALLUMER L APPAREIL AVERTISSEMENT Le non respect des instructions qui suivent peut entrainer un risque d incendie ou d explosion causant des dommages des blessures ou la mort A Cet appareil comporte pas de veilleuse est muni d un m canisme qui allume automatiquement le br leur N
124. upport terminations for both the vent flue and the combustion air intake pipe The DCVK 20 2 and DCVK 30 3 kits are certified for models listed above See specification sheets on future models for use of the vent kit Side Wall Only Concentric Vent Kit For use with high efficiency furnace models This kit is to be used with 2 3 vent systems 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 For use with high efficiency 90 furnace models This kitis to be used with 2 only vent systems The vent kit must terminate outside the structure This kitis NOT intended for use with single pipe indirect vent installations External Filter Rack Kit This kitis 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 panel and provide filter retention as well as a location for attaching return air ductwork LP Gas Low Pressure Kit Designed for application on Goodman and Amana Brand s 80 and 90 single stage and two stage gas fired furnace products installed on LP gas listed in this manual This kitincludes harness adaptors to work with White Rodgers single amp two stage gas valves Honeywell single and two stage gas valves as well as modulating gas valves Vent Drain Coupling For use when the furnaces
125. uted 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 GAS STREAM B 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 Gas PRESSURE TEST The line pressure supplied to the gas valve must be within the range specified below The supply pressure can be measured 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 pres sure use the following procedure 51 SERVICING gie o gt b OUTLET 2 Gas Valve On Off Selector Switch White Rodgers Model 36J54 Two Stage Open to Manometer Atmosphere Hose High Fire Regulator Outlet N Adjust Pressure Boss Regulator Vent el INT gt 2 Low Fire Zlew Regulator T E CE IS Eve Adjust Pressure Boss High Fire Coll C
126. where commu nicating to the outdoors through vertical ducts each opening shall have a minimum free area of 1 2 4000 Btu hr 550 min kW of total input rating of all appliances in the enclosure See Figure 9 3 3 1 1 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 A ttic 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 EE eS Figure A 9 3 3 1 1 b All 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 14 lt Chim
127. witch and an orifice change These changes are necessary to compensate for the natu ral reduction in the density of both the gasfuel and the com bustion air at higher altitude For installations above 7500 feet feet please refer to your distributor for required kit s Contact the distributor for a tabular listing of appropriate manufacturer s kits for propane gas and or high altitude installations The indicated kits must be used to insure safe and proper furnace operation All conversions must be performed by a qualified installer or service agency In some areas the gas supplier may artificially derate the gas in an effort to compensate for the effects of altitude If the gas is artificially derated the appropriate orfice size must be determined based on 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 provided by the gas supplier to determine the proper orifice size S 312 CHECKING FOR DELAYED IGNITION Delayed ignition is a delay in lighting a combustible mix ture of gas and air which has accumulated in the combus tion chamber Furnace design 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 adjustto proper pressure See S 307 CHECKING GAS PRESSURE 2 Improper burner
128. ystem 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 d arc 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 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 media air filter or electronic

Goodman GMEC96 Service Instructions

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