Goodman GMEC96 Service Instructions Manual
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Goodman GMEC96 Service Instructions Manual

Two stage furnace with multi-speed ecm motor
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See also: User's Information Manual , Instruction and Service Manual

Service Instructions

Goodman
Brand GMEC96
®
& 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.
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.

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Summary of Contents for Goodman GMEC96

  • Page 1: Service Instructions

    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.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS ACCESSORIES .......... 34 - 37 IMPORTANT INFORMATION ......2 - 6 SERVICING TABLE OF COnTENTS ....38 PRODUCT IDENTIFICATION ......7 - 8 SERVICING ..........39 - 56 INSTALLATION CONSIDERATIONS ... 9 - 26 MAINTENANCE ..........57- 58 SYSTEM OPERATION .......27 - 33 IMPORTANT INFORMATION Pride and workmanship go into every product to provide our customers with quality products.
  • Page 3 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 AMANA BRAND PRODUCTS GOODMAN BRAND PRODUCTS ® ® TOLL FREE TOLL FREE 1-877-254-4729 (U.S.

  • Page 4: Important Information

    IMPORTANT INFORMATION FOR YOUR SAFETY READ BEFORE OPERATING WARNING: Improper If you do not follow these instructions exactly, alteration, service or a fire or explosion may result causing property maintenance can damage, personal injury or loss of life. cause injury or property damage.
  • Page 5 IMPORTANT INFORMATION CONSIGNES DE SECURITE - LIRE INSTRUCTIONS DE SERVICE AVANT D'ALLUMER L'APPAREIL 1. UN INSTANT! Lisez d'abord les consignes de securite ci-dessus. 2. Reglez le thermostat a son point le plus bas. AVERTISSEMENT: Le non-respect des instructions qui suivent peut 3.
  • Page 6 IMPORTANT INFORMATION...

  • Page 7: Product Identification

    Stainless Steel tubular heat exchanger. 115 volt silicon nitride igniter. Left or right gas AMEC961004CNAA AMEC961205DNAA GMEC060302BNAA GMEC960402BNAA Goodman ® Brand 96% Two Stage Heating / Two Stage Cooling Gas Furnace, Up GMEC060603BNAA GMEC96 flow/Horizontal Left and Right, 34.5" tall, Induced Draft, Nidec multi-speed ECM motor. GMEC960803BNAA Aluminized Steel tubular heat exchanger.
  • Page 8 3 minute timed off delay when the compressor goes off. AMU1620 P1251305F AMU1625 Media Air Cleaner . The Amana (AMU*) and Goodman (GMU*) Media Air Cleaner is a high P1251306F AMU2020 efficiency air filtration device designed to remove dirt, dust, pollen and other microscopic...

  • Page 9: Installation Considerations

    INSTALLATION CONSIDERATIONS Introduction 1. Disconnect all power to the furnace. Do not touch the integrated control module or any wire connected to the This is a Category lV furnace. This furnace uses a pressur- control prior to discharging your body’s electrostatic ized venting system and must be installed per National and charge to ground.

  • Page 10: Location Requirements And Considerations

    INSTALLATION CONSIDERATIONS • If the furnace is installed in an application where the WARNING typical operating sound level of a furnace is deemed objectionable, an optional sound reduction kit is avail- O PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE, able.

  • Page 11: Minimum Clearances To Combustible Materials

    INSTALLATION CONSIDERATIONS cleaning solutions (such as perchloroethylene) • If the furnace is installed horizontally, the furnace ac- cess doors must be vertical so that the burners fire printing inks horizontally into the heat exchanger. Do not install paint removers the unit with the access doors on the “up/top” or “down/ varnishes bottom”...

  • Page 12: Furnace Suspension

    INSTALLATION CONSIDERATIONS Furnace Suspension f. After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, If suspending the furnace from rafters or joist, use 3/8" return doors, windows, exhaust fans, fireplace dampers and any threaded rod and 2”x2”x1/8”...
  • Page 13 INSTALLATION CONSIDERATIONS space with other gas appliances, such as a water heater, 21 ft Required Volume > ________ _________ other ensure there is an adequate supply of combustion and ven- other 1000 Btu/hr tilation air for the other appliances. Refer to the latest edi- tion of the National Fuel Gas Code NFPA 54/ANSI Z223.1 (2) For fan-assisted appliances, calculate using the following equation: (Section 9.3), or CAN/CGA B149 Installation Codes (Sec-...
  • Page 14 INSTALLATION CONSIDERATIONS 9.3.3.1 Two Permanent Openings Method. Two permanent open- Chimney or Gas Vent 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 NOTE: The air duct openings provided.

  • Page 15: Horizontal Installations

    INSTALLATION CONSIDERATIONS 9.3.8.3 Ducts shall serve a single space. (c) The minimum size of outdoor opening(s) shall be the full size of outdoor opening(s) calculated in accordance with 9.3.3, 9.3.8.4 Ducts shall not serve both upper and lower combustion air multiplied by the reduction factor.
  • Page 16 INSTALLATION CONSIDERATIONS Insert flange. Cut 2 ½” long. Leveling Leveling ensures proper condensate drainage from the heat R 000142 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.
  • Page 17 INSTALLATION CONSIDERATIONS Freeze Protection This furnace must not be connected to Type B, BW, or L vent or vent connector, and must not be vented into any If the drain trap and drain line will be exposed to tempera- portion of a factory built or masonry chimney except when tures near or below freezing, adequate measures must be taken to prevent condensate from freezing.
  • Page 18 INSTALLATION CONSIDERATIONS Vent/Flue Pipe Lengths (Non-Direct Vent) and Diam- • The vent termination of vent pipe run vertically through eters a roof must terminate at least 12 inches above the roof line (or the anticipated snow level) and be at least Refer to the following tables for applicable length, elbows, 12 inches from any vertical wall (including any antici- and pipe diameter for construction of the vent/flue pipe sys-...
  • Page 19 INSTALLATION CONSIDERATIONS 10”- 24” NOTE: Terminate both pipes in the same pressure zone (same side of roof, no major obstacles between pipes, etc.). 6” MAX TEE (OPTIONAL) 4” MIN COMBUSTION AIR INTAKE 12” MIN 90º OR 45° (OPTIONAL) HEIGHT DIFFERENCE ELBOW BETWEEN *Not required for...
  • Page 20 INSTALLATION CONSIDERATIONS NTAKE ERMINATIONS NSTALLATION OF 2. Do NOT terminate over public walkways. Avoid areas TIPLE IRECT URNACES where condensate may cause problems such as above If more than one direct vent furnace is to be installed verti- planters, patios, or adjacent to windows where steam cally through a common roof top, maintain the same mini- may cause fogging.
  • Page 21 INSTALLATION CONSIDERATIONS Vent CAUTION Maintain 12" (18" for Canada) minimum clearance above highest anticipated snow level. Maximum of O PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE INLET 24" above roof. GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE Combustion Air WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING.
  • Page 22 INSTALLATION CONSIDERATIONS Natural Gas Capacity of Pipe PROPANE GAS CONVERSION In Cubic Feet of Gas Per Hour (CFH) Length of Nominal Black Pipe Size WARNING Pipe in Feet 1/2" 3/4" 1" 1 1/4" 1 1/2" 1050 1600 OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR IF 1100 THE CORRECT CONVERSION KITS ARE NOT INSTALLED.
  • Page 23 INSTALLATION CONSIDERATIONS GAS PIPING CHECKS Complete information regarding tank sizing for vaporization, recommended regulator settings, and pipe sizing is avail- Before placing unit in operation, leak test the unit and gas able from most regulator manufacturers and propane gas connections. suppliers.

  • Page 24: Propane Gas Piping Charts

    INSTALLATION CONSIDERATIONS When installing a propane storage tank, the contractor must WARNING consider proper tank sizing, safety, efficiency, ground char- acteristics and aesthetics. For a residential customer, the F THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A size may range from 100-1,000 gallons, depending on house- FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL hold use.
  • Page 25 INSTALLATION CONSIDERATIONS Use a separate fused branch electrical circuit containing Turn OFF power to the furnace before installing any acces- properly sized wire, and fuse or circuit breaker. The fuse or sories. Follow the humidifier or air cleaner manufacturers’ circuit breaker must be sized in accordance with the maxi- instructions for locating, mounting, grounding, and control- mum overcurrent protection specified on the unit rating plate.
  • Page 26 INSTALLATION CONSIDERATIONS Room Furnace 1 Furnace 2 Thermostat Furnace Integrated Control Module Remote Condensing Unit (Two-Stage Cooling) Thermostat - Two-Stage Heating with Two-Stage Cooling Thermostat Wiring Diagrams INGLE TAGE EATING HERMOSTAT PPLICATION A single-stage thermostat with only one heating stage may be used to control this furnace.

  • Page 27: System Operation

    SYSTEM OPERATION 8. Heating input (W1/ W2) always has priority over all Upflow furnaces with air delivery of 1800 CFM or higher: other thermostat input. Use two side returns or one side return and one bottom 9. Cooling input (YLo/ Y) has priority over continuous fan return connection.
  • Page 28 SYSTEM OPERATION DIP SWITCH SETTING *MEC960302BN CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM CFM CFM All DIP Switch Positions All DIP Switch Positions FACTORY All DIP Switch Positions SETTING OFF OFF OFF 1146 1097 1049 1002 ON OFF OFF ON ON OFF 1146...
  • Page 29 SYSTEM OPERATION DIP SWITCH SETTING *MEC960603BN CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM CFM CFM All DIP Switch Positions All DIP Switch Positions FACTORY W2 1328 40 All DIP Switch Positions 1287 41 1249 43 1215 44 1170 46 1131 1085 1046 SETTING...
  • Page 30 SYSTEM OPERATION DIP SWITCH SETTING *MEC961004CN CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM CFM CFM All DIP Switch Positions 1522 1464 1402 1338 1280 1230 1167 1101 W1 1522 41 All DIP Switch Positions 1464 43 1402 44 1338 47 1280 49...
  • Page 31 SYSTEM OPERATION UPRIGHT FILTER INSTALLATIONS · The control will check the status of the gas valve cir- cuitry. Depending on the installation and/or customer preference, differing filter arrangements can be applied. Filters can be · Line polarity is checked. installed in the central return register and a side panel exter- ·...
  • Page 32 SYSTEM OPERATION · If the average calculated duty cycle is 50% or greater, CALL FOR 2ND STAGE AFTER FIRST STAGE: then the heating cycle will be treated as if high stage The inducer motor is enabled at high speed. is needed and the transition from low to high stage ·...
  • Page 33 SYSTEM OPERATION COOLING MODE: MANUAL FAN ON: · On a call for Fan, the G thermostat contacts close LOW STAGE COOLING MODE SEQUENCE: signaling the control module. · On a call for lo cool, the Ylo and G thermostat con- ·...

  • Page 34: Accessories

    ACCESSORIES GME95 & AMEH96 FURNACE ACCESSORIES MO DEL AS AS / EFR0 2 AFE18 - 6 0 A AMU / G MU 0 17 0 K0 0 0 0 0 S 0 17 0 K0 0 0 0 1S NUMBER G S AS Conc e ntric Conc e ntric...

  • Page 35: Side Wall Vent Kit

    ACCESSORIES EXTERNAL FILTER RACK KIT ( EFR02 ) EFR01 EXTERNAL FILTER RACK KIT Used on Models SLOTS IN FILTER CLEAR SCREWS ON UNIT 90% Upflow Model Furnaces BLOWER DECK SCREWS UNIT SIDE PANEL FRONT OF UNIT FILTER RACK ASSEMBLY (FACE FILTER OPENING BASE TOWARDS FRONT OF UNIT...

  • Page 36: Horizontal Installation

    ACCESSORIES CONCENTRIC VENT CONVERSION KIT ( DCVK-20      DCVK-30 ) ( CVENT-2 ) ( CVENT-3 ) Vent The DCVK-20 (2") or the DCVK- Maintain 12" (18" for Canada) 30 (3") is a concentric vent kit minimum clearance above highest approved with furnaces listed in anticipated snow level.
  • Page 37 ACCESSORY WIRING DIAGRAMS HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. ALL FUEL SYSTEM CONTROL BOARD - AFE1860A 24VAC POWER SUPPLY P1-8 +VDC...

  • Page 38: Servicing

    SERVICING SERVICE NUMBERS CHECKING VOLTAGE ..........................45 CHECKING WIRING ............................ 45 S-3A THERMOSTAT AND WIRING ........................45 S-3B HEATING ANTICIPATOR ..........................45 CHECKING TRANSFORMER AND CONTROL CIRCUIT ................46 S-16A CHECKING AIR CIRCULATOR BLOWER MOTOR (EEM) ................46 S-200 CHECKING DUCT STATIC ........................... 46 S-201 CHECKING TEMPERATURE RISE ......................
  • Page 39 SERVICING As more and more electronic's are introduced to the Heat- INCOMING POWER ing Trade, Polarization of incoming power and phasing of METER READS METER READS 120 VOLTS 0 VOLTS primary to secondary voltage on transformers becomes more important. Polarization has been apparent in the Appliance industry VOLT / OHM VOLT / OHM METER...
  • Page 40 SERVICING CUBIC FEET GAS RATE -- CUBIC FEET PER HOUR Size of Test Dial Size of Test Dial Seconds Seconds for One for One Revolution Revolution cu/ft cu/ft cu/ft cu/ft cu/ft cu/ft cu/ft cu/ft cu/ft cu/ft 1800 1636 1500 1385 1286 1200 1125...
  • Page 41 SERVICING Service Problem No Heat Unsatisfactory Heat POSSIBLE CAUSE Test Method DOTS IN ANALYSIS Remedy GUIDE INDICATE "POSSIBLE CAUSE" • Power Failure Test Voltage • Blown Fuse Test Voltage • Loose Connection Check Wiring • S-3A Shorted or Broken Wires Check Wiring •...

  • Page 42: Troubleshooting

    TROUBLESHOOTING Green Amber Symptoms Fault Description Check Cautions LED Code LED Code LED Code •Defective disconnect switch •Determine cause and restore •Confirm electrically safe •Furnace fails to operate •defective door switch • No •None •None •None proper high and low volt power condition before •Control board LED is off 115 volt power •No 24 volt...
  • Page 43 TROUBLESHOOTING Green Amber Symptoms Fault Description Check Cautions LED Code LED Code LED Code •Temperature rise, duct static, •Furnace does not •Four •Open limit circuit, main •Confirm electrically safe gas pressure, burner alignment, operate, four Red •None •None repeating limit, aux limit, or roll out condition before orifice plate position, wiring to flashes on control board...
  • Page 44 IAGNOSTIC HART The ignition control is equipped with a momentary push but- Refer to the Troubleshooting Chart in the back of this manual ton switch that can be used to display on the diagnostic for assistance in determining the source of unit operational prob- LED the last five faults detected by the control.

  • Page 45: Checking Voltage

    SERVICING CHECKING THERMOSTAT, WIRING S-1 CHECKING VOLTAGE AND ANTICIPATOR WARNING S-3A THERMOSTAT AND WIRING HIGH VOLTAGE WARNING ISCONNECT POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING. ULTIPLE POWER SOURCES MAY BE PRESENT. AILURE TO DO SO MAY CAUSE ISCONNECT POWER BEFORE SERVICING. PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

  • Page 46: Checking Transformer And Control Circuit

    SERVICING S-4 CHECKING TRANSFORMER AND Control CIR- S-16A CHECKING AIR CIRCULATOR BLOWER CUIT MOTOR (MULTI-SPEED ECM MOTOR) A step-down transformer 120 volt primary to 24 volt second- ary, 40 VA (Heating and Cooling Models) supplies ample WARNING capacity of power for either operation. ISCONNECT POWER BEFORE SERVICING.

  • Page 47: Checking Temperature Rise

    SERVICING 1. Operate furnace with burners firing for approximately ten To determine proper air movement, proceed as follows: minutes. Check BTU input to furnace - do not exceed 1. With clean filters in the furnace, use a draft gauge (in- input rating stamped on rating plate.

  • Page 48: Checking Auxiliary Limit Control

    SERVICING If the limit circuit opens five times within a single call for PRIMARY LIMIT heat, the furnace will go into lockout for one hour. The RED CONTROL LED will display a FOUR flash code during this time. The control board can be reset by cycling 115 volt power to the furnace.
  • Page 49 SERVICING AUXILIARY LIMIT CONTROL VOLT / OHM METER BLOWER HOUSING RESET BUTTON AUXILIARY LIMIT CONTROL COLOR IDENTIFYING Auxiliary Limit Control Location Testing Auxiliary Limit Control WARNING HIGH VOLTAGE ISCONNECT POWER BEFORE SERVICING OR INSTALLING THIS UNIT. ULTIPLE POWER SOURCES MAY BE PRESENT.

  • Page 50: Checking Flame Rollout Control

    SERVICING CHECKING FLAME ROLLOUT CONTROL 7. After check and/or replacement of rollout switch, rein- stall burner compartment door and verify proper unit op- A temperature activated manual reset control is mounted to eration. the manifold assembly as shown in the following illustration. S-303 INDUCED DRAFT BLOWER Motor FLAME ROLLOUT...

  • Page 51: Checking Main Burners

    SERVICING 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 Two stage gas valves always require 24 volts between com- is being converted for use with LP gas.
  • Page 52 SERVICING If supply pressure differs from table, make the necessary adjustments to pressure regulator, gas piping size, etc., and/or consult with local gas utility. INLET OUTLET 5. Turn OFF gas to furnace at the manual shutoff valve and disconnect manometer. Reinstall plug before turning on gas to furnace.
  • Page 53 SERVICING High Fire 6. Turn on power and close thermostat “R” and “W1” Regulator Regulator contacts to provide a call for low stage heat. Adjust Vent 7. Measure the gas manifold pressure with burners fir- ing. Adjust manifold pressure using the Manifold Gas Pressure table shown below.

  • Page 54: S-308 Checking Hot Surface Ignitor

    SERVICING The steady state current at 120V is 0.37 to 0.68 amps. e. Remove the 1/8" NPT hose barb fitting from the outlet pressure tap. Replace the outlet pressure boss plug 8. After checking and/or replacing of hot surface ignitor, re- and seal with a high quality thread sealer.

  • Page 55: High Altitude Application (Usa)

    4 seconds. gas and the altitude. Refer to the National Fuel Gas Code, Goodman ® Brand and Amana® Brand Two-Stage (*MEC96) NFPA 54/ANSI Z223.1, and information provided by the gas 1. Check for 120 volts from Line 1 (Hot) to Line 2 (Neutral) supplier to determine the proper orifice size.

  • Page 56: Checking Flame Sensor

    SERVICING CAUTION - 120V NEUTRALS WARNING HIGH VOLTAGE ISCONNECT POWER BEFORE SERVICING OR INSTALLING THIS UNIT. ULTIPLE POWER SOURCES MAY BE PRESENT. AILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. Flame current can be measured in two ways: R201 R202 R200...

  • Page 57: Maintenance

    MAINTENANCE WARNING HIGH VOLTAGE ISCONNECT POWER BEFORE SERVICING OR INSTALLING THIS UNIT. ULTIPLE POWER SOURCES MAY BE PRESENT. AILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. Maintenance CAUTION Improper filter maintenance is the most common cause of F YOU MUST HANDLE THE ITNITOR, HANDLE WITH CARE.
  • Page 58 MAINTENANCE CONDENSATE DRAINAGE SYSTEM (QUALIFIED 3. Volt-Ohm Meter - testing continuity, capacitors, and SERVICER ONLY) motor windings. The drain tubes, standpipe, and field supplied drain line must 4. Inclined Manometer - to measure static pressure, be checked annually and cleaned as often as necessary to pressure drop across coils, filters, and draft.

This manual is also suitable for:

Amec96

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