Intertek ACVC96 Service Instructions Manual
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Intertek ACVC96 Service Instructions Manual

34.5" chassis
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Service Instructions

TM
34.5" Chassis
ACVC96/AMVC96
GCVC96/GMVC96
Gas
Furnaces
This manual is to be used by qualified, professionally trained HVAC technicians only. Goodman does
RS6612010
not assume any responsibility for property damage or personal injury due to improper service
August 2014
procedures or services performed by an unqualified person.
The material in this manual does not supercede manufacturer's installation and operation instructions
is a registered trademark of Maytag Corporation or its related companies and is used under license. All rights reserved.
®
Copyright © 2014 Goodman Company, L.P.

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Summary of Contents for Intertek ACVC96

  • Page 1: Service Instructions

    Service Instructions 34.5" Chassis ACVC96/AMVC96 GCVC96/GMVC96 Furnaces This manual is to be used by qualified, professionally trained HVAC technicians only. Goodman does RS6612010 not assume any responsibility for property damage or personal injury due to improper service August 2014 procedures or services performed by an unqualified person.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS TROUBLESHOOTING ........... 45 - 50 IMPORTANT INFORMATION ........2 - 5 PRODUCT IDENITIFICATION ........6 - 10 SYSTEM OPERATION COMFORTNET™ .... 51 - 56 ACCESSORIES ............ 11 - 13 SERVICING ............57 - 75 INSTALLATION CONSIDERATIONS ...... 14 - 39 MAINTENANCE ...........

  • Page 3: Important Information

    IMPORTANT INFORMATION Special Warning for Installation of Furnace or Air Handling Units in Enclosed Areas such as Garages, Utility Rooms or Parking Areas Carbon monoxide producing devices (such as an automobile, space heater, gas water heater, etc.) should not be operated in enclosed areas such as unventilated garages, utility rooms or parking areas because of the danger of carbon monoxide (CO) poisoning resulting from the exhaust emissions.

  • Page 4: Operating Instructions

    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

    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: Product Identification

    PRODUCT IDENTIFICATION The model and manufacturing number are used for positive identification of component parts used in manufacturing. Please use these numbers when requesting service or parts information. PRODUCT FURNACE TYPE: MAJOR REVISION TYPE G: Goodman A: Initial Release E: Two-Stage/ CABINET A: Amana®...
  • Page 7 First revision of 34.5" two stage communicating capable up flow furnace Revision Attributes First revision of 34.5" modulating counter flow furnace Revision Attributes MODEL: AMVC96 MODEL: ACVC96 REV AA REV AA Equipment Type Amana Brand Residential Gas Furnace Equipment Type...
  • Page 8 PRODUCT IDENTIFICATION MODEL # MFG # DESCRIPTION Fossil Fuel Kit. The AFE18-60A control is designed for use where the indoor coil is located above/downstream of a gas or fossil fuel furnace when used with a heat pump. It will operate with single and two stage heat pumps and single and two stage furnaces.
  • Page 9 PRODUCT IDENTIFICATION MODEL # MFG # DESCRIPTION Communicating Thermostat Kit- Digitally communicating thermostat. Designed for use with compatible Amana® Brand or Goodman® Brand Air Handlers or Furnaces and outdoor split AC or Heat Pump units. The CTK02** thermostat features a full color high definition display, advanced programming options including humidification control CTK02** CTK02**...
  • Page 10 PRODUCT IDENTIFICATION MODEL # MFG # DESCRIPTION External Filter Rack Kit. For use with Goodman® and Amana® Brand 90% upflow variable speed gas furnace models. This kit is intended to provide a location, external to the furnace casing, for installation of a permanent filter. The rack is mounted over the indoor air blower EFR02 compartment area of either side panel, and provide filter retention as well as a location for attaching return air ductwork.

  • Page 11: Accessories

    ACCESSORIES 96% Com Furnace Accessories Mode l AFE18 0 - 6 0 A AMU / G MU EFR0 2 AS AS / G S AS CF S B17 CF S B2 1 CFS B2 4 RF0 0 0 14 2 Numb e r F ossil Exte rna l...
  • Page 12 ACCESSORIES SLOTS IN FILTER CLEAR SCREWS EXTERNAL FILTER RACK (EFR02) ON UNIT BLOWER DECK 96% Upflow Model Furnaces SCREWS UNIT SIDE PANEL FRONT OF UNIT FILTER RACK ASSEMBLY (FACE FILTER OPENING BASE TOWARDS FRONT OF UNIT OF UNIT) RETURN AIR CUTOUT AREA LOWER EDGE SCREW...
  • Page 13 ACCESSORIES CONCENTRIC VENT CONVERSION KIT The CVENT-2 (DCVK20) (2") or the CVENT-3 (DCVK-30) (3") is a concentric vent kit approved with furnaces listed in this manual. This concentric vent kit allows for vertical or horizontal vent termination. The illustrations give a brief view of the kit and its application.

  • Page 14: Installation Considerations

    INSTALLATION CONSIDERATIONS Safety Product Application Please adhere to the following warnings and cautions when This product is designed for use as a residential home gas installing, adjusting, altering, servicing, or operating the fur- furnace. It is not designed or certified for use in mobile home, nace.

  • Page 15: Location Requirements And Considerations

    INSTALLATION CONSIDERATIONS National Fire Protection Association • Set the 90% furnace on a level floor to enable proper condensate drainage. If the floor becomes wet or damp 1 Batterymarch Park at times, place the furnace above the floor on a con- Quincy, MA 02269 crete base sized approximately 1-1/2"...
  • Page 16 INSTALLATION CONSIDERATIONS • If the furnace is installed in a residential garage, posi- PROVIDE 8" MINIMUM CLEARANCE BETWEEN CENTER ROD AND FURNACE CABINET tion the furnace so that the burners and ignition source TO ALLOW FOR CIRCULATOR BLOWER REMOVAL. are located not less than 18 inches (457 mm) above ASSURE FURNACE IS LEVEL FROM ALTERNATE 3/8"...
  • Page 17 INSTALLATION CONSIDERATIONS which opens on humidity rise. Refer to Electrical Connec- If resizing is required on any portion of the venting system, tions - 24 Volt Dehumidistat Wiring section in this manual use the appropriate table in Appendix G in the latest edition or the installation instructions for correct installation proce- of the National Fuel Gas Code ANSI Z223.1 and/or CSA B149 dure.
  • Page 18 INSTALLATION CONSIDERATIONS Most homes will require outside air be supplied to the fur- (2) For fan-assisted appliances, calculate using the following equation: nace area by means of ventilation grilles or ducts connect- 15 ft Required Volume > ________ _________ ing directly to the outdoors or spaces open to the outdoors 1000 Btu/hr such as attics or crawl spaces.
  • Page 19 INSTALLATION CONSIDERATIONS (1)*Where directly communicating with the outdoors or where commu- Chimney or Gas Vent nicating to the outdoors through vertical ducts, each opening shall have a minimum free area of 1 in. /4000 Btu/hr (550 min /kW) of NOTE: The air duct openings total input rating of all appliances in the enclosure.
  • Page 20 INSTALLATION CONSIDERATIONS 9.3.8.4 Ducts shall not serve both upper and lower combustion air (c) The minimum size of outdoor opening(s) shall be the full size openings where both such openings are used. The separation between of outdoor opening(s) calculated in accordance with 9.3.3, ducts servicing upper and lower combustion air openings shall be main- multiplied by the reduction factor.
  • Page 21 INSTALLATION CONSIDERATIONS Installation Positions *MVC96 models may be installed up flow or horizontally with left or right side down. *CVC96 models may be installed down flow or horizontally with left or right side down. Do not install any furnace on its back. Horizontal Installations 1.
  • Page 22 INSTALLATION CONSIDERATIONS Alternate Electrical and Gas Line Connections WARNING The furnaces have provisions allowing for electrical and gas line connections through either side panel. In horizontal ap- PON COMPLETION OF THE FURNACE INSTALLATION, CAREFULLY INSPECT THE plications the connections can be made either through the ENTIRE FLUE SYSTEM BOTH INSIDE AND OUTSIDE THE FURNACE TO ASSURE IT “top”...
  • Page 23 INSTALLATION CONSIDERATIONS NOTE: This provision does not apply to the combus- Non-Direct Vent Installations tion air intake termination of a direct vent application. A minimum of one 90° elbow must be installed on the com- bustion air intake “coupling” to guard against inadvertent •...
  • Page 24 INSTALLATION CONSIDERATIONS Horizontal vent/flue pipe terminations should be as shown in 12" MINIMUM the following figure. Refer to Vent/Flue Pipe and Combus- tion Air Pipe - Termination Locations section in this manual or the installation instructions for details concerning loca- VENT/FLUE TEE tion restrictions.
  • Page 25 INSTALLATION CONSIDERATIONS 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 90° one elbow/tee. ELBOWS 3) Tee used in the vent/flue termination must be included when deter- mining the number of elbows in the piping system.
  • Page 26 INSTALLATION CONSIDERATIONS Condensate Drain Lines and Drain Trap 90° A condensing gas furnace achieves its high level of efficiency by ELBOWS extracting heat from the products of combustion to the point where condensation takes place. The condensate must be collected in the furnace drain trap and routed to an appropri- ate drain location in compliance with local and national codes.
  • Page 27 INSTALLATION CONSIDERATIONS 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.
  • Page 28 INSTALLATION CONSIDERATIONS 4. Install a drip leg to trap dirt and moisture before it can GAS PIPING CONNECTIONS enter the gas valve. The drip leg must be a minimum of three inches long. CAUTION 5. Install a 1/8" NPT pipe plug fitting, accessible for test gage connection, immediately upstream of the gas O AVOID POSSIBLE UNSATISFACTORY OPERATION OR EQUIPMENT DAMAGE supply connection to the furnace.
  • Page 29 INSTALLATION CONSIDERATIONS GAS PIPING CHECKS All propane gas equipment must conform to the safety stan- dards of the National Board of Fire Underwriters, NBFU Before placing unit in operation, leak test the unit and gas Manual 58. connections. For satisfactory operation, propane gas pressure must be 10 inch WC at the furnace manifold with all gas appliances WARNING in operation.

  • Page 30: Electrical Connections

    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 31 INSTALLATION CONSIDERATIONS Use a separate fused branch electrical circuit containing prop- Accessory Load Specifications erly sized wire, and fuse or circuit breaker. The fuse or cir- Humidifier 1.0 Amp maximum at 120 VAC cuit breaker must be sized in accordance with the maxi- mum overcurrent protection specified on the unit rating plate.
  • Page 32 INSTALLATION CONSIDERATIONS NEUTRAL 24 V UMIDIFIER A 24 volt hum circuit may be powered off of the n/c side of the low fire pressure. If added in the field, the wiring must conform to all local and national codes. Connect the COM side of the humidifier to the C terminal on the furnace control board (or to the COM side of the 24 VAC transformer).
  • Page 33 INSTALLATION CONSIDERATIONS Thermostat Wiring - Two-Stage Variable Speed In a Non-Dual Fuel ComfortNet™ Furnaces Thermostat Application, Place Jumper Two-Stage Heating Between Y1 and O For As a two-stage non-communicating furnace, the furnace with Proper Dehumidification Single-Stage Cooling Operation and Proper integrated control module provides terminals for both “W1”...
  • Page 34 INSTALLATION CONSIDERATIONS CFM CHART High High Model Stage Stage Stage Stage Cool Cool Heat Heat *M VC960403BN* 1192 1059 *MVC960603BN* 1007 1158 1212 1260 1202 1316 *MVC960803BN* 1023 1033 1389 1230 1063 1396 1228 1337 *MVC960804CN* 1182 1016 1430 1375 1077 1516 1256...
  • Page 35 INSTALLATION CONSIDERATIONS DIP SWITCHES - FURNACES EQUIPPED WITH PCBKF103 / PCBKF104 Dip Switch Switch Bank Purpose Function Heating Off Delay 2 Stage Stat Thermostat 2 Stage Stat Setup 1 Stg Stat 5 min delay 1 Stg Stat auto delay Cooling Airflow Add 5% Minus 5% Trim...
  • Page 36 INSTALLATION CONSIDERATIONS For a furnace equipped with a PCBKF103 or PCBKF104 Single-Stage Thermostat Application control board, select preferences on S5 #1 DIP switch. A single-stage thermostat with only one heating stage may be used to control this furnace. The application of a single- Fossil Fuel Applications stage thermostat does not offer “true”...
  • Page 37 INSTALLATION CONSIDERATIONS Example: Cooling Capacity of 30,000 BTU/hr. 30,000/12,000 = 2.5 Tons 100% CFM 2. Determine the proper air flow for the cooling system. Most cooling systems are designed to work with air flows between 350 and 450 CFM per ton. Most manufactur- ers recommend an air flow of about 400 CFM per ton.
  • Page 38 INSTALLATION CONSIDERATIONS Upflow furnaces with air delivery of less than 1800 CFM: SIDE RETURN BOTTOM RETURN Use one side return or one bottom return ductwork connec- Cabinet Nominal Approx. Cabinet Nominal Approx. Width Filter Flow Area Width Filter Flow Area tion.
  • Page 39 INSTALLATION CONSIDERATIONS COUNTERFLOW FILTER INSTALLATION Electronic Air Cleaner (ASAS and GSAS) or Media This furnace has provisions for the installation of return air Air Cleaner (AMU and GMU) filters at the counterflow top return. The furnace will accom- The electronic air cleaner and media air cleaner are multi- modate the following filter sizes depending on cabinet size: positional high efficiency air filtration devices that can be installed in any position, except with the access door facing...

  • Page 40: System Operation

    SYSTEM OPERATION NORMAL SEQUENCE OF OPERATION stage settings. The circulator blower will remain on high heating speed for thirty (30) seconds before OWER switching to the low heat circulating speed. The normal power up sequence is as follows: • R and W1 (or R and W1/W2) thermostat contacts •...
  • Page 41 SYSTEM OPERATION play. Next, refer to the Troubleshooting Chart - ComfortNet™ on the following pages for an interpretation of the code dis- The normal operational sequence in fan only mode is as played on the LED's for a description of the problem. follows: •...
  • Page 42 SYSTEM OPERATION the gas valve will be de-energized and another purge will 8. Low Flame Sense Signal. If the furnace continues to occur and a third ignitor warm up for an additional (2) operate and the micro-amp signal from the flame sensor seconds will occur.
  • Page 43 SYSTEM OPERATION Temperature Limit. In attempting to deliver the airflow NOTE: Turn off power to the furnace prior to inserting memory demand, the motor may exceed its temperature limit. card onto the control. With memory card inserted onto con- The motor will reduce its output in an attempt to reduce trol, turn power to furnace on.

  • Page 44: System Operation

    SYSTEM OPERATION 22. Motor Parameters. This condition occurs if the motor the shared data set. If the airflow falls below the calcu- does not receive all the information is requires to operate lated minimum, the furnace will continue to operate with or an event occurs that prevents the motor from running, the reduce airflow.

  • Page 45: Troubleshooting

    TROUBLESHOOTING ComfortNet™ Symptoms of Abnormal Diagnostic/ Thermostat Only Operation (Legacy & Status LED Fault Description Possible Causes Corrective Actions Notes & Cautions ComfortNet™ Thermostat) Codes Message Code • Furnace fails to operate None • No 115 power to INTERNAL • Manual disconnect switch •...
  • Page 46 TROUBLESHOOTING Symptoms of Abnormal ComfortNet™ Diagnostic/ Operation (Legacy Thermostat Only Status LED Fault Description Possible Causes Corrective Actions Notes & Cautions & ComfortNet™ Codes Message Code Thermostat) • Induced draft blower • Low stage PS1 OPEN • Pressure switch hose •...
  • Page 47 TROUBLESHOOTING ComfortNet™ Symptoms of Abnormal Diagnostic/ Operation (Legacy Thermostat Only Status LED Fault Description Possible Causes Corrective Actions Notes & Cautions & ComfortNet™ Codes Message Code Thermostat) • Furnace fails to operate. • Problem with IGNITER • Improperly connected • Check and correct •...
  • Page 48 TROUBLESHOOTING ComfortNet™ Symptoms of Abnormal Diagnostic/ Thermostat Only Operation (Legacy Status LED Fault Description Possible Causes Corrective Actions Notes & Cautions & ComfortNet™ Codes Message Code Thermostat) • Operation different than • Invalid memory INVALID MC • Shared data set on •...
  • Page 49 TROUBLESHOOTING ComfortNet™ Symptoms of Abnormal Diagnostic/ Thermostat Only Operation (Legacy Status LED Fault Description Possible Causes Corrective Actions Notes & Cautions & ComfortNet™ Codes Message Code Thermostat) • Circulator blower MOTOR • Turn power OFF prior • Furnace fails to operate. motor senses TRIPS to repair...
  • Page 50 TROUBLESHOOTING INTERNAL CONTROL FAULT/NO POWER NORMAL OPERATION LOCKOUT DUE TO EXCESSIVE RETRIES LOW STAGE PRESSURE SWITCH STUCK CLOSED AT START OF HEATING CYCLE LOW STAGE PRESSURE SWITCH STUCK OPEN OPEN HIGH LIMIT SWITCH FLAME DETECTED WHEN NO FLAME SHOULD BE PRESENT OPEN FUSE LOW FLAME SIGNAL IGNITER FAULT OR IMPROPER GROUNDING...

  • Page 51: System Operation Comfortnet

    SYSTEM OPERATION ComfortNet™ System 4. Dehumidification (lowering of CFM to 85%) only happens ComfortNet™ System during low stage cooling operation. The dehumidification VERVIEW feature is not active during high stage cool. The CTK03AB The ComfortNet system is a system that includes a and CTK04 can be set up to overcool the home in order ComfortNet compatible furnace and air conditioner or heat to reach the RH set point.
  • Page 52 ComfortNet™ System SYSTEM OPERATION NOTE: Use of an accessory transformer is recommended if installing a dual fuel system. Failure to use the transformer in the outdoor unit could result in overloading of the furnace transformer. CTK0*** Thermostat When using a CTK03A*or CTK04 thermostat, the included transformer must be used.
  • Page 53 SYSTEM OPERATION ComfortNet™ System URNACE DVANCED EATURES ENUS CONFIGURATION Submenu Item Indication (for Display Only; not User Modifiable) Number of Heat Stages (HT STG) Displays the number of furnace heating stages Input Rate (BTU/HR) Displays the furnace input rate in kBtu/hr Motor HP (1/2, ¾, or 1 MTR HP) Displays the furnace indoor blower motor horsepower DIAGNOSTICS...
  • Page 54 SYSTEM OPERATION ComfortNet™ System NON-COMM (APPLIES ONLY TO A COMMUNICATING COMPATIBLE FURNACE MATCHED WITH A NON-COMMUNICATING COMPATIBLE SINGLE STAGE AIR CONDITIONER) Submenu Item User Modifiable Options Comments Cool Airflow (CL CFM) 18, 24, 30, 36, 42, 48, or 60, default Selects the airflow for the non-CT is 18 compatible single stage AC unit...
  • Page 55 SYSTEM OPERATION ComfortNet™ System YSTEM ROUBLESHOOTING NOTE: Refer to the instructions accompanying the ComfortNet compatible outdoor AC/HP unit for troubleshooting information. Refer to the Troubleshooting Chart for a listing of possible furnace error codes, possible causes and corrective actions. Indication Possible Causes Corrective Action(s) Notes &...
  • Page 56 SYSTEM OPERATION ComfortNet™ System TROUBLESHOOTING Wiring issues may be confirmed (or eliminated) by using the CTK0*** thermostat and sub base, a 4-position connec- (ESD) P LECTROSTATIC ISCHARGE RECAUTIONS tor (included with the kit), and a short section (~ 2ft) of ther- mostat wire.

  • Page 57: Servicing

    SERVICING Some of the electronic boards being used today, with flame INCOMING POWER rectification, will not function properly and/or at all without METER READS METER READS 120 VOLTS 0 VOLTS polarization of incoming power. Some also require phasing between the primary and secondary sides of step-down transformers.
  • Page 58 SERVICING CUBIC FEET GAS RATE -- CUBIC FEET PER HOUR Size of Test Dial Size of Test Dial Seconds for Seconds for 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 1059 1000...
  • Page 59 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 • Shorted or Broken Wires Check Wiring S-3A •...
  • Page 60 SERVICING SERVICE NUMBERS CHECKING VOLTAGE ....... 61 S-305 CHECKING MAIN BURNERS ..... 69 S-306 CHECKING ORIFICES ....... 69 CHECKING WIRING ......61 S-307 CHECKING GAS PRESSURE ... 69 CHECKING THERMOSTAT, WIRING S-308 CHECKING AND ANTICIPATOR ......61 HOT SURFACE IGNITOR ....71 S-3A THERMOSTAT AND WIRING .....

  • Page 61: Checking Voltage

    SERVICING S-1 CHECKING VOLTAGE CHECKING THERMOSTAT, WIRING AND ANTICIPATOR WARNING S-3A THERMOSTAT AND WIRING HIGH VOLTAGE ISCONNECT POWER BEFORE SERVICING OR WARNING 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 62 SERVICING CHECKING TRANSFORMER AND Control CIRCUIT ECM Control Connections A step-down transformer 120 volt primary to 24 volt second- ECM control connections are made through the integrated ary, 40 VA (Heating and Cooling Models) supplies ample ignition control. No other control connections are needed. capacity of power for either operation.
  • Page 63 SERVICING 6. Ensure motor and wheel turn freely. Check for interfer- Replace or repair as needed. ence between wheel and housing or wheel and motor. Repair or replace as needed. 7. Check housing for cracks and/or corrosion. Repair or P o w e r G re e n M o tor In d ica tio n (s)
  • Page 64 SERVICING Motor Control/End Bell Checks AC Line Hot Connection AC Line Neutral Connection HIGH VOLTAGE! Disconnect ALL power before servicing or installing. Multiple power sources Lines 1 and 2 will be connected for 120VAC Power Connector may be present. Failure to do so may applications only cause property damage, personal injury or death.

  • Page 65: Checking Duct Static

    SERVICING Too great of an external static pressure will result in insuffi- cient air that can cause excessive temperature rise, result- ing in limit tripping, etc. Whereas not enough static may result in motor overloading. To determine proper air movement, proceed as follows: 1.

  • Page 66: Checking Primary Limit Control

    SERVICING PRIMARY LIMIT may result in condensing in or overheating of the heat ex- CONTROL changer. 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.

  • Page 67: Checking Auxiliary Limit Control

    SERVICING Manual or Automatic Reset Auxiliary Limits Located in Blower Side WARNING HIGH VOLTAGE VOLT / OHM ISCONNECT POWER BEFORE SERVICING OR METER INSTALLING THIS UNIT. ULTIPLE POWER SOURCES MAY BE PRESENT. AILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. 1.

  • Page 68: Induced Draft Blower Motor

    SERVICING FLAME 1. Remove burner compartment door to gain access to the ROLLOUT induced draft blower motor. SWITCHES 2. Disconnect the motor wire leads from its connection point at the induced draft motor. 3. Using a ohmmeter, test for continuity between each of the motor leads.

  • Page 69: Checking Main Burners

    SERVICING S-305 CHECKING MAIN BURNERS Orifices should be treated with care in order to prevent dam- age. They should be removed and installed with a box-end The main burners are used to provide complete combustion wrench in order to prevent distortion. In no instance should of various fuels in a limited space, and transfer this heat of an orifice be peened over and redrilled.
  • Page 70 SERVICING WARNING WARNING HIGH VOLTAGE ISCONNECT ELECTRICAL POWER AND SHUT OFF GAS SUPPLY. ISCONNECT ELECTRICAL POWER AND SHUT OFF GAS SUPPLY BEFORE SERVICING OR INSTALLING THIS UNIT. 1. After turning off gas to furnace at the manual gas shutoff ULTIPLE POWER SOURCES MAY BE PRESENT. AILURE TO valve external to the furnace, remove burner compart- DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

  • Page 71: Checking Hot Surface Ignitor

    SERVICING WARNING WARNING HIGH VOLTAGE INE VOLTAGE NOW PRESENT ISCONNECT ELECTRICAL POWER AND SHUT OFF GAS SUPPLY BEFORE SERVICING OR INSTALLING. 3. Turn ON the gas and electrical power supply and oper- ate the furnace. 4. White-Rodgers 36J54 Valves: Manifold Gas Pressure a.

  • Page 72: Checking For Flashback

    SERVICING 5. Reconnect ignitor. 3. Remove the pressure control hose from the control and interconnect with an inclined manometer as shown in the following figure. WARNING 4. With an ohm meter connected across the pressure switch terminals and with the inducer running, the switch INE VOLTAGE NOW PRESENT should close and the ohm meter should show a com- plete circuit across the pressure switch.

  • Page 73: Checking For Delayed Ignition

    SERVICING In some areas the gas supplier may artificially derate the These tests must be completed within a given time frame gas in an effort to compensate for the effects of altitude. If due to the operation of the ignition control. The trial for igni- the gas is artificially derated the appropriate orfice size must tion period is 4 seconds.

  • Page 74: Memory Chips

    SERVICING b. The two-stage variable speed furnaces should have 120 Volts at the motor at all times, even without a call for cooling or heating. These motors receive their op- erational signals through the 4-pin wiring harness, connected between the motor and integrated control board.

  • Page 75: Checking Flame Sensor

    SERVICING 3. Insert the memory card in the slot on the control board. 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. 1.

  • Page 76: 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. CAUTION Maintenance Improper filter maintenance is the most common cause of F YOU MUST HANDLE THE ITNITOR, HANDLE WITH CARE.
  • Page 77 MAINTENANCE To conduct a heating performance test, the BTU input to the CONDENSATE DRAINAGE SYSTEM (QUALIFIED furnace must be calculated. SERVICER ONLY) The drain tubes, trap, and field supplied drain line must be After the heating cycle has been in operation for at least checked annually and cleaned as often as necessary to fifteen minutes and with all other gas appliances turned off, ensure proper condensate drainage.

  • Page 78: Accessory Wiring Diagrams

    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 79 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. INTEGRATED IGNITION CONTROL WHITE BLACK GREEN DE-HUMIDISTAT DE-HUMIDISTAT - DEHUM1 This wiring diagram is for reference only.

This manual is also suitable for:

Amvc96Gcvc96Gmvc96

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