Heating
&
Air Conditioning
C om fort. Q uality. Tru st.
These furnaces comply with requirements embodied
in the American National Standard / National Stan-
dard of Canada ANSI Z21.47·CSA-2.3 Gas Fired
Central Furnaces.
Part No. 10318740
Printed in USA
GAS FIRED WARM AIR FURNACE
®
Goodman Company, L.P.
1810 Wilson Parkway • Fayetteville, Tennessee 37334
www.amana-hac.com
I
NSTALLATION
*GUCA/GCCA/GULA
Installer: Affix all manuals adjacent to the unit.
I
NSTRUCTIONS
*Type FSP Category IV Direct or Non
Direct Vent Forced Air Furnace.
C E R T I F I E D
January 2003

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   Summary of Contents for Amana GUCA

  • Page 1

    Air Conditioning ® NSTALLATION NSTRUCTIONS C om fort. Q uality. Tru st. *GUCA/GCCA/GULA Installer: Affix all manuals adjacent to the unit. *Type FSP Category IV Direct or Non Direct Vent Forced Air Furnace. These furnaces comply with requirements embodied in the American National Standard / National Stan- dard of Canada ANSI Z21.47·CSA-2.3 Gas Fired...

  • Page 2: Table Of Contents

    Table of Contents I. Component Identification ............................5 II. Safety ..................................6 ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ............................ 6 III. Product Application ..............................6 IV. Location Requirements and Considerations ......................7 GENERAL ..........................................7 CLEARANCES AND ACCESSIBILITY ................................. 8 FURNACE SUSPENSION ....................................8 EXISTING FURNACE REMOVAL ..................................

  • Page 3: Table Of Contents

    Table of Contents XII. Gas Supply and Piping ............................27 GENERAL ........................................... 27 High Altitude Derate ....................................27 Propane Gas Conversion .................................... 27 Gas Valve ........................................27 GAS PIPING CONNECTIONS .................................... 27 General ........................................27 Direct/Standard Inlet Piping ..................................29 Indirect/Alternate Inlet Piping ..................................

  • Page 4

    WARNING If additional information or operating instructions are re- quired, contact the dealer where the purchase was made. If the information in these instructions is not followed exactly, fire or explosion may TO THE INSTALLER result causing property damage, personal Before installing this unit, please read this manual thor- injury or loss of life.

  • Page 5: I. Component Identification

    I. Component Identification 9 10 Upflow/Horizontal Counterflow/Horizontal (GUCA/GULA Models) (GCCA Models) 1 Gas Valve 19 Coil Front Cover Pressure Tap 2 Gas Line Entrance (Alternate) 20 Coil Front Cover Drain Port 3 Pressure Switch 21 Drain Line Penetrations 4 Gas Manifold 22 Drain Trap 5 Combustion Air Intake Connection / “Coupling”...

  • Page 6: Ii. Safety, Iii. Product Application

    2. Firmly touch a clean, unpainted, metal surface of the II. Safety furnaces near the control. Any tools held in a person’s hand during grounding will be discharged. Please adhere to the following warnings and cautions when 3. Service integrated control module or connecting wiring installing, adjusting, altering, servicing, or operating the following the discharge process in step 2.

  • Page 7: Iv. Location Requirements And Considerations, General

    WARNING IV. Location Requirements Possible death, personal injury or property and Considerations damage due to fire, explosion, smoke, soot, condensation, electrical shock or carbon monoxide may result from improper GENERAL installation, repair, operation, WARNING maintenance of this product. To prevent possible death, personal injury, equipment damage, or property damage WARNING the following bullet points must be...

  • Page 8: Clearances And Accessibility, Furnace Suspension, Existing Furnace Removal

    • 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 SIDE SIDE SIDE chlorine-based swimming pool chemicals water softening chemicals BOTTOM deicing salts or chemicals...

  • Page 9: Air Requirements

    The following vent testing procedure is reproduced from the American National Standard/National Standard of Canada for Gas-Fired Central Furnaces ANSI Z21.47-1998, CSA-2.3-M98 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: DRAFTS OR DEAD SPOTS -BEHIND DOORS...

  • Page 10

    The following information on air for combustion and ventilation 5.3.3 Equipment Located in Confined Spaces: is reproduced from the National Fuel Gas Code (a) All Air from Inside the Building: The confined space shall be NFPA 54/ANSI Z223.1 Section 5.3. provided with two permanent openings communicating directly with an additional room(s) of sufficient volume so that the 5.3.1 General:...

  • Page 11

    2. When communicating with the outdoors through vertical 4. When ducts are used, they shall be of the same cross- ducts, each opening shall have a minimum free area of 1 sectional area as the free area of the openings to which they square inch per 4,000 BTU per hour of total input rating of connect.

  • Page 12: Vi. Installation Positions, General, Drain Trap And Lines, Leveling, Alternate Vent/flue And Combustion Air Connections

    VI. Installation Positions LEVELING Leveling ensures proper condensate drainage from the heat exchanger and induced draft blower. For proper flue This furnace may be installed in an upright position or pipe drainage, the furnace must be level lengthwise from horizontal on either the left or right side panel. Do not install end to end.

  • Page 13: Alternate Electrical And Gas Line Connections, Drain Pan, Freeze Protection, High Altitude Installations

    IX. Vent/Flue Pipe ALTERNATE ELECTRICAL AND GAS LINE CONNECTIONS & Combustion Air Pipe This furnace has provisions allowing for electrical and gas line connections through either side panel. In horizontal applications the connections can be made either through GENERAL the “top” or “bottom” of the furnace. WARNING DRAIN PAN Failure to follow these instructions can...

  • Page 14: Materials And Joining Methods, Proper Vent/flue And Combustion Air Piping Practices, Termination Locations

    Precautions should be taken to prevent condensate from MATERIALS AND JOINING METHODS freezing inside the vent/flue pipe and/or at the vent/flue pipe WARNING termination. All vent/flue piping exposed to freezing tem- peratures below 35°F for extended periods of time must be To avoid fire, explosion, or bodily injury, insulated with 1/2”...

  • Page 15: Canadian Venting Requirements, Standard Furnace Connections, Vent/flue Pipe, Combustion Air Pipe, Direct Vent Installations

    provided with this furnace (see “Standard Connections” NOTE: In Canada, the Canadian Fuel Gas Code takes figure). The rubber coupling allows separation of the vent/ precedence over the preceding termination restrictions. flue pipe from the furnace during servicing. NOTE: Do not use other commercially available “no hub connectors”...

  • Page 16: Alternate Vent/flue Location

    5. Remove plastic plug from alternate vent/flue location. NOTE: Standard and alternate locations can be combined Relocate and install plug in standard vent/flue location (i.e., an installation may use the standard combustion air (top cover). intake location but use the alternate vent/flue location or vice versa), if needed.

  • Page 17: Alternate Combustion Air Intake Location

    3. Remove plastic plug from alternate combustion air REMOVE REMOVE intake location. Relocate and install plug in standard air REMOVE REMOVE 4 SCREWS PIPE PIPE intake location (top cover). 4 SCREWS REMOVE Counterflow units. 3 SCREWS Remove plastic plug from alternate combustion air REMOVE REMOVE intake location.

  • Page 18: Non-direct Vent (single Pipe) Piping, Vent/flue Pipe Lengths And Diameters, Vent/flue Pipe Terminations

    NON-DIRECT VENT (SINGLE PIPE) PIPING Non-direct vent installations require only a vent/flue pipe. The vent pipe can be run horizontally with an exit through the side of the building or run vertically with an exit through 12 " Min To Roof Or the roof of the building.

  • Page 19: Direct Vent (dual Pipe) Piping, Vent/flue And Combustion Air Pipe Lengths And Diameters

    12" MIN. Direct Vent (Dual Pipe) Maximum Allowable Length of Vent/Flue & Combustion Air Intake Pipe (ft) VENT/FLUE TEE Pipe Vent/Flue/Air (1)(2)(3) 90° ELBOW TURNED Unit Input Number of Elbows Intake Size DOWN (Btu) Termination (in.) Standard 45,000 Alternate 12" MIN. ABOVE Standard HIGHEST ANTICIPATED 70,000...

  • Page 20: Vent/intake Terminations For Installation Of Multiple Direct Vent Furnaces

    90° Medium Radius Elbow Vent 12" MIN 3" MIN 24" MAX VENT/FLUE 12" Min. 3" MIN 24" MAX 24" Max. COMBUSTION Screen 3" Min. AIR INTAKE 24" Max. 90º MEDIUM RADIUS Air Intake ELBOW 12" MIN 12" MIN SCREEN 12" Min. Above Highest Anticipated Snow Level Standard Horizontal Terminations...

  • Page 21: General, Upright Installations, Standard Right Or Left Side Drain Hose Connections

    X. Condensate Drain Lines UPRIGHT INSTALLATIONS In an upright installation drain hoses are connected to drain & Drain Trap ports on the rubber elbow and the recuperator coil front cover. The drain lines are then routed through the right or GENERAL left side panel and into the drain trap secured to the outside A condensing gas furnace achieves its high level of effi-...

  • Page 22: Alternate Vent/flue Drain Hose Connections

    LEFT NOTE: Ensure hoses and tubes maintain a downward SIDE PANEL slope for proper drainage and that they are not kinked or FRONT COVER binding. RUBBER DRAIN PORT ELBOW For details concerning mounting of the drain trap, refer to RED HOSE Section X, Condensate Drain Lines and Drain Trap - Up- RUBBER CLAMP...

  • Page 23: Upright Drain Trap Mounting (left Or Right Side Panel), Horizontal Installations, Right Side Down

    the following section. FRONT COVER DRAIN PORT Upright Drain Trap Mounting (Left or Right Side RED HOSE Panel) CLAMP 1. Insert drain tubes into drain trap and position the drain HOSE A trap against the side panel. NOTE: Drain tubes must FRONT HOSE B COVER...

  • Page 24: Left Side Down

    3. Secure Hose A to front cover drain port with a red hose clamp. Route hose to rear left (down) side panel grom- met holes. NOTE: For left side drainage, grommets must be relocated to left side panel. Hose B Tube 1 INDUCED DRAFT BLOWER...

  • Page 25: Wiring Harness, Volt Line Connections

    WARNING XI. Electrical Connections In upright upflow installations, the drain trap must be mounted on the opposite side WARNING of the unit from the junction box. This will To avoid the risk of electrical shock, wiring reduce the risk of water reaching the to the unit must be properly polarized and junction box in the event of a blocked drain grounded.

  • Page 26: Volt Thermostat Wiring, Volt Line Connection Of Accessories (humidifier And Electronic Air Cleaner)

    115 VOLT LINE CONNECTION OF ACCESSORIES (HUMIDIFIER AND ELECTRONIC AIR CLEANER) WARNING To avoid electrical shock, injury or death, ALTERNATE STANDARD disconnect electrical power before JUNCTION BOX JUNCTION BOX LOCATION LOCATION servicing, or changing any electrical wiring. The furnace’s integrated control module is equipped with line voltage accessory terminals for controlling power to an optional field-supplied humidifier and/or electronic air cleaner.

  • Page 27: Xii. Gas Supply And Piping, General, High Altitude Derate, Propane Gas Conversion, Gas Valve

    XII. Gas Supply and Piping 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 an distributor for a tabular listing of appropriate altitude ranges and corre- GENERAL sponding manufacturer’s pressure switch kits.

  • Page 28: Gas Piping Connections

    MANUAL SHUT OFF VALVE GAS VALVE (UPSTREAM FROM ALTERNATE MANUAL GROUND JOINT MANIFOLD BURNERS GAS LINE SHUT OFF VALVE PIPE UNION) LOCATION (UPSTREAM FROM ALTERNATE GROUND JOINT GAS LINE PIPE UNION) LOCATION PLUG IN PLUG IN HEIGHT REQUIRED ALTERNATE ALTERNATE BY LOCAL CODE GAS LINE HEIGHT REQUIRED...

  • Page 29: Direct/standard Inlet Piping, Indirect/alternate Inlet Piping, Gas Piping Checks

    num-alloy tubing and connectors are coated to protect Natural Gas Capacity of Pipe against external corrosion when in contact with ma- In Cubic Feet of Gas Per Hour (CFH) sonry, plaster, or insulation, or subjected to repeated Length of Nominal Black Pipe Size Pipe in Feet 1/2"...

  • Page 30: Propane Gas Piping Charts

    Sizing Between First and Second Stage Regulator* Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting. Capacities in 1,000 BTU/hour. Pipe or Nominal Pipe Size Tubing Tubing Size, O.D. Type L Schedule 40 Length, 3/8"...

  • Page 31: Ductwork - Air Flow, Filters - Read This Section Before Installing The Return Air Ductwork

    XIII. Circulating Air & Filters Propane Gas Tanks and Piping WARNING DUCTWORK - AIR FLOW Duct systems and register sizes must be properly designed Propane gas is heavier than air and any for the CFM and external static pressure rating of the leaking gas can settle in any low areas or furnace.

  • Page 32: Upright Installations, Heat Anticipator Setting, Drain Trap Priming, Furnace Operation, Furnace Startup

    XIV. Startup Procedure & UPRIGHT INSTALLATIONS Depending on the installation and/or customer preference, Adjustment differing filter arrangements can be applied. Filters can be installed in the central return register or a side panel Furnace must have a 115 VAC power supply properly external filter rack kit (upflows).

  • Page 33: Furnace Shutdown, Gas Supply Pressure Measurement, White-rodgers 36f22 Gas Valve

    Furnace Shutdown Gas Line 1. Set the thermostat to the lowest setting. The integrated control will close the gas valve and Gas Shutoff Valve extinguish flame. Following a 15 second delay, the induced draft blower will be de-energized. After a 60, 90, 120, or 180 second delay period (field selectable), the circulator blower will be de-energized.

  • Page 34: White-rodgers 36g22 Gas Valve, Gas Manifold Pressure Measurement And Adjustment, White-rodgers 36f22 Gas Valve

    White-Rodgers 36G22 Gas Valve GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT The line pressure supplied to the gas valve must be within CAUTION the range specified below. The supply pressure can be measured at the gas valve inlet pressure tap or at a hose To prevent unreliable operation or fitting installed in the gas piping drip leg.

  • Page 35: Gas Input Rate Measurement (natural Gas Only), Temperature Rise

    3. Connect a calibrated water manometer and 5/16 inch GAS INPUT RATE MEASUREMENT (NATURAL GAS hose to the gas valve outlet pressure tap. Hose should ONLY) overlap tap by 3/8 inch. The gas input rate to the furnace must never be greater than 3.

  • Page 36: Circulator Blower Speeds

    To adjust the circulator blower speed, proceed as follows: HEAT EXCHANGER RADIATION "LINE OF SIGHT" 1. Turn OFF power to the furnace. 2. Select the heating and cooling blower speeds that SUPPLY match the installation requirements from the airflow table in the Specification Sheet. SUPPLY 3.

  • Page 37

    Timing Chart for Normal Heating Mode CIRCULATOR BLOWER OPEN GAS VALVE CLOSED IGNITER CLOSED PRESSURE SWITCH OPEN CONTACTS INDUCED DRAFT BLOWER THERMOSTAT 60,90, SECONDS circ 120 or FIXED HEAT IGNITER WARM UP PERIOD ON DELAY: WR50T55 (see note) 30 SECONDS HAS A FIXED 90-SECOND OFF DELAY...

  • Page 38: Power Up, Heating Mode, Cooling Mode, Burner Flame

    • Furnace circulator blower and outdoor cooling unit run, XV. Normal Sequence integrated control module monitors safety circuits con- of Operation tinuously. • R and Y thermostat contacts open, completing the call for cool. POWER UP • Outdoor fan and compressor are de-energized. The normal power up sequence is as follows: •...

  • Page 39: Integrated Control Module, General, Primary Limit, Auxiliary Limit, Rollout Limit, Pressure Switches

    PRIMARY LIMIT XVII. Safety Circuit The primary limit control guards against overheating result- Description ing from insufficient conditioned air passing over the heat exchanger. If the primary limit control does not function during this test, the cause must be determined and cor- GENERAL rected.

  • Page 40: Electrostatic Discharge (esd) Precautions, Diagnostic Chart, Annual Inspection, Filters, Maintenance

    3. Manual thermostat cycle. Lower the thermostat so that XVIII. Troubleshooting there is no longer a call for heat then reset to previous setting. Interrupt thermostat signal to the furnace for 0 - 20 seconds. ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS NOTE: If the condition which originally caused the lockout NOTE: Discharge body’s static electricity before touching still exists, the control will return to lockout.

  • Page 41: Troubleshooting Chart

    Troubleshooting Chart Associated Symptoms of Abnormal Fault Description(s) Possible Causes Corrective Action Cautions and Notes Operation LED Code • Furnace fails to operate. NONE • No 115 volt power to • Manual disconnect switch • Assure 115 and 24 volt •...

  • Page 42

    Troubleshooting Chart Associated Symptoms of Abnormal Fault Description(s) Possible Causes Corrective Action Cautions and Notes Operation LED Code • Circulator blower runs • Primary or auxiliary • Check filters and • Turn power OFF • Insufficient conditioned air continuously. No furnace limit circuit is open.

  • Page 43: Filter Removal, Upright Upflow Filter Removal, Horizontal Unit Filter Removal

    Filter Removal Front of Furnace Front of Furnace Depending on the installation, differing filter arrangements can be applied. Filters can be installed in either the central return register, the bottom of the blower compartment (upflow only) or a side panel external filter rack (upflow only).

  • Page 44: Condensate Trap And Drain System (qualified Servicer Only), Flame Sensor (qualified Servicer Only)

    XX. Before Leaving CONDENSATE TRAP AND DRAIN SYSTEM (QUALIFIED SERVICER ONLY) an Installation Annually inspect the drain tubes, drain trap, and field- supplied drain line for proper condensate drainage. Check • Cycle the furnace with the thermostat at least three drain system for hose connection tightness, blockage, and times.

This manual also for:

Gula, Gcca

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