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Amana 10759833 Installation Instructions Manual

Two-stage variable speed.
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Heating
&
Air Conditioning
®
Two-Stage Variable Speed
C om fort. Q uality. Tru st.
Gas-Fired Furnace
This Forced Air Central Furnace design complies with require-
ments embodied in
The American National Standard / National Standard of Canada
shown below:
ANSI Z21.47·CSA-2.3 Gas Fired Central Furnaces
C E R T I F I E D
Goodman Company, L.P.
Part No. 10759833
February 2003
1810 Wilson Parkway • Fayetteville, Tennessee 37334
Printed in USA
www.amana-hac.com

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   Summary of Contents for Amana 10759833

  • Page 1: Installation Instructions

    The American National Standard / National Standard of Canada shown below: ANSI Z21.47·CSA-2.3 Gas Fired Central Furnaces C E R T I F I E D Goodman Company, L.P. Part No. 10759833 February 2003 1810 Wilson Parkway • Fayetteville, Tennessee 37334 Printed in USA www.amana-hac.com...

  • Page 2: Table Of Contents

    Table of Contents Safety Instructions ......................... 4 Recognize Safety Symbols, Words, and Labels ....................4 General Information ........................6 Shipping and Handling ............................6 Product Application ..............................6 Location Requirements and Considerations ......................8 Existing Furnace Removal ............................. 9 Thermostat Requirements ............................9 Thermostat Location ..............................

  • Page 3: Table Of Contents

    Table of Contents Startup Adjustments and Measurements ................... 26 Furnace Operation ..............................26 Measure Gas Supply Pressure ..........................27 Measure and Adjust Gas Manifold Pressure ...................... 27 Measure Natural Gas Input Rate .......................... 28 Measure and Adjust Temperature Rise ....................... 28 Operational Checks ........................

  • Page 4: Safety Instructions

    Safety Instructions Recognize Safety Symbols, Words, and Labels Please adhere to the following warnings and cautions when installing, adjusting, altering, servicing, or operating the furnace. Failure to heed safety information increases the risk of personal injury, property damage, and/or product damage.

  • Page 5

    Safety Instructions WARNING To prevent possible death or personal injury due to asphyxiation, this Non-Condensing Gas Fired Warm Air Furnaces must be Category I vented. Do not vent any of these furnaces using Category III venting. Provisions must be made for venting combustion products outdoors through a proper venting system.

  • Page 6: General Information, Shipping And Handling, Product Application

    General Information Shipping and Handling All units are securely packed in shipping containers tested according to International Safe Transit Association specifications. The carton must be checked upon arrival for external damage. If damage is found, a request for inspection by carrier’s agent must be made in writing immediately. The furnace must be carefully inspected on arrival for damage and bolts or screws which may have come loose in transit.

  • Page 7

    General Information Product Application (cont’d) WARNING Possible death, personal injury or property damage due to fire, explosion, smoke, soot, condensation, electrical shock or carbon monoxide may result from improper installation, repair, operation, or maintenance of this product. WARNING To prevent death, personal injury or property damage due to fire, do not install this furnace in a mobile home, trailer, or recreational vehicle.

  • Page 8: Location Requirements And Considerations

    General Information Location Requirements and Considerations WARNING To prevent possible death, personal injury, equipment damage, or property damage the following bullet points must be observed when installing the unit. Follow the instructions listed below when selecting a furnace location. Refer also to the guidelines provided in the section Combustion and Ventilation Air Requirements.

  • Page 9: Existing Furnace Removal, Thermostat Requirements, Thermostat Location

    General Information URNACE USPENSION above, return doors, windows, exhaust fans, fireplace dampers If suspending the furnace from rafters or joist, use 3/8" and any other gas burning appliance to their previous conditions threaded rod and 2”x2”x1/8” angle iron as shown below. of use;...

  • Page 10: Combustion And Ventilation Air Requirements

    Combustion and Ventilation Air Requirements WARNING Possible death, personal injury or property damage 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 to be supplied to the furnace area.

  • Page 11

    Combustion and Ventilation Air Requirements 5.3.3 Equipment Located in Confined Spaces: 2. When communicating with the outdoors through vertical (a) All Air from Inside the Building: The confined space shall be ducts, each opening shall have a minimum free area of 1 provided with two permanent openings communicating directly square inch per 4,000 BTU per hour of total input rating of with an additional room(s) of sufficient volume so that the...

  • Page 12

    Combustion and Ventilation Air Requirements 5.3.4 Specially Engineered Installations: NOTE: The single opening must have Chimney or Gas Vent a free area of not less than one The requirements of 5.3.3 shall not necessarily govern when special square inch per 3000 BTU of the total input rating of all equip- engineering, approved by the authority having jurisdiction, pro- ment in the enclosure, but not less than...

  • Page 13: Category I Venting (vertical Venting)

    Category I Venting (Vertical Venting) WARNING To prevent possible death or personal injury due to asphyxiation, this Non-Condensing Gas Fired Warm Air Furnace must be Category I vented. Do not vent using Category III venting. Category I Venting is venting at a non-positive pressure. A furnace vented as Category I is considered a fan-assisted appliance and the vent system does not have to be “gas tight.”...

  • Page 14

    Category I Venting (Vertical Venting) NDUCED RAFT LOWER ELOCATION Upflow Upright or Horizontal units are shipped with the induced draft blower discharging from the top of the fur- nace. (“Top” is as viewed for an upflow installation.) The induced draft blower can be rotated 90 degrees counter- clockwise for Category I venting, with the airflow horizontal left to right.

  • Page 15

    Category I Venting (Vertical Venting) WARNING To prevent death, personal injury or property damage due to fire or explosion, a qualified servicer must determine the reason the rollout protection device opened before the device is reset. OLLOUT ROTECTION EVICE ELOCATION Furnaces installed horizontal right-to-left airflow, require the rollout protection device be relocated.

  • Page 16: Electrical Connections, Wiring Harness, Junction Box Relocation, Volt Line Connections

    Electrical Connections WARNING To avoid the risk of electrical shock, wiring to the unit must be properly polarized and grounded. WARNING To avoid electrical shock, injury or death, disconnect electrical power before servicing or changing any electrical wiring. CAUTION Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

  • Page 17

    Electrical Connections 6. Rotate the junction box 180 degrees so the access NOTE: Do not use gas piping as an electrical ground. panel continues to face forward. The open snap To confirm proper unit grounding, turn off the electrical bushing should now be on the left. power and perform the following check.

  • Page 18

    Electrical Connections The furnace’s integrated ignition control is equipped with Thermostat line voltage accessory terminals for controlling power to an Two-Stage Heating optional field-supplied humidifier and/or electronic air with Single-Stage Cooling cleaner. The accessory load specifications are as follows: Humidifier 1.0 Amp maximum at 120 VAC Electronic Air Cleaner 1.0 Amp maximum at 120 VAC...

  • Page 19: Gas Supply And Piping, Proper Piping Practice

    Gas Supply and Piping Proper Piping Practice The gas line installation must comply with local codes, or in the absence of local codes, with the latest edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1. IMPORTANT NOTE: This unit is factory set to operate on natural gas at the altitudes shown on the rating plate. The plate is stamped with the model number, type of gas and gas input rating.

  • Page 20: High Altitude Derate, Gas Piping Connections

    Gas Supply and Piping High Altitude Derate When this furnace is installed at high altitude, the appropriate High Altitude orifice kit must be applied. This is required due to the natural reduction in the density of both the gas fuel and combustion air as altitude increases. The kit will provide the proper design certified input rate within the specified altitude range.

  • Page 21: Inlet Piping

    Gas Supply and Piping The unit must be connected to the building piping by one of the following methods: • Rigid metallic pipe and fittings • Semirigid metallic tubing and metallic fittings (Alumi- num alloy tubing must not be used in exterior loca- tions) •...

  • Page 22: Gas Piping Checks

    Gas Supply and Piping Gas Piping Checks WARNING To avoid the possibility of explosion or fire, never use a match or open flame to test for leaks. CAUTION To prevent personal injury or property damage due to fire, the following instructions must be performed regarding gas connections, pressure testing, location of shutoff valve and installation of gas piping.

  • Page 23: Propane Gas Tanks And Piping

    Propane Gas Tanks and Piping WARNING PERSONAL INJURY HAZARD To prevent death, personal injury, or property damage due to fire or explosion from a propane gas leak, install a gas detecting warning device. A gas detecting warning device is the only reliable way to detect a propane gas leak.

  • Page 24

    Propane Gas Tanks and Piping 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 25: Circulating Air And Filters, Ductwork Sizing, Upright Installations, Horizontal Installations

    Circulating Air and Filters Ductwork Sizing NOTE: An undersized opening will cause reduced airflow. Duct systems and register sizes must be properly de- Units with an air delivery of less than 1800 CFM should signed for the CFM and external static pressure rating of either use the bottom return or one-side return.

  • Page 26: Startup Adjustments And Measurements, Furnace Operation

    Startup Adjustments and Measurements Furnace must have a 115 VAC power supply properly connected and grounded. Proper polarity must be maintained for correct operation. An interlock switch prevents furnace operation if the blower door is not in place. Keep the blower access door in place except for inspection and maintenance.

  • Page 27: Measure Gas Supply Pressure

    Startup Adjustments and Measurements Measure Gas Supply Pressure 4. Measure furnace gas supply pressure with burners firing. Supply pressure must be within the range specified in the “Inlet Gas Supply Pressure” table . If supply pressure differs from the table, make necessary CAUTION adjustments to pressure regulator, gas piping size, etc., and/or consult with local gas utility.

  • Page 28: Measure Natural Gas Input Rate, Measure And Adjust Temperature Rise

    Startup Adjustments and Measurements Measure and Adjust Temperature Rise 6. Turn the adjustment screw clockwise to increase the pressure, or counterclockwise to decrease the pres- sure. Air temperature rise is the temperature difference between 7. Securely replace the regulator cap. supply and return air.

  • Page 29: Startup Procedure And Adjustment

    Startup Procedure and Adjustment 4. Locate the blower speed selection DIP switches on the Adjust Circulator Blower Speeds integrated control module. Select the desired “cool- ing” speed tap by positioning switches 1 and 2 appro- priately. Select the desired “adjust” tap by positioning WARNING switches 3 and 4 appropriately.

  • Page 30

    Startup Procedure and Adjustment Adjust Blower Heat Off Delay 4 3 2 1 4 3 2 1 Cooling Normal Speed Tap A The integrated control module provides a selectable heat off delay function. The heat off delay period may be set to 4 3 2 1 4 3 2 1 60, 90, 120, 180 seconds using the DIP switches or jumper...

  • Page 31: Normal Sequence Of Operation, Heating Mode

    Normal Sequence of Operation Power Up The normal power up sequence is as follows: • 115 VAC power applied to furnace. • Integrated control module performs internal checks. • Integrated control module flashes LED one time. • Integrated control module monitors safety circuits continuously. •...

  • Page 32: Cooling Mode, Fan Only Mode

    Normal Sequence of Operation Cooling Mode Fan Only Mode The normal operational sequence in cooling mode is as The normal operational sequence in fan only mode is as follows: follows: • • R and YLO/G or Y/G thermostat contacts close, initiat- R and G thermostat contacts close, initiating a call for ing a call for cool.

  • Page 33

    Timing Charts For Normal Heating Operation Example 1: Continuous Call For Low Stage Heat Only High Circulator Blower Gas Valve Igniter PS2 Closed PS1 Closed Pressure Open Switches High Induced Draft Blower High Thermostat (Call for Heat) 60, 90 90, 120, 120, or 150, or Time (sec)

  • Page 34

    Timing Charts for Normal Heating Operation Example 3: Initial Call For Low Heat, Change In Call To High Heat Call Change to High Heat High Circulator Blower High Gas Valve Igniter PS2 Closed Pressure PS1 Closed Switches Open Induced Draft High Blower Thermostat...

  • Page 35

    Timing Charts for Normal Cooling Operation Example 1: Continuous Call For Low Stage Cooling Only High Circulator (88% of Low) Blower High Outdoor Fan Compressor High Thermostat (Call For Cool) Time (sec) Example 2: Continuous Call For High Stage Cooling Only High Circulator (88% of High)

  • Page 36: Operational Checks, Burner Flame

    Operational Checks These checks establish that the primary limit control is functioning and will respond to a restriction in the return air, or a circulator blower failure. If the primary limit control does not function during this test, the cause must be determined and corrected.

  • Page 37: High Or Primary Limit

    Operational Checks High or Primary Limit 3. Remove the return air blockage to clear overheating condition. After an acceptable temperature is The primary limit control guards against overheating re- reached during the cool down period, the limit control sulting from insufficient conditioned air passing over the will reset and allow the furnace to resume normal op- heat exchanger.

  • Page 38: Safety Circuit Description, Rollout Limit, Integrated Ignition Control, Pressure Switches, Auxiliary Limit, Flame Sensor

    Safety Circuit Description A number of safety circuits are employed to ensure safe and proper furnace operation. These circuits serve to control any potential safety hazards and serve as inputs in the monitoring and diagnosis of abnormal function. These circuits are continuously monitored during furnace operation by the integrated ignition control.

  • Page 39: Troubleshooting, Electrostatic Discharge (esd) Precautions, Furnace Lockout, Diagnostic Chart

    Troubleshooting Electrostatic Discharge (ESD) Precautions NOTE: Discharge body’s static electricity before touching unit. An electrostatic discharge can adversely affect electrical components. Use the following precautions during furnace installation and servicing to protect the integrated ignition control from damage. By putting the furnace, the control, and the person at the same electrostatic potential, these steps will help avoid exposing the integrated ignition control to electrostatic discharge.

  • Page 40: 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. • No 115 volt power to • Manual disconnect switch • Assure 115 and 24 volt • Turn power OFF prior NONE furnace, or no 24 volt OFF, door switch open, or...

  • Page 41

    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 ductwork • Turn power OFF • Insufficient conditioned air continuously. No furnace limit circuit is open.

  • Page 42

    Maintenance WARNING To avoid electrical shock, injury or death, disconnect electrical power before performing any maintenance. If you must handle the igniter, handle with care. Touching the igniter element with bare fingers, rough handling, or vibration could damage the igniter resulting in premature failure. Only a qualified servicer should ever handle the igniter.

  • Page 43

    Maintenance ILTER EMOVAL 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, or a side panel external filter rack kit. A media air filter or electronic air cleaner can be used as an alternate filter.

  • Page 44: Induced Draft And Circulator Blowers, Qualified Servicer Only

    Maintenance Burners ASSAGES Inspect the heat exchanger flue passageways at the be- ginning of each heating season. If it is necessary to clean Visually inspect the burner flames periodically during the them, follow the steps outlined below. heating season. Turn on the furnace at the thermostat and 1.

  • Page 45: Before Leaving An Installation, Repair And Replacement Parts

    Before Leaving an Installation • Cycle the furnace with the thermostat at least three times. Verify cooling and fan only operation. • Review the Owner’s Manual with the homeowner and discuss proper furnace operation and maintenance. • Leave literature packet near furnace. Repair and Replacement Parts •...

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