Amana AMS95 Installation Instructions Manual

Gas-fired warm air furnace (type fsp category iv direct or non direct vent air furnace)

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AMS95

-F

IRED

NSTALLATION

(Type FSP CATEGORY IV Direct or Non Direct Vent Air Furnace)

ATTENTION INSTALLING PERSONNEL

As a professional installer you have an obligation to know the product better than the customer. This includes all safety

Prior to actual installation, thoroughly familiarize yourself with this Instruction Manual. Pay special attention to all safety

warnings. Often during installation or repair it is possible to place yourself in a position which is more hazardous than

Remember, it is your responsibility to install the product safely and to know it well enough to be able to instruct a customer

Safety is a matter of common sense...a matter of thinking before acting. Most dealers have a list of specific good safety

The precautions listed in this Installation Manual are intended as supplemental to existing practices. However, if there is

a direct conflict between existing practices and the content of this manual, the precautions listed here take precedence.

IO-276A

ARM

NSTRUCTIONS

Installer: Affix all manuals adjacent to the unit.

These furnaces comply with requirements

embodied in the American National Standard

/ National Standard of Canada ANSI

Z21.47·CSA-2.3 Gas Fired Central Fur-

naces.

RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION.

precautions and related items.

when the unit is in operation.

practices...follow them.

*NOTE: Please contact your distributor or our

website for the applicable product data book

referred to in this manual.

is a trademark of Maytag Corporation and is used under

URNACE

in its safe use.

10/05

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Summary of Contents for Amana AMS95

Page 1 AMS95 IRED URNACE NSTALLATION NSTRUCTIONS Installer: Affix all manuals adjacent to the unit. (Type FSP CATEGORY IV Direct or Non Direct Vent Air Furnace) These furnaces comply with requirements embodied in the American National Standard ® / National Standard of Canada ANSI Z21.47·CSA-2.3 Gas Fired Central Fur-...
Page 2: Table Of Contents
Table of Contents I. Component Identification ............................... 5 II. Safety ....................................6 (ESD) P ....................6 LECTROSTATIC ISCHARGE RECAUTIONS III. Product Application ..............................6 IV. Location Requirements & Considerations ........................7 ................................. 7 ENERAL ........................... 8 LEARANCES AND CCESSIBILITY ............................8 URNACE USPENSION ..........................
Page 3 UALIFIED ERVICER ) ...................... 32 LAME ENSOR UALIFIED ERVICER ) ..................... 32 ASSAGES UALIFIED ERVICER XX. Internal Filter Removal ............................. 33 XXI. Before Leaving an Installation ..........................33 XXII. Repair & Replacement Parts ..........................33 AMS95 Wiring Diagram ..............................36...
Page 4 WNER WARNING It is important that you fill out the owner’s registration card and mail it today. This will assist us in contacting you should any service or F THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A warranty information change in the future. When filling in the regis- FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL tration card, be sure to include the model, manufacturing, and serial INJURY OR LOSS OF LIFE.
Page 5: Component Identification
I. COMPONENT IDENTIFICATION Upflow/Horizontal Counterflow/Horizontal Gas Valve 22 Drain Trap Gas Line Entrance (Alternate) 23 Blower Door Interlock Switch Pressure Switch 24 Capacitor Gas Manifold 25 Integrated Control Module Combustion Air Intake Connection / “Coupling” (with fuse and diagnostic LED) Hot Surface Igniter 26 24-Volt Thermostat Connections Rollout Limit...
Page 6: Safety
II. SAFETY 2. Firmly touch a clean, unpainted, metal surface of the furnaces near the control. Any tools held in a person’s Please adhere to the following warnings and cautions when in- hand during grounding will be discharged. stalling, adjusting, altering, servicing, or operating the furnace. 3.
Page 7: Location Requirements & Considerations
Section X, Condensate Drain Lines and Trap for further WARNING details. • Ensure adequate combustion air is available for the furnace. Improper or insufficient combustion air can O PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE, expose building occupants to gas combustion products DO NOT INSTALL THIS FURNACE IN A MOBILE HOME, TRAILER, OR RECREATIONAL that could include carbon monoxide.
Page 8: Clearances And Accessibility
The following steps shall be followed with each appliance connected to the LEARANCES AND CCESSIBILITY venting system placed in operation, while any other appliances con- Installations must adhere to the clearances to combustible mate- nected to the venting system are not in operation: rials to which this furnace has been design certified.
Page 9: Combustion & Ventilation Air Requirements
(b) Equipment shall be installed in a location in which the facilities for ventilation permit satisfactory combustion of gas, proper venting and the maintenance of ambient temperature at safe limits under normal conditions of use. Equipment shall be located so as not to interfere with proper circulation of air.
Page 10 Chimney or Gas Vent Chimney or Gas Vent NOTE: Each opening must have Ventilation louvers a free area of not less than one (each end of attic) square inch per 1000 BTU of NOTE: The inlet and outlet air the total input rating of all equip- openings must each have a free ment in the enclosure, but not area of not less than one square...
Page 11: Installation Positions
5. When directly communicating with the outdoors, the single open- FURNACE MUST BE LEVEL FROM END TO END ing shall have a minimum free area of 1 square inch per 3,000 ALTERNATE VENT/FLUE FURNACE MUST BE LEVEL AND COMBUSTION AIR BTU per hour of total input rating of all equipment in the enclo- OR SLIGHTLY TILTED FORWARD INTAKE LOCATIONS...
Page 12: Propane Gas /High Altitude Installations
This furnace is shipped from the factory configured for natural gas ALTERNATE FLUE AND ALTERNATE FLUE AND Bottom DISCHARGE COMBUSTION AIR PIPE COMBUSTION AIR PIPE at standard altitude. Propane gas installations require an orifice Return LOCATIONS LOCATIONS Duct change to compensate for the energy content difference between Connection natural and propane gas.
Page 13: Materials And Joining Methods
ERTIFICATION IRECT IRECT ERMINATION OCATIONS This furnace is dual certified and may be installed as a non-direct NOTES: Refer to Section IV, Location Requirements and vent (single pipe) or direct vent (dual pipe) appliance. A non-direct Considerations for combustion air contaminant restrictions. vent installation requires only a vent/flue pipe, while a direct vent installation requires both a vent/flue pipe and a combustion air The following bullets and diagram describe the restrictions con-...
Page 14: Alternate Furnace Connections
ANADIAN ENTING EQUIREMENTS OMBUSTION IRECT NSTALLATIONS In Canada, venting must conform to the requirements of the cur- On upflow units secure the combustion air intake pipe directly to rent CAN/CSA-B149 Installation Code. Use only CSA listed two or the air intake coupling. On counterflow units secure the combus- three inch diameter PVC or ABS pipe, solvent cement, and fittings tion air intake pipe to the air intake coupling using the rubber cou- throughout.
Page 15 3. Upflow and Counterflow units. REMOVE REMOVE REMOVE Loosen the worm gear hose clamps on the rubber elbow REMOVE 4 SCREWS PIPE PIPE 4 SCREWS and detach it from both the induced draft blower and the REMOVE vent/flue pipe. 3 SCREWS 4.
Page 16: Non -Direct Vent (Single Pipe ) Piping
Counterflow units. Vent (Single Pipe) Piping - Vent/Flue Pipe Terminations for spe- cific details on termination construction. Remove plastic plug from alternate combustion air intake Although non-direct vent installations do not require a combus- location. Relocate and install plug in standard air intake tion air intake pipe, a minimum of one 90°...
Page 17: Direct Vent (Dual Pipe ) Piping
the Section IX, Vent/Flue Pipe and Combustion Pipe - Standard Furnace Connections or Alternate Furnace Connections. LUE AND OMBUSTION ENGTHS AND IAMETERS 12 " Min To Roof Or Highest Anticipated Refer to the following table for applicable length, elbows, and pipe Snow Level diameter for construction of the vent/flue and combustion air intake pipe systems of a direct vent (dual pipe) installation.
Page 18: Condensate Drain Lines & Drain Trap
Horizontal terminations should be as shown in the following fig- ure. Refer to Section IX, Vent/Flue Pipe and Combustion Pipe - Termination Location for location restrictions. A 2 3/8 inch diameter wall penetration is required for 2” diameter pipe while a 3 1/2 inch diameter hole is required for 3”...
Page 19: Upright Installations
In upright installations, the furnace’s drain hoses may exit either RIGHT SIDE PANEL the right or left side of the furnace. NOTE: If the alternate vent/flue RUBBER outlet is utilized in an upright installation, the drain trap and drain ELBOW connections must be located on the same side as the alternate RUBBER ELBOW DRAIN PORT...
Page 20: Horizontal Installations
Make connections as follows: LTERNATE RAIN ONNECTIONS 1. Remove the rubber plug from the coil front cover drain port. Upright installations using the alternate vent/flue outlet will require Counterflow furnaces “right-side only” drain hoses to be connected as follows. Refer to Relocate the front cover pressure switch hose connection Section IX, Vent/Flue Pipe and Combustion Air Pipe for details on from the left side pressure tap to the right (down) side tap.
Page 21: Electrical Connections
CAUTION INDUCED DRAFT BLOWER ABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. DRAIN PORT IRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION. HOSE B ERIFY PROPER OPERATION AFTER SERVICING. FRONT HOSE A COVER IRING ARNESS PRESSURE The wiring harness is an integral part of this furnace. Field alteration GREEN HOSE to comply with electrical codes should not be required.
Page 22: Gas Supply And Piping
2. Remove and save the two screws securing the junction box 115 V ONNECTION OF CCESSORIES UMIDIFIER to the side panel. LECTRONIC LEANER 3. Relocate junction box and associated plugs and grommets to opposite side panel. Secure with screws removed in WARNING step 2.
Page 23: General
for use with propane gas by replacing the regulator spring with a CAUTION propane gas spring from an appropriate manufacturer’s propane gas conversion kit. Taps for measuring the gas supply pressure and manifold pressure are provided on the valve. O PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE INLET The gas valve has a manual ON/OFF control located on the valve GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE itself.
Page 24 • • Install a drip leg to trap dirt and moisture before it can enter Connect the furnace to the building piping by one of the the gas valve. The drip leg must be a minimum of three following methods: inches long.
Page 25: Circulating Air & Filters
the presence of gas is suspected, follow the instructions on Page 4 of this manual. CAUTION All propane gas equipment must conform to the safety standards of the National Board of Fire Underwriters, NBFU Manual 58. DGES OF SHEET METAL HOLES MAY BE SHARP. SE GLOVES AS A For satisfactory operation, propane gas pressure must be 11 inch PRECAUTION WHEN REMOVING HOLE PLUGS.
Page 26: Ductwork - Air Flow
XIII. CIRCULATING AIR & FILTERS COOLING AIRFLOW REQUIREMENT (CFM) UCTWORK 1000 1200 1400 1600 2000 Duct systems and register sizes must be properly designed for the 0453BXA 194* 194* CFM and external static pressure rating of the furnace. Ductwork 0703BXA 324* 324* 324*...
Page 27: Horizontal Installations
3. Close the manual gas shutoff valve external to the furnace. ORIZONTAL NSTALLATIONS 4. Replace the burner compartment door. Filters must be installed in either the central return register or in the return air duct work. UPPLY RESSURE EASUREMENT XIV. STARTUP PROCEDURE & ADJUSTMENT CAUTION Furnace must have a 115 VAC power supply properly connected and grounded.
Page 28: Gas Manifold Pressure Measurement And Adjustment
4. Measure furnace gas supply pressure with burners firing. ANIFOLD RESSURE EASUREMENT AND DJUSTMENT Supply pressure must be within the range specified in the Inlet Gas Supply Pressure table. CAUTION Inlet Gas Supply Pressure Natural Gas Minimum:5.0" W.C. Maximum :10.0" W.C. O PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE GAS Propane Gas Minimum:11.0"...
Page 29: Gas Input Rate Measurement (Natural Gas Only )
7. Replace regulator screw cover and finger-tighten securely. 2. Place thermometers in the return and supply ducts as close to the furnace as possible. Thermometers must not be 8. Turn OFF all electrical power to the system. influenced by radiant heat by being able to “see” the heat 9.
Page 30: Normal Sequence Of Operation
6. Verify proper temperature rise as outlined in Section XIV, • Furnace circulator blower and outdoor cooling unit run, Startup Procedure and Adjustment - Temperature Rise. integrated control module monitors safety circuits continuously. Circulator Blower Speeds • R and Y thermostat contacts open, completing the call for Medium Low Orange cool.
Page 31: Safety Circuit Description
2. Gradually block the return air to furnace. Remove airflow LAME ENSOR blockage when limit control is activated and turns off burners. The flame sensor is a probe mounted to the burner/manifold as- Airflow blockage causes unit overheating and will produce sembly which uses the principle of flame rectification to determine the following reactions: the presence or absence of flame.
Page 32: Maintenance
XIX. MAINTENANCE 2. Remove filter(s) from the central return register or ductwork. 3. Replace filter(s) by reversing the procedure for removal. 4. Turn ON electrical power to furnace. WARNING EDIA ILTER OR LECTRONIC LEANER EMOVAL O AVOID ELECTRICAL SHOCK, INJURY OR DEATH, DISCONNECT ELECTRICAL Follow the manufacturer’s directions for service.
Page 33: Internal Filter Removal
9. Clean residue from furnace using a vacuum cleaner. XXI. BEFORE LEAVING AN INSTALLATION 10. Replace the parts removed in the previous steps in reverse • Cycle the furnace with the thermostat at least three times. order. Verify cooling and fan only operation. 11.
Page 34: Troubleshooting Chart
Troubleshooting Chart Associated Associated Symptoms of Abnormal Fault Description(s) Possible Causes Fault Description(s) Possible Causes Corrective Action Cautions and Notes Operation LED Code LED Code • Furnace fails to operate. NONE • No 115 volt power to • Manual disconnect switch •...
Page 35 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 • Turn power OFF • Insufficient conditioned air • Check primary/ continuously. No furnace limit circuit is open.
Page 36: Ams95 Wiring Diagram
AMS95 WIRING DIAGRAM C I R C U L A T O R B L O W E R WARNING: STEADY ON = NORMAL OPERATION = CONTROL FAILURE 1 FLASH SYSTEM LOCKOUT (RETRIES/RECYCLES EXCEEDED) 2 FLASHES = PRESSURE SWITCH STUCK CLOSED...

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