Amana GCCA115AX50 Service manual

Model and Manufacturing numbers listed on pages

4 - 14.

Service

Instructions

40" 80% and 90% Gas Furnaces & Accessories

GUIA, GCIA, GUIB, GCIB, GUIC, GCIC, GUID,

GUIS, GCIS, GUIV, GUCA, GCCA, GUVA, GUSA

DESIGN

C E R T I F I E D

C ERTIFIED

Heating & Air Conditioning

®

This manual replaces RS6600001 Rev. 0 April 2000.

REV. 1 - New models added to manual.

This manual is to be used by qualified HVAC technicians only. Amana does not assume any responsibility for property damage or personal injury due to improper service procedures performed by an unqualified person.

RS6600001

Revision 1

October 2000

INDEX

Important Safety Information ................................................................................... 2-3

Product Identification ................................................................................................ 4-20

Accessories ............................................................................................................. 21-32

Product Design ........................................................................................................ 33-74

System Operation .................................................................................................... 75-117

Polarization and Phasing ......................................................................................... 118

Maintenance ............................................................................................................ 119-121

Servicing .................................................................................................................. 122-146

Accessory Wiring Diagrams .................................................................................... 147-153

IMPORTANT INFORMATION

Pride and workmanship go into every product to provide our customers with quality products. It is possible, however, that during its lifetime a product may require service. Products should be serviced only by a qualified service technician who is familiar with the safety procedures required in the repair and who is equipped with the proper tools, parts, testing instruments and the appropriate service manual. REVIEW ALL SERVICE INFORMATION IN THE APPROPRIATE

SERVICE MANUAL BEFORE BEGINNING REPAIRS.

IMPORTANT NOTICES FOR CONSUMERS AND SERVICERS

RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS

DANGER DANGER - Immediate hazards which WILL result in severe personal injury or death.

WARNING

WARNING - Hazards or unsafe practices which COULD result in severe personal injury or death.

CAUTION CAUTION - Hazards or unsafe practices which COULD result in minor personal injury or product or property damage.

2 Rev. 1

IMPORTANT INFORMATION

WARNING

IF REPAIRS ARE ATTEMPTED BY UNQUALIFIED PERSONS, DANGER-

OUS CONDITIONS (SUCH AS EXPOSURE TO ELECTRICAL SHOCK)

MAY RESULT. THIS MAY CAUSE SERIOUS INJURY OR DEATH.

CAUTION

AMANA WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY

DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCE-

DURES. IF YOU PERFORM SERVICE ON YOUR OWN PRODUCT, YOU

ASSUME RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROPERTY DAMAGE WHICH

MAY RESULT.

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 AFFAIRS DEPT.

AMANA HEATING & AIR CONDITIONING

FAYETTEVILLE, TN 37334

OR

CALL

1-877-254-4729 and ask for

Consumer Affairs

3 Rev. 1

PRODUCT IDENTIFICATION

This section will identify the models covered and the changes per each model group from one release to the next.

Model # Manufacturing #

GUIA***A**

GUIA***B**

GUIA***CA**

GCIA***A**

GCIA***CX**

GUIB***A**

GUIB***B**

GUIB***CX**

GCIB***A**

Description

P1177301F- P1177308F

P1206601F- P1206608F

P1207201F- P1207208F

P1177401F- P1177408F

P1207301F - P1207308F

P1186401F- P1186408F

P1206801F - P1206807F

P1207701F - P1207707F

P1186501F - P1186508F

Gas Furnace Upflow/Horizontal Induced Draft A Air Command 80 SSE

Furnace "A" Initial Design Series.

40" 80% furnace featuring integrated electronic ignition control, silicon carbide ignitor, electrodepositioned textured steel cabinet and 409 stainless steel tubular heat exchanger.


Furnace "B" Second Design Series.



Furnace "C" Third Design Series "A" Standard Unit (not NOx certified).


Gas Furnace Counterflow/Horizontal Induced Draft A Air Command 80

SSE Furnace "A" Initial Design Series.


Gas Furnace Counterflow/Horizontal Induced Draft A Air Command 80

SSE Furnace "C" Third Design Series "X" NOx Certified.

40" 80% furnace featuring integrated electronic ignition control, electrodepositioned textured steel cabinet and 409 stainless steel tubular heat exchanger.

Gas Furnace Upflow/Horizontal Induced Draft B Air Command 80 SV


40" 80% furnace featuring electronic ignition control, silicon carbide ignitor, radiant flame sensor, electrodepositioned textured steel cabinet and aluminized steel tubular heat exchanger.


Furnace "B" Second Design Series.



Furnace "C" Third Design Series "X" NOx Certified.


Gas Furnace Counterflow/Horizontal Induced Draft B Air Command 80 SV



4 Rev. 1



Model # Manufacturing # Description

GUIC***CX** P1207401F - P1207408F

GUIC***CA** P1207601F - P1207608F

GUIC***DA** P1222501F - P1222508F

GUIC***DA** P1226601F - P1226608F

GUIC***DX** P1226701F - P1226708F

GUIC***CA** P1229001F - P1229008F

Gas Furnace Upflow/Horizontal Induced Draft C Air Command 80 SSE







Furnace "D" Fourth Design Series "A" Standard Unit (not NOx certified).

40" 80% furnace featuring integrated electronic ignition control, silicon carbide ignitor, prepainted textured steel cabinet and 409 stainless steel tubular heat exchanger.


Furnace D Fourth Design Series "A" Standard Unit (not NOx certified).

40" 80% furnace featuring integrated electronic ignition control, silicon carbide ignitor and 409 stainless steel tubular heat exchanger.

Use of smooth cold rolled steel substrate and a smooth top coat for furnace cabinet to replace prepainted furnaces until new coating is approved for prepainted material.


Furnace "D" Fourth Design Series "X" NOx Certified.






5 Rev. 1




GUIC***CA** P1229101F - P1229108F



40" 80% furnace featuring integrated electronic ignition control, silicon carbide ignitor, electrodepositioned textured steel cabinet, 409 stainless steel tubular heat exchanger.

Change from embossed bottom knock-out to perforated bottom knock-out and addition of internal side filter retention.

GUIC***CX** P1229201F - P1229208F




GUIC***CX** P1229301F - P1229308F




Change from embossed bottom knock-out to perforated bottom knock-out and addition of internal side filter retention .

GCIC***CX** P1207501F - P1207508F

GCIC***DX** P1226801F - P1226807F

GCIC***CX** P1230401F - P1230408F

Gas Furnace Counterflow/Horizontal Induced Draft C Air Command 80 SSE










Release of prepainted G30 galvanized steel cabinet parts to replace post painted parts on furnace.

GCIC***CX** P1230501F - P1230508F





6 Rev. 1




GUID***CA**

GUID***CX**

GUID***CX**

GUID***CA**

GUID***DA**

GUID***DX**

GUID***CA**

GUID***CA**

GUID***CX**

GUID***CX**

Description

P1212401F - P1212407F

P1212501F - P1212507F

P1220501F - P1220507F

P1220601F - P1220607F

P1226901F - P1226911F

P1227001F - P1227009F

P1229401F - P1229407F

P1229501F - P1229507F

P1229601F - P1229607F

P1229701F - P1229705F

Gas Furnace Upflow/Horizontal Induced Draft D Air Command 80 SV


40" 80% furnace featuring integrated electronic ignition control, silicon carbide ignitor, electrodepositioned textured steel cabinet and aluminized steel tubular heat exchanger.







Release of Fasco induced draft blower to replace Jakel induced draft blower.



40" 80% furnace featuring integrated electronic ignition control, silicon carbide ignitor, prepainted textured steel cabinet and aluminized steel tubular heat exchanger.

Release of Fasco induced draft blower to replace

Jakel induced draft blower.



40" 80% furnace featuring integrated electronic ignition control, silicon carbide ignitor and aluminized steel tubular heat exchanger.





Use of 10x8 blower assembly on 070__40 model to upgrade airflow to a full 4 tons of air for air conditioning and also release of new circulation motor on 090,115 and 140__50 models.













7 Rev. 1




GUIS***CA** P1211003F - P1211008F

Gas Furnace Upflow/Horizontal Induced Draft S 2-Stage, Air Command 80 SSE II


40" 80% two-stage furnace featuring integrated electronic ignition control, two-stage gas valve, two-speed induced draft blower, silicon carbide ignitor, electrodepositioned textured steel cabinet and 409 stainless steel tubular heat exchanger.

GUIS***CX** P1211103F - P1211107F

GUIS070DA35 P1227103F



40" 80% two-stage furnace featuring integrated electronic ignition control, silicon carbide ignitor, two-stage gas valve, two-speed induced draft blower, electrodepositioned textured steel cabinet and 409 stainless steel tubular heat exchanger.



40" 80% two-stage furnace featuring integrated electronic ignition control, silicon carbide ignitor, two-stage gas valve, two-speed induced draft blower and 409 stainless steel tubular heat exchanger.


GUIS***CA** P1229803F - P1229808F



40" 80% two-stage furnace featuring integrated electronic ignition control, silicon carbide ignitor, two-stage gas valve, two-speed induced draft blower, prepainted textured steel cabinet and 409 stainless steel tubular heat exchanger.

GUIS***CA** P1229903F - P1229907F





GUIS***CX** P1230003F - P1230007F




GUIS***CX** P1230103F - P1230107F





8 Rev. 1




GCIS***CX** P1211203F - P1211205F

Gas Furnace Counterflow/Horizontal Induced Draft S 2-Stage, Air Command 80

SSE II Furnace "C" Third Design Series "X" NOx Certified.


GCIS***CX** P1230603F - P1230605F



40" 80% two-stage furnace featuring integrated electronic ignition control, silicon carbide ignitor, two-stage gas valve, two-speed induced draft blower, prepainted textured steel cabinet and 409 stainless steel tubular heat exchanger.

GCIS***CX** P1230703F - P1230705F

GUIV***DX** P1227403F - P1227408F




Change from embossed bottom knock-out to perforated bottom knockout and addition of internal side filter retention.

Gas Furnace Upflow/Horizontal Induced Draft Variable Speed, 2-Stage, Air

Command 80 SSE II Q Furnace "D" Fourth Design Series "X" NOx Certified.

40" 80% two-stage variable speed furnace featuring integrated electronic ignition control, silicon carbide ignitor, two-stage gas valve, two-speed induced draft blower, variable speed circualtor blower, electrodepositioned textured steel cabinet and 409 stainless steel tubular heat exchanger.

GUIV***CX** P1230203F - P1230208F


Command 80 SSE II Q Furnace "C" Third Design Series "X" NOx Certified.

40" 80% two-stage variable speed furnace featuring integrated electronic ignition control, silicon carbide ignitor, two-stage gas valve, two-speed induced draft blower, prepainted textured steel cabinet and 409 stainless steel tubular heat exchanger.

GUIV***CX** P1230303F - P1230308F


Command 80 SSE II Q Furnace "C" Third Design Series "X" NOx Certified.

40" 80% two-stage variable speed furnace featuring integrated electronic ignition control, silicon carbide ignitor, two-stage gas valve, two-speed induced draft blower, electrodepositioned textured steel cabinet and 409 stainless steel tubular heat exchanger.

Change from embossed bottom knock-out to perforated bottom knockout and addition of internal side filter retention.

9 Rev. 1




GUCA***AX** P1219301F - P1219306F

Gas Furnace Upflow/Horizontal Condensing A Air Command 90 Furnace

"A" First Design Series "X" NOx Certified.

40" 90% furnace featuring integrated electronic ignition control, silicon carbide mini ignitor, electrodepositioned steel cabinet and 409 stainless steel tubular heat exchanger and stainless steel recouperative coil.

GUCA***AX** P1227501F - P1227506F




GUCA***AX** P1228801F - P1228806F

Gas Furnace Upflow/Horizontal Condensing A Air Command 90 Furnace.


40" 90% furnace featuring integrated electronic ignition control, silicon carbide mini ignitor, prepainted steel cabinet and 409 stainless steel tubular heat exchanger and stainless steel recouperative coil.

GUCA***AX** P1228901F - P1228906F



40" 90% furnace featuring integrated electronic ignition control, silicon carbide mini ignitor, electrodepositioned steel cabinet and 409 stainless steel tubular heat exchanger and stainless steel recouperative coil and stainless steel recouperative coil.

GCCA***AX** P1227601F - P1227606F

Gas Furnace Counterflow/Horizontal Condensing A Air Command 90

Furnace "A" First Design Series "X" NOx Certified.


GCCA***AX** P1232401F - P1232406F

Gas Furnace Counterflow/Horizontal Condensing A Air Command 90

Furnace "A" First Design Series "X" NOx Certified.

40" 90% furnace featuring integrated electronic ignition control, silicon carbide ignitor, electrodepositioned steel cabinet and 409 stainless steel tubular heat exchanger and stainless steel recouperative coil.

10 Rev. 1




GUVA***AX** P1228301F - P1228306F

Gas Furnace Upflow/Horizontal Variable Speed, 2-Stage, Condensing A Air

Command 95 II Q Furnace "A" First Design Series "X" NOx Certified.

40" 95% two-stage variable speed furnace featuring integrated electronic ignition control, silicon carbide mini ignitor, two-stage gas valve, two-speed induced draft blower, electrodepositioned steel cabinet and 409 stainless steel tubular heat exchanger and stainless steel recouperative coil.

GUVA***AX** P1232501F - P1232506F


Command 95 II Q Furnace "A" First Design Series "X" NOx Certified.

40" 95% two-stage variable speed furnace featuring integrated electronic ignition control, silicon carbide mini ignitor, two-stage gas valve, two-speed induced draft blower, electrodepositioned steel cabinet and 409 stainless steel tubular heat exchanger and stainless steel recouperative coil.

GUVA***BX** P1234701F - P1234706F


Command 95 II Q Furnace "B" Second Design Series "X" NOx Certified.

40" 95% two-stage variable speed furnace featuring "intell-ignition" integrated electronic ignition control, silicon nitride ignitor, two-stage gas valve, two-speed induced draft blower, prepainted steel cabinet and 409 stainless steel tubular heat exchanger.

GUSA***BX** P1233902F - P1233906F

Gas Furnace Upflow/Horizontal S 2-Stage, Condensing A Air Command 90

Furnace "B" Second Design Series "X" NOx Certified.

40" 90% two-stage variable speed furnace featuring "intell-ignition" integrated electronic ignition control, silicon nitride ignitor, two-stage gas valve, two-speed induced draft blower, prepainted steel cabinet and 409 stainless steel tubular heat exchanger.

11 Rev. 1




ASB01

CFB16-24

CVK4-7

DEHUM1

EFR01

FTK03A

HAC1PS1-14

Description

P1200201F - P1200202F

P1228001F - P1228003F

P1210001F- P1210004F

P1227801F

P1221001F

P1171303F - P1171305F

P1204211F - P1204226F

Adjustable Subbase Kit. For use with Amana furnace models GCIA, GCIB,

GCIC and GCIS: Must be used to prevent excessive temperature from reaching combustible materials, if the furnace is installed on a combustible floor. This subbase effectively separated the furnace base and plenum from combustible materials. To ensure safe installation, do not install the counterflow floor base directly on carpeting, tile, or other combustible material other than wood flooring.

Counterflow Floor Base Kit. For use with Amana furnace models GCCA:

Must be used to prevent excessive temperature from reaching combustible materials, if the furnace is installed on a combustible floor. This subbase effectively separated the furnace base and plenum from combustible materials. To ensure safe installation, do not install the counterflow floor base directly on carpeting, tile, or other combustible material other than wood flooring.

Common Vent Kit. For use with Amana 80% furnace models GUIA, GUIB,

GUIC, GUID, GCIA, GCIB and GCIC. Must be used on each furnace that is common vented into type B-1 vent system. Only Amana Air Command

SSE and SV models listed can be common vented with this kit and may not be common vented with any other type furnaces. The common vent kit is not intended for use on other appliances. When the correct venting system has been designed for the installation, a Common Vent Kit is selected.

These kits come in 4, 5, 6 and 7 inch versions.

Dehumidistat. For use with Amana two-stage variable speed furnace models GUIV and GUVA. Wall mounted, 24 volt humidity control available as a Dehumidistat used to reduce the airflow in the air conditioning mode when necessary to lower the humidity in an occupied home to prevent dew build-up associated with high humidity levels. This control features a moisture-sensitive nylon element and also provides positive ON-OFF settings for manual operation. The control is a normally closed switch that opens on humidity rise causing the blower to switch to a lower speed to control the humidity within the structure.

External Filter Rack Kit. For use with Amana upflow furnace models GUIA,

GUIB, GUIC, GUID, GUIS, GUCA, GUVA and GUSA. 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 compartment area of either side panel, and provide filter retention as well as a location for attaching return air ductwork.

Furnace Twinning Kit. This kit allows two Amana Air Command gas furnaces containing an Integrated Ignition control to operate at the same time from a single thermostat. The two furnaces to be "twinned" must be the exact same model with their circulating air blowers set to deliver the same air flow at the same time. The furnaces may deliver different CFM's in the cooling mode, if applicable. This kit cannot be used to control more than two furnaces.

High Altitude Pressure Switch Kit. For use with Amana furnace models

GUIA, GUIB, GUIC, GUID, GCIA, GCIB and GCIC . These kits contain a high altitude Category I pressure switch that must be used at altitudes above the rated altitudes because of reduced air density.

12 Rev. 1




HALP05-09

HALP10

HALP11

HANG07

P1129105F - P1129111F

P1129112F

P1129113F

P1129007F - P1129010F

Description

High Altitude Propane Gas Conversion Kit. For use with Amana furnace models GUIA, GUIB, GUIC, GUID, GCIA, GCIB and GCIC. These kits are required when installing Amana Air Command 80 SSE and SV furnaces above their maximum rated altitude. These kits contain propane gas orifices.

The orifices in the kit have been selected as a result of testing with the

American Gas Association. They will provide appropriate derating at the altitude listed in the High Altitude Charts as shown in the installation instructions of the kit.

High Altitude Propane Gas Conversion Kit. For use with Amana furnace models GUCA and GCCA. This kit is required when installing Amana Air

Command 90 SSE furnaces above their maximum rated altitude. This kit contains propane gas orifices. The orifices in the kit have been selected as a result of testing with the American Gas Association. They will provide appropriate derating at the altitude listed in the High Altitude Charts as shown in the installation instructions of the kit.

High Altitude Propane Gas Conversion Kit. For use with Amana furnace models GUVA. This kit is required when installing Amana Air Command 95

SSE furnaces above their maximum rated altitude. These kits contain propane gas orifices. The orifices in the kit have been selected as a result of testing with the American Gas Association. They will provide appropriate derating at the altitude listed in the High Altitude Charts as shown in the installation instructions of the kit.

High Altitude Natural Gas Kit. For use with Amana furnace models GUIA,

GUIB, GUIC, GUID, GCIA, GCIB and GCIC. These kits are required when installing Amana Air Command 80 SSE and SV furnaces above their maximum rated altitude. This kit contains natural gas orifices. The orifices in the kit have been selected as a result of testing with the American Gas

Association. They will provide appropriate derating at the altitude listed in the

High Altitude Charts as shown in the installation instructions of the kit.

HANG11-12

HANG13-14

HAPS27-29

P1210305F - P1210306F

P1210307F - P1210308F

P1210518F - P1210520F

High Altitude Natural Gas Kit. For use with Amana furnace models GUCA and GCCA. These kits are required when installing Amana Air Command 90

SSE furnaces above their maximum rated altitude. This kit contains natural gas orifices. The orifices in the kit have been selected as a result of testing with the American Gas Association. They will provide appropriate derating at the altitude listed in the High Altitude Charts as shown in the installation instructions of the kit.

High Altitude Natural Gas Kit. For use with Amana furnace models GUVA.

These kits are required when installing Amana Air Command 95 SSE furnaces above their maximum rated altitude. This kit contains natural gas orifices. The orifices in the kit have been selected as a result of testing with the American Gas Association. They will provide appropriate derating at the altitude listed in the High Altitude Charts as shown in the installation instructions of the kit.

High Altitude Pressure Switch Kit. For use with Amana furnace models

GUCA, GCCA and GUVA. This kit contains a high altitude pressure switch that must be used at altitudes above the rated altitudes because of reduced air density.

HATS01-09 P1220406F - P1220414F

High Altitude Two-Stage Conversion Kit. For use with Amana furnace models

GUIS, GCIS and GUIV. These kits are required when installing Amana Air

Command 80 SSE II furnaces above their maximum rated altitude. These kits contain a pressure switch assembly and natural gas orifices. The orifices in the kit have been selected as a result of testing with the American Gas

Association. They will provide appropriate derating at the altitude listed in the

High Altitude Charts as shown in the installation instructions of the kit. A different pressure switch must be used at altitudes above the rated altitudes because of reduced air density.

13 Rev. 1




HCVK

LPTK09

MAC1

P1211401F

P1200108F

P1221801F

Description

Horizontal Concentric Vent Kit. For use with Amana furnace models GUCA,

GCCA, GUVA and GUSA. This kit is designed to allow terminations of a direct vent furnace to be "concentrically" vented through a wall. This kit allows a single penetration to support terminations for both the vent/flue and the combustion air intake pipe. Horizontal concentric vent kits can be installed through walls having a minimum thickness of 3/4 inch to a maximum of 13-

3/4 inches thickness. This kit is not certified for, and must not be applied to any furnace not listed above.

Propane Conversion Kit. For use with Amana Air Command furnace models

GUIA, GUIB, GUIC, GUID, GCIA, GCIB, GCIC, GUIS, GCIS, GUIV, GUCA,

GCCA, GUVA and GUSA. This kit converts Amana gas fired units from natural to propane gas. The conversion from natural gas (as shipped from the factory) to propane gas requires: replacing the burner orifices, replacing gas valve regulator spring (all single stage units), removing NOx screens/turbulators (screens/turbulators not used on all units) and applying identification labels.

Media Air Cleaner. For use with all Amana furnace models. The Amana

Media Air Cleaner (Air Bear



) is a high efficiency air filtration device designed to remove dirt, dust, pollen and other microscopic particles from the air passing through it. Flexible performance range up to 2,000 CFM capacity.

The air cleaner should be installed in the system so that all the system air is circulated through the air cleaner. The air cleaner will only remove the airborne contaminants delivered to it. Maximum performance is obtained when the system blower is set for continuous operation. Note: The Amana

Media series of air cleaners can easily be upgraded to a highly efficient EAC5

Electronic Air Cleaner with a permanent washable collecting cell.

MAF1

TSRK01

VCVK

P1221901F

P1232601F

P1211402F

Media Air Filter. The filter in the Amana Media Air Cleaner (MAC1) must be replaced periodically. The filter cartridges should be replaced with a Trion Air

Bear

 filter cartridge. These come from Amana in cartons of three. The frequency of filter replacement if best determined by visual examination. With typical residential use the approximate replacement period is 9 - 12 months.

Two-Stage Relay Kit. For use with Amana two-stage furnace models GUIS,

GCIS, GUIV and GUVA-AX. This kit enables the use of a single stage thermostat with any Amana two-stage furnace. The time delay activates the second stage of heat after the furnace has run a set period of time

(adjustable) on low stage heat. The time delay is adjustable from 6 to 20 minutes. The time delay starts the moment the thermostat initially calls for heat. Longer time delays will be more energy efficient, while shorter time delays will heat the home faster when the heating demand is high.

Vertical Concentric Vent Kit. For use with Amana furnace models GUCA,

GCCA, GUVA and GUSA. This kit is designed to allow terminations of a direct vent furnace to be "concentrically" vented through the roof. This kit allows a single penetration to support terminations for both the vent/flue and the combustion air intake pipe. Vertical concentric vent kits can be installed through roof penetrations having a minimum of 3/4 inch to a maximum of 22 inches thickness.This kit is not certified for, and must not be applied to any furnace not listed above. Note: This kit is not certified for, and must not be applied to any furnace not listed above.

14 Rev. 1


FOR YOUR SAFETY

READ BEFORE OPERATING

WARNING: If you do not follow these instructions explosion may result causing property damage, personal injury or loss of life.

A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.

B.

BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

Do not try to light any appliance.

Do not touch any electric switch; do not use any phone in your building.

Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.

If you cannot reach your gas supplier, call the fire department.

C. Use only your hand to turn the gas control knob.

Never use tools. If the knob will not turn by hand, don't try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

D. Do not use this appliance if any part has been underwater.

Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been underwater.

LIRE AVANT DE METTRE

EN MARCHELIRE

AVERTISSEMENT: Quiconque ne respecte pas á la lettre les instructions dans le présent manuel risque de déclecher un incendie ou une explosion entraînant des dammages matériels, des lésions corporelles ou la perte de vies humaines.

A.

Cet appareil ne comporte pas de veilleuse. Il est muni d'un dispositif d'allumage qui allume automatiquement le brûleur. Ne pas tenter d'allumer le brûleur manuellement.

B. AVANT DE LE FAIRE FONCTIONNER, renifler tout autour de l'appariel pour déceler une odeur de gaz. Renifler près du plancher, car certains gaz sont plus lourds que l'air et peuvent s'accumuler au niveau du so.l

QUE FAIRE S'IL Y A UNE ODEUR DE GAZ

Ne pas tenter d'allumer l'appariel

Ne toucher aucun interrupteur électrique; n'utiliser aucun téléphone dans le bâtiment.

Appeler immédiatement le fournisseur de gaz en employant le téléphone dún voisin.

Respecter à la lettre les instructions du fournisseur de gaz.

Si personne ne répond, appeler le service des incendies.

C.

Ne pousser ou tourner le robinet d'admission du gaz qu'à la main; ne jamais emploer d'outil à cet effet.

Si la manette reste coincée, ne pas tenter de la réparer; appeler un technicien qualifié. Quiconque tente de forcer la manette ou de la reparer peut déclencher une explosion ou un incendie.

D.

Ne pas se servir de cet appareil s'il a été plongé dans l'eau, complètement ou en partie. Appeler un technicien qualifié pour inspecter l'appareil et remplacer tout partie du système de contrôle et toute commande qui ont été plongés dans l'eau.

OPERATING INSTRUCTIONS MISE EN MARCHE

1.

STOP!

Read the safety information above on this label.

2. Set the thermostat to lowest setting.

3. Turn off all power to the appliance.

4. This appliance is equipped with an ignition.

device which automatically lights the burner.

Do not try to light the burner by hand.

5. Turn the gas control knob clockwise to

"OFF" Position. Do not force.

6. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you then smell gas, STOP!

Follow "B" in the safety information above on this Label.

ROBINET A GAZ

If you don't smell gas, go to MANUEL, EN POS

"ON/MARCHE" next step.

7. Turn gas control knob counterclockwise

8. Replace access panel.

to

9. Turn on all electric power to the appliance.

"ON" .

10.Set thermostat to desired setting.

11.If the appliance will not operate, follow the instructions "To Turn

Off Gas To Appliance" and call your service technician or gas company.

O N ell

F y w

O F

Hone

GAS

INLET

ARRIVEE

DU GAZ

MANUAL GAS

KNOB SHOWN

IN "ON" POSITION

1.

ARRETÊR!

Lisez les instructions de sécurité sur la portion supérieure de cette étiquette.

.

2. Régler le thermostat à la température la plus basse

3. Couper l'alimentation électrique de l'appareil.

4. Cet appareil ménager étant doté d'un système d'allumage automatique, ne pas essayer à allumer le brûleur manuellement.

5.

Torner le robinet a gaz dans le sens des aigilles d'une montre en position "OFF/ARRET"

6. Attendre cinq (5) minutes pour laisser echapper tout le gaz. Renifler tout autour de l'appareil, y compris près du plancher, pour déceler une odeur de gaz. Si c'est le cas,

ARRETER!

Passer à l'étape B des instructions de sécuritié sur la portion supérieure de cette étiquette.

S'il n'y a pas d'odeur de gaz, passer à l'étape suivanté.

7. T ourner le robinet a gaz dans le sens inverse des aigilles d'ne montre en pos "ON/MARCHE".

8. Remettre en place le panneau d'accés.

9. Mettre l'appareil sous tension.

10. Régler le thermostat à la température desirée.

11. Si l'appareil ne se met pas en marche, suiyre les instructions intitulées. Comment coupler l'admission de gaz de l'appereil et appeler un technicien qualifié ou le fourrnisseur de gaz.

TO TURN OFF GAS TO APPLIANCE


2. Turn off all electric power to the appliance if service is to be performed.



4. Replace control access panel.

POUR COUPER L'ADMISSION

DE GAZ DE L'APPAREIL

1. Régler le thermostat à la température la plus basse.

2. Couper l'alimentation électrique de l'appareil s'il faut procéder à des opérations d'entretien.

3.

Torner le robinet a gaz dans le sens des aigilles d'une montre en position "OFF/ARRET".

Ne pas forcer.

4. Remettre en place le panneau d'accès.

11072702

15 Rev. 1


FOR YOUR SAFETY




B.












EN MARCHELIRE


A.









C.



D.



1.

STOP!











If you don't smell gas, go to next step.

7. Turn gas control knob counterclockwise


to


"ON" .




O T PIL

ROBINET A GAZ

MANUEL, EN POS

"ON/MARCHE"

OFF

ON

GAS

INLET

ARRIVEE

DU GAZ

MANUAL GAS

KNOB SHOWN

IN "ON" POSITION

1.

ARRETÊR!


.




5.



ARRETER!


















3.


Ne pas forcer.


11072703

16 Rev. 1


FOR YOUR SAFETY




B.












EN MARCHELIRE


A.









C.



D.



1.

STOP!







5. Turn the gas control lever clockwise to




If you don't smell gas, go to next step.

7. Turn gas control lever counterclockwise


to


"ON" .




LEVIER A GAZ

MANUEL, EN POS

"ON/MARCHE"

GAS

INLET

ARRIVEE

DU GAZ

MANUAL GAS

LEVER SHOWN

IN "ON" POSITION

1.

ARRETÊR!


.




5.

Torner le levier a gaz dans le sens des aigilles d'une montre en position "OFF/ARRET"


ARRETER!



7.

Tourner le levier a gaz dans le sens inverse des aigilles d'ne montre en pos "ON/MARCHE".








3. Turn the gas control lever clockwise to







3.

Torner le levier a gaz dans le sens des aigilles d'une montre en position "OFF/ARRET".

Ne pas forcer.


11072706

17 Rev. 1


FOR YOUR SAFETY




B.







C. Use only your hand to push in or turn the gas control lever.

Never use tools. If the lever will not push in or turn by hand, don't try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.




EN MARCHELIRE


A.









C.

Ne pousser ou tourner le levier d'admission du gaz qu'à la main; ne jamais emploer d'outil à cet effet.


D.



1.

STOP!







5. Push the gas control lever to

Do not force.

"OFF" Position.


Follow "B" in the safety. Information above on this label if you don't smell gas, go to next step.

7. Push gas control lever

GAS

INLET to "ON" .



ARRIVEE

DU GAZ




*

*

LEVIER A GAZ

MANUEL, EN POS

"ON/MARCHE"

*

M

O

F

F

P

ON

C

*

1

3

2

*

MANUAL GAS

LEVER SHOWN

IN ON POSITION

*

*

1.

ARRETÊR!


.




5. Pousse le levier du contrôle du gaz à position.

"OFF/ ARRET"


ARRETER!




"ON/MARCHE"








3. Push the gas control lever to "OFF" Position.

Do not force.






3. Pousse le levier du contrôle du gaz à "OFF / ARRET" position.

Ne pas forcer.


11072707

18 Rev. 1


FOR YOUR SAFETY




B.












EN MARCHELIRE


A.









C.



D.



1.

STOP!











If you don't smell gas, go to

* * next step.

7. Turn gas control knob * counterclockwise


to


"ON" .




*

*

*

PILOT

*

ROBINET A GAZ

MANUEL, EN POS

"ON/MARCHE"

ON

OFF

*

*

MANUAL GAS

KNOB SHOWN

IN "ON" POSITION

GAS

INLET

ARRIVEE

DU GAZ

1.

ARRETÊR!


.




5.



ARRETER!


















3.


Ne pas forcer.


11072708

19 Rev. 1


FOR YOUR SAFETY




B.







C. Use only your hand to push in or turn the gas control lever.

Never use tools. If the lever will not push in or turn by hand, don't try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.




EN MARCHELIRE


A.









C.

Ne pousser ou tourner le levier d'admission du gaz qu'à la main; ne jamais emploer d'outil à cet effet.


D.



1.

STOP!







5. Push the gas control lever to

Do not force.

"OFF" Position.


Follow "B" in the safety. Information above on this label if you don't smell gas, go to next step.

7. Push gas control lever

GAS

INLET to "ON" .


9. Turn on all electric ARRIVEE power to the appliance.

DU GAZ




LEVIER A GAZ

MANUEL, EN POS

"ON/MARCHE"

MANUAL GAS

LEVER SHOWN

IN ON POSITION

1.

ARRETÊR!


.





"OFF/ ARRET"


ARRETER!




"ON/MARCHE"








3. Push the gas control lever to "OFF" Position.

Do not force.






3. Pousse le levier du contrôle du gaz à "OFF / ARRET" position.

Ne pas forcer.


11072710

20 Rev. 1

ACCESSORIES

Model Number

GUIA045A30

GUIA045B30

GUIA045CA30

GUIA070A30

GUIA070B30

GUIA070CA30

GUIA070A40

GUIA070B40

GUIA070CA40

GUIA090A30

GUIA090B30

GUIA090CA30

GUIA090B50

GUIA090CA50

GUIA115A40

GUIA115B40

GUIA115CA40

GUIA115A50

GUIA115B50

GUIA115CA50

GUIA140A50

GUIA140B50

GUIA140CA50

GCIA045A30

GCIA045CX30

GCIA070A30

GCIA070CX30

GCIA070A40

GCIA070CX40

GCIA090A30

GCIA090CX30

GCIA090CX50

GCIA115A40

GCIA115CX40

GCIA115CX50

GCIA140A50

GCIA140CX50

X X X X X X X X (2)

X X X X X X X X (2)

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X

X X X X X X

X X X X X X

X X X X X X

X X X X X X

X X X X X X

X X X X X X

X X X X X X

X X X X X X

X X X X X X

X X X X X X

X X X X X X

X X X X X X

X X X X X X

X X

X X

X X

X X

X X

X X

X X

X X

X X

X X

X X

X X

X X

X X

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

X - Available for this model.

(1) 7,501 to 9,500 ft.

Not used in this application.

(2) 7,501 to 11,000 ft.

(3) 0 to 7,500 ft.

(4) 9,501 to 11,000 ft.

Note: All installations above 7,500 ft. require a pressure switch change.

Note: For installations in Canada the Amana 80% furnace is certified only to 4,500 ft.

(1) (4)

(1) (4)

(1) (4)

(1)

(1)

(1) (4)

(1) (4)

(1) (4)

(1) (4)

(1) (4)

(1) (4)

(4)

(4)

(2)

(2)

(2)

(1) (4)

(1) (4)

(1) (4)

(1) (4)

(1) (4)

(2)

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

21 Rev. 1

ACCESSORIES

Model Number

GUIB045A30

GUIB045B30

GUIB045CX30

GUIB070A30

GUIB070B30

GUIB070CX30

GUIB070A40

GUIB070B40

GUIB070CX40

GUIB090A30

GUIB090B30

GUIB090CX30

GUIB090A50

GUIB090B50

GUIB090CX50

GUIB115A40

GUIB115CX40

GUIB115A50

GUIB115B50

GUIB115CX50

GUIB140A50

GCIB045A30

GCIB070A30

GCIB070A40

GCIB090A30

GCIB090A50

GCIB115A40

GCIB115A50

GCIB140A50

X X X X X X X X (2)

X X X X X X X X (2)

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X X X

X X X X X X

X X X X X X

X X X X X X

X X X X X X

X X X X X X

X X X X X X

X X X X X X

X X X X X X

X X

X X

X X

X X

X X

X X

X X

X X

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(1)


(1) 7,501 to 9,500 ft.


(2) 7,501 to 11,000 ft.

(3) 0 to 7,500 ft.

(4) 9,501 to 11,000 ft.



(4)

(1)

(1)

(1)

(1)

(1)

(4)

(4)

(4)

(4)

(4)

(1) (4)

(1) (4)

(1) (4)

(1) (4)

(1) (4)

(2)

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

(2) (2) (3) X

22 Rev. 1

ACCESSORIES

Model Number

GUIC115DX40

GUIC115CA50

GUIC115CX50

GUIC115DA50

GUIC115DX50

GUIC140CA50

GUIC140CX50

GUIC140DA50

GUIC140DX50

GCIC045CX30

GCIC070CX30

GCIC070DX30

GCIC070CX40

GCIC070DX40

GCIC090CX30

GCIC090CX50

GCIC090DA50

GCIC115CX40

GCIC115CX50

GCIC140CX50

GUIC045CA30

GUIC045CX30

GUIC045DA30

GUIC045DX30

GUIC070CA30

GUIC070CX30

GUIC070DA30

GUIC070DX30

GUIC070CA40

GUIC070DA40

GUIC070CX40

GUIC070DX40

GUIC090CA30

GUIC090CX30

GUIC090DA30

GUIC090DX30

GUIC090CA50

GUIC090CX50

GUIC090DA50

GUIC090DX50

GUIC115CA40

GUIC115CX40

GUIC115DA40

X

X

X

X

X

X

X

X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X X X X X X

X X X X X X

X X X X X X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

(1)

(1)

(1)

(1)

(1)

(1)

(1)

(1)

(1)

(1)

(1)

(1)

(1)

(1)

(1)

(4)

(4)

(4)

(4)

(4)

(4)

(4)

(4)

(4)

(4)

(4)

(4)

(4)

(4)

(4)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)


(1) 6,001 to 8,500 ft.


(2) 6,001 to 11,000 ft.

(3) 0 to 6,000 ft.

(4) 8,501 to 11,000 ft.



(3)

(3)

(3)

(3)

(3)

(3)

(3)

(3)

(3)

(3)

(3)

(3)

(3)

(3)

(3)

X

X

X

X

X

X

X

X

X

X X (1) (4) (2) (2) (3) X

X X (1) (4) (2) (2) (3) X

X X (1) (4) (2) (2) (3) X

X

X

X

X

X

X

23 Rev. 1

ACCESSORIES

Model Number

GUID045CA30

GUID045CX30

GUID045DA30

GUID045DX30

GUID070CA30

GUID070CX30

GUID070DA30

GUID070DX30

GUID070CA40

GUID070CX40

GUID070DA40

GUID070DX40

GUID090CA30

GUID090CX30

GUID090DA30

GUID090DX30

GUID090CA50

GUID090CX50

GUID090DA50

GUID090DX50

GUID115CA50

GUID115CX50

GUID115DA50

GUID115DX50

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X

X X X X X X X X (1) (4) (2) (2) (3) X


(1) 6,001 to 8,500 ft.


(2) 6,001 to 11,000 ft.

(3) 0 to 6,000 ft.

(4) 8,501 to 11,000 ft.



24 Rev. 1

ACCESSORIES

Model Number

GUIS070CX30

GUIS070CA35

GUIS070CX35

GUIS070DA35

GUIS070DX35

GUIS090CA30

GUIS090CX30

GUIS090DA30

GUIS090DX30

GUIS090CA50

GUIS090CX50

GUIS090DA50

GUIS090DX50

GUIS115CA50

GUIS115CX50

GUIS115DA50

GUIS115DX50

GUIS140CA50

GUIS140CX50

GUIS140DA50

GCIS070CX35

GCIS070DX35

GCIS090CX50

GCIS090DX50

GUIV070CX40

GUIV070DX40

GUIV090CX50

GUIV090DX50

GUIV115CX50

GUIV115DX50

GUIV140CX50

GUIV140DX50

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X (2)

X (2)

X (2)

X (2)

X (2)

X (2)

X (2)

X (2)

X (2)

X (2)

X (2)

X (2) (1)

X (2) (1)

X (2) (1)

X (2) (1)

X (2) (1)

X (2)

X (2)

X (2)

X (2)

X (2)

X (2)

X (2)

X (2)

X (2) (1)

X (2) (1)

X (2)

X (2)

X (2)

X (2)

X (2)

X (2)

(1)

(1)

(1)

(1)

(1)

(1)

(1)

(1)

(1)

(1)

(1)

(1)

(1)

(1)

(1)

(1)

(1)

(1)

(1)

(1)

(1)

(1)

(1)

(1)

(1)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2) (3) X

(2) (3) X

(2) (3) X

(2) (3) X

(3) X

(3) X

(3) X

(3) X

(3) X

(3) X

(3) X

(3) X

(3) X

(3) X

(3) X

(3) X

(3) X

(3) X

(3) X

(3) X

(3) X

(3) X

(3) X

(3) X

(3) X

(3) X

(3) X

(3) X

(3) X

(3) X

(3) X

(3) X


(1) 3,001 to 7,000 ft.


(2) 7,001 to 8,500 ft.

(3) 0 to 7,000 ft.



Note: High Altitude Natural Gas Orifices are included in all HATS kits.

25 Rev. 1

ACCESSORIES

Model Number

GUCA045AX30

GUCA070AX30

GUCA070AX40

GUCA090AX40

GUCA090AX50

GUCA115AX50

GCCA045AX30

GCCA070AX30

GCCA070AX40

GCCA090AX40

GCCA090AX50

GCCA115AX50

GUVA045AX30

GUVA070AX40

GUVA090AX50

GUVA115AX50

GUVA045BX30

GUVA070BX40

GUVA090BX50

GUVA115BX50

GUSA070BX35

GUSA090BX40

GUSA090BX50

GUSA115BX50

X

X

X

X

X

X

X X X X (3) X (2)

X X X X (3) X (2)

X X X X (3) X (2)

X X X X (3) X (2)

X X X X (3) X (2)

X X X X (3) X (2)

X X X X (3) X (2)

X X X X (3) X (2)

X X X X (3) X (2)

X X X X (3) X (2)

X X X X (3) X (2)

X X X X (3) X (2)

X X X X X (3) X

X X X X X (3) X

X X X X X (3) X

X X X X X (3) X

X X X X X (3) X

X X X X X (3) X

X X X X X (3) X

X X X X X (3) X

X X X X X (3) X

X X X X X (3) X

X X X X X (3) X

X X X X X (3) X

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(1) (4)

(1) (4)

(1) (4)

(1) (4)

(1) (4)

(1) (4)

(1) (4)

(1) (4)

(1) (4)

(1) (4)

(1) (4)

(1) (4)

(1) (4)

(1) (4)

(1) (4)

(1) (4)

(1) (4)

(1) (4)

(1) (4)

(1) (4)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

X X

X X

(2) X X

(2) X X

X

X

X

X

X

X

X

X

X

X

X

X

(2)

(2)

X

X

X

X

X

X

X

X

X - Available for this model (1) 7,001 to 9,000 ft.

(3) 0 to 7,000 ft.


(2) 7,001 to 11,000 ft.

(4) 9,001 to 11,000 ft.



Note: The GUSA High Altitude Kits have not been determined to date. Information will be provided when received.

26 Rev. 1

ACCESSORIES

D

COUNTERFLOW FLOOR BASE

Furnace

Gasket

1" Min.

Floor Base

Floor

Plenum

Duct

3/4" 3/4" F

E

Front View

Plenum

4-7/16" A

B

Side View

A

B

C Floor Base

Part Numbers

CFB16

CFB20

CFB24

Used On

Models

GCCA045__30

GCCA070__30

GCCA070__40

GCCA090__40

GCCA090__50

GCCA115__50

Floor Opening

H

16-1/2

20-1/2 23-3/4

24-1/2

J

23-3/4

23-3/4

Plenum Size

K

15

19

23

L

18-9/16

18-9/16

18-9/16

All dimension are in inches.

F

E

G

Floor Base

Part Numbers

CFB16

Used On

Models

A B

GCCA045__30

GCCA070__30

18-9/16 23-3/4

CFB20

CFB24

GCCA070__40

GCCA090__40

18-9/16 23-3/4

GCCA090__50

GCCA115__50

18-9/16 23-3/4

C

29

29

29

D

17-1/2

21-1/2

E

16-1/2

20-1/2

F

15

19

G

1-11/32

1-11/32

25-1/2 24-1/2 23 1-11/32

All dimension are in inches.

2"

3/4"

21 1/8

6 21/32

"A"

"B"

"C"

COUNTERFLOW SUBBASE

"D"

28 1/4

6 15/32

Furnace

Model

GCI_070

ASB01 or 01A

SUBBASE DIMENSIONS

Dim. "A" Dim. "B" Dim. "C"

Subbase

Width

Plenum

Chamber

Floor

Opening

17 15 16-1/8

Dim. "D"

Floor

Opening

21-1/4

GCI_090 21 19 20-1/8 21-1/4

GCI_115

GCI_140

25 23 24-1/8 21-1/4

All dimensions given in inches.

Subbase adjustable to fit all 3 cabinet sizes.

Detailed installation instructions ship with the subbase.

27 Rev. 1

ACCESSORIES

EXTERNAL FILTER RACK KIT

23.567

INTERNAL FILTER

RETAINER SCREWS

(80% MODELS ONLY)

SLOTS IN FILTER

CLEAR SCREWS

ON UNIT

BLOWER DECK

SCREWS

14.500

UNIT SIDE

PANEL

EFR01 EXTERNAL FILTER RACK KIT

Used on Models

80% Upflow Model Furnaces

90% Upflow Model Furnaces

FRONT

OF UNIT

INTERNAL

FILTER

RETAINERS

(80% MODELS

ONLY)

BASE

OF UNIT

RETURN AIR

CUTOUT AREA

LOWER EDGE

SCREW

FILTER RACK ASSEMBLY

(FACE FILTER OPENING

TOWARDS FRONT

OF UNIT)

C

ACCOMODATOR FILTER HOUSING

A

B

D

E

F

G

ACG1625-3/6, ACG2025-3/6 & ACG2424-3/6

ACCOMODATOR FILTER HOUSING

Used on Models

80% Furnaces

90% Furnaces

ACCOMODATOR FILTER HOUSING DIMENSIONS

Model

Number A

Overall

B C

Opening

D E F

Top

ACG1625-3 17-3/8 28-3/8 3-3/4 14-7/8 26 1-1/2

G

1

ACG1625-6 17-3/8 28-3/8 5-3/4 14-7/8 26 1-1/2

ACG2025-3 21-3/8 28-3/8 3-3/4 18-7/8 26 1-1/2

ACG2025-6 21-3/8 28-3/8 5-3/4 18-7/8 26 1-1/2

ACG2424-3 25-3/8 28-3/8 3-3/4 18-7/8 26 1-1/2

ACG2424-6 25-3/8 28-3/8 5-3/4 18-7/8 26 1-1/2

1

1

1

1

1


Short base handles 1" & 2" filters. Height 3-3/4".

Tall base handles 1", 2" & 4" filters. Height 5-3/4".

Filter

Size

16x25

16x25

20x25

20x25

24x24

24x24

28 Rev. 1

ACCESSORIES

HORIZONTAL FILTER HOUSING

D

C

C

E

A

MODEL HR

B

HORIZONTAL FILTER HOUSING DIMENSIONS

Model

Number

HR20

HR25

Overall Duct Opening Filter

A B C D E Size

6-5/8 25-1/2 22 19-3/4 19 20x25

6-5/8 20-1/2 27 19-3/4 19 20x25


Uses Standard Filter Sizes: 1", 2" or 4".

A

B

MODEL HRB

HR20 & HR25

HORIZONTAL FILTER HOUSING

Used on Models

80% Upflow Furnaces

90% Upflow Furnaces

MAC1 SPECIFICATIONS

CAPACITY 600-2000CFM

MEDIA SERVICE LIFE 12 MO.NOMINAL

MEDIA LISTING

DIMENSIONS

UL CLASS 2

A

B

C

D

E

CFM

600

800

1000

1200

1400

1600

1800

2000

7-1/4

25

22-1/8

22-5/8

17-11/16

RESISTANCE

INCHES W.C.

.04

.05

.09

.12

.15

.18

.22

.27

All dimensions are in inches.

MEDIA AIR CLEANER

Used On Models

80% Furnaces

90% Furnaces

MEDIA AIR CLEANER

C

A

B

D

E

29 Rev. 1

ACCESSORIES

EAC5 SPECIFICATIONS

RATED CAPACITY 2000 CFM (3400 M

3

/HR)

MAX. PRESSURE .13 in. w.g. @ 2000 CFM

CELL WEIGHT

UNIT WEIGHT

(2) 12 lbs. each

46 lbs.

POWER

ELECTRICAL INPUT

48 watts maximum

120 V , 60 HZ, 1 PH

ELECTRICAL 3.2 MA @ 6200 VDC

DIMENSIONS

E

F

G

H

A

B

C

D

4-1/2

24-7/16

7-3/16

25

20-5/16

20-3/4

22-1/2

17-3/4

All dimensions are in inches.

ELECTRONIC AIR CLEANER

30°

A

H

B

2-1/8"

C

EAC5 ELECTRONIC AIR CLEANER

Used on Models

80% Furnaces

90% Furnaces

E

D

3-1/2"

G F

DEHUMIDISTAT

DEHUM1

DEHUMIDISTAT SPECIFICATIONS

Model Number 2274W-21

Setpoint - Humidity Range

Operating Ambient

Differential

Volts

Amps

HZ

30% to 80% RH

10° to 40° C (50° to 104° F)

5%

120

1

60

DEHUM1

DEHUMIDISTAT

Used on Models

GUIV

GUVA

60

70

80

OFF

50

40

30

ON

WHITE - RODGERS

DE-HUMIDISTAT %RH

30 Rev. 1

ACCESSORIES

CONCENTRIC VENT CONVERSION KIT

Vertical

(VCVK)

Horizontal

(HCVK)

Connection for

Fresh Air Intake

Pipe to Furnace

Combustion

Air Intake Pipe Vent/Flue Termination with Tee

Vent/Flue

Termination

(Tee, Pipe, & 2" to 4" Reducer)

Combustion Air

Intake Pipe

Connection for

Vent/Flue Pipe from Furnace

Pipe to Furnace

Tee

Seal Penetration with Caulking

12" Minimum Above

Grade or Highest

Anticipated Snow Level

Wall Thickness

3/4" Minimum

13 3/4" Maximum

HVCK Installation

12" Minimum Above

Roof or Highest

Anticipated Snow Level

Outside

Seal Penetration with Flashing and Caulking

Inside

Concentric Vents Kits HVCK and VCVK are suitable for use with the following Amana 90% efficient furnace products:

CONCENTRIC VENT KIT

Used On Models

GUCA

GCCA

GUVA

GUSA

This kit is not certified for, and must not be applied to any furnace not listed in the above table.

Roof Thickness

3/4" Minimum

22" Maximum

Interior Section of Concentric Vent Assembly

Must Be Adequately

Secured and Supported

Sanitary Tee

Connection for

Fresh Air Intake

Pipe to Furnace

Connection for

Vent/ Flue Pipe

From Furnace

VCVK Installation

31 Rev. 1

ACCESSORIES

From furnace

Vent Damper

Flow To Chimney

YES

COMMMON VENT KIT

NO

YES To Chimney

NO

Install vent damper with actuator to sides of vent only.

Do not mount vent damper with actuator above or below the vent.

Flow

From furnace

Horizontal Vent Installation

CVK4-7

COMMON VENT KITS

Kit Model Vent Diameter

Numbers

CVK 4

Inches

4

CVK 5

CVK 6

CVK 7

5

6

7

Vent

Damper

Install vent damper with actuator in any position.

Vertical Vent Installation

CVK4-7

COMMON VENT KITS

Used on Models

GUIA

GUIB

GUIC

GUID

GCIA

GCIB

GCIC

32 Rev. 1

PRODUCT DESIGN

Safety

Please adhere to the following warnings and cautions when installing, adjusting, altering, servicing, or operating the furnace.

WARNING

To prevent personal injury or death due to improper installation, adjustment, alteration, service or maintenance, refer to this manual. For additional assistance or information, consult a qualified installer, service agency or the gas supplier.

3. Service integrated control module or connecting wiring following the discharge process in Step 2. Use caution not to recharge your body with static electricity; (i.e., do not move or shuffle your feet, do not touch ungrounded objects, etc.). If you come in contact with an ungrounded object, repeat Step 2 before touching control or wires.

4. Discharge any static electricity from your body to ground before removing a new control from its container. Follow

Steps 1 through 3 if installing the control on a furnace.

Return any old or new controls to their containers before touching any ungrounded object.

WARNING

This product contains or produces a chemical or chemicals which may cause serious illness or death and which are known to the State of California to cause cancer, birth defects or other reproductive harm.

WARNING

To prevent possible death, personal injury or property damage due to electrical shock, the furnace must be located to protect the electrical components from water.

CAUTION

This unit must not be used as a “construction heater” during the finishing phases of construction on a new structure. This type of use may result in premature failure of the unit due to extremely low return air temperatures and exposure to corrosive or very dirty atmospheres.

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 control module from damage. By putting the furnace, the control, and the person at the same electrostatic potential, these steps will help avoid exposing the integrated control module to electrostatic discharge. This procedure is applicable to both installed and uninstalled (ungrounded) furnaces.

1. Disconnect all power to the furnace. Do not touch the integrated control module or any wire connected to the control prior to discharging your body’s electrostatic charge to ground.

2. Firmly touch a clean, unpainted, metal surface of the furnace near the control. Any tools held in a person’s hand during grounding will be discharged.

Product Application

This product is designed for use as a residential home gas furnace. It is not designed or certified for use in mobile home, trailer, recreational vehicle, or commercial applications.

The 80% and 90% furnaces are CSA certified appliances and are appropriate for use with natural or propane gas.

(NOTE: If using propane gas, a propane conversion kit is required).

One important difference between the 80% and 90% furance is that the 90% furnace is a dual certified appliance.

Dual certification means that the combustion air inlet pipe is optional and the furnace can be vented as a:

Non-direct vent (single pipe) central forced air furnace in which combustion air is taken from the installation area or from air ducted from the outside or,

Direct vent (dual pipe) central forced air furnace in which all combustion air supplied directly to the furnace burners through a special air intake system outlined in this manual and the installation instructions.

IMPORTANT NOTE: The 80% furnace cannot be installed as a direct vent (i.e.., sealed combustion) furnace. The burner box is present only to help reduce sound transmission from the burners to the occupied space.

To ensure proper installation, operation and servicing, thoroughly read the installation and service manuals for specifics pertaining to the installation, servicing and application of this product.

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.

33 Rev. 1

PRODUCT DESIGN

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.

To ensure proper furnace operation, install, operate, maintain and service the furnace in accordance with the installation, operation and service instructions, all local building codes and ordinances. In their absence, follow the latest edition of the National Fuel Gas Code (NFPA 54/ANSI

Z223.1), and/or CAN/CGA B149 Installation Codes, local plumbing or waste water codes, and other applicable codes.

A copy of the National Fuel Gas Code (NFPA 54/ANSI

Z223.1) can be obtained from any of the following:

American National Standards Institute

1430 Broadway

New York, NY 10018

National Fire Protection Association

1 Batterymarch Park

Quincy, MA 02269

CSA International

8501 East Pleasant Valley

Cleveland, OH 44131

A copy of the CAN/CGA B149 Installation Codes can be obtained from:

CSA International

178 Rexdale Boulevard

Etobicoke, Ontario, Canada M9W, 1R3

The rated heating capacity of the furnace should be greater than or equal to the total heat loss of the area to be heated.

The total heat loss should be calculated by an approved method or in accordance with “ASHRAE Guide” or “Manual

J-Load Calculations” published by the Air Conditioning Contractors of America.

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

Combustion and Ventilation Air Requirements section in this manual or the installation instructions for details.

34 Rev. 1

• Centrally locate the furnace with respect to the proposed or existing air distribution system.

• Ensure the temperature of the return air entering the furnace is between 55°F and 100°F when the furnace is heating.

• Provide provisions for venting combustion products outdoors through a proper venting system. Special consideration should be given to vent/flue pipe routing and combustion air intake pipe when applicable.

80% Furnaces: All installations must be vented in accordance with National Fuel Gas Code, NFPA 54/

ANSI Z223.1 - lateset edition. In Canada the furnaces must be vented in accordance with the National Standard of Canada, CAN/CGA B149. NOTE: Also for the installers use, Amana ships a Category I Two

Stage Venting Manual with each two-stage 80% furnace.

90% Furnaces: Refer to the Vent/Flue Pipe and

Combustion Air Pipe -Termination Locations section in this manual or the installation instructions for appropriate termination locations. Also for 90% furnaces, refer to the Vent/Flue Pipe and Combustion

Air Pipe -Termination Locations section in this manual or the installation instructions to determine if the piping system from furnace to termination can be accomplished within the guidelines given. NOTE: The length of flue and/or combustion air piping can be a limiting factor in the location of the furnace.

• Locate the 90% furnace so that the condensate can be piped at a downward slope away from the furnace to the drain. Do not locate the furnace or its condensate drainage system in any area subject to below freezing temperatures without proper freeze protection. Refer to the Condensate Drain Lines and Trap section in this manual or the installations instructions for further details.

• Set the 90% furnace on a level floor to enable proper condensate drainage. If the floor becomes wet or damp at times, place the furnace above the floor on a concrete base sized approximately 1-1/2" larger than the base of the furnace. Refer to the Horizontal Applications and Considerations section in this manual or the installation instructions for leveling of horizontal furnaces.

• Ensure upflow or horizontal furnaces are not installed directly on carpeting, or any other combustible material. The only combustible material allowed is wood.

• A special accessory subbase must be used for upright counterflow unit installations over any combustible material (including wood). Refer to subbase instructions for installation details. (NOTE: A subbase will not be required if an air conditioning coil is located beneath the furnace between the supply air opening and the combustible floor.

PRODUCT DESIGN

• Exposure to contaminated combustion air will result in safety and performance-related problems. Do not install the furnace where the combustion air is exposed to the following substances: chlorinated waxes or cleaners chlorine-based swimming pool chemicals water softening chemicals deicing salts or chemicals carbon tetrachloride halogen type refrigerants cleaning solutions (such as perchloroethylene) printing inks paint removers varnishes hydrochloric acid cements and glues antistatic fabric softeners for clothes dryers and masonry acid washing materials

• Seal off a non-direct vent furnace if it is installed near an area frequently contaminated by any of the above substances. This protects the non-direct vent furnace from airborne contaminants. To ensure that the enclosed non-direct vent furnace has an adequate supply of combustion air, vent from a nearby uncontaminated room or from outdoors. Refer to the Combustion and Ventilation Air Requirements section in this manual or the installation instructions for details.

• If the furnace is used in connection with a cooling unit, install the furnace upstream or in parallel with the cooling unit coil. Premature heat exchanger failure will result if the cooling unit coil is placed ahead of the furnace.

• If the furnace is installed in a residential garage, position the furnace so that the burners and ignition source are located not less than 18 inches (457 mm) above the floor. Protect the furnace from physical damage by vehicles.

• If the furnace is installed horizontally, the furnace access doors must be vertical so that the burners fire horizontally into the heat exchanger. Do not install the unit with the access doors on the “up/top” or “down/ bottom” side of the furnace.

trical, and drain trap and drain line connections. If the alternate combustion air intake or vent/flue connections are used on a 90% furnace, additional clearances must be provided to accommodate these connections. Refer to Vent Flue Pipe and Combustion Air Pipe section in this manual or the installation instructions for details. NOTE: In addition to the required clearances to combustible materials, a minimum of 36 inches service clearance must be available in front of the unit.

A furnace installed in a confined space (i.e., a closet or utility room) must have two ventilation openings with a total minimum free area of 0.25 square inches per 1,000 BTU/hr of furnace input rating. One of the ventilation openings must be within 12 inches of the top; the other opening must be within 12 inches of the bottom of the confined space. In a typical construction, the clearance between the door and door frame is usually adequate to satisfy this ventilation requirement.

FURNACE SUSPENSION

If suspending the furnace from rafters or joist, use 3/8" threaded rod and 2”x2”x1/8” angle iron as shown in the following figure. If the furnace is installed in a crawl space it must also be suspended from the floor joist or supported by a concrete pad. Never install the furnace on the ground or allow it to be exposed to water. The length of rod will depend on the application and the clearances necessary.

3/8" DIAMETER

THREADED ROD

(6 PLACES)

PROVIDE 8" MINIMUM CLEARANCE BETWEEN

CENTER ROD AND FURNACE CABINET

TO ALLOW FOR CIRCULATOR BLOWER REMOVAL.

ALTERNATE

GAS PIPING

ASSURE FURNACE IS LEVEL FROM

END TO END.

ON 90% FURNACES MAKE SURE

THE UNIT HAS A SLIGHT

FORWARD TILT WITH THE FRONT

OF THE FURNACE 0"-3/4"

BELOW THE BACK OF THE FURNACE.

HOLD DOWN

NUTS

SUPPORT

NUTS

GAS PIPING

2" X 2" X 1/8" ANGLE IRON

(3 PLACES)

POSITION AS CLOSE AS POSSIBLE

TO BLOWER DECK TO ALLOW FOR

CIRCULATOR BLOWER REMOVAL.

TILT OUTWARD TO ALLOW FOR

DOOR AND CIRCULATOR BLOWER

REMOVAL.

90% Suspended Furnace Shown

(80% Furnace Similar)

CONDENSATE

DRAIN

CLEARANCES AND ACCESSIBILITY

Installations must adhere to the clearances to combustible materials which this furnace has been design certified to.

The minimum clearance information for this furnace is provided on the unit’s clearance label. These clearances must be permanently maintained. Refer to Specification Sheet for minimum clearances to combustible materials. Clearances must also accommodate an installation’s gas, elec-

EXISTING FURNACE REMOVAL

NOTE: When an existing furnace is removed from a venting system serving other appliances, the venting system may be too large to properly vent the remaining attached appliances.

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,

CAN/CGA-2.3-M98 Section 1.23.1.

35 Rev. 1

PRODUCT DESIGN

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: a. Seal any unused openings in the venting system; b. Inspect the venting system for proper size and horizontal pitch, as required by the National Fuel Gas Code, ANSI Z223.1 or the

CAN/CGA B149 Installation Codes and these instructions.

Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition; c. In so far as practical, close all building doors and windows and all doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building.

Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum speed.

Do not operate a summer exhaust fan. Close fireplace dampers; d. Follow the lighting instructions. Place the appliance being inspected in operation. Adjust thermostat so appliance shall operate continuously; e. Test for draft hood equipped appliance spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle; f.

After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous conditions of use; g. If improper venting is observed during any of the above tests, the common venting system must be corrected.

Corrections must be in accordance with the latest edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1 and/or

CAN/CGA B149 Installation Codes.

If resizing is required on any portion of the venting system, use the appropriate table in Appendix G in the latest edition of the National Fuel Gas Code ANSI Z223.1 and/or

CAN/CGA B149 Installation Codes.

THERMOSTAT REQUIREMENTS

A single-stage furnace requires a single-stage thermostat while the two-stage furnace requires a two-stage thermostat for proper operation. The single-stage thermostat provides

"W1" for only one stage of heat while the two-stage thermostat provides "W1" and a "W2" terminals for control of low stage and high stage heat. Refer to Electrical Connections - 24 Volt Thermostat Wiring section in this manual or the installation instructions for correct installation procedure for these thermostats.

NOTE: A single-stage thermostat can be used with the two-stage furnace models GUIS,GCIS, GUIV and GUVA-

AX, if a Two-Stage Relay Kit (TSRK01) is installed. The

TSRK01 does not offer “true” thermostat-driven two-stage operation. It does, however, provides a timed transition from low to high fire. For complete details on the TSRK01 refer to installation instructions provided with the kit.

NOTE: The GUVA-BX and GUSA-BX model furnaces do not require the use of the Two-Stage Relay Kit (TSRK01) for use with a single stage thermostat. These units have a thermostat jumper pin selector on the control board for selecting the use of either a single stage or two stage thermostat.

DEHUMIDISTAT REQUIREMENTS

A dehumidistat can be used in conjunction with either the two-stage 80% or 90% furnace to lower the humidity in the conditioned space. The dehumidistat will improve dehumidification of the conditioned air by prompting the furnace to reduce the speed of the circulator blower during operation in the cooling mode. To be compatible with these furnaces, a dehumidistat must operate on 24 VAC and utilize a switch which opens on humidity rise. Refer to Electrical Connections - 24 Volt Dehumidistat Wiring section in this manual or the installation instructions for correct installation procedure.

THERMOSTAT AND DEHUMIDISTAT LOCATION

In an area having good air circulation, locate the thermostat and dehumidistat (if applicable) about five feet high on a vibration-free inside wall. Do not install the thermostat or dehumidistat where it may be influenced by any of the following:

• Drafts, or dead spots behind doors, in corners, or under cabinets.

• Hot or cold air from registers.

• Radiant heat from the sun.

• Light fixtures or other appliances.

• Radiant heat from a fireplace.

• Concealed hot or cold water pipes, or chimneys.

• Unconditioned areas behind the thermostat and dehumidistat, such as an outside wall.

DRAFTS OR DEAD SPOTS

-BEHIND DOORS

-IN CORNERS

-UNDER CABINETS

Thermostat Influences

HOT

COLD

Consult the instructions packaged with the thermostat and dehumidistat for mounting instructions and further precautions.

36 Rev. 1

PRODUCT DESIGN

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.

Improved construction and additional insulation in buildings have reduced heat loss by reducing air infiltration and escape around doors and windows. These changes have helped in reducing heating/cooling costs but have created a problem supplying combustion and ventilation air for gas fired and other fuel burning appliances. Appliances that pull air out of the house (clothes dryers, exhaust fans, fireplaces, etc.) increase the problem by starving appliances for air.

If this furnace is to be installed in the same space with other gas appliances, such as a water heater, ensure there is an adequate supply of combustion and ventilation air for the other appliances. Refer to the latest edition of the National

Fuel Gas Code NFPA 54/ANSI Z223.1 (Section 5.3), or CAN/

CGA B149 Installation Codes (Sections 7.2, 7.3, or 7.4), or applicable provisions of the local building codes for determining the combustion air requirements for the appliances.

Most homes will require outside air be supplied to the furnace area by means of ventilation grilles or ducts connecting directly to the outdoors or spaces open to the outdoors such as attics or crawl spaces.

The following information on air for combustion and ventilation is reproduced from the National Fuel Gas Code NFPA 54/ANSI

Z223.1 Section 5.3.

5.3.1 General:

(a) The provisions of 5.3 apply to gas utilization equipment installed in buildings and which require air for combustion, ventilation and dilution of flue gases from within the building. They do not apply to (1) direct vent equipment which is constructed and installed so that all air for combustion is obtained from the outside atmosphere and all flue gases are discharged to the outside atmosphere, or (2) enclosed furnaces which incorporate an integral total enclosure and use only outside air for combustion and dilution of flue gases.

(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. When normal infiltration does not provide the necessary air, outside air shall be introduced.

(c) In addition to air needed for combustion, process air shall be provided as required for: cooling of equipment or material, controlling dew point, heating, drying, oxidation or dilution, safety exhaust, odor control, and air for compressors.

(d) In addition to air needed for combustion, air shall be supplied for ventilation, including all air required for comfort and proper working conditions for personnel.

(e) A draft hood or a barometric draft regulator shall be installed in the same room as the equipment served so as to prevent any difference in pressure between the hood or regulator and the combustion air supply.

(f) While all forms of building construction cannot be covered in detail, air for combustion, ventilation and dilution of flue gases for gas utilization equipment vented by natural draft normally may be obtained by application of one of the methods covered in 5.3.3

and 5.3.4.

(g) Air requirements for the operation of exhaust fans, kitchen ventilation systems, clothes dryers, and fireplaces shall be considered in determining the adequacy of a space to provide combustion air requirements.

5.3.2 Equipment Located in Unconfined Spaces:

In unconfined spaces (see definition below) in buildings, infiltration may be adequate to provide air for combustion ventila tion and dilution of flue gases. However, in buildings of tight construction (for example, weather stripping, heavily insul ated, caulked, vapor barrier, etc.), additional air may need to beprovided using the methods described in 5.3.3-b or 5.3.4.

Space, Unconfined.

For purposes of this Code, a space whose volume is not less than

50 cubic feet per 1,000 BTU per hour of the aggregate input rating of all appliances installed in that space. Rooms communicating directly with the space in which the appliances are installed through openings not furnished with doors, are considered a part of the unconfined space.

5.3.3 Equipment Located in Confined Spaces:

(a) All Air from Inside the Building: The confined space shall be provided with two permanent openings communicating directly with other spaces of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space.

The total input of all gas utilization equipment installed in the combined space shall be used to determine the required minimum volume. Each opening shall have a minimum free area of 1 square inch per 1,000 BTU per hour of the total input rating of all gas utilization equipment in the confined space, but not less than 100 square inches. One opening shall be within 12 inches of the top and one within 12 inches of the bottom of the enclosure. The minimum dimension of air openings shall not be less than 3 inches.

Chimney or Gas Vent

NOTE: Each opening must have a free area of not less than one square inch per 1000 BTU of the total input rating of all equipment in the enclosure, but not less than 100 square inches.

Furnace

Water

Heater

Opening

Opening

Equipment Located in Confined Spaces; All Air from Inside Building. See 5.3.3-a.

37 Rev. 1

PRODUCT DESIGN

(b) All Air from Outdoors: The confined space shall communicate with the outdoors in accordance with one of the following two methods: Two permanent openings, one commencing within

12 inches of the top and one commencing within 12 inches of the bottom of the enclosure or One permanent opening, commencing within 12 inches of the top of the enclosure where the equipment has clearances of at least 1 inch from the sides and back and 6 inches from the front of the appliance. The openings shall communicate directly, or by ducts, with the outdoors or spaces

(crawl or attic) that freely communicate with the outdoors.

1. When directly communicating with the outdoors, each open ing shall have a minimum free area of 1 square inch per 4,000

BTU per hour of total input rating of all equipment in the enclosure.

Chimney or Gas Vent

Ventilation louvers

(each end of attic)

NOTE: The inlet and outlet air openings must each have a free area of not less than one square inch per 4000 BTU of the total input rating of all equipment in the enclosure.

Outlet Air

3. When communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 square inch per 2,000 BTU per hour of total input rating of all equipment in the enclosure.

Chimney or Gas Vent

Furnace

Water

Heater

Outlet air duct

Inlet air duct

NOTE: The air duct openings must have a free area of not less than one square inch per

2000 BTU of the total input rating of all equipment in the enclosure*.

*If the appliance room is located against an outside wall and the air openings communicate directly with the outdoors, each opening shall have a free area of not less than one square inch per 4,000 BTU per hour of the total input rating of all appliances in the enclosure.

Furnace

Water

Heater

Inlet Air

Equipment Located in Confined Spaces; All Air from

Outdoors. See 5.3.3-b

Alternate air inlet

Ventilation louvers for unheated crawl space


Outdoors—Inlet Air from Ventilated Crawl Space and

Outlet Air to Ventilated Attic. See 5.3.3-b

4. When ducts are used, they shall be of the same cross-sectional area as the free area of the openings to which they connect. The minimum dimension of rectangular air ducts shall not be less than 3 inches.

NOTE: The single opening must have a free area of not less than one square inch per 3000 BTU of the total input rating of all equipment in the enclosure, but not less than the sum of the areas of all vent connectors in the confined space.

Chimney or Gas Vent

2. When communicating with the outdoors through vertical ducts, each opening shall have a minimum free area of 1 square inch per 4,000 BTU per hour of total input rating of all equipment in the enclosure.

Chimney or Gas Vent

Ventilation louvers

(each end of attic)

NOTE: The inlet and outlet air openings must each have a free area of not less than one square inch per 4000 BTU of the total input rating of all equipment in the enclosure.

Outlet Air

Furnace

Water

Heater

Inlet air duct

[ends 1 ft (300 mm) above floor]


Outdoors Through Ventilated Attic. See 5.3.3-b.

Furnace

Water

Heater


Outdoors - Single Air Opening. See 5.3.3-b

Opening

Alternate

Opening

Location

5. When directly communicating with the outdoors, the single opening shall have a minimum free area of 1 square inch per

3,000 BTU per hour of total input rating of all equipment in the enclosure.

5.3.4 Specially Engineered Installations:

The requirements of 5.3.3 shall not necessarily govern when special engineering, approved by the authority having jurisdiction, provides an adequate supply of air for combustion, ventilation, and dilution of flue gases.

38 Rev. 1

PRODUCT DESIGN

5.3.5 Louvers and Grilles:

In calculating free area in 5.3.3, consideration shall be given to the blocking effect of louvers, grilles or screens protecting openings. Screens used shall not be smaller than 1/4 inch mesh.

If the area through a design of louver or grille is known, it should be used in calculating the size of opening required to provide the free area specified. If the design and free area is not known, it may be assumed that wood louvers will have 20-25 percent free area and metal louvers and grilles will have 60-75 percent free area.

Louvers and grilles shall be fixed in the open position or interlocked with the equipment so that they are opened automatically during equipment operation.

5.3.6 Special Conditions Created by Mechanical Exhausting or Fireplaces:

Operation of exhaust fans, ventilation systems, clothes dryers, or fireplaces may create conditions requiring special attention to avoid unsatisfactory operation of installed gas utilization equipment. Air from Inside Building. See 5.3.3-a.

Category I Venting (Vertical Venting)

(80% Furnaces Only)

WARNING

To prevent possible death or personal injury due to asphyxiation, Amana Non-Condensing Gas Fired Warm

Air Furnaces must be Category I vented. Do not vent any of these furnaces 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 does not have to be "gas tight." NOTE:

Single-Stage and Two-Stage gas furnaces with induced draft blowers draw products of combustion through a heat exchanger allowing in some instances common venting with natural draft appliances (i.e. water heaters).

All installations must be vented in accordance with National

Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition. In

Canada, the furnaces must be vented in accordance with the National Standard of Canada, CAN/CGA B149.1 and

CAN/CGA B149.2 - latest editions and amendments.

NOTE: The vertical height of the Category I venting system must be at least as great as the horizontal length of the venting system.

WARNING

To prevent possible death or personal injury due to asphyxiation, common venting with other manufacturer’s induced draft appliances is not allowed.

Common venting two 80% furances is allowed only with

Amana Category I 80% Single-Stage furnaces with the addition of a common vent kit (CVK) for each appliance. Refer to the 80% furnace Accessory Charts in this manual for a tabular listing of appropriate manufacturer’s kits.

The minimum vent diameter for the Category I venting system is as shown in the following chart:

MINIMUM VENT DIAMETER

MODEL

45

70

90

115

140

GUI*

3 Inch

4 Inch

4 Inch

5 Inch

5 Inch

GCI*

4 Inch

4 Inch

4 Inch

5 Inch

5 Inch

Under some conditions, larger vents than those shown above may be required or allowed.

When an existing furnace is removed from a venting system serving other appliances, the venting system may be too large to properly vent the remaining attached appliances.

For complete details refer to Exisiting Furnace Removal section of this manual.

When resizing any portion of the common venting system, use the appropriate table in Appendix G in the latest edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1.

Upflow or Horizontal units are shipped with the induced draft blower discharging from the top of the furnace ("Top" is as viewed for an upflow installation). The induced draft blower can be rotated 90 degrees counterclockwise for Category I venting, with the airflow horizontal left to right. Refer to the following figure. For horizontal installations, a four inch single wall pipe can be used to extend the induced draft blower outlet 1/2” beyond the furnace cabinet. Vent the furnace in accordance with the National Fuel Gas Code

NFPA 54/ANSI Z223.1 - latest edition. In Canada, vent the furnace in accordance with the National Standard of

Canada, CAN/CGA B149.1 and CAN/CGA B149.2 - latest editions and amendments.

39 Rev. 1

PRODUCT DESIGN

Masonry Chimneys

Supply

Air

80% Upflow Rotated Induced Draft Blower

Counterflow units are shipped with the induced draft blower discharging from the top of the furnace ("Top" as viewed for a counterflow installation). The induced draft blower can be rotated 90 degrees counterclockwise for Category I venting, with the airflow horizontal right to left (Figure 6). For horizontal installations, a three inch B vent pipe can be used to extend the induced draft blower outlet 1/2” beyond the furnace cabinet. Vent the furnace in accordance with the National Fuel Gas Code NFPA 54/ANSI Z223.1 latest edition. In Canada, vent the furnace in accordance with the National Standard of Canada, CAN/CGA B149.1

AND CAN/CGA B149.2 - latest editions and amendments.

Vent

WARNING

Possibility of property damage, personal injury, or death

- Damaging condensation can occur inside masonry chimneys when a single fan assisted Category I appliance (80% AFUE furnace) is vented without adequate dilution air. Do not connect an 80% furnace to a masonry chimney unless the furnace is common vented with a draft hood equipped appliance, or the chimney is lined with a metal liner or B metal vent. All installations using Masonry chimneys must be sized in accordance with the appropriate Venting Tables.

If an 80% furnace is common vented with a draft hood equipped appliance, the potential for condensation damage may still exist with extremely cold conditions, long vent connectors, exterior chimneys, or any combination of these conditions. The risk of condensation damage is best avoided by using the masonry chimney as a pathway for properly sized metal liner or B metal vent.

Crown

Wash

Clay Tile Size Generally

12" x 12" (24" Length)

Clay Tile Size: 8" x 8" x12"

(Each x 24" Length)

Attic Floor

1/2" to 1" Air Space

Roof Line

Second Floor

Throat

Damper

Supply

Air

Return

Air

Clean Out

Breech

First Floor

F.A.F. Vent

Connector

Fan Assisted

Forced Air

Furnace

Water Heater

Vent Connector

Natural Draft

Water Heater

Basement Floor

80% Counterflow Rotated Induced Draft Blower

Typical Multiple Flue Clay Tile Chimney

WARNING

To prevent death or serious illness to building occupants due to flue products leaking into the building, proper installation of gaskets and screws is essential for providing a gas tight seal between the partition panel and the induced draft blower.

Make sure all wires are at least one inch from flue pipe.

Relocate junction box to right side of cabinet if necessary.

Refer to Electrical Connections section of this manual for instructions.

Checklist Summary

This checklist serves as a summary of the items to be checked before venting an Air Command 80 furnace into a masonry chimney. In addition, we recommend that a qualified serviceman use this checklist to perform a yearly inspection of the furnace venting system.

This checklist is only a summary. For detailed information on each of the procedures mentioned, see the paragraph referenced with each item.

40 Rev. 1

PRODUCT DESIGN

This inspection is based upon a draft topical report, "Masonry Chimney Inspection and Relining", issued by the Gas

Research Institute. While not yet finalized, we believe this report represents the best information on this subject which is currently available.

If the chimney does not meet these termination requirements, but all other requirements in the checklist can be met, it may be possible for a mason to extend the chimney.

If this will not be practical, see Fix 1.

10' or Less

Proper Chimney

Termination?

(Check 1)

Yes

No

Line, terminate with listed vent cap

(Fix 1)

2' Min.

2' Min.

3' Min.

Wall or

Parapet

Chimney

Chimney channel free of solid and liquid fuel appliances?

(Check 2)

No

Yes

Change venting arrangements

(Fix 2)

10' or Less

2' Min.

Ridge

3' Min.

Crown in good condition

(Check 3)

Yes

No

Rebuild crown

(Fix 3) and/or Reline

(Fix 4)

Chimney

Cleanout free of debris?

(Check 4)

Yes

No

Reline

(Fix 4)

Termination 10 Feet Or Less From Ridge, Wall or

Parapet

More than 10'

3' Min.

Liner in good condition?

(Check 5)

Yes

No

Reline

(Fix 4)

Wall or

Parapet

NOTE: No Height above parapet required when distance from walls or parapet is more than 10 feet.

Chimney

Dilution air available?

(Check 6)

Yes

No

Reline

(Fix 4)

Ridge

More than 10'

10'

2' Min.

Height above any roof surface within

10 feet horizontally.

3' Min.

Complete the installation.

(Check 7)

Chimney

Termination More Than 10 Feet From Ridge, Wall or

Parapet

Check 1 - Proper chimney termination.

A masonry chimney used as a vent for gas fired equipment must extend at least three feet above the highest point where it passes through the roof. It must extend at least two feet higher than any portion of a building within a horizontal distance of 10 feet. In addition, the chimney must terminate at least 3 feet above any forced air inlet located within 10 feet.

The chimney must extend at least five feet above the highest connected equipment draft hood outlet or flue collar.

Check 2 - Any solid or liquid fuel appliances vented into this chimney channel.

Solid fuel appliances include fireplaces, wood stoves, coal furnaces, and incinerators.

Liquid fuel appliances include oil furnaces, oil-fired boilers and oil-fired water heaters.

41 Rev. 1

PRODUCT DESIGN

Appliances which burn propane (sometimes referred to as

LP (liquefied petroleum)) gas are considered gas-fired appliances.

Check 3 - Chimney Crown Condition.

Damage from condensate usually shows up first in the crown. If any of the following trouble signs are present, the condition of the crown is not satisfactory: a) Crown leaning b) Bricks missing c) Mortar missing d) Tile liner cracked e) No tile liner f) Salt staining at mortar joints. (White stains, and mortar becomes sandy and/or erodes.)

For problems a, b, or c, see Fix 3. If problems d, e, or f are present, see Fix 4. IMPORTANT: It may be necessary to follow both Fix 3 and Fix 4.

Check 4 - Debris in Cleanout

A cleanout (dropleg) must be present such that the upper edge of the cleanout cover is at least 12 inches below the lower edge of the lowest chimney inlet opening.

A chimney without a cleanout could become partially blocked by debris. If no cleanout is present, the chimney must be refined (Fix 4).

Remove the cleanout cover, and examine the cleanout for debris. If significant amounts of any of the following are found:

•

•

•

•

• Fuel oil residue

Bricks

Mortar or sand

Pieces of the tile liner

Rusted pieces of the metallic liner reline the chimney (Fix 4).

Remember that all appliances must be vented inside the liner. Venting one appliance inside the liner and another appliance outside the liner is not acceptable.

Next, use a flashlight and small mirror to sight up the liner.

B vent must be supported so as to not come into direct contact with the chimney walls or tile liner. If it is not, it can probably be rehung so as to be acceptable. A thimble or fire stop may be helpful here.

Flexible liners should be hung straight or nearly straight. If it is spiraled in the chimney and in good condition, it should be rehung. To do this, break the top seal; pull up and cut off the excess liner length, and refit the top seal. Use caution when doing this, as the cut edges of flexible liners may be sharp.

The surfaces of the liner must be physically sound. If gaps or holes are present, the metal liner must be removed and replaced (Fix 4).

Finally, confirm that the metal liner is the correct size for the appliances to be installed. Use the GAMA tables and rules.

If a metal liner is not present, a clay tile liner must be present, or the chimney must be lined (Fix 4).

Use a flashlight and small mirror at the cleanout or vent connector to inspect the clay tile liner. If any of the following problems are present:

• Tile sections misaligned

• Tile sections missing

• Gaps between tile sections

• Signs of condensate drainage at the cleanout or vent connectors

• Mortar protruding from between tile sections

• Use of sewer pipe or drainage pipe rather than an approved fire clay tile reline the chimney (Fix 4).

Next, measure the size of the liner. It may be possible to do this from the cleanout. The liner must be at least as large as the minimum size established by the tables in National Fuel

Gas Code NFPA 54/ANSI Z223.1 - latest edition and in the

National Standard of Canada, CAN/CGA B149.1 and CAN/

CGA B149.2 - latest editions and amendments. If the liner is too small or too large, then the chimney must be relined

(Fix 4).

Check 5 - Liner Condition.

If a metal liner is present, it must be checked. It cannot be assumed that all existing metal liners are correctly installed and in good condition.

Remove the lowest existing vent connector, and examine the inside of the elbow or tee at the base of the liner. A small amount of soot may be considered acceptable, provided the installer vacuums it away. If rusted pieces of the liner have collected here, the metal liner must be removed and replaced (Fix 4).

Next, gently tap the inside of the liner with a Phillips screwdriver. If the screwdriver perforates the liner, or if the tapping does not sound like metal hitting metal, the liner must be removed and replaced (Fix 4).

Check 6 - Dilution Air.

If gas-fired appliances are to be vented into a clay tile liner, a source of dilution air is required.

Dilution air cannot be obtained through:

• Induced draft appliances

• Natural draft appliances with vent dampers

Sufficient dilution air can ordinarily be obtained through the draft hood of a natural draft appliance only if the appliance’s vent connector does not include a vent damper.

42 Rev. 1

PRODUCT DESIGN

If dilution air will not be available, the chimney must be relined (Fix 4).

Check 7 - Complete the Installation.

If Checks 1 through 6 have been satisfactory, and the liner is an acceptable size as determined by the tables in National Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition and in the National Standard of Canada, CAN/CGA B149.1

and CAN/CGA B149.2 - latest editions and amendments, then the clay tile liner can probably be used as a vent for the gas appliances. However, the installer must keep in mind the following factors which may render the tile liner unsuitable for use as a vent:

• Extremely cold weather

• Long vent connectors

• Masonry chimneys with no air gap between the liner and the bricks. (In practice, this can be difficult to detect.)

• Exterior chimneys (The tables in National Fuel Gas

Code NFPA 54/ANSI Z223.1 - latest edition and in the National Standard of Canada, CAN/CGA B149.1

and CAN/CGA B149.2 - latest editions and amendments assume interior chimneys.)

If, in the judgment of the local gas utility, installer, and/or local codes; one or more of the above factors is likely to present a problem, the chimney must be relined (Fix 4).

Fix 1 - Liner Termination.

Any cap or roof assembly used with a liner must be approved by the liner manufacturer for such use. The liner and cap/roof assembly must then terminate above the roof in accordance with the manufacturer’s instructions.

In some cases, a shorter extension above the roof may be possible with a liner than would be required with a masonry chimney.

For further information on relining, see Fix 4.

Fix 2 - Change Venting Arrangements

If the masonry chimney has more than one channel, it may be possible to vent the gas appliances into one channel and vent the solid or liquid fuel appliance(s) into another channel(s). Do not vent an Air Command 80 inside of a metal liner with other appliances vented outside the liner.

Alternatively, the homeowner may agree to discontinue use of the fireplace (solid fuel appliance). If so, the tile liner must be cleaned to remove creosote buildup. The fireplace opening must then be permanently sealed.

If oil-fired appliance(s) are being replaced by gas-fired appliance(s), the tile liner must first be cleaned to remove the fuel oil residue.

If none of the above options are practical, the Air Command 80 may need to be vented vertically with B vent.

Under some conditions an Air Command 90 or 95 could be installed rather than an Air Command 80. The Air Command 90 or 95 can be vented horizontally or vertically through PVC pipe.

Fix 3 - Rebuild the Crown.

If the chimney crown is damaged, a qualified mason must repair it in accordance with nationally recognized building codes or standards. One such standard which may be referenced is the Standard for Chimneys, Fireplaces, Vents, and

Solid Fuel Burning Appliances, ANSI/NFPA 211.

Fix 4 - Relining.

Relining options include B vent and flexible liners.

If the chimney has diagonal offsets, B vent probably cannot be used.

If B vent is to be used, it must be supported adequately.

Supports (such as fire stops or thimbles) must be used to prevent the B vent from coming into direct contact with the tile liner or chimney walls. Direct contact would result in higher heat loss, with an increased possibility of poor venting system performance.

It is not acceptable to vent one appliance inside the B vent and other appliances outside. The excess space between the B vent and the chimney walls must be covered at the top of the chimney by a weatherproof, corrosion resistant flashing.

The B vent should then be topped with a listed vent cap. The listed vent cap will, when installed per the manufacturer’s instructions, prevent problems due to rain, birds, or wind effects.

A B vent installed as described in this section is considered to be an enclosed vent system, and the sizing tables in

National Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition and in the National Standard of Canada, CAN/CGA

B149.1 and CAN/CGA B149.2 - latest editions and amendments may be used.

If a flexible liner is to be used, it must be made of the proper materials:

• For most residential applications, an aluminum liner should be acceptable.

• If the combustion air supplied to the furnace will be contaminated with compounds containing chlorine or fluorine, a liner of AL294C stainless steel should be used. Common sources of chlorine and fluorine compounds include indoor swimming pools and chlorine bleaches, paint strippers, adhesives, paints, varnishes, sealers, waxes (which are not yet dried) and solvents used during construction and remodeling. Various commercial and industrial processes may also be sources of chlorine/fluorine compounds.

43 Rev. 1

PRODUCT DESIGN

• Heavier gauge 300 and 400 series stainless steel liners were developed for use with oil or solid fuel appliances. They are not suitable for use with gasfired appliances. Flexible liners specifically intended and tested for gas applications are listed in the UL

"Gas and Oil Equipment Directory". (UL Standard

1777).

For sizing of flexible liners, see Note 22 and the tables in the National Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition and in the National Standard of Canada, CAN/CGA

B149.1 and CAN/CGA B149.2 - latest editions and amendments.

To install the liner, read and follow the liner manufacturer’s instructions and your local codes. Excess liner length should be pulled out of the chimney and cut off. Use caution when doing this, as the cut edges of flexible liners may be sharp.

Do not spiral excess liner inside of the chimney. Support the liner as recommended by the liner manufacturer.

Some manufacturers of flexible liners offer an insulation sleeve designed to be added to the liner before it is installed in the chimney. (Poured insulation, either vermiculite or other materials, is no longer recommended.) Insulation will need to be added to the flexible liner if:

• It is required by the liner manufacturer’s instructions.

• The previous liner was properly sized and installed, and suffered from condensation damage.

• It is required by your local building codes.

Even if none of those three conditions exist which require additional liner insulation, the installer may wish to consider it if:

• The local climate is very cold.

• The chimney is very tall.

• The vent connectors used are very long or have a large number of elbows.

• Local experience indicates that flexible liners installed without insulation are likely to have condensation problems.

Insulation must be selected and installed in accordance with the liner manufacturer’s instructions.

Finally, cap the chimney and terminate the liner in accordance with the liner manufacturer’s instructions.

(90% Furnaces Only)

ALTERNATE VENT/FLUE

AND COMBUSTION AIR

INTAKE LOCATIONS

GAS LINE WITH

DRIP LEG (3" MINIMUM)

(90% Furnaces Only)

DRAIN PAN

FURNACE MUST BE SUPPORTED

AT BOTH ENDS AND MIDDLE

FURNACE MUST BE LEVEL

FROM END TO END

(90% Furnaces Only)

FURNACE MUST BE LEVEL

OR SLIGHTLY TILTED FORWARD

WITH THE DOORS 0" - 3/4"

BELOW THE BACK PANEL

(90% Furnaces Only)

4 3/4" MINIMUM

DRAIN TRAP

CLEARANCE

(90% Furnaces Only)

DRAIN LINE WITH 1/4" PER FOOT

DOWNWARD SLOPE

36" MINIMUM SERVICE

CLEARANCE REQUIRED

90% Horizontal Furnace Shown

(80% Horizontal Furnace Similar)

DRAIN TRAP AND LINES (90% FURNACES ONLY)

In horizontal applications the condensate drain trap is secured to the furnace side panel, suspending it below the furnace. A minimum clearance of 4 3/4" below the furnace must be provided for the drain trap. Additionally, the appropriate downward piping slope must be maintained from the drain trap to the drain location. Refer to Condensate Drain

Trap and Lines section in this manual or the installation instructions for further details. If the drain trap and drain line will be exposed to temperatures near or below freezing, adequate measures must be taken to prevent condensate from freezing. NOTE: The use of insulation and/or heat tape is recommended. Failure to provide proper condensate drainage can result in property damage.

LEVELING (90% FURNACES ONLY)

Leveling ensures proper condensate drainage from the heat 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 (approximately 3/4") from the back panel. The slight tilt allows the heat exchanger condensate, generated in the recuperator coil, to flow forward to the recuperator coil front cover.

Horizontal Applications and Considerations

Horizontal applications, in particular, may dictate many of the installation’s specifics such as airflow direction, ductwork connections, flue and/or combustion air pipe connections, etc. The basic application of this furnace as a horizontal furnace differs only slightly from an upright installation. When installing a furnace horizontally, additional consideration must be given to the following:

ALTERNATE VENT/FLUE AND COMBUSTION AIR

CONNECTIONS (90% FURNACES ONLY)

In horizontal installations provisions for alternate flue and combustion air piping are available for upflow furnaces with left discharge. In these positions the flue and combustion air piping can be run vertically through the side of the furnace. Refer to the following figure "Recommended Installation Positions" for further detail. The standard piping connections may also be used in these positions. Refer to Vent/

Flue Pipe and Combustion Air Pipe section in this manual or the installation instructions for details concerning the conversion to the alternate vent/flue and combustion air connections on the 90% furnace.

44 Rev. 1

PRODUCT DESIGN

AIR

DISCHARGE

ALTERNATE FLUE AND

COMBUSTION AIR PIPE

LOCATIONS

Bottom

Return

Duct

Connection

ALTERNATE FLUE AND

COMBUSTION AIR PIPE

LOCATIONS

Propane Gas and/or High Altitude Installations

Side

Return

Duct

Connection

Side

Return

Duct

Connection

Bottom

Return

Duct

Connection

UPFLOW

UPRIGHT

ALTERNATE FLUE AND

COMBUSTION AIR PIPE

LOCATIONS

Bottom

Return

Duct

Connection

AIR

DISCHARGE

COUNTERFLOW HORIZONTAL

RIGHT AIR DISCHARGE

Bottom

Return

Duct

Connection

AIR

DISCHARGE

UPFLOW HORIZONTAL

RIGHT AIR DISCHARGE

Bottom

Return

Duct

Connection AIR

DISCHARGE

COUNTERFLOW HORIZONTAL

LEFT AIR DISCHARGE

WARNING

Possible death, personal injury or property damage may occur if the correct conversion kits are not installed.

The appropriate kits must be applied to insure safe and proper furnace operation. All conversions must be performed by a qualified installer or service agency.

AIR

DISCHARGE

Bottom

Return

Duct

Connection

UPFLOW HORIZONTAL

LEFT AIR DISCHARGE

AIR

DISCHARGE

COUNTERFLOW

UPRIGHT

ALTERNATE FLUE AND

COMBUSTION AIR PIPE

LOCATIONS

This furnace is shipped from the factory configured for natural gas at standard altitude. Propane gas installations require an orifice change to compensate for the energy content difference between natural and propane gas.

High altitude installations may require both a pressure switch and an orifice change. These changes are necessary to compensate for the natural reduction in the density of both the gas fuel and the combustion air at higher altitude.

Refer to the Accessories Charts in this manual or product

Specification Sheet for a tabular listing of appropriate manufacturer’s kits for propane gas and/or high altitude installations. The indicated kits must be used to insure safe and proper furnace operation. All conversions must be performed by a qualified installer, or service agency.

90% Furnace Recommended Installation Positions

NOTE: Alternate "vertical" piping connections can not be used when an upflow 90% furnace is installed with supply air discharging to the right or left. In this case, use the standard flue and combustion air piping connections

Vent/Flue Pipe and Combustion Air Pipe (90%

Furnaces Only)

WARNING

Failure to follow these instructions can result in bodily injury or death. Carefully read and follow all instructions given in this section.

ALTERNATE ELECTRICAL AND GAS LINE

CONNECTIONS

The 80% & 90% furnaces have provisions allowing for electrical and gas line connections through either side panel. In horizontal applications the connections can be made either through the “top” or “bottom” of the furnace.

DRAIN PAN (90% FURNACES ONLY)

A drain pan must be provided if the furnace is installed above a conditioned area. The drain pan must cover the entire area under the furnace (and air conditioning coil if applicable).

FREEZE PROTECTION (90% FURNACES ONLY)

If the drain trap and drain line will be exposed to temperatures near or below freezing, adequate measures must be taken to prevent condensate from freezing. NOTE: The use of insulation and/or heat tape is recommended. Failure to provide proper condensate drainage can result in property damage.

WARNING

Upon completion of the furnace installation, carefully inspect the entire flue system both inside and outside the furnace to assure it is properly sealed. Leaks in the flue system can result in serious personal injury or death due to exposure to flue products, including carbon monoxide.

A condensing gas furnace achieves its high level of efficiency by extracting almost all of the heat from the products of combustion and cooling them to the point where condensation takes place. Because of the relatively low flue gas temperature and water condensation requirements, PVC pipe is used as venting material.

This furnace must not be connected to Type B, BW, or L vent or vent connector, and must not be vented into any portion of a factory built or masonry chimney except when used as a pathway for PVC as described later in this section. Never common vent this appliance with another appliance or use a vent which is used by a solid fuel appliance.

Do not use commercially available “no hub connectors” other than those shipped with this product.

45 Rev. 1

PRODUCT DESIGN

It is the responsibility of the installer to follow the manufacturers’ recommendations and to verify that all vent/flue piping and connectors are compatible with furnace flue products. Additionally, it is the responsibility of the installer to ensure that all piping and connections possess adequate structural integrity and support to prevent flue pipe separation, shifting, or sagging during furnace operation.

DUAL CERTIFICATION: NON-DIRECT/DIRECT VENT

(90% FURNACES ONLY)

The 90% furnace is dual certified and may be installed as a non-direct vent (single pipe) or direct vent (dual pipe) appliance. A non-direct vent installation requires only a vent/flue pipe, while a direct vent installation requires both a vent/flue pipe and a combustion air intake pipe. Refer to the appropriate section for details concerning piping size, length, number of elbows, furnace connections, and terminations.

MATERIALS AND JOINING METHODS (90%

FURNACES ONLY)

WARNING

To avoid fire, explosion, or bodily injury, solvent cements must be kept away from all ignition sources (i.e., sparks, open flames, and excessive heat) as they are combustible liquids. Avoid breathing cement vapors or contact with skin and/or eyes.

Two or three inch nominal diameter PVC Schedule 40 pipe meeting ASTM D1785, PVC primer meeting ASTM F656, and PVC solvent cement meeting ASTM D2564 specifications must be used. Fittings must be DWV type fittings meeting ASTM D2665 and ASTM D3311. Carefully follow the manufacturer’s instructions for cutting, cleaning, and solvent cementing of PVC.

As an alternative to PVC pipe, primer, solvent cement, and fittings, ABS materials which are in compliance with the following specifications may be used. Two or three inch

ABS Schedule 40 pipe must meet ASTM D1527 and, if used in Canada, must be CSA listed. Solvent cement for

ABS to ABS joints must meet ASTM D2235 and, if used in

Canada, must be CSA listed. The solvent cement for the

PVC to ABS transition joint must meet ASTM D3138. Fittings must be DWV type fittings meeting ASTM D2661 and

ASTM D3311 and, if used in Canada, must be CSA listed.

Carefully follow the manufacturers’ instructions for cutting, cleaning, and solvent cementing PVC and/or ABS.

All 90° elbows must be medium radius (1/4 bend DWV) or long radius (Long sweep 1/4 bend DWV) types conforming to ASTM D3311. A medium radius (1/4 bend DWV) elbow measures 3 1/16" minimum from the plane of one opening to the centerline of the other opening for 2" diameter pipe, and 4 9/16" minimum for 3" pipe.

PROPER VENT/FLUE AND COMBUSTION AIR PIPING

PRACTICES (90% FURNACES ONLY)

Adhere to these instructions to ensure safe and proper furnace performance. The length, diameter, and number of elbows of the vent/flue pipe and combustion air pipe (when applicable) affects the performance of the furnace and must be carefully sized. All piping must be installed in accordance with local codes and these instructions.

Piping must be adequately secured and supported to prohibit sagging, joint separation, and/or detachment from the furnace. Horizontal runs of vent/flue piping must be supported every three feet and must maintain a 1/4 inch per foot downward slope, back towards the furnace, to properly return condensate to the furnace’s drain system. Allowances should be made for minor expansion and contraction due to temperature variations. For this reason, particular care must be taken to secure piping when a long run is followed by a short offset of less than 40 inches.

Precautions should be taken to prevent condensate from freezing inside the vent/flue pipe and/or at the vent/flue pipe termination. All vent/flue piping exposed to freezing termperatures below 35° F for extended periods of time must be insulated with 1/2" thick closed cell foam. Also all vent/ flue piping exposed outdoors in excess of the terminations shown in this manual (or in unheated areas) must be insulated with 1/2" thick closed cell foam such as "Armaflex" or

"Insultube". Inspect piping for leaks prior to installing insulation.

TERMINATION LOCATIONS (90% FURNACES ONLY)

NOTES: Refer to Location Requirements and Considerations section of this manual or the installation instructions for combustion air contaminant restrictions.

The following bullets and diagram describe the restrictions concerning the appropriate location of vent/flue pipe and combustion air intake pipe (when applicable) terminations. Refer to Non-Direct Vent (Single Pipe) Piping and Direct Vent

(Dual Pipe) Piping sections located in this manual or the installation instructions for specific details on termination construction.

• All terminations must be located at least 12 inches above ground level or the anticipated snow level.

• Vent terminations must terminate at least 3 feet above any forced air inlet located within 10 feet.

NOTE: This provision does not apply to the combustion air intake termination of a direct vent application.

• The vent termination of a non-direct vent application must terminate at least 4 feet below, 4 feet horizontally from, or 1 foot above any door, window, or gravity air inlet into any building.

• The vent termination of a direct vent application must terminate at least 12 inches from any opening through which flue gases may enter a building (door, window, or gravity air inlet).

46 Rev. 1

PRODUCT DESIGN

• The vent termination of vent pipe run vertically through a roof must terminate at least 12 inches above the roof line (or the anticipated snow level) and be at least

12 inches from any vertical wall (including any anticipated snow build up).

• A vent termination shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves, or other equipment.

• The combustion air intake termination of a direct vent application should not terminate in an area which is frequently dusty or dirty.

NOTE: In Canada, the Canadian Fuel Gas Code takes precedence over the preceding termination restrictions.

OTHER THAN

COMBUSTION AIR

TERMINATION INTAKE

• Less than 72 inches from the combustion air intake of another appliance.

• Directly above a gas utility meter or service regulator.

• Over a walkway unless located 84 inches above grade.

STANDARD FURNACE CONNECTIONS (90%

FURNACES ONLY)

It is the responsibility of the installer to ensure that the piping connections to the furnace are secure, airtight, and adequately supported.

As shipped, attachment "couplings" for vent/flue and combustion air intake pipe connections are provided on the furnace’s top cover (upflow). To use the standard connections, field supplied vent/flue pipe and combustion air intake pipe (when applicable) should be secured directly to the furnace at these locations.

NON-DIRECT VENT

VENT/FLUE TERMINATION

10'

3"

12"

NO TERMINATIONS

ABOVE WALKWAY

GRADE OR HIGHEST

ANTICIPATED

SNOW LEVEL

12"

12"

FORCED AIR

INLET

DIRECT VENT


4'

12"

4'

NON-DIRECT VENT


90% Furnace Vent Termination Clearances

CANADIAN VENTING REQUIREMENTS (90%

FURNACES ONLY)

In Canada, venting must conform to the requirements of the current CAN/CGA-B149 Installation Code. Use only CSA listed two or three inch diameter PVC or ABS pipe, solvent cement, and fittings throughout. Carefully follow the manufacturers’ instructions for cutting, cleaning, and solvent cementing PVC and/or ABS.

The vent can be run through an existing unused chimney provided the space between the vent pipe and the chimney is insulated and closed with a weather-tight, corrosion-resistant flashing.

The vent shall not be located:

• Less than 12 inches above the finished grade line.

• Less than 36 inches from any building opening or any gas service regulator. For gas service regulators in the Province of Ontario, 72 inches.

Vent/Flue Pipe (90% Furnaces Only)

Vent/flue pipe can be secured to the vent/flue coupling using the rubber coupling and worm gear hose clamps provided with this furnace. Torque hose clamps to 20 inch-lbs

(see "Standard Connections" figure). The rubber coupling allows separation of the vent/flue pipe from the furnace during servicing. NOTE: Do not use other commercially available "no hub connectors" due to possible material conflicts. The vent/flue pipe can also be secured using a PVC or ABS elbow or coupling using the appropriate glue (see

Materials and Joining Methods section in this manual or the installation instructions for further details).

NOTE: For non-direct vent installations, a minimum of one

90° elbow must be installed on the combustion air intake coupling to guard against inadvertent blockage.

Combustion Air Pipe (90% Furnaces Only)

Direct Vent Installations

On upflow units secure the combustion air intake pipe directly to the air intake coupling. On counterflow units secure the combustion air intake pipe to the air intake coupling using the rubber coupling and worm gear hose clamps provided with the unit. The counterflow rubber coupling allows service removal of air intake piping internal to the furnace blower compartment. NOTE: Because of probable material conflicts, do not use other commercially available

“no hub connectors”. The combustion air intake pipe can also be secured directly to the counterflow unit air intake pipe coupling.

47 Rev. 1

PRODUCT DESIGN

Non-Direct Vent Installations

A minimum of one 90° elbow must be installed on the combustion air intake “coupling” to guard against inadvertent blockage.

COMBUSTION

AIR PIPE

(DIRECT VENT ONLY)

90 PVC

ELBOW

(NON-DIRECT VENT)

OR

UPFLOW

VENT/FLUE

PIPE

RUBBER

COUPLING

WITH WORM

GEAR CLAMPS

90 PVC

ELBOW

(NON-DIRECT VENT)

COMBUSTION

AIR PIPE

(DIRECT VENT ONLY)

OR

RUBBER

COUPLINGS

WITH WORM

GEAR CLAMPS

90% Furnace Vent/Flue & Combustion Air

Standard Connections

VENT/FLUE

PIPE

COUNTERFLOW

ALTERNATE FURNACE CONNECTIONS (90%

FURNACES ONLY)

If the standard locations are undesirable for a specific installation, alternate side panel locations are available for both combustion air inlet and vent/flue pipe connections. These locations may be of particular benefit to upright upflow installations requiring additional access to an A coil or to horizontal installations desiring vent/flue (and combustion air intake) piping run vertically from the side of the cabinet.

NOTE: Standard and alternate locations can be combined

(i.e., an installation may use the standard combustion air intake location but use the alternate vent/flue location or vice versa), if needed.

CAUTION

Edges of sheet metal holes may be sharp. Use gloves as a precaution when removing hole plugs.

The alternate vent/flue location is the large hole directly in line with the induced draft blower outlet. Refer to the following “Alternate Vent/Flue Location” figure for details.

For upright installations, externally mount the rubber elbow to the vent/flue coupling using a worm gear hose clamp.

Secure field supplied vent/flue piping to the rubber elbow using a worm gear hose clamp. NOTE: Use of the alternate vent/flue location for upright installations, requires the drain trap be installed on the same side of the unit as the flue pipe.

For horizontal installations, externally secure the fieldsupplied vent/flue pipe directly to the vent/flue coupling using a PVC or ABS coupling or elbow.

3

REMOVE

PIPE

1

REMOVE

4 SCREWS

1.

REMOVE

4 SCREWS

3

REMOVE

PIPE

1

REMOVE

3 SCREWS

O N

5

REMOVE

AND RELOCATE

2

DETACH RUBBER

ELBOW FROM

ID BLOWER AND

VENT/FLUE

PIPE

5

REMOVE

AND RELOCATE

2

DETATCH RUBBER

ELBOW FROM

ID BLOWER AND

VENT/FLUE

PIPE

UPFLOW COUNTERFLOW

5

ADDITIONAL PLUG

FROM DRAIN KIT

ON

**

7

EXTERNALLY

MOUNT

RUBBER ELBOW

6

SECURE TO

ID BLOWER WITH

RUBBER COUPLING

AND HOSE

CLAMPS

COUNTERFLOW/UPRIGHT

(UPFLOW SIMILAR)

6

SECURE TO

ID BLOWER WITH

RUBBER COUPLING

AND HOSE

CLAMPS

O N

6

SECURE TO

CABINET WITH

SCREWS

UPFLOW/HORIZONTAL

(COUNTERFLOW SIMILAR)

WARNING

The rubber elbow is not designed to support a load.

When the rubber elbow is mounted externally to the furnace cabinet, extreme care must be taken to adequately support field-supplied vent/flue piping. Damage can result in leaks causing bodily injury or death due to exposure to flue gases, including carbon monoxide.

90% Furnace Alternate Vent/Flue Location

Alternate Combustion Air Intake Location (90% Furnaces Only)

The alternate combustion air intake location is the large hole not in line with the induced draft blower outlet. Refer to the following "Alternate Combustion Air Intake Location” figure for details.

48 Rev. 1

PRODUCT DESIGN

CAUTION

Be sure not to damage internal wiring or other components, when reinstalling coupling and screws.

For non-direct vent installations installed horizontally, a minimum of one 90° elbow must be installed on the combustion air intake coupling to guard against inadvertent blockage. No elbow is required on the alternate combustion air intake of upright installations, however, a minimum clearance of 2 inches is required to assure proper air supply.

For direct vent installations, secure field-supplied combustion air intake pipe directly to the air intake coupling.

1

REMOVE

4 SCREWS

2

REMOVE

2

3

REMOVE

AND CUT

1

REMOVE

REMOVE 3 SCREWS

AND

RELOCATE

3

ADDITIONAL

PLUG FROM

DRAIN KIT

UPFLOW

4

SECURE

TO CABINET

5

1

REMOVE

4 SCREWS

COUNTERFLOW

REMOVE

AND

RELOCATE

UPFLOW/HORIZONTAL SHOWN

(COUNTERFLOW SIMILAR)

5

2" CLEARANCE

REQUIRED

(NON-DIRECT

VENT)

90% Furnace Alternate Combustion

Air Intake Location

NON-DIRECT VENT (SINGLE PIPE) PIPING (90%

FURNACES ONLY)

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 the roof of the building. The vent can also be run through an existing unused chimney; however, it must extend a minimum of 12 inches above the top of the chimney. The space between the vent pipe and the chimney must be closed with a weather-tight, corrosion-resistant flashing. For details concerning connection of the vent/flue pipe to the furnace, refer to Vent/Flue Pipe and Combustion Air Pipe -

Standard Furnace Connections or Alternate Furnace Connections section in this manual or the installation instructions for specific details. Refer to the following Non-Direct

Vent (Single Pipe) Piping - Vent/Flue Pipe Terminations section in this manual or the installation instructions for specific details on termination construction.

Although non-direct vent installations do not require a combustion air intake pipe, a minimum of one 90° elbow must be attached to the furnace’s combustion air intake if, an upright installation uses the standard intake location, or a horizontal installation uses the alternate air intake location.

This elbow will guard against inadvertent blockage of the air intake.

Vent/Flue Pipe Lengths and Diameters (90% Furnaces

Only)

Refer to the following tables for applicable length, elbows, and pipe diameter for construction of the vent/flue pipe system of a non-direct vent installation. In addition to the vent/ flue pipe, a single 90° elbow must be secured to the combustion air intake to prevent inadvertent blockage. The tee or elbows used in the vent/flue termination must be included when determining the number of elbows in the piping system.

GUCA & GCCA Model Furnaces

Non-Direct Vent (Single Pipe) Venting Table

Maximum Allowable Length of Vent/Flue Pipe (ft)

(1) (2)

Pipe

(4)

Unit Input

(BTU)

Size

(inch) 2 3

Number of Elbows

4 5 6

(3)

7

45,000

70,000

90,000

115,000

[0 - 4,500 ft]

115,000

[4,500 - 11,000 ft]

2

2

2

2

3

2

3

68

68

60

45

111

25

58

65

65

57

42

107

22

55

62

62

55

40

104

20

52

59

59

52

37

100

17

49

56

56

50

35

97

15

46

53

53

47

32

93

12

43

8

50

50

45

30

90

10

40

GUVA Model Furnaces



(1) (2)

Pipe

(4)

Unit Input

(Btu)

Size

(inch) 1 2

Number of Elbows

3 4 5

(3)

6 7

45,000

70,000

90,000

115,000

2

2

3

3

3

8

71 68 65 62 59 56 53 50

49 46 43 40 37 34 31 28

71 68 65 62 59 56 53 50

71 68 65 62 59 56 53 50

49 46 43 40 37 34 31 28

GUSA Model Furnaces



(1) (2)

Pipe

(4)

Unit Input

(BTU)

Size

(inch) 1 2

Number of Elbows

3 4 5

(3)

6 7

70,000

90,000

115,000

2

2

3

3

8

71 68 65 62 59 56 53 50

61 58 55 52 49 46 43 40

71 68 65 62 59 56 53 50

71 68 65 62 59 56 53 50

(1) One 90° elbow must be secured to the combustion air intake connection.

(2) Minimum vent length is five feet and one elbow/tee.

(3) Tee or elbows used in the vent/flue termination must be included when determining the number of elbows in the piping system.

(4) 3" diameter pipe can be used in place of 2" diameter pipe.

49 Rev. 1

PRODUCT DESIGN

Vent/Flue Pipe Terminations (90% Furnaces Only)

The vent/flue pipe may terminate vertically, as through a roof, or horizontally, as through an outside wall.

Vertical vent/flue pipe termination should be as shown in the following figures. Refer to Vent/Flue Pipe and Combustion Air Pipe - Termination Locations section in this manual or the installation instructions for details concerning location restrictions. The penetration of the vent through the roof must be sealed tight with proper flashing such as is used with a plastic plumbing vent.

TEE

12 " MINIMUM TO

ROOF OR

HIGHEST ANTICIPATED

SNOW LEVEL

Horizontal vent/flue pipe terminations should be as shown in the following figure. Refer to Vent/Flue Pipe and Combustion Air Pipe - Termination Locations section in this manual or the installation instructions for details concerning location restrictions. A 2 3/8" diameter wall penetration is required for 2" diameter pipe while a 3 1/2" diameter hole is required for 3" diameter pipe. To secure the pipe passing through the wall and prohibit damage to piping connections, a coupling should be installed on either side of the wall and solvent cemented to a length of pipe connecting the two couplings. The length of pipe should be the wall thickness plus the depth of the socket fittings to be installed on the inside and outside of the wall. The wall penetration should be sealed with silicone caulking material.

WALL

INSIDE OUTSIDE

TEE or

ELBOW

TURNED

DOWN

ELBOW OR

COUPLING

COUPLING

MINIMUM

12"

FROM

WALL

12"

TO GROUND OR

HIGHEST ANTICIPATED

SNOW LEVEL

90% Furnace Standard Vertical Termination

(Single Pipe)

90º

MEDIUM RADIUS

ELBOW

90% Furnace Horizontal Termination (Single Pipe)

12" MINIMUM

VENT/FLUE TEE

OR

90° ELBOW TURNED

DOWN

12" MINIMUM ABOVE

HIGHEST ANTICIPATED

SNOW LEVEL

12" MINIMUM

90% Furnace Alternate Vertical Termination

(Single Pipe)

90% Furnace Horizontal Termination (Single Pipe)

Above Highest Anticipated Snow Level

In a basement installation, the vent/flue pipe can be run between joist spaces. If the vent pipe must go below a joist and then up into the last joist space to penetrate the header, two 45° elbows should be used to reach the header rather than two 90° elbows.

50 Rev. 1

PRODUCT DESIGN

DIRECT VENT (DUAL PIPE) PIPING (90% FURNACES

ONLY)

Direct vent installations require both a combustion air intake and a vent/flue pipe. The pipes may be run horizontally and exit through the side of the building or run vertically and exit through the roof of the building. The pipes may be run through an existing unused chimney; however, they must extend a minimum of 12 inches above the top of the chimney. The space between the pipes and the chimney must be closed with a weather tight, corrosion resistant flashing. Both the combustion air intake and a vent/ flue pipe terminations must be in the same atmospheric pressure zone. Refer to Vent/Flue and Combustion Air Pipe

- Termination Locations or Concentric Vent Termination section in this manual or the installation instructions for specific details on termination construction. For details concerning connection of pipes to the furnace, refer to the Vent/

Flue Pipe and Combustion Pipe - Standard Furnace Connections or Alternate Furnace Connections section in this manual or the installation instructions.

Vent/Flue and Combustion Air Pipe Lengths and

Diameters (90% Furnaces Only)

Refer to the following tables for applicable length, elbows, and pipe diameter for construction of the vent/flue and combustion air intake pipe systems of a direct vent (dual pipe) installation. The number of elbows tabulated represents the number of elbows and/or tees in each (Vent/Flue & Combustion Air Intake) pipe. Elbows and/or tees used in the terminations must be included when determining the number of elbows in the piping systems.

If the combustion air intake pipe is to be installed above a finished ceiling or other area where dripping of condensate will be objectionable, insulation of the combustion air pipe may be required. Use 1/2" thick closed cell foam insulation such as "Armaflex" or "Insultube" where required.

Unit Input

(Btu)

45,000

70,000

90,000

115,000

115,000

GUCA & GCCA Model Furnaces

Direct Vent (Dual Pipe) Venting Table

Maximum Allowable Length of Vent/Flue & Combustion

Termination

Style

Air Intake Pipe (ft)

Pipe

(4)

Number of Elbows

(1) (2) (3)

Size

(inch)

2 3 4 5 6 7

Standard

Alternate

Standard

Alternate

Standard

Alternate

Standard

Alternate

Standard

Alternate

2

2

2

2

2

2

2

2

3

3

8

68 65 62 59 56 53 50

55 52 49 46 43 40 37

68 65 62 59 56 53 50

5 52 49 46 43 40 37

55 52 49 46 43 40 37

42 39 36 33 30 27 24

26 23 20

7 10

Not Recommended

Not Recommended

88 87 80 76 72 68 64

74 70 66 62 58 54 50

Unit Input

(Btu)

45,000

GUVA Model Furnaces


Maximum Allowable Length of Vent/Flue Pipe & Combustion

Termination

Style


Pipe

(4)

Size

(inch) 1 2

Number of Elbows

(1) (2) (3)

3 4 5 6

Standard

Alternate

2

2

7 8

71 68 65 62 59 56 53 50

58 55 52 49 46 43 40 37

70,000

90,000

115,000

Standard

Alternate

Standard

Alternate

Standard

Alternate

2

3

2

3

3

3

3

3

49 46 43 40 37 34 31 28

71 68 65 62 59 56 53 50

36 33 30 27 24 21 18 15

57 54 51 48 45 42 39 36

71 68 65 62 59 56 53 50

57 54 51 48 45 42 39 36

49 46 43 40 37 34 31 28

35 32 29 26 23 20 17 14

Unit Input

(Btu)

GUSA Model Furnaces


Maximum Allowable Length of Vent/Flue & Combustion


Termination

Style

Pipe

(4)

Size

(inch)

1 2

Number of Elbows

3 4 5

(1) (2) (3)

6 7 8

70,000

90,000

Standard

Alternate

Standard

Alternate

2

2

2

2

71 68

57 54

61 58

47 44

65 62 59

51 48 45

55 52 49

41 28 35

56 53 50

42 39 36

46 43 40

32 29 26

115,000

Standard

Alternate

2

2

71 68

57 54

65 62 59

51 48 45

56 53 50

42 39 36

(1)

Elbows and/or Tees used in the terminations must be included when determining the number of elbows in the piping system.

(2)

Number of elbows tabulated are for each (Vent/Flue & Combustion air intake) pipe.

(3)

Minimum length of each Vent/Flue & Combustion Air Intake pipe is five feet and one elbow/tee.

(4)

3" diameter pipe can be used in place of 2" diameter pipe.

Vent/Flue and Combustion Air Pipe Terminations

(90% Furnaces Only)

The vent/flue and combustion air pipes may terminate vertically, as through a roof, or horizontally, as through an outside wall.

Vertical pipe terminations should be as shown in the following figure. Refer to Vent/Flue Pipe and Combustion Pipe -

Termination Locations section in this manual or the installation instructions. The penetrations through the roof must be sealed tight with proper flashing such as is used with a plastic plumbing vent.

COMBUSTION

AIR INTAKE

12" MINIMUM

12" MINIMUM

TO ROOF OR

HIGHEST

ANTICIPATED

SNOW LEVEL

SCREEN

90º

MEDIUM RADIUS

ELBOWS

TEE

VENT/FLUE

24" MAXIMUM

3" MINIMUM

90% Furnace Vertical Terminations (Dual Pipe)

51 Rev. 1

PRODUCT DESIGN

Horizontal terminations should be as shown in the following figure. Refer to Vent/Flue Pipe and Combustion Pipe -

Termination Location section in this manual or the installation instructions for location restrictions. A 2 3/8" diameter wall penetration is required for 2" diameter pipe while a

3 1/2" diameter hole is required for 3" diameter pipe. To secure the pipe passing through the wall and prohibit damage to piping connections, a coupling should be installed on either side of the wall and solvent cemented to a pipe connecting the two couplings. The pipe length should be the wall thickness plus the depth of the socket fittings to be installed on the inside and outside of the wall. The wall penetration should be sealed with silicone caulking material.

SUPPORT

STRAPS

3" MINIMUM

24" MAXIMUM

12" MINIMUM

VENT/FLUE

TEE

COMBUSTION

AIR INTAKE

SCREEN

90°

MEDIUM

RADIUS

ELBOWS





SNOW LEVEL

SNOW LEVEL

3" MINIMUM

24" MAXIMUM

12" MINIMUM 90% Furnace Standard Horizontal Terminations

Above Anticipated Snow Level

(Dual Pipe)

VENT/FLUE

TEE

3" MINIMUM

24" MAXIMUM

COMBUSTION

AIR INTAKE

90°

MEDIUM RADIUS

ELBOWS

VENT

90°

MEDIUM RADIUS

ELBOW

12" MINIMUM

12" MINIMUM

12" MINIMUM

SCREEN

SCREEN

24" MAXIMUM

24" MAXIMUM

3" MINIMUM

AIR INTAKE

90% Furnace Standard Horizontal Terminations

(Dual Pipe)



SNOW LEVEL

VENT

90°

MEDIUM

RADIUS

ELBOW

12" MINIMUM

90% Furnace Alternate Horizontal Terminations

Above Anticipated Snow Level

(Dual Pipe)

24" MAXIMUM

24" MAXIMUM

3" MINIMUM

AIR

INTAKE

12" MINIMUM

SCREEN

In a basement installation, the pipes may be run between the joist spaces. If the pipes must go below the joist and then up into the last joist space to penetrate the header, two

45° elbows should be used to reach the header rather than two 90° elbows.

90% Furnace Alternate Horizontal Vent Termination

(Dual Pipe)

Vent/Intake Terminations for Installation of Multiple

Direct Vent Furnaces (90% Furnaces Only)

If more than one direct vent furnace is to be installed vertically through a common roof top, maintain the same minimum clearances between the exhaust vent and air intake terminations of adjacent units as with the exhaust vent and air intake terminations of a single unit.

52 Rev. 1

PRODUCT DESIGN

If more than one direct vent furnace is to be installed horizontally through a common side wall, use the alternate termination style and maintain the clearances as shown in the following horizontal venting of multiple units. Always terminate all exhaust vent outlets at the same elevations and always terminate all air intakes at the same elevation.

24" MAX

90°

MEDIUM

RADIUS

ELBOWS

24" MAX

3" MIN

3" MIN

24" MAX

3" MIN

VENTS

12" MIN

Condensate Drain Lines and Drain Trap (90% Furnaces

Only)

A condensing gas furnace achieves its high level of efficiency by extracting almost all of the heat from the products of combustion and cooling them to the point where condensation takes place. The condensate which is generated must be piped to an appropriate drain location.

In upright installations, the furnace’s drain hoses may exit either the right or left side of the furnace. NOTE: If the alternate vent/flue outlet is utilized in an upright installation, the drain trap and drain connections must be located on the same side as the alternate vent/flue outlet.

In horizontal installations, the drain hoses will exit through the bottom (down side) of the unit with the drain trap suspended beneath the furnace. The field-supplied drain system must be in accordance with all local codes and the instructions in the following sections.

AIR

INTAKES

12" MIN

SCREEN

90% Furnace Horizontal Venting of Multiple Units

(Dual Pipe)

CONCENTRIC VENT TERMINATION (90% FURNACES

ONLY)

The Concentric Vent Kits HCVK and VCVK are designed to allow the terminations of a direct vent furnace to be "concentrically" vented through a wall (HCVK) or roof (VCVK).

These kits allow a single penetration to support terminations for both the vent/flue pipe and the combustion air intake pipe. HCVK is designed for horizontal, through the wall terminations, while the VCVK is designed for vertical, through the roof terminations. The appropriate kit must be used for a given termination placement (horizontal or vertical).

Concentric Vent Kits HVCK and VCVK are suitable for use with the following Amana 90% efficient furnaces:

CONCENTRIC VENT KIT

Used On Models

GUCA

GCCA

GUVA

GUSA

NOTE: This kit is not certified for, and must not be applied to any furnace not listed in the above table.

Refer to the directions provided with the concentric vent kit for installation specifications.

WARNING

In upright installations, the drain must not be mounted directly above the electrical junction box. This will reduce the risk of water reaching the junction box in the event of a blocked drain condition. Failure to follow these instructions can result in possible death, personal injury, or property damage due to electrical shock.

Follow the bullets listed below when installing the drain system. Refer to the following sections for specific details concerning furnace drain trap installation and drain hose hook ups.

• The drain trap supplied with the furnace must be used.

• The drain line between furnace and drain location must be constructed of 3/4" PVC or CPVC.

• The drain line between furnace and drain location must maintain a 1/4" per foot downward slope toward the drain.

• Do not trap the drain line in any other location than at the drain trap supplied with the furnace.

• Do not route the drain line outside where it may freeze.

• If the drain line is routed through an area which may see temperatures near or below freezing, precautions must be taken to prevent condensate from freezing within the drain line.

• If an air conditioning coil is installed with the furnace, a common drain may be used. An open tee must be installed in the drain line, near the cooling coil, to relieve positive air pressure from the coil’s plenum. This is necessary to prohibit any interference with the function of the furnace’s drain trap.

53 Rev. 1

PRODUCT DESIGN

UPRIGHT INSTALLATIONS

In an upright installation drain hoses are connected to drain ports on the rubber elbow and the recouperator coil front cover. The drain lines are then routed through the right or left side panel and into the drain trap secured to the outside of the cabinet.

NOTE: Refer to Condensate Drain Lines and Drain Trap -

Alternate Vent/Flue Hose Connections section in this manual or the installation instructions for upright installations using an alternate vent/flue outlet.

Alternate Vent/Flue Drain Hose Connections

Upright installations using the alternate vent/flue outlet will require "right-side only" drain hoses to be connected as shown in the following figure. Refer to Vent/Flue Pipe and

Combustion Air Pipe section in this manual or the installation instructions for details on alternate vent/flue pipe connection.

Standard Right or Left Side Drain Hose Connections

Upright installations using the standard vent/flue outlet require drain hoses to be connected as shown in the following figures.

NOTE: For left side drainage, grommets will have to be relocated to left side panel.

FRONT COVER

DRAIN PORT

RED HOSE

CLAMP

HOSE

A GREEN

HOSE

CLAMPS

(3 PLACES)

RIGHT SIDE

PANEL

RUBBER

ELBOW

RUBBER ELBOW

DRAIN PORT

RED HOSE CLAMP

TUBE 1

HOSE

B

SIDE PANEL

GROMMET

HOLES

TUBE(S) 2

DRAIN

TRAP

DRAIN

TRAP

90% Furnace Upright “Standard”

Drain Hose Connections (Right Side)

LEFT

SIDE PANEL

FRONT COVER

DRAIN PORT

RED HOSE

CLAMP

HOSE A

SIDE PANEL

GROMMET

HOLES

TUBE(S) 2

RUBBER

ELBOW

HOSE B

RUBBER

ELBOW

DRAIN PORT

RED HOSE

CLAMP

TUBE 1

GREEN HOSE

CLAMPS

(3 PLACES)

FRONT COVER

DRAIN PORT

HOSE A

TUBE(S) 2

RUBBER ELBOW

(EXTERNALLY

MOUNTED)

RUBBER

ELBOW

DRAIN PORT

TUBE 1 HOSE

CLAMPS

(5 PLACES)

HOSE B

SIDE PANEL

GROMMET

HOLES

DRAIN TRAP

90% Furnace Upright “Alternate”

Drain Hose Connections (Right Side Only)

NOTE: Ensure hoses and tubes maintain a downward slope for proper drainage and are not kinked or binding.

For details concerning mounting of the drain trap, refer to the following section.

Upright Drain Trap Mounting (Left or Right Side Panel)

1. Insert drain tubes into drain trap and position the drain trap against the side panel. NOTE: Drain tubes must reach the bottom of the drain trap.

2. Secure drain trap to side panel at the mounting holes located below the grommet drain holes.

3. Attach PVC drain line to drain trap outlet with either a

90° elbow or coupling.

NOTE: Ensure hoses and tubes maintain a downward slope for proper drainage and that they are not kinked or binding.

90% Furnace Upright “Standard”

Drain Hose Connections (Left Side)


54 Rev. 1

PRODUCT DESIGN

HORIZONTAL INSTALLATIONS

Right Side Down

Horizontal installations with the right side down require that the drain hoses be connected to the right side front cover drain port and the rubber elbow drain port.

FRONT COVER

DRAIN PORT

HOSE A

RED HOSE

CLAMP

HOSE B

SIDE PANEL

GROMMET

HOLES

FRONT

COVER

PRESSURE

TAP

RUBBER

ELBOW

TUBES 2

DRAIN TRAP

GREEN

HOSE

CLAMP

(3 PLACES)

TUBE 1

RIGHT

SIDE

PANEL

RUBBER ELBOW

DRAIN PORT

RED HOSE

CLAMP

90% Furnace Horizontal

Drain Hose Connections (Right Side Down)

INDUCED

DRAFT BLOWER

DRAIN PORT

HOSE B

FRONT

COVER

PRESSURE

TAP

HOSE A

GREEN HOSE

CLAMPS

(3 PLACES)

TUBE(S) 2 LEFT SIDE

PANEL FRONT COVER

DRAIN PORT

RED HOSE CLAMP

SIDE PANEL

GROMMET

HOLES

DRAIN TRAP

90% Furnace Horizontal

Drain Hose Connections (Left Side Down)


For details concerning mounting of the drain trap, refer to

Condensate Drain Lines and Drain Trap - Horizontal Drain

Trap Mounting in this manual or the installation instructions.

NOTE: Ensure hoses and tubes maintain a downward slope for proper drainage and are not kinked or bound.

For details concerning mounting of the drain trap, refer to

Condensate Drain Lines and Drain Trap - Horizontal Drain

Trap Mounting section in this manual or the installation instructions.

Left Side Down

Horizontal installations with the left side panel down will require drain hoses to be connected to the left side front cover drain port and the induced draft blower drain port.

NOTE: On upflow models, relocation of the front cover pressure switch hose is required from the right side (as shipped) pressure tap to the left (down) side tap. The pressure switch hose must be connected to the down side to guard against blocked drain conditions. The hose must be cut to appropriate length to minimize sagging.

Horizontal Drain Trap Mounting (Left or Right Side

Panel)

1. Position the drain trap against side panel with drain tubes inserted into trap. Note that the trap may be orientated with the outlet facing either the furnace’s top cover or base pan.

2. Secure drain trap to side panel at the dimples or crosshairs located on either side of the grommet drain holes.

3. Confirm that tubes reach bottom of drain trap and that all hoses maintain a downward slope and are not kinked or binding.

4. Attach PVC drain line to drain trap outlet with either a

90° elbow or coupling.

55 Rev. 1

PRODUCT DESIGN

Gas Supply and Piping

The furnace rating plate includes the approved furnace gas input rating and gas types. The furnace must be equipped to operate on the type of gas applied. This includes any conversion kits required for alternate fuels and/or high altitude.

CAUTION

To prevent unreliable operation or equipment damage, the inlet gas supply pressure must be as specified on the unit rating plate with all other household gas fired appliances operating.

Inlet gas supply pressures must be maintained within the ranges specified below. The supply pressure must be constant and available with all other household gas fired appliances operating. The minimum gas supply pressure must be maintained to prevent unreliable ignition. The maximum must not be exceeded to prevent unit overfiring.

Inlet Gas Supply Pressure

Natural Gas Minimum: 5.0" W.C. Maximum :10.0" W.C.

Propane Gas Minimum:11.0" W.C. Maximum :13.0" W.C.

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.

High altitude kits are purchased according to the installation altitude and usage of either natural or propane gas. Refer to the product Specification Sheet or Technical Manual for a tabular listing of appropriate altitude ranges and corresponding manufacturer’s high altitude (Natural, Propane gas, and/ or Pressure Switch) kits.

Do not derate the furnace by adjusting the manifold pressure to a lower pressure than specified on the furnace rating plate. The combination of the lower air density and a lower manifold pressure will prohibit the burner orifice from drawing the proper amount of air into the burner. This may cause incomplete combustion, flashback, and possible yellow tipping.

In some areas the gas supplier may artificially derate the gas in an effort to compensate for the effects of altitude. If the gas is artificially derated, the appropriate orifice size must be determined based upon the BTU/ft 3 content of the derated gas and the altitude. Refer to the National Fuel Gas

Code, NFPA 54/ANSI Z223.1, and information provided by the gas supplier to determine the proper orifice size.

A different pressure switch may be required at high altitude regardless of the BTU/ft 3 content of the fuel used. Refer to the product Specification Sheet or Technical Manual for a tabular listing of appropriate altitude ranges and corresponding manufacturer’s pressure switch kits.

Propane Gas Conversion

WARNING

Possible death, personal injury or property damage may occur if the correct conversion kits are not installed.

The appropriate kits must be applied to insure safe and proper furnace operation. All conversions must be performed by a qualified installer or service agency.

This unit is configured for natural gas. The appropriate manufacturer’s propane gas conversion kit, must be applied for propane gas installations. Refer to the “propane gas and/ or High Altitude Installations” section for details.

Gas Valve

This unit is equipped with a 24 volt gas valve controlled during furnace operation by the integrated control module. As shipped, the valve is configured for natural gas. The valve is field convertible for use with propane gas by using the appropriate propane gas conversion kit. Taps for measuring the gas supply pressure and manifold pressure are provided on the valve.

The gas valve has a manual ON/OFF control located on the valve itself. This control may be set only to the “ON” or “OFF” position. Refer to the Lighting Instructions Label or the “Putting the Furnace Into Operation” section of this manual or the installation instructions for use of this control during start up and shut down periods.

GAS PIPING CONNECTIONS

CAUTION

To avoid possible unsatisfactory operation or equipment damage due to underfiring of equipment, use the proper size of natural/propane gas piping needed when running pipe from the meter/tank to the furnace.

When sizing a trunk line, be sure to include all appliances which will operate simultaneously when sizing a trunk line.

The gas piping supplying the furnace must be properly sized based on the gas flow required, specific gravity of the gas, and length of the run. The gas line installation must comply with local codes, or in their absence, with the latest edition of the National Fuel Gas Code, NFPA 54/ANSI Z223.1.

56 Rev. 1

PRODUCT DESIGN

Natural Gas Capacity of Pipe

In Cubic Feet of Gas Per Hour (CFH)

Length of

Pipe in Feet

10

20

30

40

50

60

70

63

56

50

46

1/2"

132

92

73

Nominal Black Pipe Size

3/4"

278

190

152

130

115

105

96

1"

520

350

285

245

215

195

180

1 1/4"

1050

730

590

500

440

400

370

1 1/2"

1600

1100

980

760

670

610

560

80

90

43

40

90

84

170

160

350

320

530

490

100 38 79 150 305 460

(Pressure 0.5 psig or less and pressure drop of 0.3" W.C.; Based on 0.60 Specific

Gravity Gas)

CFH =

BTUH Furnace Input

Heating Value of Gas (BTU/Cubic Foot)

To connect the furnace to the building’s gas piping, the installer must supply a ground joint union, drip leg, manual shutoff valve, and line and fittings to connect to gas valve.

In some cases, the installer may also need to supply a transition piece from 1/2" pipe to a larger pipe size.

The following stipulations apply when connecting gas piping. Refer to the following figures for typical gas line connections to the furnace.

1. Use black iron or steel pipe and fittings for the building piping.

2. Use pipe joint compound on male threads only. Pipe joint compound must be resistant to the action of the fuel used.

3. Use ground joint unions.

4. Install a drip leg to trap dirt and moisture before it can enter the gas valve. The drip leg must be a minimum of three inches long.

5. Install a 1/8" NPT pipe plug fitting, accessible for test gage connection, immediately upstream of the gas supply connection to the furnace.

6. Use two pipe wrenches when making connection to the gas valve to keep it from turning. The orientation of the gas valve on the manifold must be maintained as shipped from the factory.

7. Install a manual shutoff valve between the gas meter and unit within six feet of the unit. If a union is installed, the union must be downstream of the manual shutoff valve, between the shutoff valve and the furnace.

8. Tighten all joints securely.

9. Connect the furnace to the building piping by one of the following methods:

– Rigid metallic pipe and fittings.

– Semi-rigid metallic tubing and metallic fittings. Alu minum alloy tubing must not be used in exterior locations. In order to seal the grommet cabinet penetration, rigid pipe must be used to reach the outside of the cabinet. A semi-rigid connector to the gas piping may be used from there.

10. Use listed gas appliance connectors in accordance with their instructions. Connectors must be fully in the same room as the furnace.

11. Protect connectors and semi-rigid tubing against physical and thermal damage when installed. Ensure aluminum-alloy tubing and connectors are coated to protect against external corrosion when in contact with masonry, plaster, or insulation, or subjected to repeated wetting by liquids such as water (except rain water), detergents, or sewage.

CAUTION


Direct/Standard Inlet Piping

When gas piping enters directly to the gas valve through the standard inlet hole (upflow through the right side panel), the installer must supply straight pipe with a ground joint union to reach the exterior of the furnace. NOTE: The rigid pipe must be long enough to reach the outside of the cabinet to seal the grommet cabinet penetration on the 90% &

95% furnaces. A semi-rigid connector to the gas piping can be used outside the cabinet per local codes.

Indirect/Alternate Inlet Piping

When gas piping enters indirectly to the gas valve through the alternate gas inlet hole the installer must supply the following fittings (starting from the gas valve) to reach the outside of the cabinet (NOTE: On the 90% & 95% furnaces the installer must swap the alternate inlet hole plug with the standard inlet grommet in order to seal the cabinet):

• Coupling.

• 90 degree elbow.

• 2 inch close nipple.

• 90 degree elbow.

• Straight pipe, with a ground joint union, to reach the exterior of the furnace. NOTE: The rigid pipe must be long enough to reach the outside of the cabinet so as to seal the grommet cabinet penetration on the

90% & 95% furnaces. A semi-rigid connector to the gas piping can be used outside the cabinet per local codes.

57 Rev. 1

PRODUCT DESIGN

GAS VALVE

MANIFOLD BURNERS

MANUAL

SHUT OFF VALVE

(UPSTREAM FROM

GROUND JOINT

PIPE UNION)

MANUAL

SHUT OFF VALVE

(UPSTREAM FROM

GROUND JOINT

PIPE UNION)

ALTERNATE

GAS LINE

LOCATION

GROUND JOINT

PIPE UNION

GROUND JOINT

PIPE UNION

GAS VALVE

BURNERS

* *

*

*

*

UPFLOW

MANUAL SHUT-OFF VALVE

(UPSTREAM FROM GROUND

JOINT PIPE UNION)

DRIP LEG

GROMMET IN STANDARD

GAS LINE HOLE

HEIGHT REQUIRED

BY LOCAL CODE

HEIGHT REQUIRED

BY LOCAL CODE

DRIP LEG

GROMMET

IN STANDARD

GAS LINE HOLE

GROMMET

IN STANDARD

GAS LINE HOLE

DRIP LEG

PLUG IN

ALTERNATE

GAS LINE

HOLE

*

*

*

*

*

*

GROUND JOINT

PIPE UNION

COUNTERFLOW

GAS VALVE

MANIFOLD

BURNERS

GROUND JOINT

PIPE UNION

BURNERS

GAS VALVE

MANUAL SHUT-OFF VALVE

(UPSTREAM FROM GROUND

JOINT PIPE UNION)

DRIP LEG

GROMMET IN STANDARD

GAS LINE HOLE

DRAIN TRAP

MANIFOLD

ALTERNATE GAS

LINE LOCATION

PLUG IN ALTERNATE

GAS LINE HOLE

HORIZONTAL(UPFLOW MODEL)

DRAIN TRAP

ALTERNATE

GAS LINE LOCATION

MANIFOLD PLUG IN ALTERNATE

GAS LINE HOLE

HORIZONTAL(COUNTERFLOW)

NOTES

:

1. WHEN GAS LINE IS IN THE ALTERNATE

LOCATION

,

SWAP THE POSITION OF

THE PLUG AND GROMMET

.

2. DRIP LEG MAY TERMINATE WITH

A 1/2" X 1/8" PIPE PLUG TO

ACCOMMODATE LINE GAS

PRESSURE MEASUREMENT.

Gas Piping Connections

(90% Furnace Shown, 80% Furnace Similar)

58 Rev. 1

PRODUCT DESIGN

Gas Piping Checks

Before placing unit in operation, leak test the unit and gas connections.

WARNING

To avoid the possibility of explosion or fire, never use a match or open flame to test for leaks.

Check for leaks using an approved chloride-free soap and water solution, an electronic combustible gas detector, or other approved testing methods.

NOTE: Never exceed specified pressures for testing. Higher pressure may damage the gas valve and cause subsequent overfiring, resulting in heat exchanger failure. Disconnect this unit and shutoff valve from the gas supply piping system before pressure testing the supply piping system with pressures in excess of 1/2 psig (3.48 kPa). Isolate this unit from the gas supply piping system by closing its external manual gas shutoff valve before pressure testing supply piping system with test pressures equal to or less than 1/2 psig (3.48

kPa).

3. Pressure drop in lines between regulators, and between second stage regulator and the appliance. Pipe size will depend on length of pipe run and total load of all appliances.

Complete information regarding tank sizing for vaporization, recommended regulator settings, and pipe sizing is available from most regulator manufacturers and propane gas suppliers.

Since propane gas will quickly dissolve white lead and most standard commercial compounds, special pipe dope must be used. Shellac-based compounds resistant to the actions of liquefied petroleum gases such as Gasolac ® , Stalactic ® ,

Clyde’s ® or John Crane ® are satisfactory.

Refer to the following illustration for typical propane gas installations and piping.

First Stage

Regulator

200 PSIG

Maximum

5 to 15 PSIG

(20 PSIG Max.)

Continuous

11" W.C.

Second Stage

Regulator

Propane Gas Tanks and Piping

WARNING

Propane gas is heavier than air and any leaking gas can settle in any low areas or confined spaces. To prevent death, personal injury, or property damage due to fire or explosion caused by a propane gas leak, install a gas detection warning device.

A gas detecting warning system is the only reliable way to detect a propane gas leak. Iron oxide (rust) can reduce the level of odorant in propane gas. Do not rely on your sense of smell. Contact a local propane gas supplier about installing a gas detecting warning system. If the presence of gas is suspected, follow the instructions on Pages 14-19 of this manual.

All propane gas equipment must conform to the safety standards of the National Board of Fire Underwriters, NBFU

Manual 58.

For satisfactory operation, propane gas pressure must be

11 inch WC at the furnace manifold with all gas appliances in operation. Maintaining proper gas pressure depends on three main factors:

1. Vaporization rate, depending on temperature of the liquid, and “wetted surface” area of the container or containers.

2. Proper pressure regulation. (Two-stage regulation is recommended for both cost and efficiency).

Typical Propane Gas Installation

WARNING

If your propane gas furnace is installed in a basement, an excavated area or a confined space, we strongly recommend that you contact your propane supplier about installing a warning device that would alert you to a gas leak.

. . . Propane gas is heavier than air and any leaking gas can settle in any low areas or confined spaces.

. . . Propane gas odorant may fade, making the gas undetectable except with a warning device.

An undetected gas leak would create a danger of explosion or fire. If you suspect the presence of gas, follow the instructions below. Failure to do so could result in SERIOUS PERSONAL INJURY OR DEATH.

59 Rev. 1

PRODUCT DESIGN

WARNING

If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

- Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

- WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

- Installation and service must be performed by a qualified installer, service agency or the gas supplier.

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

Tubing

Length,

Feet

3/8"

Tubing Size, O.D. Type L

1/2" 5/8" 3/4" 7/8"

Nominal Pipe Size

Schedule 40

1/2" 3/4"

10

20

30

40

50

60

80

100

125

150

175

200

730

500

400

370

330

300

260

220

200

190

170

160

1,700

1,100

920

850

770

700

610

540

490

430

400

380

3,200

2,200

2,000

1,700

1,500

1,300

1,200

1,000

900

830

780

730

5,300

3,700

2,900

2,700

2,400

2,200

1,900

1,700

1,400

1,300

1,200

1,100

8,300

5,800

4,700

4,100

3,700

3,300

2,900

2,600

2,300

2,100

1,900

1,800

3,200

2,200

1,800

1,600

1,500

1,300

1,200

1,000

900

830

770

720

7,500

4,200

4,000

3,700

3,400

3,100

2,600

2,300

2,100

1,900

1,700

1,500

To convert to capacities at 15 psig settings - multiply by 1.130

To convert to capacities at 5 psig settings - multiply by 0.879

household use. Typically, a 500 gallon tank is ample for an average four-bedroom home. However, it is best to consult your local propane supplier to ensure the proper sizing for propane storage requirements. Determining the correct tank size for each household is a function of demand, economy, efficiency and convenience. It is a process that requires cooperation between the propane supplier and customer.

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. Verify proper operation after servicing.

WIRING HARNESS

The wiring harness is an integral part of this furnace. Field alteration to comply with electrical codes should not be required. Wires are color and number coded for identification purposes. Refer to the wiring diagram for wire routings. If any of the original wire as supplied with the furnace must be replaced, it must be replaced with wiring material having a temperature rating of at least 105° C. Any replacement wiring must be copper conductor.

Sizing Between Single or Second Stage Regulator and Appliance*

Maximum Propane Capacities Listed are Based on 1/2" W.C. pressure drop at 11" W.C. setting.

Capacities in 1,000 BTU/hour.

50

60

80

100

125

150

200

250

Pipe or

Tubing

Length,

Feet

10

20

30

40

3/8"

39

26

21

19

18

16

13

11

10

9

8

8

Tubing Size, O.D. Type L

1/2"

92

62

50

41

37

35

29

26

24

21

19

17

5/8"

199

131

107

90

79

72

62

55

48

43

39

36

3/4"

329 501

216 346

181 277

145 233

131 198

121 187

104 155

90

81

72

66

60

7/8"

138

122

109

100

93

1-1/8"

935

630

500

427

376

340

289

255

224

202

187

172

1/2"

Nominal Pipe Size

Schedule 40

3/4" 1" 1-1/4" 1-1/2"

275 567 1,071 2,205 3,307

189 393 732 1,496 2,299

152 315

129 267

114 237

103 217

89

78

69

63

54

48

185

162

146

132

112

100

590

504

448

409

346

307

1,212 1,858

1,039 1,559

913

834

724

630

275 567

252 511

209 439

185 390

1,417

1,275

1,066

976

866

787

665

590

*Data in accordance with NFPA pamphlet NO. 54

Propane Gas Piping Charts

When installing a propane storage tank, the contractor must consider proper tank sizing, safety, efficiency, ground characteristics and aesthetics. For a residential customer, the size may range from 100-1,000 gallons, depending on

60 Rev. 1

115 VOLT LINE CONNECTIONS

Before proceeding with electrical connections, ensure that the supply voltage, frequency, and phase correspond to that specified on the unit rating plate. Power supply to the furnace must be N.E.C. Class 1, and must comply with all applicable codes. The furnace must be electrically grounded in accordance with local codes or, in their absence, with the latest edition of The National Electric Code, ANSI NFPA 70 and/or The Canadian Electric Code CSA C22.1.

Use a separate fused branch electrical circuit containing properly sized wire, and fuse or circuit breaker. The fuse or circuit breaker must be sized in accordance with the maximum overcurrent protection specified on the unit rating plate.

An electrical disconnect must be provided at the furnace location.

NOTE: Line polarity must be observed when making field connections.

PRODUCT DESIGN

WARNING

In 90% furnace upright upflow installations, the drain trap must be mounted on the opposite side of the unit from the junction box. This will reduce the risk of water reaching the junction box in the event of a blocked drain condition.

Connect hot, neutral, and ground wires as shown in the wiring diagram located on the unit’s blower door. Line polarity must be observed when making field connections. Line voltage connections can be made through either the right or left side panel.

The 80% and 90% furnaces are shipped configured for a left side electrical connection with the junction box located inside the burner compartment on 80% furnaces and inside the blower compartment on 90% furnaces. To make electrical connections through the opposite side of the furnace, the junction box must be relocated to the other side of the burner compartment on 80% furnaces and to the other side of the blower compartment on 90% furnaces prior to making electrical connections, refer to the following figures.

CAUTION


STANDARD

JUNCTION BOX

LOCATION

ALTERNATE

JUNCTION BOX

LOCATION

WARNING

To avoid the risk of electrical shock, injury, or death, the furnace must be electrically grounded in accordance with local codes or, in their absence, with the latest edition of the National Electric Code.

115 VOLT LINE CONNECTION OF ACCESSORIES

(HUMIDIFIER AND ELECTRONIC AIR CLEANER)

WARNING

To avoid electrical shock, injury or death, disconnect electrical power before servicing, or changing any electrical wiring.

All 80% & 90% furnaces, except the 80% GUIB & GCIB model furnaces, have an integrated ignition control that is equipped with line voltage accessory terminals for controlling power to an optional field-supplied humidifier and/or electronic air cleaner.

Accessory Load Specifications

Humidifier 1.0 Amp maximum at 120 VAC

Electronic Air Cleaner 1.0 Amp maximum at 120 VAC

Turn OFF power to the furnace before installing any accessories. Follow the humidifier or air cleaner manufacturers’ instructions for locating, mounting, grounding, and controlling these accessories.

Refer to the following two figures for installation of either an

Electronic Air Cleaner or Humidifier on GUIB or GCIB model furnaces that have a WR50A52 ignition control.

F L O W A C T U A T E D

S W IT C H

L 1

E L E C T R O N IC

A IR C L E A N E R

N

80% Furnace Junction Box Relocation Electronic Air Cleaner Wiring

(GUIB/GCIB with WR50A52 Ignition Control)

H

E

A

T

INTEGRATED CONTROL MODULE

HOT 120 VAC NEUTRAL 120 VAC

L

I

N

E

L

I

N

E

STANDARD

JUNCTION BOX

LOCATION

ALTERNATE

JUNCTION BOX

LOCATION

90% Furnace Junction Box Relocation

NOTE: Wire routing must not interfere with circulator blower operation, filter removal, or routine maintenance.

•

•

•

•

1 2 0 V

•

•

•

R E L A Y

H U M ID IF IE R

T O IN D O O R B L O W E R

H E A T IN G S P E E D

Humidifier Wiring

(GUIB/GCIB with WR50A52 Ignition Control)

61 Rev. 1

PRODUCT DESIGN

On all other 80% & 90% furnaces, accessory wiring connections are to be made through the 1/4" quick connect terminals provided on the furnace integrated control module. The Humidifier and Electronic Air Cleaner hot and neutral terminals are identified as HUM and EAC. All field wiring must conform to applicable codes. Connections should be made as shown below.

Hot 120 VAC

Control Module

Neutral 120 VAC

Optional

Accessories

{

Air Cleaner

Humidifier

Accessory Wiring

(WR50A51 Ignition Control Shown,

WR50A50 & HSI 1-1A Ignition Controls Similar)

If it is necessary for the installer to supply additional line voltage wiring to the inside of the furnace, the wiring must conform to all local codes, and have a minimum temperature rating of 105°C. All line voltage wire splices must be made inside the furnace junction box.

The integrated control module humidifier terminals (HUM) are energized with 115 volts whenever the induced draft blower is energized. The integrated control module electronic air cleaner terminals (EAC) are energized with 115 volts whenever the circulator blower is energized on all single stage ignition controls.

NOTE: The EAC (Electronic Air Cleaner) terminals on the two-stage variable speed integrated control module (50A51-

225 used on GUIV-CA/DX models & 50A51-235 used on

GUVA-AX models) will not energize when "G" from the thermostat is connected to "G" on the Air Circulator Motor Interface Board. To energize the EAC terminals, the "G" wire from the thermostat must be connected directly to the "G" terminal on the two-stage integrated control module.

OPTIONAL

ACCESSORIES

ELECTRONIC

AIR CLEANER

HUMIDIFIER

120 VAC

HOT AND

PARK

TERMINALS

HUM-N

EAC-N

12 PIN

CONNECTOR

120 VAC

NEUTRAL

TERMINALS

INTEGRATED

CONTROL

MODULE


(WR50A55 Ignition Control Shown,

HSI-2 Ignition Control Similar)

24 VOLT THERMOSTAT WIRING

NOTE: Low voltage connections can be made through either the right or left side panel. Wire routing must not interfere with circulator blower operation, filter removal, or routine maintenance.

A 40 V.A. transformer and an integrated electronic control are built into the furnace to allow use with most cooling equipment. Consult the wiring diagram, located in the Technical

Manual or on the blower door for further details of 115 Volt and 24 Volt wiring.

Thermostat Wiring - 80% & 90% Single-Stage Furnaces

The single stage furnace will have a "W1" terminal and will use a single stage thermostat. The following drawing illustrates the typical field wiring for a heat only single stage system and a single stage heating/single stage cooling system. Refer to the following figures for proper connections to the integrated control module.

(

Thermostat

Single-Stage Heating

)

12 CIRCUIT

CONNECTOR

W

INTEGRATED

CONTROL MODULE

G R

Y C G R W

Furnace Integrated

Control Module

Single-Stage Heating Only

HUMIDIFIER

ELECTRONIC

AIR CLEANER

OPTIONAL ACCESSORIES


(WR50M-61 & 50V-61 Ignition Control)

62 Rev. 1

PRODUCT DESIGN

Y

W

( Thermostat

Single-Stage Heating with

Single-Stage Cooling

)

C

G R

Y C G R W

Furnace Integrated

Control Module

Y W

( Thermostat



)

G R

Y B/C G R W1 W2 DEHUM

TWIN

Furnace Integrated

Control Module

Y C

Remote

Condensing Unit

(Single-Stage Cooling)

Single-Stage Heating with Single-Stage Cooling

Typical Field Wiring for Single-Stage Gas Furnaces

(24 VAC Control Circuit)

Thermostat Wiring - 80% GUIS, GCIS & 90% GUSA-

BX Two-Stage Furnaces

As a two-stage furnace, the furnace’s integrated control module provides terminals for both "W1" and "W2" and "Y" thermostat connections. This allows the furnace to support the following system applications: ‘Two-Stage Heating Only' or 'Two-Stage Heating with Single-Stage Cooling’. Refer to the following figures for proper connections to the integrated control module.

W2

W1

(

Thermostat

Two-Stage Heating

)

C

G R

Y C G R W1 W2

Furnace Integrated

Control Module

Two-Stage Heating Only

Y C

Twinning

Communication

[Optional]

Remote

Condensing Unit



NOTE: To apply a single-stage heating thermostat, the thermostat selector jumper on the integrated control module must be set on single stage.

Y

W2

W1 with


G R

Y B/C G R W1 W2 DEHUM

TWIN

Furnace Integrated

Control Module

Y C

Twinning

Communication

[Optional]

Remote

Condensing Unit

Two-Stage Heating with Single-Stage Cooling

Typical Field Wiring for GUSA-BX

Two-Stage Gas Furnaces

(24VAC Control CIrcuit)

W2

Y W1

( Thermostat

Two-Stage Heating with


)

G R

Y C G R W1 W2

Furnace Integrated

Control Module

Y C

Remote

Condensing Unit


Typical Field Wiring for GUIS and GCIS

Two-Stage Gas Furnaces

(24 VAC Control Circuit)

63 Rev. 1

PRODUCT DESIGN

Thermostat Wiring - 80% GUIV-CA/DX & 90% GUVA-

AX Two-Stage Variable Speed Furnaces

As a two-stage furnace, the furnace’s integrated control module and/or circulator blower interface board provide terminals for both "W1" and "W2", and "Y1" and "Y/Y2" thermostat connections. This allows the furnace to support the following system applications: ‘Two-Stage Heating Only’,

‘Two-Stage Heating with Single-Stage Cooling’, and ‘Two-

Stage Heating with Two-Stage Cooling’. Refer to the following figures and also the table on the following page for proper connections to the integrated control module and/or circulator blower interface board. Options applicable to the connection of “Y” and “G” from the thermostat are discussed in Circulator Blower Timings and Continuous Fan Operation section of this manual.

Two-Stage Heating

Thermostat

(G e

) (G a

)

G

R

(G d

) (G b

)

NOTES:

(G

*

)

Indicate connection options.

Refer to Circulator Blower Timings and

Speeds Cooling Operation, and

Continuous Fan Operation Section for details concerning "G" and "Y" connection options.

W2 W1

(G a

)

B/C G R Y W2 W1

Two-Stage Heating/


Thermostat

G

R

Y

W2 W1

(Y a

)

(Y b

)

Y/Y2

Y1 G R1 DE

Two-Stage Integrated

Control Module

(Furnace)

Circulator Blower

Interface Board

(Furnace)

Two-Stage Heating Only Application

(G c

) (G b

NOTES:

(G

*

)

Indicate connection options

(Y

*

)

)

Refer to Circulator Blower Timings and Speeds Cooling Operation and


Two-Stage Heating/

Two-Stage Cooling

Thermostat

(G a

)

W2

(Y d

)

G

R

Y/Y2

Y1

W1

(Y e

)

(G b

)

NOTES:

(G

*

)

(Y

*

)

Indicate connection options.

Refer to Circulator Blower Timings and

Speeds Cooling Operation and


B/C G R Y W2 W1

(Y e

)

Y/Y2 Y1 G R1 DE

(Y b

)

Y1 Y2 C

(Y d

)


Control Module

(Furnace)

Circulator Blower

Interface Board

(Furnace)

Two-Stage

Condensing Unit

Two-Stage Heating with Two-Stage Cooling

Typical Field Wiring for GUIV-CA/DX & GUVA-AX

Two-Stage Variable Speed Gas Furnaces

(24VAC Control Circuit)

Thermostat Wiring - 90% GUVA-BX Two-Stage

Variable Speed Furnaces

As a two-stage furnace, the furnace’s integrated control module and/or circulator blower interface board provide terminals for both "W1" and "W2", and "YLO" and "Y" thermostat connections. This allows the furnace to support the following system applications: ‘Two-Stage Heating Only’, ‘Two-

Stage Heating with Single-Stage Cooling’, and ‘Two-Stage

Heating with Two-Stage Cooling’. Refer to the following figures for proper connections to the integrated control module and/or circulator blower interface board.

Y

G R

W

( Thermostat



)

B/C G R Y W2 W1 Y/Y2 Y1 G R1 DE

(Y b

)

Y C

(Y a

)


Control Module

(Furnace)

Circulator Blower

Interface Board

(Furnace)

Single-Stage

Remote Condensing

Unit


O YLO Y B/C G R W1 W2 DEHUM

TWIN

Furnace Integrated

Control Module

NEU

Y C

HOT Dehumidistat

[Optional]

Remote

Condensing Unit



NOTE: To apply a single-stage heating thermostat, the thermostat selector jumper on the integrated Control module must be set on single stage.

64 Rev. 1

PRODUCT DESIGN

W2

W1

( Thermostat



)

Y

T

W

O

S

I

N

G

L

E

TSTAT

ON

T-Stat selection jumper in single-stage thermostat position.

3

2

1

T

W

O

S

I

N

G

L

E

TSTAT

OFF

3

2

1

G R


TWIN

Furnace Integrated

Control Module

DIP switch position 3: ON

Delay Period: 10 minutes.

DIP switch position 3: OFF

Delay Period: 5 minutes.

Y

Remote

Condensing Unit



Y

C

YLO W2

G R

NEU

HOT

W1

( Thermostat


Two-Stage Cooling

)


TWIN

Furnace Integrated

Control Module

NEU

YLO Y C

HOT Dehumidistat

[Optional]

Remote

Condensing Unit

(Two-Stage Cooling)

Two-Stage Heating with Two-Stage Cooling

Typical Field Wiring for GUVA-BX

Two-Stage Variable Speed Gas Furnaces

(24VAC Control Circuit)

Single-Stage Thermostat Application - 90% GUSA-BX

Two-Stage and GUVA-BX Two-Stage Variable Speed

Models Only

A single-stage thermostat with only one heating stage can be used to control this furnace. The application of a singlestage thermostat does not offer “true” thermostat-driven twostage operation, but provides a timed transition from low to high fire. The furnace will run on low stage for a fixed period of time before stepping up to high stage to satisfy the thermostat’s call for heat. The delay period prior to stepping up can be set at either 5 or 10 minutes through the DIP switch adjacent to the Heat Off delay DIP switches on the integrated control module. To use a single-stage thermostat, turn off power to the furnace, move the thermostat selection jumper on the integrated control module from the

“two-stage” position to the “single-stage” position, turn power back on. Refer to the following figures.

Single-Stage Thermostat Application

(GUSA-BX and GUVA-BX Models)

24 Volt Dehumidistat Wiring - Typical Field Wiring for

80% GUIV-CA/DX & 90% GUVA-AX/BX Two-Stage

Variable Speed Gas Furnaces

The optional usage of a dehumidistat allows the furnace’s circulator blower to operate at a slightly lower speed during a combined thermostat call for cooling and dehumidistat call for dehumidification. This lower blower speed enhances dehumidification of the conditioned air as it passes through the AC coil. For proper function, a dehumidistat applied to this furnace must operate on 24 VAC and utilize a switch which opens on humidity rise.

To install/connect a dehumidistat:

1. Turn OFF power to furnace.

2. Secure the dehumidistat neutral wire (typically the white lead) to the screw terminal marked "DEHUM" on the furnace’s circulator blower interface board on GUIV-CA/

DX & GUVA-AX models or the furnace's integrated control module on GUVA-BX models.

3. Secure the dehumidistat hot wire (typically the black lead) to the screw terminal marked "R1" on the furnace circulator blower interface board on GUIV-CA/DX &

GUVA-AX models or to the screw terminal marked "R" on the furnace's integrated control module on GUVA-BX models.

4. Secure the dehumidistat ground wire (typically the green lead) to the ground screw on the furnace junction box.

NOTE: Ground wire may not be present on all dehumidistats.

5. Turn ON power to furnace.

To enable the dehumidify function on the circulator blower interface board:

1. Cut the jumper wire labeled "CUT TO ENABLE" located within the box labeled "DEHUMIDIFY" on the circulator blower interface board on GUIV-CA/DX & GUVA-AX models or adjacent to the DEHUM screw terminal on the furnace's integrated control module on the GUVA-

BX models. Refer to the following figures.

65 Rev. 1

PRODUCT DESIGN

Mode

GUIV-CA/DX & GUVA-AX Two-Stage Variable Speed Furnace

Thermostat Wiring Reference Chart

Thermostat Connection Connection Options

Furnace Circulator Blower Operation

During Call From Thermostat

24 Volts HOT

24 Volts COMMON

R

C

From Room

Thermostat

From Room

Thermostat

To

To

R

C

On Two-Stage

Integrated

Control Module

On Two-Stage

Integrated

Control Module

N/A

N/A

Low Stage Connection

For

"Two-Stage" Heating

W1

From Room

Thermostat

High Stage

Connection For

"Two-Stage" Heating

W2

From Room

Thermostat

Circulator blower will operate on selected

Low Stage Heating speed tap


High Stage Heating speed tap

Connection For

"Single-Stage" Cooling

Y

From Room

Thermostat

Low Stage Connection

For

"Two-Stage" Cooling

Y1

From Room

Thermostat

High Stage

Connection For

"Two-Stage" Cooling

Y2

From Room

Thermostat

Continuous Fan

Connection

[Any Application]

Contiuous Fan

Connection

[HEAT W/ SINGLE

STAGE COOLING

ONLY]

Continuous Fan

Connection

[HEAT ONLY/NO

COOLING]

G

From Room

Thermostat

G

From Room

Thermostat

G

From Room

Thermostat

To W1

To

W2

On Two-Stage

Integrated

Control Module

On Two-Stage

Integrated

Control Module

To

To

To

To

To

Y

Y/Y2

Y1

Y

Y/Y2

On Two-Stage

Integrated

Control Module

On Circulator

Blower

Interface Board

(Screw Terminal)

On Circulator

Blower

Interface Board

(Screw Terminal)

On Two-Stage

Integrated

Control Module

On Circulator

Blower

Interface Board

(Screw Terminal)

To

To

G

G

On Two-Stage

Integrated

Control Module

On Circulator

Blower

Interface Board

(Screw Terminal)

To

Y1

To

Y1

To

Y

On Circulator

Blower

Interface Board

(Screw Terminal)

On Circulator

Blower

Interface Board

(Screw Terminal)

On Two-Stage

Integrated

Control Module


High Stage Cooling speed tap (5 second "ON" delay and 45 second "OFF" delay)


High Stage Cooling speed tap

(No "ON" delay or "OFF" delays)

Circulator blower will operate at 65% of selected High Stage Cooling speed tap


High Stage Cooling speed tap (5 second "ON" delay and 45 second "OFF" delay)



(No "ON" delay or "OFF" delays)


Low Stage Heating speed tap


NOTE: EAC terminals on the two-stage

Integrated Control Module will not energize with this method.









Option

Ref.

---

---

W a

W b

Y a

Y b

Y c

Y d

Y e

G a

G b

G c

G d

G e

66 Rev. 1

PRODUCT DESIGN

DEHUMIDIFICATION

LED (GREEN)

ADJUST

NORM

(+)

(-)

TEST

A

B

C

D

COOL

C

D

A

B

HEAT furnace control board and must wire to the “FURNACE” terminal strip on the fossil fuel control board.

Space provisions on the control panel have been made to fasten the Amana FFK03A Fossil Fuel Control Board on the

GUIV-CA/DX or GUVA-AX Two-Stage Variable Speed Furnace Models only. Refer to the following FFK03A Fossil Fuel

Mounting Kit Location figure.

CUT TO

ENABLE

DEHUMIDIFICATION

JUMPER WIRE

(CUT TO ENABLE)

DEHUMIDIFY

Air Circulating

Motor Interface

Board

Air Circulating Motor Interface Board

(GUIV-CA/DX & GUVA-AX Models)

Integrated

Furnace

Control

0 YL0 Y B/C G R

DEHUM

W1 W2 TWIN

T P1

DEHUMIDIFICATION

LED (YELLOW)

0 YL0 Y B/C

R 84

G

D S5 D S4

R 22

D S3

R

R 85

W1 W2

1 R 19

W14

8 CUT FOR

DEHUM

2 R 12

R 12

5 C R3

W 3

D S7

T P2

DEHUMIDIFICATION

JUMPER WIRE

(CUT TO ENABLE)

FFK03A

Fossil Fuel Kit

Mounting

Location

50V61 Integrated Ignition Control Module

(GUVA-BX Models)

Amana FFK03A Fossil Fuel Kit Mounting Location

(GUIV-CA/DX & GUVA-AX Models Only)

CONTINUOUS FAN OPERATION

Once the jumper wire is cut, the dehumidify function is enabled during a combination call for cooling (T-Stat) and dehumidification (Dehum-Stat). The green LED Located within the box labeled "DEHUMIDIFY" on the circulator blower interface board on GUIV-CA/DX & GUVA-AX models or the yellow LED adjacent to the "DEHUM" screw terminal on GUVA-BX models will be illuminated during dehumidification.

80% & 90% Single Stage Furnaces

The single stage furnace control will energize the cooling circulator fan speed when the fan switch on the thermostat is turned to the "ON" position.

Fossil Fuel Applications

The 80% & 90% Single-Stage and Two-Stage furnaces can be used in conjunction with a heat pump in a fossil fuel application. A fossil fuel application is where an outdoor temperature sensor determines the most cost efficient means of heating (heat pump, gas furnace, or both).

A heat pump thermostat with two stages of heat is required to properly use the single-stage furnace with a heat pump while a heat pump thermostat with three stages of heat is required to properly use the two-stage furnace with a heat pump. Refer to the fossil fuel kit installation manual for additional thermostat requirements.

To install, strictly follow the wiring guidelines in the fossil fuel kit installation. Do not connect the "O" and "EM" lines from the heat pump or thermostat directly to the "O" and

"EM/W2" terminals on the air circulating motor interface board on GUIV-CA/DX or GUVA-AX models. All connections to the furnace must be to the two-stage integrated

80% Two Stage Furnaces

The two stage furnace control will energize the low heat circulator fan speed when the fan switch on the thermostat is turned to the "ON" position. This fan speed will provide circulation with less electricity than conventional single stage equipment.

NOTE: For two stage heat only (no cooling) applications, the continuous fan speed may be increased by jumpering

"Y" to "G". Thermostat must have a "G" terminal to make use of this feature.

80% GUIV-CA/DX & 90% GUVA-AX Two-Stage

Variable Speed Furnaces

"G" from the thermostat can be connected to: "G" on the furnace two-stage integrated control module, "G" on the circulator blower interface board, “Y1” on the circulator blower interface board (single-stage cooling or no cooling), or "Y" on the furnace tow-stage integrated control module

(no cooling). In CONTINUOUS FAN mode, the circulator blower used.

speed will differ depending on which connection is

67 Rev. 1

PRODUCT DESIGN

1. In any application:

If "G" from the thermostat is connected to "G" on the furnace two-stage integrated control module, then the continuous fan blower speed will be the same as the selected low stage heating speed tap.

If "G" from the thermostat is connected to "G" on the circulator blower interface board, then the continuous fan blower speed will be 75% of the selected high stage cooling speed tap.

NOTE: The EAC (Electronic Air Cleaner) terminals on the two-stage integrated control module will not energize using this method. To energize the EAC terminals, the "G" wire from the thermostat must be connected directly to the "G" terminal on the two-stage integrated control module.

2. In two-stage heating/single-stage (or no) cooling applications:

If "G" from the thermostat is connected to "Y1" on the circulator blower interface board, then the continuous fan blower speed will be 65% of the selected high-stage cooling speed tap.

NOTE: The EAC (Electronic Air Cleaner) terminals on the two-stage integrated control module will not energize using this method. To energize the EAC terminals, the "G" wire from the thermostat must be connected directly to the "G" terminal on the two-stage integrated control module.

3. In two-stage heating only/no cooling applications:

If "G" from the thermostat is connected to "Y" on the furnace two-stage integrated control module, then the

Continuous Fan blower speed will be the same as the selected high stage cooling speed tap.

Depending on the heating input of the furnace and the capacity of the accompanying cooling system, one continuous fan speed may be preferable to another. The lower the continuous fan speed, the lower the electrical consumption.

When using an electronic air cleaner, make sure the continuous fan speed's CFM is within the CFM range listed for the electronic air cleaner. Refer to Fan Speed Charts in the furnace Technical Manual or the product Specification Sheet for proper blower speed pin selection.

CIRCULATOR BLOWER SPEED ADJUSTMENT

WARNING

To avoid death or personal injury due to electrical shock, turn off power to the furnace before changing speed taps.

All 80% & 90% single-stage and two-stage furnaces ship at high speed for cooling and the speeds listed in the Specification Sheet for heating. These speeds should be adjusted by the installer to match the job requirements. See Specification Sheet or Technical Manual for details.

68 Rev. 1

Connect the correct motor leads to the COOL, LO HEAT,

HI HEAT, and PARK terminals. If high heating speed equals cooling speed, use the jumper wire provided. All unused motor leads that are not connected to "PARK" terminals on the control must be taped to prevent shorts.

All 80% & 90% Two-Stage Variable Speed furnaces are shipped with heating speed set at “B” and cooling speed set at “D”. Use the following procedure to select the heating and cooling speed needed for your unit.

To verify airflow quantity use the "RED" CFM LED on the circulator blower interface board on GUIV/CA/DX & GUVA-

AX models or "GREEN" CFM LED adjacent to the integrated control module fuse on GUVA-BX models to verify airflow quantity. The red or green CFM LED blinks once for each

100 CFM of airflow.

1. Determine the tonnage of the cooling system installed with the furnace. If the cooling capacity is in BTU/hr divide it by 12,000 to convert capacity to TONs.

EXAMPLE: Cooling Capacity of 30,000 BTU/hr.

30,000/12,000 = 2.5 Tons

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 manufacturers recommend an air flow of about 400 CFM per ton.

EXAMPLE: 2.5 tons X 400 CFM per ton = 1000 CFM

The cooling system manufacturer’s instructions must be checked for required air flow. Any electronic air cleaners or other devices may require specific air flows, consult installation instructions of those devices for requirements.

3. Knowing the furnace model, locate the high stage cooling air flow charts in the specification sheet. Look up the cooling air flow determined in step 2 and find the required cooling speed and adjustment setting.

EXAMPLE: A GUVA070AX40 furnace installed with a

2.5 ton air conditioning system. The air flow needed is

1000 CFM. Looking at the cooling speed chart for

GUVA070AX40, find the air flow closest to 1000 CFM.

A cooling airflow of 990 CFM may be attained by setting the cooling speed to “C” and the adjustment to “-”

(minus).

4. Locate the circulator blower interface board on the control panel in the blower compartment. On the circulator blower interface board, find the "COOL" speed tap selector pin and move it to the proper speed. Next find the

"ADJUST" tap selector pin and move it to the proper adjust level. Verify CFM by counting blinks of the "RED"

CFM LED. Refer to the following figure.

PRODUCT DESIGN

CFM LED (RED)

CIRCULATOR BLOWER

SPEED TAP

SELECTOR PINS

CFM

CUT TO

ENABLE

DEHUMIDIFY

ADJUST

NORM

(+)

(-)

TEST

A

COOL

B

C

D

JW03

VSPD

A

B

C

D

HEAT

Circulator Blower Speed Tap Selector Pin Location

(GUIV-CA/DX & GUVA-AX Models)

EXAMPLE: On the example used, move the "COOL" speed tap selector pin to "C" and move the "ADJUST" tap selector to "-" (minus).

Do NOT move the Adjust pin to "TEST".

5. Select the heating speed from the heating speed chart in the specification sheet for your model. The adjust setting (already established by the cooling speed selection) will determine which set of speeds are available.

The selected speed must provide a temperature rise within the rise range listed with the particular model.

EXAMPLE: The GUVA070AX40 is set for 990 CFM on cooling, the “ADJUST” is set to “-” (minus). The four heating speeds available are "A Minus", "B Minus", "C

Minus", and "D Minus". "A Minus" has a rise of 56°F for both stages which is within the 30-60°F rise range for the GUVA070AX40. This setting will keep electrical consumption to a minimum. Move the "Heat" speed pin selector to "A".

In general lower heating speeds will: reduce electrical consumption, lower operating sound levels of the blower, and increase the outlet air temperature delivered to the home.

The speeds available allow the blower performance to be optimized for the particular homeowner’s needs.

6. The continuous fan speed may be selected from one of three speeds. Knowing the heating speed selection, look up the heating-based continuous fan air flow (see Specification Sheet). Knowing the cooling speed selection, look up the cooling-based continuous fan air flows options A & B (see Specification Sheet). NOTE: Option B is NOT applicable if a two-stage cooling system is used.

Knowing the three possible continuous fan speeds, select the speed that better fits the application. The lower

CFM will use less electricity and minimize operating sound levels.

EXAMPLE: With the GUVA070AX40 set to "A Minus" on heating, the heating-based continuous fan speed will be 756 CFM (refer to specification sheet or technical manual for airflows). The cooling speed was set to "C

Minus" so the cooling-based continuous fan speeds are

743 CFM (Option A) or 644 CFM (Option B). Because, the cooling-based continuous fan speed is lower, it should be selected.

7. Knowing the continuous fan speed desired, the unit should be wired to accommodate this speed. If the continuous fan speed desired is based on the heating speed, connect "G" from the thermostat to "G" on the two-stage integrated control module. If the continuous fan speed desired is based on the cooling speed option A, connect "G" from the thermostat to "G" on the air circulating blower interface board. If the continuous fan speed desired is based on the cooling speed Option B, connect "G" from the thermostat to "Y1" on the circulator board interface board.

NOTE: The EAC (Electronic Air Cleaner) terminals on the two-stage integrated control module on the GUIV-CA/DX

& GUVA-AX models will not energize using this method.

To energize the EAC terminals, the "G" wire from the thermostat must be connected directly to the "G" terminal on the two-stage integrated control module.

NOTE: The GUVA-BX models do not use a separate circluator blower interface board. The circulator blower speeds are adjusted by speed selection DIP switches located on the integrated ignition control module. Refer to the following figure.

8 7 4 3 2 1 8 7 4 3 2 1

Cooling

Speed

Tap A

Normal

*

8 7

O

F

F

4 3 2 1

O

F

F

8 7

O

F

F

O

F

F

4 3 2 1

Cooling

Speed

Tap B

+ (Plus)

Adjust

8 7

O

F

F

4 3 2 1

O

N

8 7

O

F

F

O

N

4 3 2 1

Cooling

Speed

Tap C

- (Minus)

Adjust

8 7

O

N

O

F

F

4 3 2 1

O

N

O

F

F

Cooling

Speed

*

Tap D

Adjust Taps

(

* indicates factory setting)

O

N

O

N

8 7 4 3 2 1

Cooling Speed Taps

(


Heating

Speed

Tap A O

F

F

O

F

F

8 7 4 3 2 1

Heating

Speed

Tap B

*

O O

F

F

N

8 7 4 3 2 1

Heating

Speed

Tap C

O

N

O

F

F

8 7 4 3 2 1

Heating

Speed

Tap D

O

N

O

N

Heating Speed Taps

(


Circulator Blower Speed Tap DIP Swithces

(GUVA-BX Models)

69 Rev. 1

PRODUCT DESIGN

CIRCULATOR BLOWER TIMINGS

Single Stage 80% & 90% Furnaces and 80% Two

Stage Furnaces

All items in this section refer to the air circulation blower, not to the induced draft blower. The timing sequence for the induced draft blower is not adjustable.

When a call for cooling occurs, the circulation fan will come on. It will remain on for 45 seconds after the call for cooling ends. This fan timing is not adjustable.

If “Y” from the thermostat is connected to "Y/Y2" on the air circulation motor interface board, then the following on and off sequences will occur.

Air Circulator Blower Operation

100 %

Cooling On Delay:

Cooling On Ramp Up:

Cooling Off Delay:

Cooling Off Ramp Down:

0 seconds

30 seconds

0 seconds

30 seconds

50 %

Cooling

Speed

0

Call

For

Cool

30 X

Call

Satisfied

X

+30

Time

(sec)

NOTE: This option of no cooling "ON" or "OFF" air circulator blower delay is only available on GUIV-CA/DX & GUVA-

AX models.

Blower Heat Off Delay Timing

The integrated control module provides a selectable heat off delay function. The heat off delay period may be set to 60,

90, 120, 180 seconds using the DIP switches or jumper provided on the control module. The delay is factory shipped at 90 seconds but may be changed to suit the installation requirements and/or homeowner preference. Refer to the following figures for switch positions and corresponding delay times.

60

Second

Delay

90

Second

Delay

120

Second

Delay

180

Second

Delay

Style A Style B

B2

B1 B3

B4

B2

B1 B3

B4

B2

B1 B3

B4

B2

B1 B3

B4

Heat Off Delay Adjustments

80% & 90% Two-Stage Variable Speed Furnaces

All items in this section refer to the air circulation blower not to the induced draft blower. The timing sequence for the induced draft blower is not adjustable.

Cooling Fan Timing

The cooling system may be attached in one of two ways.

The following will explain the two possible operations:

If "Y" from the thermostat is connected to "Y" on the Twostage Integrated Furnace Control, then the following on and off sequences will occur.


100 %

Cooling On Delay:

Cooling On Ramp Up:

Cooling Off Delay:

Cooling Off Ramp Down:

5 seconds

30 seconds

45 seconds

30 seconds

50 %

Cooling

Speed

0 5

Call

For Cool

35 X

Call

Satisfied

X

+45

X

+75

Time

(sec)

Heating Fan Timing

The heating fan timing has a fixed on sequence with an adjustable delay off timing. The delay timing may be adjusted using the switches near the low voltage terminal strip

(see the previous switch position figure). For heating operation "W1" from the thermostat must be connected to

"W1" on the two-stage integrated furnace control. "W2" from the thermostat must be connected to "W2" on the two-stage integrated furnace control. The thermostat connections have no bearing on the operational sequence timings of the circulator blower durign heating. The following on and off sequences of the air circulating blower fan will occur:


100 %

Heating On Delay:

Heating On Ramp Up:

30 seconds

30 seconds

Heating Off Delay: 60, 90, 120, or 180 seconds (Adjustable)

Heating Off Ramp Down: 30 seconds

50 %

Heating

Speed

0 30

Call

For

Heat

60 X

Call

Satisfied

X+

60

90

120

180

X+

90

120

150

210

Time

(sec)

CIRCULATING AIR AND FILTERS

DUCTWORK - AIR FLOW

Duct systems and register sizes must be properly designed for the C.F.M. and external static pressure rating of the furnace. Ductwork should be designed in accordance with the recommended methods of "Air Conditioning Contractors of America" manual D.

A duct system should be installed in accordance with Standards of the National Board of Fire Underwriters for the Installation of Air Conditioning, Warm Air Heating and Ventilating Systems, Pamphlets No. 90A and 90B.

A return air filter is not supplied with the furnace. The installer must supply a means of filtering all of the return air.

Filter(s) shall comply with UL900 or CAN/ULC-S111 Standards. If the furnace is installed without filters, the warranty will be voided.

The following two charts show the bottom and side return filter sizes available for each size furnace. Larger sizes are also acceptable.

70 Rev. 1

PRODUCT DESIGN

BOTTOM RETURN AIR FILTER SIZES

Cabinet Width Filter Size (Inches) Filter Area (in2)

16 1/2 14 X 25 X 1 350

20 1/2

24 1/2

16 X 25 X 1

20 X 25 X 1

400

500

SIDE RETURN AIR FILTER SIZE

Cabinet Width Filter Size (Inches) Filter Area (in

2

)

All Widths 16 x 25 x 1 400

The sketch below shows how the filter is retained over the bottom return air opening.

FILTER

RETAINER

CAPTIVE LANCES

IN BACK PANEL

FILTER

FURNACE BOTTOM

Bottom Return Filter Retention

Guide dimples locate the side and bottom return cutout locations. Use a straight edge to scribe lines connecting the dimples. Cut out the opening on these lines. An undersized opening will cause reduced airflow. For bottom return connection, remove the bottom of the cabinet before setting the furnace on the raised platform or return air duct.

A closed return duct system must be used, with the return duct connected to the furnace. NOTE: Ductwork must never be attached to the back of the furnace. Supply and return connections to the furnace may be made with flexible joints to reduce noise transmission, if desired. If a central return is used, a connecting duct must be installed between the unit and the utility room wall so the blower will not interfere with combustion air or draft. The room, closet, or alcove must not be used as a return air chamber.

When the furnace is used in connection with a cooling unit, the furnace should be installed in parallel with or on the upstream side of the cooling unit to avoid condensation in the heating element. With a parallel flow arrangement, the dampers or other means used to control the flow of air must be adequate to prevent chilled air from entering the furnace and, if manually operated, must be equipped with means to prevent operation of either unit unless the damper is in the full heat or cool position.

When the furnace is heating, the temperature of the return air entering the furnace must be between 55°F and 100°F.

One inch throwaway filters should be sized for a face velocity of 300 feet per minute or less (14x25x1 throwaway = 730

CFM maximum, 16x25x1 throwaway = 830 CFM maximum,

18x25x1 throwaway = 940 CFM maximum, 20x25x1 throwaway = 1040 CFM maximum) All other filters should be sized according to their manufacturer's instructions.

To find the miminum filter requirement (in 2 ) for either permanent or disposable filters multiply the required airflow (CFM) by 144ft 2 and then divide this number by rated velocity of the filter, either 300ft/min for disposable filter or 600ft/min for permanent filter.

EXAMPLE:

Filter Size (in

2

) =

Filter Size (in

2

) =

Required Airflow (CFM) x 144ft

2

300 (Disposable) or 600 (Permanent)

1400 CFM x 144ft

2

300 (Disposable) or 600 (Permanent)

Filter Size = 672in

2

Disposable

Filter Size = 336in

2

Permanent

For air delivery of less than 1800 CFM:

Use one side return or one bottom return ductwork connection.

For air delivery of 1800 CFM or higher:

Use two side returns or one side return and one bottom return connection.

Upright Installations

Depending on the installation and/or customer preference, differing filter arrangements can be applied. Filters can be installed in the central return register, the bottom of the blower compartment (upflows), a side panel external filter rack kit

(upflows), or inside the side panel (upflows), or the ductwork above a counterflow furnace. As an alternative a media air filter or electronic air cleaner can be used as the requested filter. Refer to the following minimum filter requirement charts for determination of the minimum filter area to ensure proper unit performance. The following figures show possible filter locations. NOTE: A ductwork access door must be used in counterflow applications to allow filter removal. If the filter rack is used, the side of the plenum must be at least as tall as dimension "A" shown in the following illustration. For dimension of "A" refer to the following chart.

COUNTERFLOW TOP RETURN AIR FILTER SIZES

Cabinet Width QTY Filter Size (Inches) Filter Area (in2) Dimension "A"

16 1/2 2 15 X 20 X 1 600 14.2

20 1/2

24 1/2

16 1/2

2

2

2

15 X 20 X 1

15 X 20 X 1

20 X 20 X 1

600

600

800

13

11.3

19.7

20 1/2

24 1/2

16 1/2

20 1/2

24 1/2

2

2

2

2

2

20 X 20 X 1

20 X 20 X 1

25 X 20 X 1

25 X 20 X 1

25 X 20 X 1

800

800

1000

1000

1000

18.8

17.7

25.0

24.3

23.4

71 Rev. 1

PRODUCT DESIGN

Model

G(C/U)CA045--30

G(C/U)CA070--30

G(C/U)CA070--40

G(C/U)CA090--40

G(C/U)CA090--50

G(C/U)CA115--50

Minimum Filter Requirement (in

2

)

Permanent Filters

Airflow Requirements (Nominal)

600 CFM 800 CFM 1000 CFM 1200 CFM 1400 CFM 1600 CFM 2000 CFM

188 *

----

----

----

----

----

192

282 *

----

----

----

----

240

282 *

260 *

376 *

----

----

288

282 *

260 *

376 *

376 *

470 *

----

336

336

376 *

376 *

470 *

----

----

384

384

384

470 *

----

----

----

----

480

480

GUVA045--30

GUVA070--40

GUVA090--50

GUVA115--50

GUSA070--35

GUSA090--40

GUSA090--50

GUSA115--50

209 *

----

----

----

----

----

----

----

209 *

----

----

----

282 *

----

----

----

240

313 *

----

----

282 *

376 *

----

----

288

313 *

418 *

470 *

282 *

376 *

376 *

470 *

----

336

418 *

470 *

336

376 *

376 *

470 *

----

384

418 *

470 *

----

384

384

470 *

----

----

480

480

----

----

480

480

GUI(A/B/C/D)045--30

GUI(A/B/C/D)070--30

GUI(A/B/C/D)070--40

GUI(A/B/C/D)090--30

GUI(A/B/C/D)090--50

GUI(A/B/C/D)115--40

GUI(A/B/C/D)115--50

GUI(A/B/C/D)140--50

GUIS070--35

GUIS090--30

GUIS090--50

GUIS115--40

GUIS115--50

GUIS140--50

GUIV070--40

GUIV090--50

GUIV115--50

GUIV140--50

----

305 *

----

----

----

----

279*

----

----

----

168 *

251 *

----

305 *

----

----

----

----

----

305 *

----

----

----

----

279*

----

----

----

192

251 *

----

305 *

----

----

----

----

251 *

305 *

----

381 *

----

----

279 *

335*

419*

419*

240

251 *

251 *

305 *

----

381 *

----

----

GCI(A/B/C)045--30

GCI(A/B/C)070--30

GCI(A/B/C)070--40

GCI(A/B/C)090--30

GCI(A/B/C)090--50

GCI(A/B/C)115--40

GCI(A/B/C)115--50

GCI(A/B/C)140--50

168 *

210 *

----

279 *

----

----

----

----

192

210 *

----

279 *

----

----

----

----

240

240

240

279 *

----

349 *

----

----

288

288

288

288

288

349 *

349 *

419 *

GCIS070--35

GCIS090--50

----

----

251 *

----

251 *

----

288

288

* Mimimum Filter Area Based on Heating Airflow Requirement

NOTE: The dashed (----) areas indicate not used in this application.

288

305 *

305 *

381 *

381 *

419 *

288

335*

419 *

419 *

288

288

288

305 *

305 *

381 *

381 *

419 *

72 Rev. 1

----

----

336

----

336

349 *

349 *

419 *

336

336

336

----

336

381 *

381 *

419 *

336

336

419 *

419 *

----

----

336

----

336

381 *

381 *

419 *

----

----

384

----

384

384

384

419 *

----

384

----

----

384

384

384

419 *

384

384

419 *

419 *

----

----

384

----

384

384

384

419 *

----

----

----

----

480

----

480

480

----

480

----

----

480

----

480

480

----

480

480

480

----

----

----

----

480

----

480

480

PRODUCT DESIGN

Model

G(C/U)CA045--30

G(C/U)CA070--30

G(C/U)CA070--40

G(C/U)CA090--40

G(C/U)CA090--50

G(C/U)CA115--50

Minimum Filter Requirement (in

2

)

Disposable Filters

Airflow Requirements (Nominal)

600 CFM 800 CFM 1000 CFM 1200 CFM 1400 CFM 1600 CFM 2000 CFM

376 *

----

----

----

----

----

384

564 *

----

----

----

----

480

564 *

564 *

752 *

----

----

576

564 *

564 *

752 *

752 *

940 *

----

672

672

752 *

752 *

940 *

----

----

768

768

768

940 *

----

----

----

----

960

960

GUVA045--30

GUVA070--40

GUVA090--50

GUVA115--50

GUSA070--35

GUSA090--40

GUSA090--50

GUSA115--50

GUI(A/B/C/D)045--30

GUI(A/B/C/D)070--30

GUI(A/B/C/D)070--40

GUI(A/B/C/D)090--30

GUI(A/B/C/D)090--50

GUI(A/B/C/D)115--40

GUI(A/B/C/D)115--50

GUI(A/B/C/D)140--50

GUIS070--35

GUIS090--30

GUIS090--50

GUIS115--40

GUIS115--50

GUIS140--50

GUIV070--40

GUIV090--50

GUIV115--50

GUIV140--50

376 *

----

----

----

376 *

----

----

----

335 *

503 *

----

610 *

----

----

----

----

----

610 *

----

----

----

----

559*

----

----

----

384

----

----

----

384

----

----

----

384

503 *

----

610 *

----

----

----

----

----

610 *

----

----

----

----

559*

----

----

----

GCI(A/B/C)045--30

GCI(A/B/C)070--30

GCI(A/B/C)070--40

GCI(A/B/C)090--30

GCI(A/B/C)090--50

GCI(A/B/C)115--40

GCI(A/B/C)115--50

GCI(A/B/C)140--50

335 *

419 *

----

559 *

----

----

----

----

384

419 *

----

559 *

----

----

----

----

480

480

480

559 *

----

699 *

----

----

576

576

576

576

576

699 *

699 *

838 *

GCIS070--35

GCIS090--50

----

----

503 *

----

503 *

----

576

576

* Mimimum Filter Area Based on Heating Airflow Requirement

NOTE: The dashed (----) areas indicate not used in this application.

480

503 *

503 *

610 *

----

762 *

----

----

503 *

610 *

----

762 *

----

----

559 *

671*

----

----

480

627*

----

----

480

627 *

----

----

576

576

576

610 *

610 *

762 *

762 *

838 *

576

610 *

610 *

762 *

762 *

838 *

576

671 *

838 *

838 *

576

627 *

836 *

940 *

576

627 *

836 *

940 *

----

----

672

----

672

762 *

762 *

838 *

672

----

672

762 *

762 *

838 *

672

672

838 *

838 *

----

672

836 *

940 *

----

672

836 *

940 *

----

----

672

----

672

699 *

699 *

838 *

672

672

----

----

768

----

768

768

768

838 *

----

----

768

768

768

838 *

768

768

838 *

838 *

----

768

836 *

940 *

----

768

836 *

940 *

----

----

768

----

768

768

768

838 *

----

768

----

----

960

----

960

960

----

----

----

----

960

----

960

960

----

960

960

960

----

----

960

960

----

----

960

960

----

----

----

----

960

----

960

960

----

960

73 Rev. 1

PRODUCT DESIGN

CENTRAL

RETURN

GRILLE

OPTIONAL

FILTER

ACCESS

DOOR

RETURN

DUCT

BOTTOM

RETURN

AIR FLOW

POSSIBLE UPRIGHT UPFLOW

FILTER LOCATIONS

FI

LTE

R

FI

LT

ER "A"

Min

FILTER

EXTERNAL

FILTER

RACK KIT

CENTRAL

RETURN

GRILLE

ADDITIONAL FILTERING ACCESSORIES

External Filter Rack Kit (EFR01)

The external filter rack kit is intended to provide a location external to the furnace casing, for installation of a permanent filter on upflow model furnaces. The rack is designed to mount over the indoor blower compartment area of either side panel, and provide filter retention as well as a location for attaching return air ductwork.

Electronic Air Cleaner (EAC5) or Media Air Cleaner

(MAC1)

The electronic air cleaner and media air cleaner are multipositional high efficiency air filtration devices that can be installed in any position, except with the access door facing down. The best location for the air cleaner is in the return air duct next to the blower compartment. Before installing the air cleaner, consider the application. The electronic air cleaner must be readily accessible for periodic inspection and cleaning of the pre-filters and electronic cells while the media air cleaner must be readily accessible for periodic inspection and replacement of the media cartridge (MAF), to maintain maximum efficiency and trouble-free operation.

JUNCTION

BOX

Accomodator Filter Housing (ACG1625-3/6, ACG2025-

3/6 and ACG2424-3/6)

The Accomodator ia a filter cabinet that provides a location external to the furnace casing for installation of a filter on upflow model furnaces using bottom return. The

Accomodater gives the homeowner the option of using many choices of filter types and sizes. The filter sizes that may be used are 1", 2" and 4".

AIR FLOW

POSSIBLE UPRIGHT COUNTERFLOW

FILTER LOCATIONS

(90% Furnace Shown, 80% Similar)

Horizontal Installations

Filter(s) must be installed external to the furnace casing for horizontal installations. For most installations it is preferable to use a central return with filters installed in the duct behind the return air grill. In this way filter replacement is relatively simple by merely removing the grille, rather than going into the attic or crawl space.

Refer to the previous Upflow/Horizontal Filter Size charts on

Recommended Minimum Filter Sizes.

Horizontal Filter Housing (HR20 & HR25)

The Horizontal Filter Housing provides a location external to the furnace casing for installation of a filter(s) on upflow model furnaces using side air return(s). The Horizontal Filter Housing gives the homeowner the option of using many choices of filter types and sizes. The filter sizes that may be used are 1", 2" or 4".

NOTE: For complete details on each of the additional filtering accessories, refer to the instructions provided with each accessory.

74 Rev. 1

SYSTEM OPERATION

NORMAL SEQUENCE OF OPERATION

(80% or 90% Models with White-Rodgers 50A50 or

Heatcraft HSI 1-1A Integrated Ignition Control)

Power Up

The normal power up sequence is as follows:

1. 115 VAC power applied to furnace.

2. Integrated control module performs internal checks.

3. Integrated control module flashes LED one time.

4. Integrated control module monitors safety circuits continuously.

5. Furnace awaits call from thermostat.

Heating Mode

The normal operational sequence in heating mode is as follows:

1. R and W thermostat contacts close, initiating a call for heat.

2. Integrated control module performs safety circuit checks.

3. Induced draft blower is energized causing pressure switch contacts to close. Humidifier terminals are energized with induced draft blower.

4. Ignitor warm up begins upon close of pressure switch contacts.

5. Gas valve opens at end of ignitor warm up period, delivering gas to burners and establishing flame.

6. Integrated control module monitors flame presence. Gas valve will remain open only if flame is sensed.

7. Circulator blower is energized on heat speed following a fixed thirty second blower on delay. Electronic air cleaner terminals are energized with circulator blower.

8. Furnace runs, integrated control module monitors safety circuits continuously.

9. R and W thermostat contacts open, completing the call for heat.

10. Gas valve closes, extinguishing flame.

11. Induced draft blower is de-energized following a fifteen second post purge. Humidifier terminals are de-energized.

12. Circulator blower is de-energized following a selectable heat off delay period (60, 90, 120, or 180 seconds). Electronic air cleaner terminals are de-energized.

13. Furnace awaits next call from thermostat.

Cooling Mode

The normal operational sequence in cooling mode is as follows:

1. R and Y thermostat contacts close, initiating a call for cool.


3. Outdoor fan and compressor are energized.

4. Circulator blower is energized on cool speed following a fixed five second on delay. Electronic air cleaner terminals are energized with circulator blower.

5. Furnace circulator blower and outdoor cooling unit run, integrated control module monitors safety circuits continuously.

6. R and Y thermostat contacts open, completing the call for cool.

7. Outdoor fan and compressor are de-energized.

8. Circulator blower is de-energized following a fixed forty five second cool off delay period. Electronic air cleaner terminals are de-energized.


Fan Only Mode

The normal operational sequence in fan only mode is as follows:

1. R and G thermostat contacts close, initiating a call for fan.


3. Circulator blower is energized on cool speed. Electronic air cleaner terminals are energized.

4. Circulator blower runs, integrated control module monitors safety circuits continuously.

5. R and G thermostat contacts open, completing the call for fan.

6. Circulator blower is de-energized. Electronic air cleaner terminals are de-energized.


75 Rev. 1


HEATING TIMING CHART FOR WHITE-RODGERS 50A50 AND HEATCRAFT HSI 1-1A

INTEGRATED IGNITION CONTROL OPERATION

Air Circulator Blower

ON

OFF

Gas Valve

OPEN

CLOSED

Ignitor

Pressure Switch

ON

OFF

CLOSED

OPEN

Induced Draft Blower

Thermostat

(Call for Heat)

ON

OFF

ON

OFF

Seconds 0 17 21 24 54 0 15 90

COOLING TIMING CHART FOR WHITE-RODGERS 50A50 AND HEATCRAFT HSI 1-1A


Indoor Fan

ON

OFF

Outdoor Fan and

Compressor

ON

OFF

Thermostat

(Call for Cool)

Seconds

ON

OFF

0 5 0 45

76 Rev. 1


ABNORMAL OPERATION


Heatcraft HSI 1-1A Integrated Ignition Control)

The following presents the probable causes of questionable furnace operation and how to fix them. Look through the observation window in the blower access door and make a note of the number of flashes in sequence between pauses.

Next, refer to the Diagnostic Signal Chart below for an interpretation of the LED signals and to the information in this section for a description of the problem.

1. Internal Control Failure with Integrated Ignition Con-

trol. If the control determines it has an internal fault, it enters a locked-out state, and the diagnostic light will

light continuously with no flashes. The control should be replaced.

2. System Lockout. If a flame is not sensed during the first seven (7) seconds after the gas valve is energized, the control turns off the gas. There will then be a 60 second delay while the induced draft blower is energized to purge the heat exchanger. The ignitor will next be energized and preheated for 27 seconds. The gas valve will then be energized. If flame is not sensed in seven (7) seconds the gas valve will be de-energized and another purge will occur. The control will cycle the gas valve a total of three (3) times before it determines it cannot establish measurable combustion and enters a locked out state. If flame is sensed but lost after ten

(10) seconds, the control will recycle this series of three tries four (4) more times before locking out. The diagnostic light code for this problem is one short flash followed by a longer pause. The control can be reset and brought out of lockout mode by turning the thermostat off and then back on. It can also be reset by turning off the electrical disconnect switch to the furnace for 30 seconds.

NOTE: The control board will automatically reset one hour after lockout occurs. If the furnace frequently has to be reset, it means that a problem exists that should be corrected.

3. Pressure Switch Stuck Closed. If the control senses the pressure switch is closed when the induced draft blower is off, it waits until the fault is corrected. The diagnostic light code for this problem is two short flashes followed by a longer pause. The probable cause is either a faulty pressure switch or wiring.

4. Pressure Switch Stuck Open. If, after the induced draft blower is energized, the pressure switch does not close, the control will keep the blower on and wait for the switch to close. The diagnostic light code for this problem is

three short flashes followed by a pause. The probable cause is either disconnected hose to the pressure switch, faulty pressure switch or wiring, or restricted air intake or flue piping.

5. Open Limit Control. If the limit control opens, the air circulator and induced draft blower will be turned on until the limit closes. The diagnostic light code for this problem is four short flashes followed by a pause. The probable cause is either low conditioned air flow due to dirty filter or resistance in duct work, faulty limit, faulty blower, or blower speed set to low.

6. Open Rollout Control. If the rollout control opens, the air circulator blower and induced draft blower will be energized all the time. The diagnostic light code for this problem is five flashes followed by a pause. The probable cause is either restricted flue piping or improper air requirements.

7. Flame Sensed with No Call for Heat. If the control senses a flame when the gas valve is de-energized, it will run the air circulator blower and the induced draft blower continuously. The diagnostic light code for this problem is continuous light flashing. The probable causes are either a short to ground in flame sense circuit, miswiring, lingering burner flame or a slow closing gas valve.

50A50 or HSI 1-1A INTEGRATED IGNITION CONTROL

DIAGNOSTIC SIGNAL CHART

LIGHT SIGNAL

Continuous Light

1 Flash

2 Flashes

3 Flashes

4 Flashes

5 Flashes

Continuous Flashing

FOR CORRECTIVE ACTION REFER TO

ABNORMAL OPERATION NUMBER

1. Internal Control Failure

2. System Lockout

3. Pressure Switch Stuck Closed

4. Pressure Switch Stuck Open

5. Open Limit Control

6. Open Rollout Control

7. Flame Sensed No Call For Heat

77 Rev. 1




Heatcraft HSI-2 Integrated Ignition Control)

Power Up







Heating Mode





4. Ignitor warm up begins upon close of pressure switch contacts. Note: Heatcraft HSI-2 ignition control has a fixed standard s even-second ignitor warm-up period and the White-Rodgers 50A55 ignition control has a variable standard ignitor warm up period between a 17-second maximum and a five-second minimum.

5. Gas valve opens at end of ignitor warm up period, delivering gas to burners and establishing flame.

6. Integrated control module monitors flame presence.

Gas valve will remain open only if flame is sensed.

7. Circulator blower is energized on heat speed following a fixed thirty second blower on delay. Electronic air cleaner terminals are energized with circulator blower.





12. Circulator blower is de-energized following a selectable heat off delay period (60, 90, 120, or 180 seconds). Electronic air cleaner terminals are de-energized.


Cooling Mode





4. Circulator blower is energized on cool speed following a fixed five second on delay. Electronic air cleaner terminals are energized with circulator blower.




8. Circulator blower is de-energized following a fixed forty five second cool off delay period. Electronic air cleaner terminals are de-energized.


Fan Only Mode




3. Circulator blower is energized on cool speed. Electronic air cleaner terminals are energized.





78 Rev. 1


HEATING TIMING CHART FOR WHITE-RODGERS 50A55 AND HEATCRAFT HSI-2


Air Circulator Blower

ON

OFF

Gas Valve

Ignitor

Pressure Switch

OPEN

CLOSED

ON

OFF

CLOSED

OPEN

Induced Draft Blower

Thermostat

(Call for Heat)

ON

OFF

ON

OFF

Seconds 0 t ign

Ignitor

Warm Up Period

(see note)

Fixed eEat on Delay:

30 Seconds t circ 0 15

NOTE: HEATCRAFT INTEGRATED CONTROL MODULE HAS A FIXED

STANDARD SEVEN-SECOND IGNITER WARM UP PERIOD

(MINI IGNITER).

WHITE-RODGERS INTEGRATED CONTROL MODULE HAS A

VARIABLE STANDARD IGNITER WARM UP PERIOD BETWEEN

A 17-SECOND MAXIMUM AND A FIVE-SECOND MINIMUM.

60,90,

120 or

180

COOLING TIMING CHART FOR WHITE-RODGERS 50A55 AND HEATCRAFT HSI-2


Indoor Fan ON

OFF

Outdoor Fan and

Compressor

ON

OFF

Thermostat ON

OFF

Seconds 0 5 0 45

79 Rev. 1




Heatcraft HSI-2 Integrated Ignition Control)


Next, refer to the Troubleshooting Chart on the following pages for an interpretation of the LED signals and to the information in this section for a description of the problem.

1. Internal Control Failure with Integrated Ignition

Control. If the control determines it has an internal fault, it enters a locked-out state, and the diagnostic light will


2. System Lockout. If a flame is not sensed during the first seven (7) seconds after the gas valve is energized, the control turns off the gas. There will then be a 60 second delay while the induced draft blower is energized to purge the heat exchanger. The ignitor will next be energized and preheated for 27 seconds. The gas valve will then be energized. If flame is not sensed in seven (7) seconds the gas valve will be de-energized and another purge will occur. The control will cycle the gas valve a total of three (3) times before it determines it cannot establish measurable combustion and enters a locked out state. If flame is sensed but lost after ten (10) seconds, the control will recycle this series of three tries four (4) more times before locking out. The diagnostic light code for this problem is one short flash followed by a longer pause. The control can be reset and brought out of lockout mode by turning the thermostat off and then back on. It can also be reset by turning off the electrical disconnect switch to the furnace for 30 seconds.


Refer to Troubleshooting Chart on the following pages for aid in determining the cause.


4. Pressure Switch Stuck Open. If, after the induced draft blower is energized, the pressure switch does not close, the control will keep the induced draft blower on and wait for the switch to close. The diagnostic light code for this problem is three short flashes followed by a pause.

The probable causes are either disconnected hose to the pressure switch, faulty pressure switch or wiring, or restricted air intake or flue piping.

5. Open Primary or Auxiliary Limit. If the limit control opens, the air circulator blower and induced draft blower will be turned on until the limit closes. The diagnostic light code for this problem is four short flashes followed by a pause. The probable cause is either low conditioned air flow due to dirty filter or resistance in duct work, faulty limit, faulty blower, or blower speed set to low.

6. Open Rollout Limit. If the rollout control opens, the air circulator blower will be energized all the time. The diagnostic light code for this problem is five flashes followed by a pause. The probable cause is either restricted flue piping or improper air requirements.

7. Reversed Polarity. If the 115V or 24V AC power leads are reversed, the furnace will fail to operate. The diagnostic light code for this problem is six flashes followed by a pause. The probable cause is either the 115V AC power to furnace or integrated control module is reversed, the 24V AC orange and gray wires to transformer are reversed, or poor unit ground.

8. Low Flame Sense Signal. (White-Rodgers 50A55 Control Only). If the furnace continues to operate and the micro-amp signal from the flame sensor falls below specified level. The diagnostic light code for this problem is

seven flashes followed by a pause. The probable cause is either a coated/oxidized sensor, incorrectly positioned senser in burner flame or lazy burner flame due to improper gas pressure or combustion air.

9. Pressure Switch Opened Five Times During A Single

Call for Heat. If the furnace fails to operate due to pressure switch opening five times during a single call for heat. The diagnostic light code for this problem is eight

flashes followed by a pause. The probable cause is either the pressure switch hose is blocked, pinched, or misconnected, blocked flue or drain system, weak induced draft blower, incorrect pressure switch set point or faulty pressure switch, or loose or misconnected wiring.

80 Rev. 1


NOTE: There is a twenty minute lockout if the pressure switch has tripped five times during a single call for heat.

10. Primary or Auxiliary Limit Opened Five Times Dur- ing a Single Call for Heat. (Heatcraft HSI-2 Control

Only). If the furnace fails to operate due to primary or auxiliary limit opening five times during a single call for heat, the control will run the air circulation blower continuously with no further furnace operation. The diagnostic light code for this problem is nine flashes followed by a pause. The probable cause is either low conditioned air flow due to dirty filter(s) or resistance in duct work, faulty limit, faulty blower, or blower speed set to low.

NOTE: There is a one hour lockout if either the primary or auxiliary limit has tripped five times during a single call for heat.

11. Flame Sensed with No Call for Heat. If the control senses a flame when the gas valve is de-energized, it will run the air circulation blower and the induced draft blower continuously with no further furnace operation.

The diagnostic flash code for this is a continuous flash.

The probable causes are either a short to ground in flame sense circuit, miswiring, lingering burner flame or a slow closing gas valve.

81 Rev. 1

Troubleshooting Chart for 50A55 & HSI-2 Integrated Ignition Controls

Symptoms of

Abnormal

Operation

- Furnace fails to operate.

and

- Integrated control module

RED diagnostic LED provides no signal.

Associated

Red LED Code

(See Note 2)

None

Fault Description(s)

- No 115 V power to furnace, or no

24 V power to integrated control module.

- Blown fuse, or circuit breaker.

- No signal from thermostat.

Possible Causes

- Manual disconnect switch OFF, door switch open, or 24 V wires miswired or loose.


- Improper thermostat connection or setting.

Corrective Action

- Assure 115 V and 24 V power to furnace and integrated control module.

- Check integrated control module fuse (3 A). Replace if necessary.

- Check for possible shorts in 115 V and 24 V circuits. Repair as necessary.


and


RED diagnostic LED is lit continuously.

ON

Continuous On

- Integrated control module has an internal fault.


- Replace bad integrated control module with known good control module.

- Furnace is not operating and


RED diagnostic LED is flashing one flash.

1

1 Flash

- Furnace lockout due to an excessive number of ignition "retries" (3 total attempts), or "recycles" (5 total recycles). See note 1.

- Failure to establish flame. Cause may be no gas to burners, front cover pressure switch stuck open, bad ignitor or ignitor alignment, improper orifices, or coated/ oxidized or misconnected flame sensor.

- Loss of flame after establishment. Cause may be interrupted gas supply, lazy burner flames (improper gas pressure or restriction in flue and/or combustion air piping, front cover pressure switch opening, or improper induced draft blower performance.

- Locate and correct gas interruption.

- Check front cover pressure switch operation (hose, wiring, contact operation). Correct if necessary.

- Replace or realign ignitor.

- Check flame sense signal. Sand sensor if coated/oxidized.

- Check flue piping for blockage, proper length, elbows, and termination.

- Verify proper induced draft blower performance.


and


RED diagnostic LED is flashing two flashes.

2 - Pressure switch circuit is closed even though induced draft blower is not operating.

- Induced draft blower pressure switch contacts sticking.

- Shorts in pressure switch circuit.

- Replace induced draft blower pressure switch if bad.

- Check for and correct shorted wiring.

2 Flashes

- Induced draft blower runs continuously with no further furnace operation.

and


RED diagnostic LED is flashing three flashes.

3

3 Flashes

- Pressure switch circuit does not close in response to induced draft blower operation.

- Pressure switch hose blocked, pinched, or misconnected.

- Blocked flue and/or inlet air pipe, blocked drain system, or weak induced draft blower.

- Incorrect pressure switch set point or malfunctioning switch contacts.

- Loose or incorrect wiring.

- Check and correct pressure switch hose.

- Check flue and/or inlet air piping for blockage, proper length, elbows and termination. Check drain system.

- Verify proper pressure switch set point and contact motion.

- Check and correct wiring.

- Circulator blower runs continuously with no further furnace operation.

and


RED diagnostic LED is flashing four flashes.


and


RED diagnostic LED is flashing five flashes.

4

4 Flashes

5 Flashes

- Primary limit circuit is open.

(Primary or auxiliary limit).

- Rollout limit circuit is open.

- Insufficient conditioned air over the heat exchanger.

- Cause may be blocked filters, restrictive ductwork, improper circulator blower speed, or failed circulator blower.

- Loose or misconnected wiring.

- Rollout limit(s) is(are) open due to flame rollout.

Cause may be misaligned burners, blocked flue and/or air inlet pipe, or failed induced draft blower.


- Check filters and ductwork for blockage. Clean filters or remove obstruction.

- Check for proper circulator blower speed and performance.

Correct speed or replace blower if necessary.


- Check burners for proper alignment.

- Check flue and/or air inlet piping for blockage, proper length, elbows, and termination.

- Check induced draft blower for proper performance. Replace if necessary.


NOTES:

1) Integrated control module will automatically attempt to reset from lock out after one hour.

2) LED flash code will cease if power to the control module is interrupted through the disconnect or door switch.

3) Integrated control module will automatically attempt to reset from lock out after 20 minutes.

Cautions and

Notes

- Turn power OFF prior to repair.

- Replace integrated control module fuse with

3 A automotive style fuse.


- Read precautions in "Electrostatic

Discharge" section of manual.


- Ignitor is fragile, handle with care.

- Sand flame sensor with steel wool.

- See "Flue and Combustion Air Pipe" section for piping details.


- Replace pressure switch with proper replacement part.





- See Specification Sheet for allowable rise range and proper circulator blower speed.



- Replace induced draft blower with proper replacement part.

Troubleshooting Chart for 50A55 & HSI-2 Integrated Ignition Controls

Symptoms of

Abnormal

Operation


and

- Integrated control module red diagnostic LED is flashing six flashes.

Associated

Red LED Code

(See Note 2)

6

6 Flashes


- Polarity of 115 V or 24 V AC power is reversed.

Possible Causes

- Polarity of 115 V AC power to furnace or integrated control module is reversed.

- Orange and gray wires to transformer are reversed.

- Poor unit ground.

Corrective Action

- Review wiring diagram.

- Verify proper grounding.


- Clean flame sensor if coated/oxidized.

- Inspect for proper sensor alignment.

- Check inlet air piping for blockage, proper length, elbows, and termination.

- Check for proper gas pressures.

- Normal furnace operation.

but

- Interated control module red diagnostic LED is flashing seven flashes.

7

7 Flashes

White-Rodgers 50A55

Control Only

- Flame sense micro-amp signal is low.

- Flame sensor is coated/oxidized.

- Flame sensor incorrectly positioned in burner flame.

- Lazy burner flame due to improper gas pressure, or combustion air.


- Integrated control module diagnostic LED is flashing eight flashes.

8 - Pressure switch circuit has opened five times during a single call for heat. See note 3.

8 Flashes

- Circulator blower runing continuously with no further furnace operation and

- Integrated control module diagnostic LED is flashing nine flashes.

9

9 Flashes

Heatcraft HSI-2 Control

Only

- Limit circuit (primary or auxiliary) has opened five times during a single call for heat. See note 1.

- Induced draft and circulator blower run continuously with no further furnace operation.

and

- Integrated control module red diagnostic LED is flashing continuously.

C

Continuous

Flashing

- Flame has been sensed with no call for heat.








- Short to ground in flame sense circuit.

- Lingering burner flame.

- Slow closing gas valve.









- Correct short at flame sensor or in flame sensor wiring.

- Check for lingering flame.

- Verify proper operation of gas valve.

NOTES:



3) Integrated control module will automatically attempt to reset from lock out after 20 minutes.

Cautions and

Notes



- Sand flame sensor with emery cloth.


- See rating plate for proper gas pressures.










(80% Models with White-Rodgers 50A52 Radiant Sense

Ignition Control)

Power Up






Heating Mode





4. Ignitor warm up begins upon close of pressure switch contacts. It will heat for at least 17 seconds, and will continue to heat until the radiant sensor determines the ignitor is hot enough (i.e., until a heat signal is produced).

5. Gas valve opens at end of ignitor warm up period, delivering gas to burners and establishing flame. One second after the gas valve opens, the ignitor is de-energized.

6. The radiant sensor monitors the flame. As long as flame is present and the call for heat continues, the gas valve will remain open. Either a hot ignitor or a flame can produce a heat signal. Gas valve will remain open only if flame is sensed.

7. Circulator blower is energized on heat speed 45 seconds after the gas valve opens.



10. Gas valve closes, extinguishing flame and the induced draft blower is de-energized.

11. Circulator blower is de-energized 90 seconds after the gas valve closes.


Cooling Mode





4. Circulator blower is energized on cool speed following a fixed five second on delay.




8. Circulator blower is de-energized following a fixed forty five second cool off delay period.


Fan Only Mode




3. Circulator blower is energized on cool speed.



6. Circulator blower is de-energized.


84 Rev. 1


HEATING TIMING CHART FOR WHITE-RODGERS 50A52

RADIANT SENSE IGNITION CONTROL

Air Circulator Blower

ON

OFF

Gas Valve

Ignitor

OPEN

CLOSED

ON

OFF

Pressure Switch

Induced Draft Blower

Thermostat

(Call for Heat)

OPEN

CLOSED

ON

OFF

ON

OFF

0 T T+1 T+45 0

T = 17 Seconds (Minimum) - 90 Seconds (Maximum)

Normal Operation, T = 17 Seconds or Slightly Longer

90

Indoor Fan

COOLING TIMING CHART FOR WHITE-RODGERS 50A52

RADIANT SENSE IGNITION CONTROL

ON

OFF

Outdoor Fan and

Compressor

ON

OFF

Thermostat

Seconds

ON

OFF

0 5 0 45

85 Rev. 1



(80% Models with White-Rodgers 50A52 Radiant Sense

Ignition Control)

1. Internal Control Failure. The system will lockout

2. Pressure Switch Stuck Closed. If the control senses that the pressure switch is closed while the induced draft blower is off, it waits until the switch opens—until then, no heating components are energized. The probable cause is either bad pressure switch or miswiring.

3. Pressure Switch Stuck Open. If the induced draft blower is energized and the pressure switch does not close, the control will keep the induced draft blower running until the switch closes—until then, no other heating components will be energized. The probable cause is either disconnected hose to pressure switch, restricted vent system, bad pressure switch or miswiring.

4. Ignitor failure. If the ignitor will not produce a heat signal within 90 seconds, the control will hold the gas valve closed and the system will lockout. The probable cause is either cracked ignitor, miswiring, or faulty radiant sensor.

5. Flame lost within 90 seconds. If the heat signal is lost

(while the call for heat continues) from 0 to 90 seconds after the gas valve opens, the system will retry once.

The probable cause is either the gas valve manually closed, air in gas line, incorrect gas pressures, incorrect burner alignment, incorrect burner gap, faulty gas valve, or faulty radiant sensor.

During a retry, the gas valve closes, and the induced draft blower runs for 60 seconds. After the 60 seconds are up, a new ignition sequence begins. The system will only retry once. If the retry does not produce a flame that lasts for at least 90 seconds, the furnace will lockout.

6. Flame lost later than 90 seconds. If the heat signal is lost (while the call for heat continues) more than 90 seconds after the gas valve opens, the system will recycle.

During a recycle, the gas valve closes, and a new ignition sequence begins. No matter how many recycles may occur, this alone will not cause the furnace to lockout.

7. Trip on High Limit or Auxiliary Limit. If the high limit or auxiliary limit control opens during a heating cycle, the gas valve closes. The induced draft blower runs, and the air circulator blower runs at "Heating" speed. This continues until the limit closes (Note: Auxiliary limit is manual reset, so it will never close on its own.). When the limit closes, the induced draft blower shuts off immediately, but the air circulator blower continues to run for 90 seconds. After this 90 second cooldown is completed, a normal heating sequence can begin. The probable cause is either low airflow due to dirty filter, dirty coil, or restricted ductwork or blower speed set too low, gas input set too high, faulty limit or faulty blower.

8. Interruption of Power Supply. If the line voltage power is interrupted, the gas valve closes. It will remain closed until line voltage power is restored and a low voltage call for heat occurs at the room thermostat. At that time, a new ignition sequence will begin.

9. Open Rollout Thermostat. If the rollout thermostat opens during a heating cycle, the gas valve closes. The induced draft blower runs, and the air circulator blower runs at "Heating" speed (same symptoms as trip on high limit). This will continue until the rollout thermostat is manually reset. The probable cause is either incorrect gas pressures, improper burner alignment, faulty orifice(s), or restricted crossover gap(s).

OTHER ITEMS

A. Lockout (see previous Numbers 1, 4, 5). The gas valve, ignitor, and induced draft blower are de-energized immediately (Exception: If a trip on high/auxiliary/rollout limit is combined with a lockout, the induced blower will remain energized until the limit closes.). The air circulator blower runs for 90 seconds, and then shuts off.

To manually end a lockout, interrupt the call for heat for at least 1 second, but not more than 20 seconds.

To automatically end a lockout, wait three hours. The control will automatically reset itself and try again.

B. Constant Fan. During normal operation, the air circulation blower will continually run at "Cooling" speed as long as power is present at terminal G. If a call for heat occurs, the blower will continue to run at cooling speed throughout the heating cycle.

If a trip on high/auxiliary/rollout limit occurs, the air circulation blower will run at "Heating" speed. Even if power is present at the G terminal the blower will run at heating speed until the limit closes.

C. Cooling Operation. With the thermostat in the COOL;

FAN-AUTO position, the air circulator blower will start and stop at the same time as the compressor. No fan time delay will occur.

D. Fan On/Off Timings are as described above. They are not adjustable.

IMPORTANT: If the furnace frequently has to be reset, it means that a problem exists that should be corrected.

86 Rev. 1



(80% Two-Stage Models with White-Rodgers 50A51-215

Integrated Ignition Control)

Power Up







Heating Mode


1. R and W1 (or R and W1 and W2) thermostat contacts close, initiating a call for heat.

2. The induced draft blower is energized on high speed for a 10 second prepurge. Humidifier terminals are energized with induced draft blower.

3. The induced draft blower steps to low speed following prepurge. Low stage pressure switch contacts are closed.

4. The ignitor is energized and is allowed to preheat for 17 seconds.

5. The gas valve is energized delivering gas to the burners at the low stage heat flow rate.

6. The control checks for a signal from the flame sensor within seven seconds after the gas valve is energized

(opens). Gas will only continue to flow if a signal is present.

7. The control checks the thermostat to see whether the call for heat is for low stage heat or high stage heat. If the call is for high stage heat, the induced draft blower is switched to high speed and the gas valve is energized on high flow rate.

8. The control waits 30 seconds and turns on the air circulator blower to the appropriate speed (high heat speed for high heat or low heat speed for low heat). Electronic air cleaner terminals are energized with the circulator blower.

On some Amana models, the high heat air circulator speed may be the same as the low heat circulator speed.

These models are factory shipped to be within the rise range on both stages with the same air circulator speed.

9. The furnace is now operating on the specified stage called out by the two stage thermostat.

10. If the two stage thermostat changes the call from low heat to high heat, the control will immediately switch the vent blower motor, gas valve, and air circulating speed to their high stage setting.

11. If the two stage thermostat changes the call from high heat to low heat, the control will immediately switch the induced draft blower motor to low speed and switch the flow rate on the gas valve to low. The air circulator blower will remain on high heating speed for thirty seconds before switching to the low heat circulating speed. The 30 second delay feature on the circulator speed eliminates the possibility of tripping the high (primary) limit when the high stage flue products are traveling through the heat exchanger upon a call for low stage heat.

12. R and W1 (or R and W1 and W2) thermostat contacts open, completing the call for heat.

13. The control turns the gas valve off, extingushing flame.

14. After a five second delay while flue products are purged from the heat exchanger, the induced draft blower motor is turned off (the induced draft blower is on low speed during the five second post purge.) Humidifier terminals are de-energized.

15. The air circulator blower has an adjustable delay-off timing of 60, 90, 120, or 180 seconds (starting from the time the gas valve closes). The speed(s) run during this period depend on the last heat call seen by the thermostat.

If the last call for heat was a call for low heat, the air circulator blower will run on the low heat speed for the duration of the adjusted delay-off timing (60, 90, 120, or

180 seconds).

If the last call for heat was a call for high heat, the air circulating blower run on the high heating speed for thirty seconds and then switch to the low heating speed for the balance of the adjusted delay-off timing (30, 60,

90, or 150 seconds).

16. Electronic air cleaner terminals are de-energized.


87 Rev. 1


Cooling Mode





4. Circulator blower is energized following a fixed five second on delay. Electronic air cleaner terminals are energized with circulator blower.

5. Furnace circulator blower and outdoor cooling unit run and integrated control module monitors safety circuits continuously.


7. Outdoor fan and compressor are de-energized. Electronic air cleaner terminals are de-energized.



Fan Only Mode


1 R and G thermostat contacts close, initiating a call for fan.


3. Circulator blower is energized on low heat speed. Electronic air cleaner terminals are energized.





88 Rev. 1


HEATING TIMING CHARTS FOR WHITE-RODGERS 50A51-215

TWO-STAGE INTEGRATED IGNITION CONTROL OPERATION

GUIS/GCIS Example 1: Continuous Call For Low Stage Heat Only

Air

Circulator

Blower

High

Low

Off

Gas Valve On

Off

Ignitor

Pressure

Switches

Induced Draft

Blower

Thermostat

On

Off

PS2 Closed

PS1 Closed

Open

High

Low

Off

High

Low

Off

0 10 27 31 34 64 0 5 30 60, 90

120, or 180

Air

Circulator

Blower

Gas Valve

Ignitor

Pressure

Switches

Induced Draft

Blower

Thermostat

On

Off

PS2 Closed

PS1 Closed

Open

High

Low

Off

High

Low

Off

High

Low

Off

High

Low

Off

GUIS/GCIS Example 2: Continuous Call For High Stage Heat Only

0 10 27 31 34 64 0 5 30 60, 90

120, or 180

89 Rev. 1




Air

Circulator

Blower

GUIS/GCIS Example 3: Initial Call For Low Heat, Change In Call To High Heat

Call Change to High Heat

High

Low

Off

Gas Valve On

Off

Ignitor

Pressure

Switches

Induced Draft

Blower

On

Off

PS2 Closed

PS1 Closed

Open

High

Low

Off

Thermostat

High

Low

Off

0 10 27 31 34 64 0 5 30

Air

Circulator

Blower

Gas Valve

60, 90

120, or 190

GUIS/GCIS Example 4: Initial Call For High Heat, Subsequent Call To Low Heat

Call Change to Low Heat

30 Seconds After Call Change to Low Heat

High

Low

Off

High

Low

Off

Ignitor

Pressure

Switches

Induced Draft

Blower

Thermostat

On

Off

PS2 Closed

PS1 Closed

Open

High

Low

Off

High

Low

Off

0 10 27 31 34 64 0 5 30 60, 90

120, or 190

90 Rev. 1


COOLING TIMING CHART FOR WHITE-RODGERS 50A51-215


Indoor Fan ON

OFF

Outdoor Fan and

Compressor

ON

OFF

Thermostat

ON

OFF

Seconds 0 5 0 45

91 Rev. 1



(80% Two Stage Models with White-Rodgers 50A51-215

Integrated Ignition Control)


Next, refer to the Diagnostic Signal Chart below for an interpretation of the LED signals and to the information in this section for a description of the problem.

1. Internal Lockout. If, during a self test cycle, the control determines an internal fault, the control stops and the diagnostic light will light continuously. The control should be replaced.

2. External Lockout. If flame was not sensed during the first 7 seconds after the gas valve was energized, the control turns off the gas. There will be a 120 second delay with the induced draft blower motor energized to purge the heat exchanger. The ignitor will then be energized for 27 seconds. The gas valve will be energized on low stage flow rate. If flame is not sensed in 7 seconds the gas valve will be de-energized and another purge will occur. The control will cycle the gas valve a total of three tries before it determines it cannot establish measurable combustion and enters a locked out state. If flame is sensed but lost after 10 seconds, the control will recycle this series of three tries four more times before locking out. The diagnostic light code for this problem is one short flash followed by a longer pause. The control can be reset and brought out of lockout mode by turning the thermostat off and then back on. It can also be reset by turning off the electrical disconnect switch to the furnace for 30 seconds.

NOTE: The control board will automatically reset two hours after the lockout occurs. If the furnace frequently has to be reset, it means that a problem exists that should be corrected.

3. Pressure Switch Stuck Closed. If the control senses that either pressure switch is closed when the induced draft blower is off, it waits until the fault is corrected. The diagnostic light code for this problem is two short flashes followed by a longer pause. The probable cause is either a faulty pressure switch or miswiring.

4. Pressure Switch Stuck Open. If, after the induced draft blower is energized, the appropriate pressure switch checked does not close, the control will keep the blower on and wait for the switch to close. The diagnostic light code for this problem is three short flashes followed by a longer pause. The probable cause is either a restricted air intake, restricted flue piping, disconnected hose to pressure switches, miswiring, or faulty pressure switch.

5. Open Thermal Protection Device. If the primary (high) limit, auxiliary limit, or rollout limit control opens, the gas valve is de-energized. Both the induced draft blower motor and air circulator blower are energized on low heat speed. The diagnostic light code for this problem is four short flashes followed by a longer pause.

If the primary or auxiliary limit is open, the probable cause is either: low conditioned air flow due to dirty filter or high resistance in duct work, faulty limit, faulty blower, or blower speed set too low. The primary limit will automatically reset, while the auxiliary limit control must be manually reset.

If the rollout limit control is open, the probable cause is insufficient combustion air, restricted flue passage, or restricted heat exchanger. The rollout limit control must be manually reset.

6. Flame Sensed with No Call for Heat. If the control senses a flame when the gas valve is de-energized it will run the induced draft blower and air circulator blower continuously on the low heat speed for each. The diagnostic light code for this problem is continuous flashing. The probable causes are either a short to ground in flame sense circuit, miswiring, lingering burner flame or a slow closing gas valve.

92 Rev. 1

LIGHT SIGNAL

Continuous Light

1 Flash

2 Flashes

3 Flashes

4 Flashes

50A51 INTEGRATED IGNITION CONTROL

DIAGNOSTIC SIGNAL CHART

Continuous Flashing

FOR CORRECTIVE ACTION REFER TO

ABNORMAL OPERATION NUMBER

1. Internal Control Failure

2. System Lockout

3. Pressure Switch Stuck Closed

4. Pressure Switch Stuck Open

5. Thermal Protection Device Open

6. Flame Sensed No Call For Heat

Stat Recovery (1/4 Second on, 1/4 Second Off)



(80% Two-Stage Variable Speed Models with White-

Rodgers 50A51-225 Integrated Ignition Control)


Rodgers 50A51-235 Integrated Ignition Control)

Power Up







Heating Mode



2. The induced draft blower is energized on high speed for a 10 second prepurge. Humidifier terminals are energized with induced draft blower.

3. The induce draft blower steps down to low speed following prepurge.

4. The ignitor is energized and is allowed to preheat for 17 seconds.

5. The gas valve is energized delivering gas to the burners at the low stage heat flow rate.

6. The control checks for a signal from the flame sensor within seven seconds after the gas valve is energized

(opens). Gas will only continue to flow if a signal is present.

7. The control checks the thermostat to see whether the call for heat is for low stage heat or high stage heat. If the call is for high stage heat, the induced blower is switched to high speed and the gas valve is energized on high flow rate.

8. The control waits 30 seconds and turns on the air circulator blower to the appropriate speed (high heat speed for high heat or low heat speed for low heat). The circulator blower will take 30 seconds to ramp up to full speed.

Electronic air cleaner terminals are energized with the circulator blower.

9. The furnace is now operating on the specified stage called out by the two-stage thermostat.

10. If the two-stage thermostat changes the call from low heat to high heat, the control will immediately switch the induced draft blower motor, gas valve, and air circulating speed to their high stage setting.

11. If the two-stage thermostat changes the call from high heat to low heat, the control will immediately switch the induced draft blower motor to low speed and switch the flow rate on the gas valve to low. The air circulator blower will remain on high heating speed for thirty seconds before switching to the low heat circulating speed. The 30 second delay feature on the circulator speed eliminates the possibility of tripping the high (primary) limit when the high stage flue products are traveling through the heat exchanger upon a call for low stage heat.


13. The control turns the gas valve off, extingushing flame.

14. After a five second delay while flue products are purged from the heat exchanger, the induced draft blower motor is turned off (the induced blower is on low speed during the five second post purge). Humidifier terminals are de-energized.

15. The air circulator blower fan has an adjustable delayoff timing of 60, 90, 120, or 180 seconds (starting from the time the gas valve closes). The speeds run during this period depend on the last heat call seen by the thermostat.

If the last call for heat was a call for low heat, the air circulator blower will run on the low heat speed for the duration of the adjusted delay-off timing (60, 90, 120, or

180 seconds).

If the last call for heat was a call for high heat, the air circulator blower run on the high heating speed for thirty seconds and then switch to the low heating speed for the balance of the adjusted delay-off timing (30, 60,

90, or 150 seconds).

Example: A GUIV090DX50 has the heating blower off delay set to 120 seconds by the installer. When the thermostat is satisfied after a call for high heat, the air circulator blower will run on high speed for 30 seconds and then switch to low circulator speed for 120 - 30 =

90 seconds.

The adjustable delay-off timing allows for more heat transferred to the conditioned space from the furnace. After the delay time has elapsed, the air circulator blower is de-energized. The adjustable delay-off timing feature allows the installer to customize the comfort level based on the predominant staging requirements of the living space.

16. The air circulator blower will ramp down for another 30 seconds and shut down.

17. Electronic air cleaner terminals are de-energized.


93 Rev. 1


Cooling Mode





4. Circulator blower is energized following a fixed five second on delay. The circulator blower will take 30 seconds to ramp up to full speed. Electronic air cleaner terminals are energized with circulator blower.




8. Circulator blower is de-energized following a fixed forty five second cool off delay period. The air circulator blower will ramp down for another 30 seconds and shut down.


Fan Only Mode







5. Circulator blower is de-energized. Electronic air cleaner terminals are de-energized. The air circulator blower will ramp down for another 30 seconds and shut down.


94 Rev. 1




Example 1: Continuous Call For Low Stage Heat Only

Air

Circulator

Blower

High

Low

Off

Gas Valve

Ignitor

Pressure

Switches

Induced

Draft

Blower

Thermostat

PS2 Closed

PS1 Closed

Open

High

Low

Off

High

Low

Off

On

Off

On

Off

0 10 27 31 34 64 94 0 5 30 60, 90 90, 120,

120, or 150, or

180 210

Example 2: Continuous Call For High Stage Heat Only

Air

Circulator

Blower

Gas Valve

Ignitor

Pressure

Switches

Induced

Draft

Blower

Thermostat

On

Off

PS2 Closed

PS1 Closed

Open

High

Low

Off

High

Low

Off

High

Low

Off

High

Low

Off

0 10 27 31 34 64 94 0 5 30 60, 90 90, 120,

120, or 150, or

180 210

95 Rev. 1




Air

Circulator

Blower

Gas Valve On

Off

Ignitor

Pressure

Switches

Induced

Draft

Blower

Thermostat

On

Off

PS2 Closed

PS1 Closed

Open

High

Low

Off

High

Low

Off

High

Low

Off

Example 3: Initial Call For Low Heat, Change In Call To High Heat


0 10 27 31 34 64 94 0 5 30 60, 90 90, 120,

120, or 150, or

180 210

Air

Circulator

Blower

Gas Valve

Ignitor

Pressure

Switches

Induced

Draft

Blower

Thermostat

On

Off

PS2 Closed

PS1 Closed

Open

High

Low

Off

High

Low

Off

High

Low

Off

High

Low

Off

Example 4: Initial Call For High Heat, Subsequent Call To Low Heat



0 10 27 31 34 64 94 0 5 30 60, 90 90, 120,

120, or 150, or

180 210

96 Rev. 1





Air

Circulator

Blower

Gas Valve

Igniter

On

Off

Pressure

Switches

Induced Draft

Blower

PS2 Closed

PS1 Closed

Open

High

Low

Off

Thermostat

High

Low

Off

High

Low

Off

On

Off

0 10 27 28 31 61 91

Time (sec)

0 15 30 60, 90 90, 120,

120, or 150, or

180 210


Air

Circulator

Blower

Gas Valve

Igniter

On

Off

Pressure

Switches

Induced Draft

Blower

PS2 Closed

PS1 Closed

Open

High

Low

Off

Thermostat

High

Low

Off

High

Low

Off

High

Low

Off

0 10 27 28 31 61 91

Time (sec)

0 15 30 60, 90 90, 120,

120, or 150, or

180 210

97 Rev. 1




Air

Circulator

Blower

Gas Valve

Igniter

Thermostat

On

Off

Pressure

Switches

Induced Draft

Blower

PS2 Closed

PS1 Closed

Open

High

Low

Off

High

Low

Off

High

Low

Off

On

Off

Example 3: Initial Call For Low Heat, Change In Call To High Heat


0 10 27 28 31 61 91

Time (sec)

0 15 30 60, 90 90, 120,

120, or 150, or

180 210

Air

Circulator

Blower

Gas Valve

Igniter

Pressure

Switches

Induced Draft

Blower

On

Off

PS2 Closed

PS1 Closed

Open

High

Low

Off

Thermostat

High

Low

Off

High

Low

Off

High

Low

Off




0 10 27 28 31 61 91

Time (sec)

0 15 30 60, 90 90, 120,

120, or 150, or

180 210

98 Rev. 1


COOLING TIMING CHART FOR WHITE-RODGERS

50A51-225 & 50A51-235 TWO-STAGE VARIABLE SPEED


(With "Y" from the Thermostat Connected to "Y" on Integrated Ignition Control)

Indoor Fan

On

Off

Outdoor Fan

And

Compressor

On

Off

Thermostat

On

Off

0 5 35

Time (sec)

0 45 75

(With "Y" from the Thermostat Connected to "Y/Y2" on Circulator Blower Interface Board)

Indoor Fan

On

Off

Outdoor Fan

And

Compressor

On

Off

Thermostat

On

Off

0 30

Time (sec)

0 30

99 Rev. 1


Abnormal Operation


Rodgers 50A51-225 Ignition Control)


Rodgers 50A51-235 Ignition Control)


Next, refer to the Troubleshooting Chart on the following page for an interpretation of the LED signals and to the information in this section for a description of the problem.




2. External Lockout. An external lockout occurs when the integrated ignition control determines that a measurable combustion cannot be established or maintained after three consecutive tries (four, if flame is established then lost) to turn on the furnace.

If a flame is not sensed during the first seven seconds after a gas valve has been energized, the ignition control will internally turn off the gas. After 120 seconds for

50A51-225 and after 60 seconds for 50A51-235, during which time the induced draft blower purges the heat exchanger, the ignitor will reenergize and preheat for

27 seconds. The gas valve is then reenergized. If a flame is not sensed again in seven seconds, the gas valve will de-energize and another purge is performed. The ignition control will cycle the gas valve three times before it determines it cannot establish measurable combustion and enter a lockout state. If a flame is sensed but lost after 10 seconds, the control will cycle four more times before locking out. A lockout stops ignition attempts and causes the air blower to run continuously.

The diagnostic light code for either problem is one short

flash followed by a longer pause. The control can be reset and brought out of lockout mode by turning the thermostat off and then back on. It can also reset by turning off the electrical disconnect switch to the furnace for 30 seconds. The 50A51-225 control will reset after two hours and the 50A51-235 will reset after one hour.

IMPORTANT: If you have to frequently reset your furnace, it means that a problem exists that should be corrected.

Contact a qualified servicer for further information.

3. Pressure Switch Stuck Closed. A sticking pressure switch can be caused by either a faulty pressure switch, faulty wiring, a disconnected hose, or a restricted intake or flue piping. In the case of a pressure switch sticking closed, the probable cause is a faulty pressure switch or wiring.

If the ignition control senses that the pressure switch is closed and the induced draft blower is off, it will shut down the unit until the fault is corrected. The light code for this problem is two short flashes followed by a longer pause.

4. Pressure Switch Stuck Open. A sticking open pressure switch can be caused by a faulty pressure switch, a blocked, pinched or disconnected hose to the pressure switch, a restricted air intake or flue piping, or faulty wiring.

If the ignition control senses that the induced draft blower is energized, but the pressure switch is not closed, the control will keep the blower on and wait for the switch to close. The diagnostic light code for this problem is three

short flashes followed by a pause.

5. Open Thermal Protection Device. If the primary (high) limit, auxiliary limit, or rollout limit control opens, the gas valve is de-energized. Both the induced draft blower motor and air circulator blower are energized on low heat speed. The diagnostic light code for this problem is four short flashes followed by a longer pause.

If the primary or auxiliary limit is open, the probable cause is either: low conditioned air flow due to dirty filter or high resistance in duct work, faulty limit, faulty blower, or blower speed set too low. The primary limit will automatically reset, while the auxiliary limit control must be manually reset.

If the rollout limit control is open, the probable cause is insufficient combustion air, restricted flue passage, or restricted heat exchanger. The rollout limit control must be manually reset.

6. Flame Sensed with No Call for Heat. If the control senses a flame when the gas valve is de-energized it will run the induced draft blower and air circulator blower continuously on the low heat speed for each. The diagnostic light code for this problem is continuous

flashing.The probable causes are either a short to ground in flame sense circuit, miswiring, lingering burner flame or a slow closing gas valve.

100 Rev. 1

Symptoms of

Abnormal

Operation


and


RED diagnostic LED provides no signal.


and


RED diagnostic LED is lit continuously.

Associated

Red LED Code

(See Note 2)

None

ON

Continuous On

Troubleshooting Chart for 50A51-225 & 50A51-235 Integrated Ignition Controls


- No 115 V power to furnace, or no 24 V power to integrated control module.




Possible Causes

- Manual disconnect switch OFF, door switch open, or 24 V wires miswired or loose.






RED diagnostic LED is flashing one flash.

1

- Furnace lockout due to an excessive number of ignition "retries" (3 total attempts), or "recycles" (5 total recycles). See note 1 & 2.

- Failure to establish flame. Cause may be no gas to burners, front cover pressure switch stuck open, bad ignitor or ignitor alignment, improper orifices, or coated/ oxidized or misconnected flame sensor.

- Loss of flame after establishment. Cause may be interrupted gas supply, lazy burner flames (improper gas pressure or restriction in flue and/or combustion air piping, front cover pressure switch opening, or improper induced draft blower performance.

1 Flash


and


RED diagnostic LED is flashing two flashes.

- Induced draft blower runs continuously with no further furnace operation.

and


RED diagnostic LED is flashing three flashes.


and


RED diagnostic LED is flashing four flashes.

2

2 Flashes

3

3 Flashes

4

4 Flashes

- Pressure switch circuit is closed even though induced draft blower is not operating.

- Pressure switch circuit does not close in response to induced draft blower operation.









- Loose or incorrect wiring.




- Rollout limit(s) is(are) open due to flame rollout.

Cause may be misaligned burners, blocked flue and/or air inlet pipe, or failed induced draft blower.



and


RED diagnostic LED is flashing continuously.

C

Continuous

Flashing





NOTES:

1) 50A51-235 Integrated control module will automatically attempt to reset from lock out after one hour.

2) 50A51-225 Integrated control module will automatically attempt to reset from lock out after two hours.


Corrective Action


- Check integrated control module fuse (3 A). Replace if necessary.

- Check for possible shorts in 115 V and 24 V circuits.

Repair as necessary.




- Replace or realign igniter.



- Verify proper induced draft blower performance.







- Check filters and ductwork for blockage.

Clean filters or remove obstruction.

- Check for proper circulator blower speed and performance.

Correct speed or replace blower if necessary.




- Check induced draft blower for proper performance.

Replace if necessary.





Cautions and

Notes


- Replace integrated control module fuse with

3 A automotive style fuse.


- Read precautions in "Electrostatic

Discharge" section of manual.


- Ignitor is fragile, handle with care.
















(90% Two-Stage Models with White- Rodgers 50M61-

288 Integrated Ignition Control)

Power Up







Heating Mode




3. Induced draft blower is energized on high speed for a 10second prepurge. Humidifier terminals are energized with induced draft blower.

4. Induced draft blower steps to low speed following prepurge. Low stage pressure switch contacts are closed.

5. Ignitor warm up (20 seconds) begins upon step to low speed and presence of closed low stage pressure switch contacts.

6. After 20-second ignitor warm up period, low stage gas valve is energized (4-second ignition trial) delivering gas to burners and establishing flame. Ignitor remains on for

3 seconds after gas valve is opened (ignition activation period).

7. Integrated control module monitors flame presence and control begins timing 30-second heat on delay. Gas valve will remain open only if flame is sensed.

8. If the thermostat call is for low heat, gas valve and induced draft blower will continue on low stage. If the call is for high heat, the gas valve and induced draft blower will change to high stage .

9. Circulator blower is energized on the appropriate heat speed following a fixed thirty second blower on delay.

Electronic air cleaner terminals are energized with circulator blower.

10. Furnace is now operating on the specified stage called for by the two-stage thermostat.


12. If the two-stage thermostat changes the call from low heat to high heat, the integrated control module will immediately switch the induced draft blower, gas valve, and circulator blower to their high stage settings.

13. If the two-stage thermostat changes the call from high heat to low heat, the control will immediately switch the induced draft blower and gas valve to their low stage settings. The circulator blower will remain on high heating speed for thirty seconds before switching to the low heat circulating speed.




17. Circulator blower continues running for the selected heat off delay period (60, 90, 120, or 180 seconds). The speed run during this period depends on the last heat call provided by the thermostat.

If the last call for heat was a call for low heat, the air circulator blower will run on the low heat speed for the duration of the heat off delay period (60, 90, 120, or 180 seconds).

If the last call for heat was a call for high heat, the air circulator blower will run on the high heating speed for thirty seconds and then switch to the low heating speed for the balance of the heat off delay period (30, 60, 90, or 150 seconds).

18. Circulator blower and electronic air cleaner terminals are de-energized


102 Rev. 1


Cooling Mode





4. Circulator blower is energized following a fixed five second on delay. Electronic air cleaner terminals are energized with circulator blower.






Fan Only Mode









103 Rev. 1


HEATING TIMING CHARTS FOR WHITE-RODGERS 50M61-288



Air

Circulator

Blower

Gas Valve

High

Low

Off

High

Low

Off

Igniter

Pressure

Switches

Induced Draft

Blower

Thermostat

(Call for Heat)

On

Off

PS2 Closed

PS1 Closed

Open

High

Low

Off

High

Low

Off

0 10 30 33 34

4-second maximum trial for ignition period

64

Time (sec)

0 15 30 60, 90

120, or

180


Air

Circulator

Blower

Gas Valve

Igniter On

Off

Pressure

Switches

Induced Draft

Blower

PS2 Closed

PS1 Closed

Open

High

Low

Off

Thermostat

(Call for Heat)

High

Low

Off

High

Low

Off

High

Low

Off

0 10 30 33 34


64

Time (sec)

0 15 30 60, 90

120, or

180

104 Rev. 1




Example 3: Initial Call For Low Heat, Change To High Heat


Air

Circulator

Blower

Gas Valve

High

Low

Off

High

Low

Off

Igniter

Pressure

Switches

Induced Draft

Blower

Thermostat

(Call for Heat)

On

Off

PS2 Closed

PS1 Closed

Open

High

Low

Off

High

Low

Off

0 10 30 33 34 64


Time (sec)

0 15 30




60, 90

120, or

180

Air

Circulator

Blower

Gas Valve

High

Low

Off

High

Low

Off

Igniter

Pressure

Switches

Induced Draft

Blower

Thermostat

(Call for Heat)

On

Off

PS2 Closed

PS1 Closed

Open

High

Low

Off

High

Low

Off

0 10 30 33 34 64


Time (sec)

0 15 60, 90

120, or

180

105 Rev. 1


COOLING TIMING CHART FOR WHITE-RODGERS 50M61-288


Circulator

Blower

On

Off

Outdoor Fan

And

Compressor

On

Off

Thermostat

(Call For Cool)

On

Off

Time (sec)

0 5 0 45

TIMING CHART FOR NORMAL FAN OPERATION

Circulator

Blower

Thermostat

(Call For Fan)

On

Off

On

Off

0

Time (sec)

0

106 Rev. 1



(90% Two-Stage Models with White- Rodgers 50M61-

288 Ignition Control)






2. System Lockout. If a flame is not sensed during the first seven (7) seconds after the gas valve is energized, the control turns off the gas. There will then be a 60 second delay while the induced draft blower is energized to purge the heat exchanger. The ignitor will next be energized and preheated for 20 seconds. The gas valve will then be energized. If flame is not sensed in seven (7) seconds the gas valve will be de-energized and another purge will occur. The control will cycle the gas valve a total of three (3) times before it determines it cannot establish measurable combustion and enters a locked out state. If flame is sensed but lost after ten (10) seconds, the control will recycle this series of three tries five (5) more times before locking out. The diagnostic light code for this problem is one short flash followed by a longer pause. The control can be reset and brought out of lockout mode by turning the thermostat off and then back on. It can also be reset by turning off the electrical disconnect switch to the furnace for 30 seconds.




4. Pressure Switch Stuck Open. If, after the induced draft blower is energized, the pressure switch does not close, the control will keep the induced draft blower on and wait for the switch to close. The diagnostic light code for this problem is three short flashes followed by a pause. The probable causes are either a blocked, pinched or disconnected hose to the pressure switch, faulty pressure switch or loosse or misconnected wiring, restricted air intake or flue piping, blocked drain system or weak induced draft blower.

5. Open Primary, Auxiliary or Rollout Limit. If the limit control opens, the air circulator blower will be turned on until the limit closes. The diagnostic light code for this problem is four short flashes followed by a pause. The probable cause for either an open primary or auxiliary limit is low conditioned air flow due to dirty filter or resistance in duct work, faulty limit, faulty blower, blower speed set to low or loose or misconnected wiring. The rollout limit(s) is(are) open due to flame rollout. The probable cause for an open rollout limit is misaligned burners, blocked flue and/or air inlet pipe, failed induced draft blower or loose or misconnected wiring.


7. Low Flame Sense Signal. If the furnace continues to operate and the micro-amp signal from the flame sensor falls below specified level. The diagnostic light code for this problem is seven flashes followed by a pause. The probable cause is either a coated/oxidized sensor, incorrectly positioned senser in burner flame or lazy burner flame due to improper gas pressure or combustion air.

8. Ignitor Circuit Problem. If the furnace fails to operate due to a problem with the ignitor. The diagnostic code for this problem is eight flashes followed by a pause.

The probable cause is either loose or misconnected wiring or a bad ignitor.

9. Furnace Operating on Low Stage Gas with High

Stage Induced Draft Blower and High Stage Circu-

lator Blower. If the furnaces high stage pressure switch circuit fails to close in rspone to hihg stage induced draft blower operation. The diagnostic light code for this problem is nine flashes followed by a pause. The probable causes are either a blocked, pinched or disconnected hose to the pressure switch, faulty pressure switch or loose of misconnected wiring, restricted air intake or flue piping, blocked drain system or weak induced draft blower.

10. Flame Sensed with No Call for Heat. If the control senses a flame when the gas valve is de-energized, it will run the air circulator blower and the induced draft blower continuously with no further furnace operation.



107 Rev. 1




Rodgers 50V61-288 Integrated Ignition Control)

Power Up







Heating Mode




3. Induced draft blower is energized on high speed for a 10second prepurge. Humidifier terminals are energized with induced draft blower.

4. Induced draft blower steps to low speed following prepurge. Low stage pressure switch contacts are closed.

5. Ignitor warm up (20 seconds) begins upon step to low speed and presence of closed low stage pressure switch contacts.

6. After 20-second ignitor warm up period, low stage gas valve is energized (4-second ignition trial) delivering gas to burners and establishing flame. Ignitor remains on for

3 seconds after gas valve is opened (ignition activation period).

7. Integrated control module monitors flame presence and control begins timing 30-second heat on delay. Gas valve will remain open only if flame is sensed.

8. If the thermostat call is for low heat, gas valve and induced draft blower will continue on low stage. If the call is for high heat, the gas valve and induced draft blower will change to high stage .

9. Circulator blower is energized on the appropriate heat speed following a fixed thirty second blower on delay.

The circulator blower requires 30 seconds to ramp up to full speed. Electronic air cleaner terminals are energized with circulator blower.

10. Furnace is now operating on the specified stage called for by the two-stage thermostat.


12. If the two-stage thermostat changes the call from low heat to high heat, the integrated control module will immediately switch the induced draft blower, gas valve, and circulator blower to their high stage settings.

13. If the two-stage thermostat changes the call from high heat to low heat, the control will immediately switch the induced draft blower and gas valve to their low stage settings. The circulator blower will remain on high heating speed for thirty seconds before switching to the low heat circulating speed.




17. Circulator blower continues running for the selected heat off delay period (60, 90, 120, or 180 seconds). The speed run during this period depends on the last heat call provided by the thermostat.

If the last call for heat was a call for low heat, the air circulator blower will run on low heat speed for the duration of the heat off delay period (60, 90, 120, or 180 seconds).

If the last call for heat was a call for high heat, the air circulating blower will run on the high heating speed for thirty seconds and then switch to the low heating speed for the balance of the heat off delay period (30, 60, 90, or 150 seconds).

18. Circulator blower and electronic air cleaner terminals are de-energized

19. Circulator blower ramps down to OFF during the 30 seconds following the heat off delay period.


108 Rev. 1


Cooling Mode


1. R and YLO or Y thermostat contacts close, initiating a call for cool.


3. Outdoor fan and compressor are energized to their appropriate speed.

4. Circulator blower is energized on the appropriate cool speed following a fixed five second on delay. The circulator blower requires 30 seconds to ramp up to full speed.

Electronic air cleaner terminals are energized with circulator blower.

5. Furnace circulator blower and outdoor cooling unit run their appropriate speed, integrated control module monitors safety circuits continuously.

6. R and YLO or Y thermostat contacts open, completing the call for cool.


8. Circulator blower continues running for a fixed 45-second cool off delay period. The speed run during this period depends on the last cooling call from the thermostat. If the call was for low cool, the blower will operate at 88% of low cool speed. If call was for high cool, blower operate at 88% of high cool speed.

9. Electronic air cleaner terminals and circulator blower are de-energized.


Fan Only Mode




3. Circulator blower is energized on continuous fan speed

(56% of high stage cooling) following a five (5) second delay. Electronic air cleaner terminals are energized.





109 Rev. 1


HEATING TIMING CHARTS FOR WHITE-RODGERS 50V61-288



Air

Circulator

Blower

Gas Valve

High

Low

Off

On

Off

Igniter

Pressure

Switches

Induced Draft

Blower

Thermostat

(Call for Heat)

On

Off

PS2 Closed

PS1 Closed

Open

High

Low

Off

High

Low

Off

0 10 30 33 34


64 94

Time (sec)

0 15 30 60, 90 90, 120,

120, or 150, or

180 210


Air

Circulator

Blower

Gas Valve

Igniter

On

Off

Pressure

Switches

Induced Draft

Blower

PS2 Closed

PS1 Closed

Open

High

Low

Off

Thermostat

(Call for Heat)

High

Low

Off

High

Low

Off

High

Low

Off

0 10 30 33 34


64 94

Time (sec)

0 15 30 60, 90 90, 120,

120, or 150, or

180 210

110 Rev. 1




Example 3: Initial Call For Low Heat, Change To High Heat


Air

Circulator

Blower

Gas Valve

High

Low

Off

High

Low

Off

Igniter

Pressure

Switches

Induced Draft

Blower

Thermostat

(Call for Heat)

On

Off

PS2 Closed

PS1 Closed

Open

High

Low

Off

High

Low

Off

0 10 30 33 34 64


Time (sec)

0 15 30




60, 90

120, or

180

Air

Circulator

Blower

Gas Valve

High

Low

Off

High

Low

Off

Igniter

Pressure

Switches

Induced Draft

Blower

Thermostat

(Call for Heat)

On

Off

PS2 Closed

PS1 Closed

Open

High

Low

Off

High

Low

Off

0 10 30 33 34 64


Time (sec)

0 15 60, 90

120, or

180

111 Rev. 1


COOLING TIMING CHARTS FOR WHITE-RODGERS 50V61-288

TWO-STAGE VARIABLE SPEED INTEGRATED IGNITION CONTROL OPERATION

Air

Circulator

Blower

Example 1: Continuous Call for Low Stage Cooling Only

High

Low

Off (88% of Low)

Outdoor Fan

And

Compressor

High

Low

Off

Thermostat

(Call for Cool)

Air

Circulator

Blower

High

Low

Off

0 5 35

Time (sec)

0

Example 2: Continuous Call For High Stage Cooling Only

High

Low

Off

(88% of High)

45

Outdoor Fan

And

Compressor

High

Low

Off

Thermostat

(Call for Cool)

High

Low

Off

Time (sec)

0 5 35 0 45

CONTINUOUS FAN TIMING CHART FOR WHITE-RODGERS 50V61-288

TWO-STAGE VARIABLE SPEED INTEGRATED IGNITION CONTROL OPERATION

Air

Circulator

Blower

Thermostat

(Call For Fan)

112 Rev. 1

On

Off

On

Off

0 5

Time (sec)

0




Rodgers 50V61-228 Ignition Control)






2. System Lockout. If a flame is not sensed during the first seven (7) seconds after the gas valve is energized, the control turns off the gas. There will then be a 60 second delay while the induced draft blower is energized to purge the heat exchanger. The ignitor will next be energized and preheated for 20 seconds. The gas valve will then be energized. If flame is not sensed in seven (7) seconds the gas valve will be de-energized and another purge will occur. The control will cycle the gas valve a total of three (3) times before it determines it cannot establish measurable combustion and enters a locked out state. If flame is sensed but lost after ten (10) seconds, the control will recycle this series of three tries five (5) more times before locking out. The diagnostic light code for this problem is one short flash followed by a longer pause. The control can be reset and brought out of lockout mode by turning the thermostat off and then back on. It can also be reset by turning off the electrical disconnect switch to the furnace for 30 seconds.




4. Pressure Switch Stuck Open. If, after the induced draft blower is energized, the pressure switch does not close, the control will keep the induced draft blower on and wait for the switch to close. The diagnostic light code for this problem is three short flashes followed by a pause. The probable causes are either a blocked, pinched or disconnected hose to the pressure switch, faulty pressure switch or loosse or misconnected wiring, restricted air intake or flue piping, blocked drain system or weak induced draft blower.

5. Open Primary, Auxiliary or Rollout Limit. If the limit control opens, the air circulator blower will be turned on until the limit closes. The diagnostic light code for this problem is four short flashes followed by a pause. The probable cause for either an open primary or auxiliary limit is low conditioned air flow due to dirty filter or resistance in duct work, faulty limit, faulty blower, blower speed set to low or loose or misconnected wiring. The rollout limit(s) is(are) open due to flame rollout. The probable cause for an open rollout limit is misaligned burners, blocked flue and/or air inlet pipe, failed induced draft blower or loose or misconnected wiring.


7. Low Flame Sense Signal. If the furnace continues to operate and the micro-amp signal from the flame sensor falls below specified level. The diagnostic light code for this problem is seven flashes followed by a pause. The probable cause is either a coated/oxidized sensor, incorrectly positioned senser in burner flame or lazy burner flame due to improper gas pressure or combustion air.

8. Ignitor Circuit Problem. If the furnace fails to operate due to a problem with the ignitor. The diagnostic code for this problem is eight flashes followed by a pause.

The probable cause is either loose or misconnected wiring or a bad ignitor.

9. Furnace Operating on Low Stage Gas with High

Stage Induced Draft Blower and High Stage Circu-

lator Blower. If the furnaces high stage pressure switch circuit fails to close in rspone to hihg stage induced draft blower operation. The diagnostic light code for this problem is nine flashes followed by a pause. The probable causes are either a blocked, pinched or disconnected hose to the pressure switch, faulty pressure switch or loose of misconnected wiring, restricted air intake or flue piping, blocked drain system or weak induced draft blower.

10. Flame Sensed with No Call for Heat. If the control senses a flame when the gas valve is de-energized, it will run the air circulation blower and the induced draft blower continuously with no further furnace operation.



113 Rev. 1

Symptoms of Abnormal

Operation

- Furnace fails to operate and

- Integrated control module RED diagnostic LED provides no signal.


- Integrated control module RED diagnostic LED is lit continuously.


- Integrated control module RED diagnostic LED is flashing one flash.


- Integrated control module RED diagnostic LED is flashing two flashes.

- Induced draft blower cycles ON for one minute and OFF for three minutes with no further furnace operation.

and

- Integrated control module RED diagnostic LED is flashing three flashes.


and

- Integrated control module RED diagnostic LED is flashing four flashes.

Troubleshooting Chart for 50M61-288 and 50V61-288 Integrated Ignition Controls

Associated

RED LED Code

(See Note 2)

Fault Descriptions Possible Causes Corrective Action

- No 115 V power to furnace, or no

24 V power to integrated control module.

- Manual disconnect switch OFF, door switch open, or 24 V wires miswired, loose or misconnected.


None

- Check integrated control module fuse (3 A).

Replace if necessary.

- Blown fuse or circuit breaker.




- Check for possible shorts in 115 V and 24 V circuits. Repair as necessary.

ON

Continuous On




1 Flash

2

2 Flashes

4

1

3

3 Flashes

4 Flashes

- Furnace lockout due to an excessive number of ignition

"retries" (three total attempts) or "recycles" (five total recycles).

See Note 1.

- Pressure switch circuit is closed even though induced draft blower is not operating.

- Low stage pressure switch circuit does not close in response to induced draft blower operation.




- Failure to establish flame Cause may be no gas to burners, front cover pressure switch stuck open, bad igniter or igniter alignment, improper orifices, or coated/oxidized or misconnected flame sensor.

- Loss of flame after establishment. Cause may be interrupted gas supply, lazy burner flames (improper gas pressure or restriction in flue and/or combustion air switch, or improper induced draft blower performance.





- Incorrect low stage pressure switch set point or malfunctioning switch contacts.



Cause may be blocked filters, restrictive ductwork, improper circulator blower speed, or failed circulator blower.


- Rollout limit(s) is(are) open due to flame rollout. Cause may be misaligned burners, blocked flue and/or air inlet pipe, or failed induced draft blower.




- Replace or realign ignitor.







- Verify proper low stage pressure switch set point and contact motion.


- Check filters and ductwork for blockage. Clean filters or remove obstruction.

- Check for proper circulator blower speed and performance. Correct speed or replace blower if necessary.




- Check induced draft blower for proper performance. Replace if necessary.


Notes:



Cautions and

Notes


- Replace integrated control module fuse with 3 A automotive style fuse.


- Read precautions in "Electrostatic Discharge" section of manual.


- Igniter is fragile, handle with care.













Symptoms of Abnormal

Operation


and

- Integrated control module RED diagnostic LED is flashing six flashes.

- Normal furnace operation.

but

- Integrated control module RED diagnostic LED is flashing seven flashes.

- Furnace is not operating.

and

- Integrated control module RED diagnostic LED is flashing eight flashes.

- Furnace operating on low stage gas with high stage induced draft blower and high stage circulator blower (temperature, of conditioned air, lower than typical) and

- Integrated control module RED diagnostic LED is flashing nine flashes.


and

- Integrated control module RED diagnostic LED is flashing continuously.

Troubleshooting Chart for 50M61-288 and 50V61-288 Integrated Ignition Controls

Associated

RED LED Code

(See Note 2)

Fault Descriptions Possible Causes Corrective Action

6

6 Flashes

- Polarity of 115 V power is reversed.

- Polarity of 115 VAC power to furnace or integrated control module is reversed.

- Poor unit ground.

- Review wiring diagram.

- Verify proper grounding.


7

7 Flashes

8

8 Flashes

9

9 Flashes

C

Continuous

Flashing

- Flame sense micro-amp signal is low.

- Problem with ignitor circuit.

- High stage pressure switch circuit does not close in response to high stage induced draft blower operation.


- Flame sensor is coated/oxidized.

- Flame sensor incorrectly positioned in burner flame.

- Lazy burner flame due to improper gas pressure, or combustion air.

- Misconnected ignitor.

- Bad ignitor.

- Poor unit ground.



- Incorrect high stage pressure switch set point or malfunctioning switch contacts.





- Sand flame sensor if coated/oxidized. Inspect for proper sensor alignment.

- Check inlet air piping for blockage, proper length, elbows, and termination.

- Check for proper gas pressures.

- Check and correct wiring from integrated control module to ignitor.

- Replace bad ignitor.



- Check flue and/or inlet piping for blockage, proper length, elbows, and termination. Check drain system.

- Verify proper high stage pressure switch set point and contact motion.





NOTES:



Cautions and

Notes




- See "Flue and Combustion Air Pipe" section or piping details.

- See rating plate for proper gas pressures.


- Replace ignitor with proper silicon nitride replacement part.


- See "Flue and Combustion Air Pipe" section or piping details.




OPERATING INSTRUCTIONS

1. Close the manual gas valve external to the furnace.

2. Turn off the electrical power supply to the furnace.

3. Set room thermostat to lowest possible setting.

4. Remove the door on the front of the furnace.

5. This furnace is equipped with an ignition device which automatically lights the burner. Do not try to light burner by hand.

6. Turn the gas control valve clockwise to the "Off" position for either the Honeywell VR-8205 gas valve or the White Rodgers 36E35,36E36 and 36E96 gas valves.

The knob should turn easily. Do not use excessive force.

For the Robertshaw 7222 gas valve, push in and slide the valve lever on the lefthand side of the valve to the

"Off" position and for the White Rodgers 36E22 and

36E54 gas valve slide the switch on top of the valve to the "Off" position. Do not force.

7. Wait five (5) minutes to clear out any gas, then smell for gas, including near the floor.

8. If you smell gas following the five (5) minute waiting period in Step 7, follow the instructions on Pages 8 and 9.

If you do not smell gas, then turn the gas control knob counterclockwise to the "On" position for either the

Honeywell VR-8205 gas valve or the White Rodgers

36E35, 36E36 and 36E96 gas valves. The knob should turn easily. Do not use excessive force. For the

Robertshaw 7222 gas valve push in and slide the valve lever on the lefthand side of the valve to the "On" position and for the White Rodgers 36E22 and 36E54 gas valve push the selector switch on top of the valve to the "On" position.

9. Replace the door on the front of the furnace.

10. Open the manual gas valve external to the furnace.

11. Turn on the electrical power supply to the furnace.

12. Set the room thermostat to the desired temperature.

NOTE: There is approximately 20 second delay between thermostat energizing and burner firing.

PRESSURE REGULATOR

ADJUSTMENT

(UNDER CAP SCREW

INLET

INLET PRESSURE TAP

GAS VALVE

ON/OFF

CONTROL KNOB

INLET

INLET PRESSURE TAP

(SIDE OF VALVE)

OFF

PILOT ADJ

PRESSURE REGULATOR

ADJUSTMENT

(UNDER CAP SCREW)

OUTLET (MANIFOLD)

PRESSURE TAP

White-Rodgers Model: 36E36 Type 230

GUIA,GCIA / GUIC,GCIC

GAS VALVE

ON/OFF

CONTROL KNOB

INLET

ON

ON

Honeywell

OFF

GAS VALVE

ON/OFF

CONTROL KNOB

WR

ON

OUTLET (MANIFOLD)

PRESSURE TAP

Honeywell Model: VR-8205

GUIA,GCIA / GUIC,GCIC

OUTLET

OUTLET

OUTLET

OFF

PILOT ADJ

INLET PRESSURE TAP

(SIDE OF VALVE)

PRESSURE REGULATOR

ADJUSTMENT

(UNDER CAP SCREW)

OUTLET (MANIFOLD)

PRESSURE TAP

White-Rodgers Model: 36E35 Type 205

GUIB / GCIB

116 Rev. 1


GAS VALVE

ON/OFF

CONTROL LEVER

IN ON POSITION

OUTLET (MANIFOLD)

PRESSURE TAP

(SIDE OF VALVE)

HIGH MANIFOLD

REGULATOR ADJUSTMENT

SCREW (UNDER CAP)

PM

C

HI

Inlet Outlet

OFF

INLET OUTLET

ON

INLET PRESSURE TAP

(SIDE OF VALVE)

PRESSURE REGULATOR

ADJUSTMENT

(UNDER CAP SCREW)

Robertshaw Model: 7222

GUID

INLET PRESSURE TAP

(SIDE OF VALVE)

GAS VALVE

ON/OFF

CONTROL KNOB

LOW MANIFOLD



OUTLET (MANIFOLD)

PRESSURE TAP

(SIDE OF VALVE)

White-Rodgers Model: 36E96

GUIS / GCIS / GUIV

GAS VALVE

ON/OFF

SELECTOR

SWITCH

INLET

M

O

F

F

P

ON

C

1

3

2

OUTLET

OUTLET (MANIFOLD)

PRESSURE TAP

(SIDE OF VALVE)

LOW MANIFOLD


GAS VALVE

ON/OFF

SCREW (UNDER CAP) SELECTOR

SWITCH

INLET PRESSURE TAP

(SIDE OF VALVE)

Outlet

Inlet

INLET PRESSURE TAP

(SIDE OF VALVE)

OUTLET(MANIFOLD)

PRESSURE TAP

(SIDE OF VALVE)

PRESSUER REGULATOR

ADJUSTMENT

(UNDER CAP SCREW)


GUIA,GCIA / GUIC,GCIC / GUID

HIGH MANIFOLD




GUIS / GCIS / GUIV / GUSA / GUVA

117 Rev. 1

POLARIZATION AND PHASING

As more and more electronic's are introduced to the Heating Trade, Polarization of incoming power and phasing of primary to secondary voltage on transformers becomes more important.

Polarization has been apparent in the Appliance industry since the introduction of the three prong plug, however, the Heating Industry does not use a plug for incoming power, but is hard wired.

Some of the electronic boards being used today, with flame rectification, will not function properly and/or at all without polarization of incoming power. Some also require phasing between the primary and secondary sides of step-down transformers.

To instill new working habits for our trade, we recommend that these two items be checked during normal installation and/or service calls. See as follows:

INCOMING POWER

METER READS

120 VOLTS

METER READS

0 VOLTS

VOLT / OHM

METER

VOLT / OHM

METER

THIS IS L1 OR THE

HOT POWER LEG

THIS IS THE COMMON

OR NEUTRAL LEG

These then should be wired to the furnace accordingly.

CHECKING FOR PHASING - PRIMARY TO SECONDARY OF UNMARKED TRANSFORMERS*

METER READS

24 VOLTS

.

. .

.

.

.

METER READS

120 VOLTS

C G

N

D

R

N

L1

V O L T / O H M

M E TE R

V O L T / O H M

M E TE R

C G

N

D

TRANSFORMER

LINE VOLTAGE

(NEUTRAL)

R

LINE VOLTAGE

L1 (HOT)

V O L T / O H M

M E TE R

READS 96 VOLTS - IN PHASE

C

G

N

D

R

N

L1

VO L T / O H M

M E TE R

VO L T / O H M

M E TE R

READS 144 VOLTS - OUT OF PHASE

If meter reads approximately 96 volts - the primary to secondary are in phase - if reads approximately 144 volts out of phase

- reverse low voltage wires.

*NOTE: For flame rectification the common side of the secondary voltage (24 V) is cabinet grounded. If you were to bench test a transformer the primary neutral and secondary common must be connected together for testing purposes.

C

R

G

N

D

24 V 120 V

NEUTRAL

L1

Some transformers will display phasing symbols as shown in the illustration to the left to assist in determining proper transformer phasing.

Checking for polarization and phasing should become a habit in servicing. Let's start now.

NOTE: Newer integrated ignition controls have a diagnostic flash code for reversed polarity (Refer to Troubleshooting-Diagnostic Chart for LED Codes).

PHASING SYMBOL

118 Rev. 1

MAINTENANCE

WARNING

TO AVOID ELECTRICAL SHOCK, INJURY OR DEATH,

DISCONNECT ELECTRICAL POWER BEFORE PER-

FORMING ANY MAINTENANCE.

WARNING

DISCONNECT THE ELECTRICAL POWER TO THE FUR-

NACE BEFORE REMOVING THE FILTER OR PERFORM-

ING ANY OTHER MAINTENANCE.

CAUTION

IF YOU MUST HANDLE THE IGNITOR, HANDLE WITH

CARE. TOUCHING THE IGNITOR BODY WITH BARE FIN-

GERS, ROUGH HANDLING, OR VIBRATION COULD RE-

SULT IN EARLY IGNITOR FAILURE. ONLY A QUALIFIED

SERVICER SHOULD EVER HANDLE THE IGNITOR.

Maintenance

Improper filter maintenance is the most common cause of inadequate heating or cooling performance. Filters should be cleaned (permanent) or replaced (disposable) every two months or as required. It is the owner's responsibility to keep air filters clean. When replacing a filter, it must be replaced with a filter of the same type and size.

ANNUAL INSPECTION

The furnace should be inspected by a qualified installer, or service agency at least once per year. This check should be performed at the beginning of the heating season. This will ensure that all furnace components are in proper working order and that the heating system functions appropriately.

Pay particular attention to the following items. Repair or service as necessary.

• Flue pipe system. Check for blockage and/or leakage. Check the outside termination and the connections at and internal to the furnace.

• Combustion air intake pipe system (where applicable).

Check for blockage and/or leakage. Check the outside termination and the connection at the furnace.

• Heat exchanger. Check for corrosion and/or buildup within the heat exchanger passageways.

• Burners. Check for proper ignition, burner flame, and flame sense.

• Drainage system. Check for blockage and/or leakage.

Check hose connections at and internal to furnace.

• Wiring. Check electrical connections for tightness and/ or corrosion. Check wires for damage.

• Filters.

AIR FILTER

WARNING

NEVER OPERATE FURNACE WITHOUT A FILTER IN-

STALLED AS DUST AND LINT WILL BUILD UP ON IN-

TERNAL PARTS RESULTING IN LOSS OF EFFICIENCY,

EQUIPMENT DAMAGE, AND POSSIBLE FIRE.

Filters must be used with this furnace. Filters do not ship with these furnaces but must be provided by the installer for proper furnace for proper operation.

Remember that dirty filters are the most common cause of inadequate heating or cooling performance.

Filter Removal

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 (upflow only), a side panel external filter rack kit (upflow only), or the ductwork above a counterflow furnace. A media air filter or electronic air cleaner can be used as an alternate filter. The filter sizes given in the Product Design section of this manual or the product Specification Sheet must be followed to ensure proper unit performance. Refer to the following information for removal and installation of filters.

Upright Upflow Filter Removal

To remove an internal filter from the bottom of the blower compartment:

1. Set the thermostat to the OFF position or turn OFF electrical power to furnace.

2. Remove blower compartment door.

3. Push back and up on the wire filter retainer to release it from under the front lip of the furnace basepan. Do not remove. To access the filter, tilt the wire filter retainer upwards.

4. Slide filter forward and out. Vacuum blower compartment.

5. Replace filter and secure retainer opposite of removal.

6. Replace blower compartment door and turn ON thermostat or electrical power to furnace.

To remove filters from an external filter rack in an upright upflow installation, follow the directions provided with external filter rack kit.

To remove internal filter(s) from the retaining rails on the side(s) of the blower compartment in an upright installation:

1. Set the thermostat to the OFF position or turn OFF electrical power to furnace.

2. Remove the blower compartment door.

3. Grasping the lower portion of the filter, disengage the filter from the lower railing by lifting it up and toward the blower. Lower the filter down and pull outward.

119 Rev. 1

MAINTENANCE

4. Replace filter and blower compartment door opposite of removal and turn ON thermostat or electrical power.

FRONT OF FURNACE FRONT OF FURNACE

INDUCED DRAFT AND CIRCULATION BLOWERS

The bearings in the induced draft blower and circulator blower motors are permanently lubricated by the manufacturer. No further lubrication is required. Check motor windings for accumulation of dust which may cause overheating. Clean as necessary.

BLOWER BLOWER

CONDENSATE DRAINAGE SYSTEM (QUALIFIED

SERVICER ONLY)

The drain tubes, standpipe, and field supplied drain line must be checked annually and cleaned as often as necessary to ensure proper condensate drainage.

GRAB HERE

AND LIFT a. Lift filter above bottom b. Tilt filter to clear rail.

rail

FLUE PASSAGES (QUALIFIED SERVICER ONLY)

At the start of each heating season, inspect and, if necessary, clean the furnace flue passages.

FRONT OF FURNACE

BLOWER c. Lower filter below top rail.

FRONT OF FURNACE

BLOWER d. Slide filter out.

Filter Removal Procedure

Media Air Filter or Electronic Air Cleaner Removal

Follow the manufacturer’s directions for service.

Upright Counterflow Filter Removal

To remove filters from the ductwork above an upright counterflow installation:

1. Turn off electrical power to furnace.

2. Remove access door in ductwork above furnace.

3. Remove filters

4. Remove blower compartment door. Vacuum compartment. Replace blower compartment door.

5. Replace filters opposite of removal.

6. Replace access door in ductwork.

Horizontal Unit Filter Removal

Filters in horizontal installations are located in the central return register.

CLEANING FLUE PASSAGES (QUALIFIED SERVICER

ONLY)

1. Turn OFF the electrical power and gas supply to the furnace.

2. Disconnect the gas line and remove the burner/ manifold assembly by removing the screws securing the assembly to the partition panel.

3. Disconnect the flue pipe system from the induced draft blower.

4. Remove the induced draft blower and, drain and pressure tap hoses from the recuperator coil front cover.

5. Remove the recuperator coil front cover to expose the coil tubes and turbulators.

6. Remove the recuperator coil turbulators individually by slowly pulling each turbulator forward firmly.

7. Clean the recuperator coil tubes using a long handle wire brush, such as a gun cleaning brush.

8. Clean the primary heat exchanger tubes using a wire brush attached to a length of high grade stainless steel cable, such as drain cleanout cable. Attach a variable speed reversible drill to the other end of the cable. Slowly rotate the cable with the drill and insert it into one of the heat exchanger tubes. While reversing the drill, work the cable in and out several times to obtain sufficient cleaning. Repeat for each tube.

9. Clean residue from furnace using a vacuum cleaner.

10. Replace the parts removed in the previous steps in reverse order.

11. Turn on electrical power and gas to furnace. Check for leaks and proper unit operation.

12. Severe heat exchanger fouling is an indication of an operational problem. Perform the steps listed in the System Operation section of this manual to reduce the chances of repeated fouling.

120 Rev. 1

MAINTENANCE

FLAME SENSOR (QUALIFIED SERVICER ONLY)

Under some conditions, the fuel or air supply can create a nearly invisible coating on the flame sensor. This coating acts as an insulator, causing a drop in the flame sensing signal. If this occurs, a qualified servicer must carefully clean the flame sensor with steel wool. After cleaning, the flame sensor output should be as listed on the specification sheet.

BURNERS

WARNING

ELECTRICAL COMPONENTS ARE CONTAINED IN BOTH

COMPARTMENTS. TO AVOID ELECTRICAL SHOCK, IN-

JURY OR DEATH, DO NOT REMOVE ANY INTERNAL

COMPARTMENT COVERS OR ATTEMPT ANY ADJUST-

MENT. CONTACT A QUALIFIED SERVICE AGENT AT

ONCE IF AN ABNORMAL FLAME APPEARANCE SHOULD

DEVELOP.

Periodically during the heating season make a visual check of the burner flames. Turn the furnace on at the thermostat.

Wait a few minutes, since any dislodged dust will alter the normal flames appearance. Flames should be stable, quiet, soft and blue with slightly orange tips. They should not be yellow. They should extend directly outward from the burner ports without curling downward, floating or lifting off the ports.

Check the burner flames for:

1. Good adjustment

2. Stable, soft and blue

3. Not curling, floating, or lifting off.

Burner Flame

121 Rev. 1

SERVICING

TEST EQUIPMENT

Proper test equipment for accurate diagnosis is as essential as regulator hand tools.

The following is a must for every service technician and service shop.

1. Dial type thermometers or thermocouple meter (optional) - to measure dry bulb temperature.

2. Amprobe - to measure amperage and voltage.

3. Volt-Ohm Meter - testing continuity, capacitors, and motor windings.

4. Inclined Manometer - to measure static pressure, pressure drop across coils, filters, and draft.

5. Water Manometer (12") - to test gas inlet and manifold pressure.

Other recording type instruments can be essential in solving abnormal problems, however, in many instances they may be rented from local sources.

Proper equipment promotes faster, more efficient service and accurate repairs resulting in fewer call backs.

HEATING PERFORMANCE TEST

Before attempting to diagnose an operating fault, run a heating performance test and apply the results to the Service

Problem Analysis Guide.

To conduct a heating performance test, the BTU input to the furnace must be calculated.

After the heating cycle has been in operation for at least fifteen minutes and with all other gas appliances turned off, the gas meter should be clocked.

To find the BTU input, multiply the number of cubic feet of gas consumed per hour by the heating value of the gas being used. (The calorific value of the gas being used is found by contacting your local utility.)

EXAMPLE: It is found by the gas meter, that it takes forty

(40) seconds for the hand on the cubic foot dial to make one complete revolution, with all appliances off, except the furnace. Take this information and locate it on the gas rate chart. Observe the forty (40) seconds, locate and read across to the one (1) cubic foot dial column. There we find the number 90, which shows that ninety (90) cubic feet of gas will be consumed in one (1) hour.

Let's assume the local gas utility has stated that the calorific value of the gas is 1025 BTU.

Multiplying the ninety (90) cubic feet by 1025 BTU gives us an input of 92,250 BTUH.

Checking the BTU input on the rating plate of the furnace being tested.

EXAMPLE: GUCA090AX40

INPUT: 92,000 BTU/HR

OUTPUT CAP: 84,000

Should the figure you calculated not fall within five (5) percent of the nameplate rating of the unit, adjust the gas valve pressure regulator or resize orifices.

CAUTION

ALWAYS CONNECT A MANOMETER TO THE 1/8" PIPE

TAP AT THE GAS VALVE BEFORE ADJUSTING THE

PRESSURE REGULATOR. IN NO CASE SHOULD THE

FINAL MANIFOLD PRESSURE VARY MORE THAN PLUS

OR MINUS .3 INCHES WATER COLUMN FROM 3.5

INCHES WATER COLUMN FOR NATURAL GAS OR 10

INCHES WATER COLUMN FOR PROPANE GAS.

To adjust the pressure regulator on the gas valve, turn down

(clockwise) to increase pressure and input, and out (counterclockwise) to decrease pressure and input.

Since normally propane gas is not installed with a gas meter, clocking will be virtually impossible. The gas orifices used with propane are calculated for 2500 BTU gas and with proper inlet pressures and correct piping size, full capacity will be obtained.

With propane gas, no unit gas valve regulator is used; however, the second stage supply line pressure regulator should be adjusted to give 11" water column with all other gas consuming appliances running.

The dissipation of the heat transferred to the heat exchanger is now controlled by the amount of air circulated over its surface.

The amount (CFM) of air circulated is governed by the external static pressure in inches of water column of duct work, cooling coil, registers and etc., applied externally to the unit versus the motor speed tap (direct drive) or pulley adjustments of the motor and blower (belt drive).

A properly operating unit must have the BTU input and CFM of air, within the limits shown to prevent short cycling of the equipment. As the external static pressure goes up, the temperature rise will also increase. Consult the proper tables for temperature rise limitation.

122 Rev. 1

SERVICING

2

1

3

0

9

4

5

1 Million

6

8

7

8

9 1

2

7

6 4

5

100 Thousand

3

1

0

9

2 8

3

4

5

6

10 Thousand

7

9 1

8 2

7

6 4

5

1 Thousand

3

Quarter One

Foot

CUBIC

FEET

Foot

Seconds for

One

Revolution

31

32

33

34

35

23

24

25

26

27

28

29

30

15

16

17

18

19

20

21

22

10

11

12

13

14

1/4 cu/ft

--

28

--

26

--

39

37

36

34

33

32

31

30

60

56

53

50

47

45

43

41

90

82

75

69

64

--

56

--

53

--

78

75

72

69

67

64

62

60

120

113

106

100

95

90

86

82

180

164

150

138

129

GAS RATE -- CUBIC FEET PER HOUR

Size of Test Dial

1/2 1 2 cu/ft cu/ft cu/ft

5 cu/ft

Seconds for

One

Revolution

1/4 cu/ft

Size of Test Dial

1/2 1 2 cu/ft cu/ft cu/ft

116

113

109

106

103

157

150

144

138

133

129

124

120

240

225

212

200

189

180

171

164

360

327

300

277

257

232

225

218

212

206

313

300

288

277

265

257

248

240

480

450

424

400

379

360

343

327

720

655

600

555

514

49

50

51

52

53

54

55

56

57

58

59

60

41

42

43

44

45

46

47

48

36

37

38

39

40

581

563

545

529

514

783

750

720

692

667

643

621

600

1800

1636

1500

1385

1286

1200

1125

1059

1000

947

900

857

818

--

18

--

--

17

--

--

16

--

--

--

15

--

21

--

--

20

--

19

--

25

--

23

--

22

--

36

--

--

34

--

--

32

--

31

--

30

--

43

--

41

40

--

38

--

50

--

47

--

45

--

72

--

69

--

67

--

64

--

62

--

60

--

86

--

82

80

78

76

75

100

97

95

92

90

147

144

141

138

136

133

131

129

126

124

122

120

176

172

167

164

160

157

153

150

200

195

189

185

180

5 cu/ft

367

360

355

346

340

333

327

321

316

310

305

300

439

429

419

409

400

391

383

375

500

486

474

462

450

123 Rev. 1

SERVICING

Complaint No Heat Unsatisfactory Heat

POSSIBLE CAUSE

DOTS IN ANALYSIS

GUIDE INDICATE

"POSSIBLE CAUSE"

Test Method

Remedy

Power Failure

Blown Fuse

Loose Connection

Shorted or Broken Wires

No Low Voltage

Faulty Thermostat

Faulty Transformer

Poor or High Resistance Ground

Improper Heat Anticipator Setting

Improper Thermostat Location

Faulty Limit or Roll Out Switch

Faulty Flame Sensor

Faulty Ignition Control

Gas Valve or Gas Supply Shut Off

Faulty Induced Draft Blower

Broken or Shorted Ignitor

Dirty Flame Sensor, Low uA

Flame Sensor not in Flame, Low uA

Faulty Gas Valve

Open Auxiliary Limit

Improper Air Flow or Distribution

Cycling on Limit

Delayed Ignition

Flashback

Orifice Size

Gas Pressure

Cracked Heat Exchanger

Stuck Gas Valve

Furnace Undersized

Faulty Pressure Switch

Blocked or Restricted Flue

Open Roll Out Switch

Bouncing On Pressure Switch

••••

••••

••••

••••

••••

••••

••••

••••

••••

•••• •••• ••••

••••

Test Voltage

Test Voltage

Check Wiring

Check Wiring

Check Transformer

•••• •••• ••••

Check Thermostat

Check Transformer

Measure Ground Resistance

•••• •••• •••• ••••

Adjust Heat Anticipator Setting

•••• •••• •••• ••••

Relocate Thermostat

Test Control

Test Flame Sensor

Test Control

Turn Valves to On Position

Test Blower

Test Ignitor

S-5 & 7

S-14

S-13

S-11

S-9

S-12

Clean Flame Sensor S-14

Test/Adjust Position of Flame Sensor

•••• ••••

Replace Gas Valve

••••

Reset Control

Check Duct Static

Check Controls & Temperature Rise

Test for Delayed Ignition

S-14

S-11

S-6

S-21

S-5 & 22

S-19

••••

Test for Flashback

Check Orifices

•••• •••• ••••

Check Gas Pressure

Check Burner Flames

•••• ••••

Replace Gas Valve

••••

Replace with Proper Size Furnace

Test Pressure Switch

••••

Check Flue/Drawdown Pressure

Test Control

S-20

S-16

S-18

S-15

S-11

S-8

S-8

S-7

Test Negative Pressure S-8

S-1

S-4

S-2

S-3

S-4

S-3

S-4

S-13

S-3

124 Rev. 1

SERVICING

SERVICING SECTION INDEX

S-1 Checking Voltage

S-2 Checking Wiring

S-3 Checking Thermostat, Wiring, and Anticipator

S-4 Checking Transformer and Control Circuit

S-5 Checking Primary Limit Control

S-6 Checking Auxiliary Limit Control

S-7 Checking Flame Rollout Control

S-8 Checking Pressure Control

S-9 Checking Air Circulator Blower Motor

or Induced Draft Blower Motor

S-9A Checking Variable Speed Air Circulator Blower Motor

S-10 Checking Capacitor

S-10A Resistance Check

S-10B Capacitance Check

S-11 Checking Gas Valve

S-12 Checking Hot Surface Ignitor

S-13 Checking White-Rodgers 50A50, 50A51, 50M61 & 50V61

and Heatcraft HSI 1-1A or HSI-2 Ignition Controls

S-13A Checking White-Rodgers 50A52 Ignition Control

S-14 Checking Flame Rectification Flame Sensor

S-14A Checking Radiant Flame Sensor

S-15 Checking Main Burners

S-16 Checking Orifices

S-17 High Altitude Application (USA)

S-18 Checking Gas Pressure

S-19 Checking for Delayed Ignition

S-20 Checking for Flashback

S-21 Checking Duct Static

S-22 Checking Temperature Rise

132

132-136

136

136

136

136-137

137

126

126

126-127

127

127-128

129-130

130-131

131-132

144

145

145

146

137-139

139

140

140-141

141

141

142

142-144

125 Rev. 1

SERVICING

S-1 CHECKING VOLTAGE

WARNING

Disconnect Electrical Power Supply:

1. Remove the burner door on 80% furnace or blower compartment door on 90% furnace to gain entry to Junction

Box.

2. Remove cover from Junction Box and gain access to incoming power lines.

With Power ON:

WARNING

LINE VOLTAGE NOW PRESENT.

3. Using a voltmeter, measure the voltage across the hot and neutral connections.

NOTE: To energize the furnace, the Door Interlock Switch must be engaged at this point.

4. No reading - indicates open wiring, open fuse, no power, or etc. from unit to fused disconnect service. Repair as needed.

5. With ample voltage at line voltage connectors, energize the furnace blower motor by jumpering terminals R to

G on the integrated ignition control.

6. With the blower motor in operation, the voltage should be 115 volts ± 10 percent.

7. If the reading falls below the minimum voltage, check the line wire size. Long runs of undersized wire can cause low voltage. If wire size is adequate, notify the local power company of the condition.

8. After completing check and/or repair, replace Junction

Box cover and reinstall burner compartment door on

80% or blower compartment door on 90% furnace.

9. Turn on electrical power and verify proper unit operation.

S-3 CHECKING THERMOSTAT, WIRING AND AN-

TICIPATOR

S-3A Thermostat and Wiring

WARNING


1. Remove the blower compartment door to gain access to the thermostat low voltage wires located at the furnace integrated control module terminals.

2. Remove the thermostat low voltage wires at the furnace control panel terminal board.

3. Jumper terminals R to W (W1 and W2) on the integrated ignition control.

With Power On (and Door Interlock Switch closed):

WARNING


4. Induced Draft Motor must run and pull in pressure switch.

5. If the hot surface ignitor heats and at the end of the this ignitor warm-up period the gas valve opens and the burners ignite, the trouble is in the thermostat or wiring.

6. With power off, check the continuity of the thermostat and wiring. Repair or replace as necessary.

If checking the furnace in the air conditioning mode, proceed as follows.

7. With power off, Jumper terminals R to Y (Y1 or Y2) to G.

8. Turn on the power.

9. If the furnace blower motor starts and the condensing unit runs, then the trouble is in the thermostat or wiring.

Repair or replace as necessary.

10. After completing check and/or repair of wiring and check and/or replacement of thermostat, reinstall blower compartment door.


S-2 CHECKING WIRING

WARNING


1. Check wiring visually for signs of overheating, damaged insulations and loose connections.

2. Using an ohmmeter to check continuity of any suspected open wires.

3. If any wires must be replaced, replace with AWM, 105°C.

4/64 thick insulation of the same gauge or its equivalent.

S-3B Heating Anticipator

The heating anticipator is a wire wound adjustable heater which is energized during the "ON" cycle to help prevent overheating of the conditioned space.

The anticipator is a part of the thermostat and if it should fail for any reason, the thermostat must be replaced.

The heating anticipator setting for furnaces covered in this manual is 0.70 Amps.

126 Rev. 1

SERVICING

If the anticipator current draw is unknown, then an amp draw should be taken to determine the anticipator setting.

Use an amprobe as shown in the following drawing.

10 TURNS OF

THERMOSTAT WIRE

(From "W" on thermostat)

STATIONARY JAW

OF AMPROBE

READS 4 AMPS

CURRENT DRAW

WOULD BE .4 AMPS

Checking Heating Anticipator Current (Amp) Draw

WARNING


3. Use a voltmeter, check voltage across terminals R and

C. Must read 24 VAC.

4. No voltage indicates faulty transformer, open fuse, bad wiring, bad splice, or open door interlock switch.

5. Check transformer primary voltage at incoming line voltage connections, fuse, splices, and blower door interlock switch.

6. If line voltage is available to the primary side of transformer and not at secondary side, the transformer is inoperative. Replace.

7. After completing check and/or replacement of transformer and check and/or repair of control circuit, reinstall blower compartment door.


S-3C Cooling Anticipator

The cooling anticipator is a small heater (resistor) in the thermostat. During the "OFF" cycle it heats the bimetal element helping the thermostat call for the next cooling cycle.

This prevents the room temperature from rising too high before the system is restarted. A properly sized anticipator should maintain room temperature within 1 1/2 to 2 degrees range.

The anticipator is fixed in the subbase and is not to be replaced. If the anticipator should fail for any reason, the subbase must be changed.

S-5 CHECKING PRIMARY LIMIT CONTROL

All 80% furnaces use a nonadjustable, automatic reset,

Klixon type limit control (stat on a stick), part number

107283_ _. Refer to the following drawing for location of the primary limit on the 80% furnaces.

PRIMARY LIMIT

CONTROL

S-4 CHECKING TRANSFORMER AND CONTROL

CIRCUIT

A step-down transformer 120 volt primary to 24 volt secondary, 40 VA (Heating and Cooling Models) supplies ample capacity of power for either operation.

WARNING


1. Remove blower compartment door to gain access to the thermostat low voltage wires located at the furnace integrated control module.

2. Remove the thermostat low voltage wires at the furnace integrated control module terminals.

With Power On (and Door Interlock Switch closed):

Primary Limit Control Location

(80% Upflow Furnace Shown, Counterflow Similar)

Style 1 is an open face limit, styles 2 and 3 are closed face limits. Limit styles are not interchangeable, use only the limit listed for that furnace. The following drawing illustrates the different styles of limit switches used on the 80% furnaces.

127 Rev. 1

SERVICING

STYLE 1 & 3

WARNING


1. Remove burner compartment door to gain access to the primary limit.

2. Remove low voltage wires at limit control terminals.

3. With an ohmmeter, test between these two terminals as shown in the following drawing. Should read continuous unless heat exchanger temperature is above limit control setting. If not as above, replace the control.

STYLE 2

Primary Limit Control Styles

(80% Furnaces)

All 90% furnaces use a nonadjustable, automatic reset,

Klixon type limit control part number 201629_ _. Refer to the following drawing for location of the primary limit on the

90% furnaces.

PRIMARY LIMIT

CONTROL

Volt / Ohm

Meter

COLOR

IDENTIFYING

SLEEVES

Testing Primary Limit Control

(80% Furnaces)

*

*

*

*

*

*

*

VOLT / OHM

METER

Primary Limit Control Location


The following drawing illustrates the style of limit switches used on the 90% furnaces.

ENCLOSED DISK

COLOR

IDENTIFYING

TAB

Testing Primary Limit Control

(90% Furnaces)

4. After completing check and/or replacement of primary limit control, reinstall burner compartment door.


To aid in identifying these controls, refer to the T.O.D. Primary Limit Charts in furnace Technical Manual for style number, temperature setting and sleeve color(s) code.

FRONT VIEW SIDE VIEW

128 Rev. 1

Primary Limit Control Style

(90% Furnaces)

SERVICING

S-6 CHECKING AUXILIARY LIMIT CONTROL

All the 80% and 90% furnaces use an additional limit switch required for safety control of high temperature within the furnace or duct work. This control is preset, nonadjustable and must be manually reset. The control is located in the blower compartment of the furnace either on the blower deck or blower housing.

The auxiliary manual reset limit is located on the lower side of the blower deck, near the center, on all 80% furnaces and on the 90% GUCA and GUSA furnaces, as shown in the following illustration.

AUXILIARY LIMIT

CONTROL

If this limit control opens, the air circulation blower and induced draft blower will run continuously on models with White-

Rodgers 50A50, 50A51 or Heatcraft HSI 1-1A ignition control. On models with the White-Rodgers 50A55, 50M61,

50V61 or Heatcraft HSI-2 ignition control, "only" the air circualtion blower will run continuously. The diagnostic light will flash four times. These symptoms are identical to a trip of the primary limit control.

The auxiliary limit control is designed to prevent furnace operation in case of main blower failure on horizontal or counterflow installations. It may also open if the power supply is interrupted while the furnace is firing.

The auxiliary limit control is suitable for both horizontal right and horizontal left installations. Regardless of airflow direction, it does not need to be relocated.

BLOWER DECK

Auxiliary Limit Control Location

(All 80% Furnaces & 90% GUCA Furnace)

The auxiliary manual reset limits (Qty 2) are located on the blower housing (one on each side) on 90% GCCA and GUVA furnaces, as shown in the following illustration.

WARNING

Disconnect Electrical Power Supply

1. Remove blower compartment door to gain access to the auxiliary limit control which is located on the lower side of the blower deck on all 80% furnaces and on 90% GUCA and GUSA furnaces, or on the blower housing on 90%

GCCA and GUVA furnaces.

2. Remove the wires from the auxiliary limit control terminals.

3. Use an ohmmeter, test for continuity across the two terminals (refer to the following auxiliary limit control figure). No reading indicates the control is open. Push red reset button, test again - if still open, replace the control.

AUXILIARY LIMIT

CONTROL

VOLT / OHM

METER

BLOWER HOUSING

RED

RESET

BUTTON

AUXILIARY LIMIT

CONTROL

Auxiliary Limit Control Location

(90% GCCA & GUVA Furnaces)

The auxiliary limit control is connected in series with the primary limit control wiring to the integrated ignition control.

If its temperature should be exceeded, it will open, interrupting the voltage to the gas valve causing it to close.

COLOR

IDENTIFYING

TAB

Testing Auxiliary Limit Control

(80% & 90% Furnaces)

129 Rev. 1

SERVICING

WARNING

To avoid possible fire, only reset the auxiliary limit control once. If it should open a second time, a qualified servicer must determine why the auxiliary limit opened before resetting again.

NOTE: If it becomes necessary to slide the blower assembly out of any of the 80% furnaces or the 90% GUCA or

GUSA furnace, the auxiliary limit control must be removed from the blower deck before the blower assembly can be removed. After the blower assembly is reinstalled, the auxiliary limit must be reinstalled.

To aid in identifying these controls, color coded labels are attached to the back of the controls. Refer to the Auxiliary

Limit Charts in furnace Technical Manual for color codes and temperature settings.

The control is designed to open should a flame roll out occur. An over firing condition or flame impingement on the heat shield may also cause the control to open. If the rollout control opens, the air circulation blower and vent blower will run continuously. On models with the White-Rodgers

50A51, 50M61 and 50V61 or Heatcraft HSI 1-1A ignition controls the diagnostic light will flash four times. These symptoms are identical to a trip of the primary limit control.

On models with the White-Rodgers 50A50, 50A55 or

Heatcraft HSI-2 ignition control the diagnostic light will flash five times indicating a trip of the rollout switch.

To aid in identifying these controls, color coded labels have been affixed to the back of these controls. Refer to the Rollout

Limit Charts in furnace Technical Manual for temperature settings and color codes.

If the rollout control has opened the circuit between the ignition control and gas valve will be interrupted.

S-7 CHECKING FLAME ROLLOUT CONTROL

A temperature activated manual reset control is mounted to the manifold assembly on 80% & 90% furnaces, as shown in the following illustrations.

FLAME

ROLLOUT

SWITCH

WARNING


1. Remove the burner compartment door to gain access to the rollout switch(es) mounted to burner bracket.

The servicer should reset the ignition control by opening and closing the thermostat circuit. Then look for the ignitor glowing which indicates there is power to the ignition control.

Measure the voltage between each side of the rollout control and ground while the ignition control tries to power the gas valve.

2. Measure the voltage between each side of the rollout control and ground during the ignition attempt. Refer to the following figure.

Flame Rollout Switch Location


FLAME

ROLLOUT

SWITCHES

VOLT / OHM

METER

RED

RESET

BUTTON

GND

*

*

*

*

*

*

*

Flame Rollout Switch Location


130 Rev. 1

COLOR

IDENTIFYING

TAB

Checking Flame Rollout Switch

(80% & 90% Furnaces) a. If no voltage is measured on either side of control it indicates ignition control or wiring to control problem.

b. If voltage is measured on one side of the control and not the other it indicates the control is open.

SERVICING c. If voltage is measured on both sides of the control the wiring to gas valve or valve is a fault.

3. After check and/or replacement of rollout switch, reinstall burner compartment door and verify proper unit operation.

S-8 CHECKING PRESSURE CONTROL

The pressure control is a safety device to prevent the combustion cycle from occurring with inadequate venting caused by a restricted or blocked vent pipe on the 80% and 90% furnaces. Also on the 90% furnaces there is a pressure control that will prevent the combustion cycle from occuring with inadequate condensate drainage due to a partial or blocked recouperator coil or drain.

INDUCED DRAFT BLOWER

PRESSURE SWITCH

ON

PRESSURE SWITCH

HOSE

OPEN TO

ATMOSPHERE

1/4" TEE

COIL COVER

PRESSURE SWITCH

INCLINED MANOMETER

INDUCED

DRAFT

BLOWER

HOSE TO INDUCED

DRAFT BLOWER TAP

ID Blower Pressure Switch

Negative Pressure Measurement


WARNING


1. Remove burner compartment door to gain access to pressure switch(es).

2. Remove wires from the pressure switch(es) electrical terminals.

3. Using a VOM check from common terminal to NC (Normally Closed) - should read closed. Check from Common to NO (Normally Open) - should read open.

If switch reads as above proceed to Step 4, otherwise replace control.

4. Remove the pressure control hose from the control and interconnect with an inclined manometer as shown in the following figures.


PRESSURE SWITCH

PRESSURE SWITCH

HOSE

OPEN TO

ATMOSPHERE

1/4" TEE


HOSE TO INDUCED

DRAFT BLOWER TAP

INDUCED

DRAFT

BLOWER

ID Blower Pressure Switch



COIL COVER

PRESSURE SWITCH

ON


PRESSURE SWITCH

1/4" TEE

OPEN TO

ATMOSPHERE

PRESSURE SWITCH

HOSE

INDUCED

DRAFT

BLOWER


HOSE TO COIL

COVER TAP

Coil Cover Pressure Switch



Reconnect pressure switch electrical wires.

!

WARNING


4. Energize furnace for heating cycle. The induced draft blower motor will begin to run. The inclined manometer should read approximately the negative pressure shown in the Pressure Switch Trip Points and Usage Chart.

These charts can be found in furnace Technical Manual for each model furnace.

NOTE: GUIA/B and GCIA/B furnaces can pull negative pressures in excess of -3.0" WC. Use appropriate manometer for measuring negative pressure. Refer to the Pressure Switch Trip Points and Usage Charts in furnace Technical Manual for pressure switch usage and trip points.

5. Remove and check the two electrical wires and using the VOM check from Common to NC (Normally Closed)

- should read open. Check from Common to NO (Normally Open) - should read closed. If not as above, replace control.

6. Reconnect wires to the control and place in a heating cycle.

131 Rev. 1

SERVICING

7. Begin to restrict the flue outlet until the pressure control trips - cycling OFF the burner. Also a blocked drain test will need to be performed until the coil cover pressure control trips - cycling OFF the burner. The trip points should be as shown in the Pressure Switch Trip Points and Usage Charts in furnace Technical Manual.

8. If not as listed, replace control.

9. After completing check and/or repair of pressure switch, reinstall burner compartment door.


The pressure readings listed in the Pressure Switch Trip

Points and Usage Charts in furnace Technical Manual must be adhered to for proper operation.

S-9 CHECKING AIR CIRCULATOR BLOWER MO-

TOR OR INDUCED DRAFT BLOWER MOTOR

WARNING

Disconnect Electrical Power Supply

1. Remove blower compartment door to gain access to the circulator blower motor and induced draft blower motor wire leads connected at integrated ignition control.

2. Disconnect the motor wire leads from its connection point at integrated ignition control module and capacitor if applicable.

3. Using and ohmmeter, test for continuity between each of the motor leads.

4. Touch one probe of the ohmmeter to the motor frame

(ground) and the other probe in turn to each lead.

If the windings do not test continuous or a reading is obtained to ground, replace the motor.

5. After completing check and/or replacement of circulator blower motor or induced draft blower motor, reinstall blower compartment door.


S-9A CHECKING VARIABLE SPEED AIR CIRCU-

LATOR BLOWER MOTOR

The 80% and 90% Two-Stage Variable Speed furnaces incorporate the GE © ICM or variable speed blower motors for greater efficiency. ECM/ICM motors vary the motor

RPMs to provide a set volume of air over a wide range of conditions. These motors use an electronic control module attached to the motors end bell to control motor operation.

Some unique features of these motors are:

1. Constant Airflow. These motors will maintain constant airflow in excess of .80 static. In other words, as the static increases so does the motors RPM so that a constant CFM is maintained.

NOTE: The motor in these units will move more air under higher static conditions than a similar sized unit using a

PSC motor. Because this motor does not load up and reduce airflow like a PSC motor, in some undersized duct installations this may cause noise or high airflow complaints.

2. Ramp-up/Ramp-down feature. These motors ramp up and down at the beginning or end of a cycle to reduce air rush noise.

3. High voltage is present at these motors all the time.

Motor operation is controlled through the low voltage motor interface board.

On GUIV-CA/DX and GUVA-AX models, a motor interface board mounted on the control bracket is used to control blower operation in 3 modes of operation. Fan only, cooling speed and heating speed. Refer to the Airflow Charts in furnace Technical Manuals for details.

The cooling and heating speeds are adjusted by relocating the jumper pins on the motor interface board.

There is a LED, located on the blower interface board on

GUIV-CA/DX and GUVA-AX models or on the integrated ignition control on GUVA-BX models, that serves to indicate the airflow that the motor is supposed to be delivering, depending upon the positioning of the pin selectors on the interface board on the GUIV-CA/DX and GUVA-AX models or on the DIP switches on the integrated ignition control on the

GUVA-BX models. The number of blinks multiplied by 100 yields the programmed CFM (Example: 10 Blinks x 100 =

1000 CFM). The indicated CFM may vary, depending on the mode of operation and the signals being sent to the control board at the time.

ECM/ICM Control Connections

Control functions (G, Y, YI, Y2, W, W1, W2) may be active at less than 1/2 control voltage. (i.e. 12 volts). Relay contacts on control functions must reliably switch low currents

(less than 5 MA). Some thermostats (with triac switches) and Solid State Relays may allow enough "leakage" current to turn on "G". Thermostats that "steal" power thru "Y" or other functions are not compatible.

The ECM control interface can be as simple as a direct connection to the thermostat. For example: "R" to "G" will cause the fan to come at "Fan-Only" CFM, "R" to "G" to "Y" will cause the fan to come on at Cooling speed and R to G to W will cause the fan to come on at heating speed. The

ECM/ICM control requires a common connection from the transformer (transformer common to C1, C2 on control). In typical applications C1 and C2 will be tied together. Additional features can be utilized through the motor interface control board, these features include; 2 Cool CFMs, 2 Dehumidification CFMs, 2 Heat CFMs, separate Fan-Only

CFM, and feed back information (CFM demand).

132 Rev. 1

SERVICING

Power

Conditioning

AC to DC

Conversion

Inverter

ECM

Blower

Motor

HVAC System Control

INPUTS

24 Volts A/C

Compressor

On/Hi/Low

Fan On

Reversing Valve

Aux./Emergency Heat

Capacity Select

Motor

Control

Outputs

CFM Demand

ECM/ICM CONTROL FLOW CHART

NOTE: An inductor (Power Correction Factor Choke) is required when powering the 3/4 and 1 horsepower motors with 115 volts. The operation of this inductor is to reduce the line current by storing the electrical energy in a magnetic field, such that the voltage AC waveform leads the current AC waveform. In other words, the inductor reduces line current which extends the life of the 3/4 and 1 horsepower motors. The furnaces requiring an inductor are shown in the following chart.

80% Models

GUIV090**50

GUIV115**50

90% Models

GUVA070**40

GUVA090**50

GUVA115**50

IMPORTANT: If the inductor fails, there will be no motor operation since this is the "LINE" power supply, black wire

(BK-6), from the integrated ignition control to the motor. To determine if the inductor is at fault, you can bypass by the inductor by disconnecting the black wire (BK-6) wire from the inductor and connecting it directly to the motor. If the motor operates then the inductor will need to be replaced.

WARNING

LINE VOLTAGE NOW PRESENT

Check for line voltage on terminals 4 and 5. Verify terminal 3 is ground. terminals. Terminals 1 and 2 are jumpered in the harness for 120VAC operation.

5

4

3

2

1

AC Line Hot Connection

AC Line Neutral Connection

Gnd

}

Lines 1 and 2 will be connected for 120VAC Power Connector applications only

POWER CONNECTOR

(1/2 HP MOTORS)

"Motor Half“

(Viewed from Plug End)

Checking ECM/ICM Motors

ECM/ICM motors connect directly to the AC Line Voltage.

DO NOT insert contactors in series with the ECM/ICM Motor AC Line. The control is powered continuously to insure reliable start-up. The connector plug is polarized, verify and reverify correct connector orientation before applying power.

DO NOT force plug into motor and make sure power is off before inserting power connector. DO NOT apply voltage to terminals 1 or 2.

5

4

3

2

1 inductor

AC Line Hot Connection

AC Line Neutral Connection

Gnd

}

Lines 1 and 2 will be connected for 120VAC Power Connector applications only

POWER CONNECTOR

(3/4 & 1 HP MOTORS)

"Motor Half“

(Viewed from Plug End)

133 Rev. 1

Troubleshooting Chart for ECM/ICM Variable Speed Air Circulator Blower Motors

Symptoms of

Abnormal

Operation

- Motor rocks slightly when starting.

Fault Description(s) Possible Causes

- This is normal start-up for variable speed motor.

----

- Motor won't start.

- No movement.

- Manual disconnect switch off or door switch open.


- 24 Vac wires miswired.

- Unseated pins in wiring harness connectors.

- Bad motor/control module.

- Moisture present in motor or control module.

- Motor rocks, but won't start.

- Loose motor mount.

- Blower wheel not tight on motor shaft.

- Bad motor/control module.

- Motor oscillates up & down while being tested off of blower.

- Motor starts, but runs erratically.

- It is normal for motor to oscillate with no load on shaft.

- Varies up and down or intermittent.

- "Hunts" or "puffs" at high CFM

(speed).

- Stays at low CFM despite system call for cool or heat CFM.

- Stays at high CFM.

----

- Variation in 115 Vac to motor.

- Unseated pins in wiring harness connectors.

- Erratic CFM command from "BK" terminal.


- Moisture present in motor/control module.

- Incorrect or dirty filter(s).

- Incorrect supply or return ductwork.

- Incorrect blower speed setting.

- 24 Vac wires miswired or loose.

- "R" missing/not connected at motor.

- Fan is delay mode.

- "R" missing/not connected at motor.

- Fan is delay mode.

Corrective Action

----

- Check 115 Vac power at motor.

- Check low voltage (24 Vac R to C) at motor.

- Check low voltage connections (G, Y, W, R, C) at motor.

- Check for unseated pins in connectors on motor harness.

- Test with a temporary jumper between R - G.

- Check motor for tight shaft.

- Perform motor/control replacement check, ICM-2 motors only.

- Run Moisture Check.*

- Check for loose motor mount.

- Make sure blower wheel is tight on shaft.


----

- Check line voltage for variation or "sag".

- Check low voltage connections (G, Y, W, R, C) at motor, unseated pins in motor harness connectors.

- Check-out system controls - Thermostat.

- Perform Moisture Check.*

- Does removing panel or filter reduce "puffing"?

- Check/replace filter.

- Check/correct duct restrictions.

- Adjust to correct blower speed setting.

- Check low voltage (Thermostat) wires and connections.

- Verify fan is not in delay mode - wait until delay complete.


- Is fan in delay mode? - wait until delay time complete.


- Check for Triac switched t'stat or solid state relay.


Cautions and

Notes

----

- Turn power OFF prior to repair. Wait 5 minutes after disconnecting power before opening motor.

- Handle electronic motor/control with care.



----







- Blower won't shut off.

- Current leakage from controls into G, Y, or W.

- Excessive noise.

- Air noise.

- Noisy blower or cabinet.

- "Hunts" or "puffs" at high CFM

(speed).

- High static creating high blower speed.




- Loose blower housing, panels, etc.


- Air leaks in ductwork, cabinets, or panels.





- Evidence of Moisture.

- Motor failure or malfunction has occurred and moisture is present.

- Moisture in motor/control module.

*Moisture Check

- Connectors are oriented "down" (or as recommended by equipment manufacturer).

- Arrange harnesses with "drip loop" under motor.

- Is condensate drain plugged?

- Check for low airflow (too much latent capacity).

- Check for undercharged condition.

- Check and plug leaks in return ducts, cabinet.




- Check for loose blower housing, panels, etc.

- Check for air whistling thru seams in ducts, cabinets or panels.

- Check for cabinet/duct deformation.

- Does removing panel or filter reduce "puffing"?




- Replace motor and perform Moisture Check.*






Note: You must use the correct replacement control/motor module since they are factory programmed for specific operating modes. Even though they look alike, different modules may have completely different functionality. The ICM-2 variable speed motors are currently the only motors that can have the motor/control module replaced.

Important Note: Using the wrong motor/control module voids all product warranties and may produce unexpected results.

SERVICING

OUT -

ADJUST +/-

Y 1

COOL

DELAY

COMMON 2

W/W1

COMMON 1

8

7

6

5

4

3

2

1

16

OUT +

15

G (fan)

14

Y/Y2

13

EM HT/W2

12

24VAC (R)

11

HEAT

10

BK/Pwm (Speed)

9

O (Rev Valve)

CONTROL CONNECTOR

"Motor Half“

(Viewed from connector end)

CAUTION

High Voltage on Control Pins will Destroy Motor

Do not apply 24 volts to terminals "Out +" or "Out -".

Make sure connector is fully seated.

Make sure pins are fully seated in connector housing.

Verify C1 and C2 are connected to transformer common.

Verify "R" is connected to transformer hot.

After verifying above connections, motor can be tested by applying 24 volts to control pins. Example: R to G will cause the fan to come at "Fan-Only" CFM, R to G to Y will cause the fan to come on at cooling speed and R to G to W will cause the fan to come on at heating speed.

If motor does not respond as noted, ICM control unit is bad and should be replaced.

Replacing ICM Control Module

Use the following steps to replace the control module for the

GE © variable speed indoor blower motor.

1. You must have the correct replacement module. The controls are factory programmed for specific operating modes. Even though they look alike, different modules may have completely different functionality. Using the wrong control module voids all product warranties and may produce unexpected results.

2. Remove all power from the unit being serviced. Do not work on the motor with power applied. Wait at least 5 minutes after disconnecting power from the equipment before opening the motor.

3. It is usually not necessary to remove the motor from the blower assembly. However it is recommended that the whole blower assembly, with the motor, be removed.

Unplug the two cable connectors to the motor. There are latches on each connector. Do not pull on the wires.

The plugs remove easily when properly released.

4. Observe the flat end of the motor control module casting and located the two standard ¼" hex head bolts.

Remove these bolts from the motor while holding the control module. Do not remove the two torx head

screws.

5. The control module is now free of the motor but still attacked by a plug and cable. Carefully rotate the control so as to gain access to the plug on the end of the cable.

Squeeze the release latch and gently pull the plug out of the control module. Do not pull on the wires. Grip the plug only.

6. The control module is now completely detached from the motor. Verify with a standard ohmmeter that the resistance from each motor lead (in the motor plug just removed) to the motor shell is greater than 100k ohms.

(Measure resistance to unpainted motor end plate). If any motor lead fails this test do not proceed to install the control module. The motor is defective and must be replaced. Installing the new control module will cause it to fail also.

7. Verify that the replacement control module is correct for your application. If so, orient the new module next to the motor arid carefully insert the plug removed in step 5. Be sure the plug latches. It will click when properly inserted.

8. Install the new control module back on the motor being careful to engage the locating pin into the appropriate mating motor hole. Replace the two 1/4" hex head bolts.

Tighten the bolts snugly. It is not necessary to overtighten.

Note: Before replacing the blower/motor assembly, it is important to look at the installation to see if some application fault has caused the motor to fail.

Is there any evidence of water damage to the failed control?

(Corrosion on the inside or outside of the casting.) If yes, do moisture check.

9. Re-install the blower/motor assembly into the furnace.

10. Plug the 16-pin control plug into the motor. The plug is keyed. Make sure the connector is properly seated and latched.

11. Plug the 5 pin power connector into the motor even though the plug is keyed, observe the proper orientation. Do not force the connector. It plugs in very easily when properly oriented. Reversing this plug will cause immediate

failure of the control module.

12. Final installation check. Make sure the motor is installed as follows: a. As far into the blower housing as possible.

b. Belly bands not covering vent holes or on the control module.

c. Motor connectors should oriented as to prevent the accumulation of moisture in the control.

d. Use wire ties to create a drip loop in the motor cables.

135 Rev. 1

SERVICING

13. The installation is now complete. Reapply power to the furnace and verify that the new motor control module is working properly.

For complete troubleshooting information on the variable speed air circulator blower motors, refer to the Troubleshooting Chart for ECM/ICM Variable Speed Air Circulator Blower

Motors in this manual.

S-10 CHECKING CAPACITOR

The direct drive motors are of the permanent split capacitor design. A run capacitor is wired across the auxiliary and a portion of the main windings. The capacitors primary function is to reduce the line current while greatly improving the torque characteristics of a motor. This is accomplished by using the 90° phase relationship between the capacitor current and voltage in conjunction with the motor windings so that the motor will give two phase operation when connected to a single phase circuit. The capacitor also reduces the line current to the motor by improving the power factor to the load.

3. Set an ohmmeter on its highest ohm scale and connect the leads to the capacitor.

a.

Good Condition - indicator swings to zero and slowly returns toward infinity.

b.

Shorted - indicator swings to zero and stops there

- replace.

c.

Open - no reading - replace. Reverse leads. Check again no reading - replace.

d.

Reverse leads and recheck.

S-10B Capacitance Check

VOLT / OHM

METER

WARNING

DISCHARGE CAPACITOR THROUGH A 20 TO 30 OHM

RESISTOR BEFORE HANDLING

Two quick ways to test a capacitor are a resistance and a capacitance check. Refer to the next two figures for proper meter connections for the resistance and capacitance testing of the capacitor.

AMMETER

15 AMP FUSE

S-10A Resistance Check

VOLT / OHM

METER

C

A

PA

C

IT

O

R

Testing Capacitance

With power On (and Door Interlock Switch closed):

WARNING


Using a hookup as shown above, take the amperage and voltage readings and use them in the formula:

Capacitance (MFD)= 2650 x Amperage/Voltage

4. After completing check and/or replacement of capacitor, reinstall blower compartment door.


Testing Capacitor Resistance

WARNING


1. Remove blower compartment door to gain access to capacitor.

2. Discharge capacitor and remove wire leads.

S-11 CHECKING GAS VALVE (Redundant)

A combination redundant operator type gas valve which provides all manual and automatic control functions required for gas fired heating equipment is used.

The valve provides control of main burner gas flow, pressure regulation, and 100 percent safety shut-off.

136 Rev. 1

SERVICING

WARNING


1. Remove wire connections from gas valve terminals.

2. Using an ohmmeter, test across the gas valve coil terminals, both the redundant and the main valve.

3. Should read approximately 130 Ohms for the Robertshaw main valve operator coils and 100 Ohms for

Honeywell. The redundant coil will vary somewhat as well.

4. Reverse leads Some redundant coils have (dividers) diodes.

Resistance of the redundant and 2nd stage coils on White-

Rodgers 36E series gas valves can't be measured at the valve terminals with an ohmmeter because of diodes. The on/off switch may efffect the resistance measurement.

1. Remove the switch panel and measure the coils directly.

2. Using an ohmmeter, test across the coils. A coil's resistance increases with increasing temperature.

Nominal Coil Resistance:

Main = 95 ohms

Redundant = 98 ohms

2nd Stage = 180 ohms

3. Allow at least 20% tolerance for temperature and meter variation. Most of the time coils will fail as open circuit.

If not as above, replace the entire valve.

80% Furnaces: Should read between 50 to 200 ohms.

90% GUCA,GCCA and GUVA-AX Model Furnaces:

Should read between 50 to 300 ohms for mini ignitor part number 20165701, used in initial production of GUCA and GCCA models.

90% GUCA, GCCA and GUVA-AX Model Furnaces:

Should read between 30 to 175 ohms for mini ignitor part number 20165702, used in later production of GUCA,

GCCA and also used on GUVA models.

90% GUSA-BX and GUVA-BX Model Furnaces: Should read between a minimum of 10.9 to a maximum of 19.7

ohms.

5. Reconnect ignitor.

WARNING


6. Place unit in heating cycle, measure current draw of ignitor during preheat cycle.

80% Furnaces: Should read approximately 4 to 5 amps.

90% GUCA, GCCA and GUVA-AX Model Furnaces:

Should read approximately 1 amp maximum. The steady state current at 120V is a nominal of .7 plus or minus .3

amps.

90% GUSA-BX and GUVA-BX Model Furnaces: Should read approximately 1 to 3 amps. NOTE: Due to the

"Adaptive Ignitor Modulation Routine" of the 50M/V61 integrated ignition controls, the amp reading will fluctuate when reading with standard amp meter.

7. After check and/or replacement of hot surface ignitor, reinstall burner compartment door and verify proper unit operation.

S-12 CHECKING HOT SURFACE IGNITOR

The 80% furnaces use a 120V silicone carbide resistive element ignitor for ignition. The normal operating temperature is approximately 2550°F. The 90% GUCA, GCCA and

GUVA-AX model furnaces use a 120V ceramic/metallic composite mini-ignitor for ignition. The normal operating temperature is approximately 2192° - 2642°F. The 90%

GUSA-BX and GUVA-BX model furnaces use a 120V Silicon Nitride (SiNi) ignitor for ignition. The nominal operating temperature is approximately 2174°F. NOTE: The Silicon

Nitride Ignitor is not interchangeable with carbide ignition controls.

S-13 CHECKING WHITE-RODGERS 50A50,

50A51, 50M61 or 50V61 AND HEATCRAFT

HSI 1-1A OR HSI-2 INTEGRATED IGNITION

CONTROLS

NOTE: Failure to earth ground the furnace, reversing the neutral and hot wire connection to the line (polarity), or a high resistance connection in the neutral line may cause the control to lockout due to failure to sense flame.

WARNING


1. Remove burner compartment door to gain access to the ignitor.

2. Ignitor cool - approximately 70 - 77°F.

3. Disconnect the ignitor from the Ignition Control.

4. Using an ohmmeter measure the resistance of the ignitor:

CAUTION

To avoid the risk of electrical shock, wiring to the unit must be properly polarized and grounded. Disconnect power before performing service listed below.

The ground wire must run from the furnace all the way back to the electrical panel. Proper grounding can be confirmed by disconnecting the electrical power and measuring resistance between the neutral (white) connection and the burner closest to the flame sensor. Resistance should be less than

10 ohms.

137 Rev. 1

SERVICING

The ignition control is a combination electronic and electromechanical device and is not field repairable. Complete unit must be replaced.

The White-Rodgers 50A50 or 50A51 and the Heatcraft HSI

1-1A or HSI-2 ignition controls, control all furnace operations including blower operation in air conditioning. Blower time delays are controlled by the ignition control, see Circulator Blower Timings section in this manual for blower delay information.

WARNING


These tests must be completed within a given time frame due to the operation of the ignition control. Refer to Sequence of Operation section of this manual for corresponding timing charts.

The ignition control is capable of diagnosing many furnace failures to speed troubleshooting. A flashing red or green diagnostic indicator light on the control flashes a code for any discovered failures.

When the control is powered up normally the light will flash once for about one second. This can be used to test for 120 volts and 24 volts to the control since both must be present for the light to flash. If this step fails, check for 120 volts to the control and check the transformer and its associated wiring. If this step is successful give the control a call for heat and wait five (5) seconds or until the furnace goes into lockout. If the control detects a failure it will now be shown on the diagnostic indicator light. Refer to the Abnormal Operation section in the Sequence of Operation section of this manual for more detail on failure codes.

The indicator light may be viewed by looking through the sight glass in the blower compartment door. If the blower compartment door is removed, failure to hold the door switch closed while removing the blower compartment door will result in the loss of the stored failure code. In most cases recycling the ignition control will result in the same failure code originally displayed.

1. Check for 120 volts from Line 1 ( BK-6 wire on GUIA,

GCIA, GUIC, GCIC, GUID, GUIS, GCIS and GUIV models or BK-4 wire on GUCA, GCCA, GUVA and GUSA models) to line 2 neutral ( WH-33 wire on GUIA, GCIA,

GUIC, GCIC, GUID, GUIS, GCIS and GUIV models or

WH-5 wire on GUCA, GCCA, GUVA and GUSA models) at the ignition control. No voltage - check the door switch connections and wire harness for continuity.

2. Check for 24 volts from W to C at the thermostat connections on the ignition control. No voltage - check transformer, room thermostat, and wiring.

3. Check for 120 volts to the induced draft blower by measuring voltage between terminals IND ( VT-55 wire on

GUIA, GCIA, GUIC, GCIC and GUID models, or BK and RD wires on GUIS, GCIS and GUIV models, or

BK-3 wire on GUCA and GCCA models, or RD-15 and

BK-3 wires on GUVA and GUSA models) and neutral.

No voltage - replace ignition control.

4. If voltage is present in Steps 1 through 3 and the induced draft blower is operating, check for 120 volts to the ignitor during the preheat cycle. Measure voltage between terminals IGN ( RD-22 wire on GUIA, GCIA,

GUIC, GCIC, GUID, GUIS, GCIS and GUIV models, or

RD-2 wire on GUCA, GCCA, GUVA and GUSA models) and neutral. No voltage - check pressure switch.

5. After the ignitor warmup time (see notes below), begin checking for 24 volts to the gas valve. Voltage will be present for seven seconds only if proof of flame has been established.

a. On GUIA, GCIA, GUIC, GCIC and GUID models:

Measure voltage from Pin 9 MV/M1 terminal ( GY-47 wire) to Pin 12 C/C2 terminal ( BR-21 wire) on the ignition control 12 Pin connector. No voltage - replace ignition control.

b. On GUIS, GCIS and GUIV models: Measure voltage from either Pin 7 PM terminal ( GY-47 wire) or Pin 1

HI terminal ( YL-11 wire) to Pin 8 C terminal (BR-21 wire) on the ignition control 12 Pin connector. No voltage - replace ignition control.

c. On GUCA and GCCA models: Measure voltage from

Pin 9 C2 terminal (BR-13 wire) to Pin 12 M1 terminal

(GY-12 wire) on the ignition control 12 Pin connector. No voltage - replace ignition control.

d. On GUVA and GUSA models: Measure voltage from either Pin 7 PM terminal ( GY-12 wire) or Pin 2 HI terminal ( YL-20 wire) to Pin 8 C terminal (BR-13 wire) on the ignition control 12 Pin connector. no voltage replace ignition control.

IMPORTANT: The GUCA, GCCA, GUSA and GUVA model furnaces have a "Coil Cover Pressure Switch" in series with the M1 side of the gas valve.

NOTE: The White-Rodgers 50A55 control has an adaptive alogrithm that adjusts the duration of ignitor warmup for the purpose of extending igniter life. Following application of power, the warmup time will be 17 seconds for the first 64 successful ignitions. Each subsequent warmup time will be decreased by 1 second until flame fails to be achieved

(resulting in a retry) or until the minimum of 5 seconds is achieved.

NOTE: The Heatrcraft HSI-2 ignition control has an initial ignitor warmup time of 7 seconds. In the event of a retry, the warmup time will be increased by two seconds and that duration will remain effective until another retry. In which case, the warmup time is again increased by two seconds but never more than 11 seconds. At the end of the heat cycle, the warmup time is reset back to the minimum time setting.

NOTE: The White-Rodgers 50M61 and 50V61 ignition controls have an initial ignitor warmup time of 20 seconds.

These controls have a built-in learning routine that gradu-

138 Rev. 1

SERVICING ally reduces the "ON" time of the ignitor. The effect is that the ignitor operates at a cooler temperature. The learning routine will eventually reduce the ignitor "ON" time to a point at which the ignitor is too cold to ignite the gas. The control will then increase the "ON" time and initiate an ignition retry. The furnace will light. The control will remain at this point for 256 thermostat cycles, after which it will re-enter the learning routine. IMPORTANT: The "ONLY" way to determine if the ignitor "ON" time is changing is to view the ignitor voltage wave form with an oscilliscope.

6. If proof of flame was established voltage will be provided to the air circulation blower following the heat on delay period.

a. Check for 120 volts from the CIR terminal ( WH wire on GUIA, GCIA, GUIC, GCIC, GUID, GUCA, GCCA and GUSA models, or WH-33 wire on GUIS and GCIS models) to the heat terminal ( Heat terminal on GUIA,

GCIA, GUIC, GCIC, GUID, GUCA, GCCA and GUSA models, or Heat-High and Heat-Low terminals on

GUIS, GCIS and GUSA models) on the ignition control. No voltage - replace ignition control.

b. On the 80% GUIV and 90% GUVA two-stage variable speed furnaces, 120 Volts will be present at the motor at all times ( WH-33 and BK-6 wires on GUIV and WH-45 and BK-37 wires on GUVA), even without a call for cooling or heating. These motors receive their operational signals (24 Volts) through the

16-pin wiring harness (connected between the motor and interface board on GUIV-CA/DX models and

GUVA-AX models or connected between the motor and ignition control on GUVA-BX models). NOTE:

For complete troubleshooting information on units using the ECM/ICM blower motors, refer to the servicing section - Checking Air Circulator Blowers (S-

9A ECM/ICM) in this service manual.

NOTE: Accessory Electronic Air Cleaners and Humidifiers powered through the ignition control accessory terminals, under some circumstances can create interference with the ignition control causing intermittent lockouts. If the source of the lockouts cannot be otherwise determined, it is recommended that these accessories be disconnected from the ignition control and powered through alternate means.

S-13A CHECKING WR50A52 INTEGRATED IGNI-

TION CONTROL (RADIANT SENSE)

NOTE: Failure to earth ground the furnace, reversing the neutral and hot wire connection to the line (polarity), or a high resistance connection in the neutral line may cause the control to lockout due to failure to sense flame.

CAUTION

To avoid the risk of electrical shock, wiring to the unit must be properly polarized and grounded. Disconnect power before performing the following service.

The ground wire must run from the furnace all the way back to the electrical panel. Proper grounding can be confirmed by disconnecting the electrical power and measuring resistance between the neutral (white) connection and the burner closest to the flame sensor. Resistance should be less than

10 ohms.

The ignition control module is a combination electronic and electromechanical device and is not field repairable. Complete unit must be replaced.

The WR50A52 ignition control, controls all furnace operations including blower operation in air conditioning. Blower time delays are controlled by the ignition control and are nonadjustable, see the specification section for blower delay information.

WARNING


These tests must be completed within a given time frame due to the operation of the ignition control. See "Sequence of Operation" section for timing chart.

1. Check for 120 volts from Line 1 (BK6 wire) to line 2 neutral (WH-33 wire) at the ignition control. No voltage

- check the door switch connections and wire harness for continuity.

2. Check for 24 volts from W to C at the thermostat connections on the ignition control. No voltage - check transformer, room thermostat, and wiring.

3. Check for 120 volts to the induced draft blower by measuring voltage between IND (VT-55) and neutral. No voltage - check for pressure switch stuck closed. If pressure switch in N.O. position replace ignition control.

4. If voltage is present in Steps 1 through 3 and the induced draft blower is operating, check for 120 volts to the ignitor during the 17 second preheat cycle. If the flame switch has not transferred, the control will continue to power the ignitor until the flame switch transfers, or for 90 seconds. Voltage will be present for one second after the gas valve has opened. Measure voltage between terminals IGN (RD-22) and neutral. No voltage - check pressure switch.

5. Seventeen seconds after a call for heat begin checking for 24 volts to the gas valve. Measure voltage from terminal 5 (YL-8 wire) to terminal 3 (RD-5) on the gas valve.

No voltage - check flame switch and ignitor position.

6. If proof of flame was established 120 volts will be provided to the air circulation blower 45 seconds after the gas valve opens. Check for 120 volts from the CIR terminal (WH) wire to the heat terminal on the ignition control. No voltage - replace ignition control.

NOTE: If cycling the ignition control during testing, the flame switch must be allow to cool and switch back to the N.C.

position before the next ignition attempt.

139 Rev. 1

SERVICING

S-14 CHECKING FLAME RECTIFICATION

FLAME SENSOR

A flame sensing device is used in conjunction with the ignition control module to prove combustion. If proof of flame is not present the control will de-energize the gas valve and

"retry" for ignition or lockout.

The following drawings illustrate from a bottom view, the approximate distances for the ignitor and flame sensor to the gas inshot burner. You will note they are in the main burner stream, not in the carry over ports as shown in the following figure.

IGNITOR FLAME SENSOR

1/4

± .1/16

3/8" ± .1/16"

WARNING


4. Place the unit into a heating cycle.

5. As soon as flame is established a micro-amp reading should be evident once proof of flame (micro-amp reading) is established, the hot surface ignitor will be deenergized.

6. The Integrated Ignition controls will have 1 to 4 microamps. If the micro-amp reading is less than the minimum specified, check for high resistance wiring connections, sensor to burner gap, dirty flame sensor, or poor grounding.

7. If absolutely no reading, check for continuity on all components and if good - replace ignition control module.

NOTE: Contaminated fuel or combustion air can create a nearly invisible coating on the flame sensor. This coating works as an insulator causing a loss in the flame sense signal. If this situation occurs the flame sensor must be cleaned with steel wool.

Models with Integrated Ignition

Control & Flame Sensor Probe

(80% Upflow Model Shown, Counterflow Similar)

3/16" + 1/16"

DISTANCE OF

IGNITOR TO BURNER

IGNITOR FLAME SENSOR

23/64" + 1/64"

DISTANCE OF

SENSOR TO BURNER

BURNERS

Models with Integrated Ignition

Control & Flame Sensor Probe

(90% Upflow Model Shown, Counterflow SImilar)

S-14A CHECKING RADIANT SENSE FLAME SEN-

SOR

The Radiant Sensor is a single pole double throw switch that is activated by a combination of the heat radiating from the burner flame, and the reflected heat from the ignitor.

Once the pressure switch contacts close, power is supplied through the N.C. contacts of the Radiant Sensor to the gas valves terminal 4 (GN-7 wire). When the Radiant

Sensor senses sufficient heat from the ignitor, the sensor will switch to the N.O. position suppling 24V. to the gas valves terminal 5 (YL-8 wire).

If you should experience a flame sense problem with the

GUIB or GCIB series furnace, it is important to verify correct positioning and alignment of the components before replacing the flame sensor. The following drawing illustrates the proper positioning and alignment of the ignitor, radiant shield, and flame sensor.

FLAME SWITCH

(RADIANT SENSE MODELS)

WARNING


1. Disconnect the flame sensor BU-36 wire from the sensor terminal.

2. Connect a micro-amp meter in series with this wire and the sensor terminal.

3. Be sure the negative side of the meter is to BU-36 wire and the positive side of the meter is to sensor terminal.

37°

IGNITOR

5/16"

Models with WER50A52 Integrated Ignition

Control & Radiant Sense Flame Sensor

(80% GUIB & GCIB Models Only)

140 Rev. 1

SERVICING

NOTE: Any bending, twisting, or distortion of the electrical tabs on the sensor will adversely affect the calibration of the switch and result in unacceptable performance of the sensor.

Refer to the Radiant Sense System Wiring Diagram in

GUIB/GCIB Technical Manual for details.

WARNING

Disconnect Gas and Electrical Power Supply:

In checking main burners, look for signs of rust, oversized and undersized carry over ports restricted with foreign material, etc, refer to previous drawing.

WARNING


1 Remove burner compartment door to gain access to the radiant flame sensor.

2. Disconnect the wires from the Radiant Sensor.

3. Using a VOM check from common terminal to NC (Normally Closed) - should read closed. Check from Common to NO (Normally Open) - should read open.

WARNING


4. Place unit into a heating cycle.

5. Using a VOM check from chassis ground, to pin 8 FSO

(GR-9 wire) on ignition control. No power check pressure switch and ignition control.

6. Within the ignitor preheat period, check from chassis ground, to pin 12 FSI (BR-10 wire) on ignition control.

No power check BR-10 wire.

6. When the Radiant Sensor senses sufficient heat it will close the N.O. contacts. Power should now be read at pin 4 MV FS (VT-12 wire). No power check VT-12 wire, replace Radiant Sensor if necessary.

7. After check and/or replacement of radiant flame sensor, reinstall burner compartment door and verify proper unit operation.

S-16 CHECKING ORIFICES

A predetermined fixed gas orifice is used in all of these furnaces. That is an orifice which has a fixed bore and position as shown in the following drawing.

No resizing should be attempted until all factors are taken into consideration such as inlet an manifold gas pressure, alignment, and positioning, specific gravity and BTU content of the gas being consumed.

The only time resizing is required is when a reduction in firing rate is required for an increase in altitude.

Orifices should be treated with care in order to prevent damage. They should be removed and installed with a box-end wrench in order to prevent distortion. In no instance should an orifice be peened over and redrilled. This will change the angle or deflection of the vacuum effect or entraining of primary air, which will make it difficult to adjust the flame properly. This same problem can occur if an orifice spud of a different length is substituted.

WARNING

Disconnect Gas and Electrical Power Supply:

1. Check orifice visually for distortion and/or burrs.

2. Check orifice size with orifice sizing drills.

3. If resizing is required, a new orifice of the same physical size and angle with proper drill size opening should be installed.

A

S-15 CHECKING MAIN BURNERS

The main burners are used to provide complete combustion of various fuels in a limited space, and transfer this heat of the burning process to the heat exchanger.

Proper ignition, combustion, and extinction are primarily due to burner design, orifice sizing, gas pressure, primary and secondary air, vent and proper seating of burners.

GAS

STREAM B

.023" - .027"

The length of Dimension "A" determines the angle of Gas

Stream "B".

DENT OR

BURR

GAS

STREAM B

Beckett Burner

A dent or burr will cause a severe deflection of the gas stream.

141 Rev. 1

SERVICING

S-17 HIGH ALTITUDE APPLICATION (USA)

When these furnaces are installed at high altitude, the appropriate High Altitude Orifice or Pressure Switch 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 High Altitude Orifice Kit will provide the proper design certified input rate within the specified altitude range.

High Altitude Orifice or Pressure Switch Kits are purchased according to the installation altitude and usage of either natural or propane gas. Refer to the Technical Manual or product

Specification Sheet for a tabular listing of appropriate altitude ranges and corresponding manufacturer's high altitude

(Natural or Propane Gas) orifice or pressure switch kits.

Do not derate the furnace by adjusting the manifold pressure to a lower pressure than specified on the furnace rating plate. The combination of the lower air densiry and a lower manifold pressure will prohibit the burner orifice from drawing the proper amount of air into the burner. This may cause incomplete combustion, flashback, and possible yellow tipping.

In some areas the gas supplier may artificially derate the gas in an effort to compensate for te effects of altitude. If the gas is artificially derated the appropriate orfice size must be determined based on the BTU/ft 3 content of the derated gas and the altitude. Refer to th e National Fuel Gas Code,

NFPA 54/ANSI Z223.1, and information provided by the gas supplier to determine the proper orifice size.

3. Connect a calibrated water manometer (or appropriate gas pressure gauge) at either the gas valve inlet pressure tap or the gas piping drip leg as shown in the following two figures.

NOTE: At either location, a hose fitting must be installed prior to making the hose connection.

GAS VALVE CONTROL

ON/Off SWITCH

INLET

OPEN TO

ATMOSPHERE

M

WR

1

O

F

F

P

ON

C

3

2

OUTLET

INLET PRESSURE TAP

SIDE OF VALVE)

OUTLET (MANIFOLD) PRESSURE TAP

(SIDE OF VALVE)

MANOMETER HOSE

PRESSURE REGULATOR ADJUSTMENT

(UNDER CAP SCREW)

MANOMETER

Measuring Inlet Gas Pressure

(Gas Valve Tap)

GAS LINE

GAS SHUTOFF VALVE

GAS LINE

TO FURNACE

OPEN TO

ATMOSPHERE

S-18 CHECKING GAS PRESSURE

Gas Supply Pressure Measurement

DRIP LEG CAP

WITH FITTING

MANOMETER HOSE

CAUTION

To prevent unreliable operation or equipment damage, the inlet gas supply pressure must be as specified on the unit rating plate with all other household gas fired appliances operating.

Gas inlet and manifold pressures should be checked and adjusted in accordance to the type of fuel being consumed.

The line pressure supplied to the gas valve must be within the range specified below. The supply pressure can be measured at the gas valve inlet pressure tap or at a hose fitting installed in the gas piping drip leg. The supply pressure must be measured with the burners operating. To measure the gas supply pressure, use the following procedure.

WARNING

Disconnect Electrical Power and Shut Off Gas Supply:

1. After turning off gas to furnace at the manual gas shutoff valve external to the furnace, remove burner compartment door to gain access to the gas valve.

MANOMETER

Measuring Inlet Gas Pressure

(Alternate Method)

4. Turn ON the gas and electrical power supply and operate the furnace and all other gas consuming appliances on the same gas supply line.

5. Measure furnace gas supply pressure with burners firing. Supply pressure must be within the range specified in the following table.

Inlet Gas Supply Pressure

Natural Gas Minimum: 5.0" W.C. Maximum :10.0" W.C.

Propane Gas Minimum:11.0" W.C. Maximum :13.0" W.C.

If supply pressure differs from above, make necessary adjustments to pressure regulator, gas piping size, etc., and/ or consult with local gas utility.

142 Rev. 1

SERVICING

WARNING


6. Disconnect manometer after turning off gas at manual shutoff valve. Reinstall plug before turning on gas to furnace.

7. Turn OFF any unnecessary gas appliances started in step 3.

8. Turn on gas to furnace and check for leaks. If leaks are found, repair and then reinstall burner compartment door.


WARNING


3. Turn ON the gas and electrical power supply and operate the furnace.

4. Measure gas manifold pressure with burners firing. Adjust manifold pressure using the table below.

Manifold Gas Pressure

Natural Gas

Propane Gas

3.5" w.c.

10.0" w.c.

The final manifold pressure must not vary more than ± 0.3 “ w.c. from the above specified pressures. Any necessary major changes in gas flow rate should be made by changing the size of the burner orifice.

Gas Manifold Pressure Measurement and Adjustment

(80% & 90% Single-Stage Furnaces)

CAUTION

To prevent unreliable operation or equipment damage, the gas manifold pressure must be as specified on the unit rating plate. Only minor adjustments should be made by adjusting the gas valve pressure regulator.

Only small variations in gas pressure should be made by adjusting the gas valve pressure regulator. The manifold pressure must be measured with the burners operating. To measure and adjust the manifold pressure, use the following procedure.

WARNING


8. Disconnect manometer after turning off gas at manual shutoff valve. Reinstall gas valve outlet pressure tap plug before turning on gas to furnace.



WARNING



2. Connect a calibrated water manometer (or appropriate gas pressure gauge) at the gas valve outlet pressure tap as shown in the following figure.

GAS VALVE CONTROL

ON/Off SWITCH

INLET

P

O

F

F

ON

C

M

WR

1

3

2

OUTLET

MANOMETER HOSE

OPEN TO

ATMOSPHERE

INLET PRESSURE TAP

(SIDE OF VALVE) OUTLET(MANIFOLD) PRESSURE TAP

(SIDE OF VALVE)

PRESSURE REGULATOR ADJUSTMENT

(UNDER CAP SCREW)

5. To adjust the gas valve pressure regulator, remove the regulator cap.

6. Turn the adjustment screw clockwise to increase the pressure, or counterclockwise to decrease the pressure.

7. Securely replace the regulator cap.

Gas Manifold Pressure Measurement and Adjustment

(80% & 90% Two-Stage Furnaces)

Natural Gas Adjustments

WARNING



2. Connect a calibrated water manometer (or appropriate gas pressure gauge) at the gas valve outlet pressure tap. Refer to previous Measuring Manifold Gas Pressure figure for proper connection.

Measuring Manifold Gas Pressure

(Gas Valve Tap)

MANOMETER

WARNING



143 Rev. 1

SERVICING

4. Remove the cap screw from the high stage manifold pressure regulator.

5. Using a 3/32" Allen wrench, adjust the high stage manifold pressue regulator to the required pressure setting.

6. Reinstall high stage cap screw and recheck manifold pressure setting with cap on.

7. Remove the cap screw from the low stage manifold pressure regulator.

8. Using a 3/32" Allen wrench, adjust the low stage regulator to the required pressure setting.

9. Reinstall low stage cap screw and recheck manifold pressure setting with cap on.

5. Using a 3/32" Allen wrench, increase low fire manifold pressure by adjusting the low stage manifold regulator so the furnace will light and carryover.

6. Remove the cap screw from the high stage manifold pressure regulator adjustment location.

7. Using a 3/32" Allen wrench, adjust the high stage manifold pressure regulator to the required manifold pressure.

8. Reinstall high stage manifold regulator cap screw. Recheck manifold pressure setting with cap on.

9. Using a 3/32" Allen wrench, adjust the low stage manifold pressure regulator to the required manifold pressure.

10. Reinstall low stage manifold cap screw and recheck manifold pressure setting with cap on.

WARNING





Make sure furnace operates at the proper manifold pressure at both high and low stage outputs.

Gas

Natural Gas


Rate Range Nominal

High Stage 3.0 to 3.6" w.c.

3.5" w.c.

Low Stage 1.6 to 2.2" w.c.

1.9" w.c.

WARNING




13. Turn on electrical power and verify proper unit operation. Make sure furnace operates at the proper manifold pressure at both high and low stage outputs.

Gas

Propane Gas


Rate Range Nominal

High Stage 9.7 to 10.3" w.c. 10.0" w.c.

Low Stage 5.7 to 6.3" w.c.

6.0" w.c.

Propane Gas Adjustments

WARNING



2. Connect a calibrated water manometer (or appropriate gas pressure gauge) at the gas valve outlet pressure tap. Refer to previous Measuring Manifold Gas Pressure figure for proper connection.

WARNING



4. Remove the cap screw from the low stage manifold pressure regulator.

S-19 CHECKING FOR DELAYED IGNITION

Delayed ignition is a delay in lighting a combustible mixture of gas and air which has accumulated in the combustion chamber.

When the mixture does ignite, it may explode and/or rollout causing burning in the burner venturi.

If delayed ignition should occur, the following should be checked:

1. Improper gas pressure - adjust to proper pressure (See

S-18 CHECKING GAS PRESSURE).

2. Improper burner positioning - burners should be in locating slots, level front to rear and left to right.

3. Carry over (lighter tube or cross lighter) obstructed clean.

4. Main burner orifice(s) deformed, or out of alignment to burner - replace.

144 Rev. 1

SERVICING

S-20 CHECKING FOR FLASHBACK

Flashback will also cause burning in the burner venturi, but is caused by the burning speed being greater than the gasair flow velocity coming from a burner port.

Flashback may occur at the moment of ignition, after a burner heats up or when the burner turns off. The latter is known as extinction pop.

Since the end results of flashback and delayed ignition can be the same (burning in the burner venturi) a definite attempt should be made to determine which has occurred.

If flashback should occur, check for the following:

1. Improper gas pressure - adjust to proper pressure (See

S-18 CHECKING GAS PRESSURE)..

2. Check burner for proper alignment and/or replace burner.

3. Improper orifice size - check orifice for obstruction.

NOTE: Both readings may be taken simultaneously and read directly on the manometer if so desired. If an air conditioning coil or Electronic Air Cleaner is used in conjunction with the furnace, the readings must also include these components, as shown in the following drawing.

4. Consult proper tables for the quantity of air.

If the total external static pressure exceeds the minimum or maximum allowable statics, check for closed dampers, registers, undersized and/or oversized poorly laid out duct work.

SUPPLY

AIR

CUTAWAY OF DUCTWORK

TO EXPOSE COIL

S-21 CHECKING DUCT STATIC

The maximum and minimum allowable external static pressures are found in the specification section. These tables also show the amount of air being delivered at a given static by a given motor speed or pulley adjustment.

The furnace motor cannot deliver proper air quantities (CFM) against statics other than those listed.

Too great of an external static pressure will result in insufficient air that can cause excessive temperature rise, resulting in limit tripping, etc. Whereas not enough static may result in motor overloading.

To determine proper air movement, proceed as follows:

1. With clean filters in the furnace, use a draft gauge (inclined manometer) to measure the static pressure of the return duct at the inlet of the furnace. (Negative Pressure)

2. Measure the static pressure of the supply duct. (Positive Pressure)

3. Add the two (2) readings together for total external static pressure.

AIR COMMAND

HI EFFICIENCY 80 GAS FURNACE

Amana

Elect ronic Air Cl eaner

Caution

High Vo lta ge

To avoid personalinjury,wait 15 seconds after de- energizingunit before touching unit interior .

INCLINED

MANOMETER

RETURN

AIR

Checking Static Pressure


145 Rev. 1

SERVICING

S-22 CHECKING TEMPERATURE RISE

The more air (CFM) being delivered through a given furnace, the less the rise will be; so the less air (CFM) being delivered, the greater the rise. The temperature rise should be adjusted in accordance to a given furnace specifications and its external static pressure. An incorrect temperature rise may result in condensing in or overheating of the heat exchanger. 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. Check BTU input to furnace - do not exceed input rating stamped on rating plate. Ensure all registers are open and all duct dampers are in their final (fully or partially open) position.

2. Place thermometers in the return and supply ducts as close to the furnace as possible. Thermometers must not be influenced by radiant heat by being able to “see” the heat exchanger.

HEAT EXCHANGER

RADIATION "LINE OF SIGHT"

SUPPLY

AIR

3. Subtract the return air temperature from the supply air temperature to determine the air temperature rise. Allow adequate time for thermometer readings to stabilize.

4. Adjust temperature rise by adjusting the circulator blower speed. Increase blower speed to reduce temperature rise.

Decrease blower speed to increase temperature rise.

Refer to Circulator Blower Speed section in the Product

Design section of this manual for speed changing details. Temperature rise is related to the BTUH output of the furnace and the amount of air (CFM) circulated over the heat exchanger. Take motor amperage draw to determine that the motor is not overloaded during adjustments.

T

SUPPLY

AIR COMMAND

HI EFFICIENCY 80 GASFURNACE

RISE = T SUPPLY T RETURN

T

RETURN

RETURN

AIR

Checking Temperature Rise


146 Rev. 1

ACCESSORY WIRING DIAGRAMS

30

C

YL

06

G R W Y

OR

04

B 17 156

M HU

RK PA

RK PA

AT HE

OL CO

C

MR XF

TP

EA

E LIN

ERSED

1 20

REV

U T

T

GIS

KO

AN

OC

RT

WIR

LL

CE

LW

IMPO

ERVI

RO

TS

CO NT

VOL

M

C

E

MR XF

LIN

EA

CIR

HU

1

2

R1

5

4

3

VT 02

2

1

R2

4

5

3

VT

01

VT

55

WH

33

VT

03

BU

08

OR

05

BK

09

YL

06

YL

07

LOAD

LINE

YL

07

BK

09

OR

05

BU

09

WH

33

4 R1

250

SW

2 1 3

T1

N.C.

K1

N.O.

NORMAL

SERVICE

C

MOTOR

K1

N.O.

S1

C

N.C.

N.O.

S2

C

N.C.

T2

VENT DAMPER

HIGH

VOLTAGE

JUNCTION

BOX

WH

VT

03

BK

COMBUSTION

BLOWER

Point to Point Wiring

FURNACE COMMON VENT KIT- CVK4-7

(80% Furnaces with White-Rodgers 50A50 Integrated Ignition Control)

This wiring diagram is for reference only. Not all wiring is as shown above, refer to the appropriate wiring diagram for the unit being serviced.

(For use only with 80% Single-Stage Furnaces)

147 Rev. 1


COOL-H

E17

E1 6

HE AT-H

PARK

E2 8

EAC-H

E1 8

P ARK

E2 7

E1 4

LINE -H

X FMR-H

E1 3

E2 0

HUM-H

LINE-N

E7

HIM- N

E8

E4

EAC- N

E9

XFMR -N

E1 0

CIR- N

E1 1

OF F

ON

1

2

!

WARNING

DISCO NNECT POWER

BEFORE SERVICING

-NOT FIELD REPAIRABLE

REPLA CE ONL Y WITH

EXACT MODEL NUMBER .

EXPL OSION A ND SERIOUS

INJU RY COU LD RESULT

PS

HLO

HL1

1 R O

FP

S R O

G ND

156-4063B

TH

TR

MV

MV

Y W R G C

E1

1

2

R1

5

3

4

VT 02

VT

01

VT

55

WH

33

VT

03

2

1

R2

4

5

3

BU

08

OR

05

BK

09

OR

04

YL

06

YL

07

LOAD

LINE

YL

07

BK

09

OR

05

BU

09

WH

33

4 R1

250

SW

2 1 3

N.C.

K1

N.O.

NORMAL

SERVICE

C

MOTOR

K1

N.O.

S1

C

N.C.

N.O.

S2

C

N.C.

T1 T2

VENT DAMPER

HIGH

VOLTAGE

JUNCTION

BOX

WH

VT

03

BK

Point to Point Wiring

COMBUSTION

BLOWER

148 Rev. 1

FURNACE COMMON VENT KIT- CVK4-7

(80% Furnaces with White-Rodgers 50A55 Integrated Ignition Control)


(For use only with 80% Single-Stage Furnaces)


Furnace 2

WHT (with terminal) *

WHT (without terminal) *

BLK

BLK

Heat

Speed

Cool

Speed

T'Stat Connections

G Y W R C

Fan/LED

Sensor

RED

BLK

WHT

Furnace 1

G Y W R C

T'Stat Connections

Cool

Speed

Heat

Speed

WHT

BLK

RED

BLK

BLK

WHT (with terminal) *

WHT (without terminal) *

Fan/LED

Sensor

Twinning Control

FAULT

SIGNAL

RED

BLK

WHT

FLASH 1 = FURNACE 1

FLASH 2 = FURNACE 2

FLASH 3 = BOTH

FAN/LED

SENSOR

INPUTS

C (COM)

R (24V)

W (HEAT)

Y (COOL)

G (FAN)

G (FAN)

Y (COOL)

W (HEAT)

R (24V)

C (COM)

WHT

BLK

RED

FURNACE

T'STAT

INPUTS

FURNACE

T'STAT

INPUTS

FAN/LED

SENSOR

INPUTS

F

U

R

N

A

C

E

2

1

A

C

E

F

U

R

N

(+)

(-)

REMOTE FAULT

SIGNAL OUTPUT

SEE INSTRUCTIONS FOR ELECTRICAL

SPECIFICATIONS OF REMOTE DEVICE.

Y88FA-3

TWINNING

CONTROL

THERMOSTAT

CONNECTIONS

(1STSTAGE HEAT) W1

(2NDSTAGE HEAT) W2

(1STSTAGECOOL) Y1

(2ND STAGE COOL) Y2

(FAN) G

(SUPPLY) R

(COMMON) C

FOR SINGLE STAGE OPERATION:

HEATING : JUM PER W 1-W 2

CO OLING: JU MPER Y1-Y2

INPUT: 24VAC , 50/60 Hz

(FRO M FURN ACE 1X FM R)

OU TPUTS: 2 A MAX . (EAC H FUNCT.)

T'STAT AN TICIPATION SETTIN G: 0.16 A

C O N

J OHNS

O

ON

PA TE NT S PE NDING

R

Remote LED

(Optional)

W1

W2

Y1

Y2

G

R

C twin-2

FURNACE TWINING KIT - FTK03A


(For use only with 80% or 90% Single-Stage Furnaces)

149 Rev. 1


OUTDOOR

THERMOSTAT

BU6

BU6

HEAT PUMP

THERMOSTAT

CONNECTIONS

E

O

Y

W

R

C/X

DUAL FUEL

RELAY

#1

OD

STA

O

Y

W

R

C

RELAY

#2

FURNACE

1 2 R WG C Y

O

Y

W

G

C

R

SEE NOTE 1 (RESISTOR)

ROOM

THERMOSTAT

E

L

O

Y

W OR W2

G

C/X

R

B

W3

SEE NOTE 2

(JUMPER)

SEE NOTE 3

(JUMPER)

R W

OR

G C

OR

Y

W1 B

W2

GAS FURNACE THERMOSTAT

CONNECTIONS,

SINGLE AND TWO STAGE

FURNACE

1 2 R C G WY

TYPICAL

OIL

FURNACE

R C G T T

FIELD

SUPPLIED

RELAY

Notes:

1. Resistor must be installed between "W" and "C" if an electronic room thermostat is used.

2. Some room thermostats will require a jumper between "E" and "W" in order to energize furanace in emergency heat mode.

3. Intall jumper from "1" to "2" for air tempering during defrost.

FOSSIL FUEL KIT - FFK03A


(For use with Amana Heat Pumps in conjunction with 80% or 90%

Single-Stage or Two-Stage Furnaces)

150 Rev. 1


White Wire

Blue Wire

B/C G R Y W2 W1

TIME DELAY

2

NC

1

C

NO

Black Wire

INTEGRATED

FURNACE

CONTROL

TWO-STAGE RELAY KIT - TSRK01


(For use only with GUIV-CA/DX or GUVA-AX Two-Stage Furnaces)

151 Rev. 1


GREEN

BLACK

WHITE

60

70

50

40

80

OFF

30

ON

DE-HUMIDISTAT

WHITE - RODGERS

DE-HUMIDISTAT %RH

Thermostat

Connections

Y/Y2 Y1 G R1 DEHUM

Y/Y2 G C2 C1 R3 R2 O EM/W2 W1

CFM

JW03

VSPD

{

CUT TO

ENABLE

DEHUMIDIFY

ADJUST

NORM

(+)

(-)

TEST

A

B

C

D

COOL

A

B

C

D

HEAT

BLOWER

INTERFACE

BOARD

152 Rev. 1

DE-HUMIDISTAT - DEHUM1


(GUIV-CA/DX or GUVA-AX Two-Stage Variable Speed Furnaces)


GREEN

BLACK

WHITE

60

70

80

OFF

50

40

30

ON

DE-HUMIDISTAT

WHITE - RODGERS

DE-HUMIDISTAT %RH

CFM

8 7

S4

8 7

4 3 21

4 3 21

OFF

ON

S3

3

0 YLO Y B/C G R W1 W2

DEHUM

TWIN

0 YLO Y B/C G R W1 W2

CUT FOR

DEHUM

TSTAT

ON S1

3

2

1

OFF

WHITE RODGERS

C

C

US

LO HEAT

HI HEAT

EAC COOL PARK LINE XFMR HUM HUM CIRC

EAC

XFMR

3

4

LINE

5

1

2

LO HEAT HI HEAT EAC COOL

PARK

HOT

LINE XFMR HUM HUM

CIRC EAC

NEUTRAL

XFMR LINE

INTEGRATED IGNITION CONTROL

(50V61-288)

DE-HUMIDISTAT - DEHUM1


(GUVA-BX Two-Stage Variable Speed Furnace)

153 Rev. 1

Amana GCCA115AX50 Service manual

Service

Instructions

40" 80% and 90% Gas Furnaces & Accessories

GUIA, GCIA, GUIB, GCIB, GUIC, GCIC, GUID,

GUIS, GCIS, GUIV, GUCA, GCCA, GUVA, GUSA

INDEX

IMPORTANT INFORMATION

IMPORTANT NOTICES FOR CONSUMERS AND SERVICERS

IMPORTANT INFORMATION

IF REPAIRS ARE ATTEMPTED BY UNQUALIFIED PERSONS, DANGER-

OUS CONDITIONS (SUCH AS EXPOSURE TO ELECTRICAL SHOCK)

MAY RESULT. THIS MAY CAUSE SERIOUS INJURY OR DEATH.

AMANA WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY

DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCE-

DURES. IF YOU PERFORM SERVICE ON YOUR OWN PRODUCT, YOU

ASSUME RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROPERTY DAMAGE WHICH

MAY RESULT.

COUNTERFLOW FLOOR BASE

COUNTERFLOW SUBBASE

EXTERNAL FILTER RACK KIT

ACCOMODATOR FILTER HOUSING

HORIZONTAL FILTER HOUSING

MEDIA AIR CLEANER

ELECTRONIC AIR CLEANER

30°

A

H

B

2-1/8"

C

E

D

3-1/2"

G F

DEHUMIDISTAT

CONCENTRIC VENT CONVERSION KIT

COMMMON VENT KIT

Horizontal Vent Installation

Install vent damper with actuator in any position.

Vertical Vent Installation

Single-Stage Heating Only

Single-Stage Heating with Single-Stage Cooling

Two-Stage Heating Only

Single-Stage Heating with Single-Stage Cooling

Two-Stage Heating with Single-Stage Cooling

Single-Stage Heating with Single-Stage Cooling

Two-Stage Heating with Single-Stage Cooling

Two-Stage Heating with Two-Stage Cooling

GUIV-CA/DX & GUVA-AX Two-Stage Variable Speed Furnace

Thermostat Wiring Reference Chart

Model

Minimum Filter Requirement (in

)

Permanent Filters

Airflow Requirements (Nominal)

Model

Minimum Filter Requirement (in

)

Disposable Filters

Airflow Requirements (Nominal)

HEATING TIMING CHART FOR WHITE-RODGERS 50A50 AND HEATCRAFT HSI 1-1A

INTEGRATED IGNITION CONTROL OPERATION

COOLING TIMING CHART FOR WHITE-RODGERS 50A50 AND HEATCRAFT HSI 1-1A

INTEGRATED IGNITION CONTROL OPERATION

HEATING TIMING CHART FOR WHITE-RODGERS 50A55 AND HEATCRAFT HSI-2

INTEGRATED IGNITION CONTROL OPERATION

NOTE: HEATCRAFT INTEGRATED CONTROL MODULE HAS A FIXED

STANDARD SEVEN-SECOND IGNITER WARM UP PERIOD

(MINI IGNITER).

WHITE-RODGERS INTEGRATED CONTROL MODULE HAS A

VARIABLE STANDARD IGNITER WARM UP PERIOD BETWEEN

A 17-SECOND MAXIMUM AND A FIVE-SECOND MINIMUM.

COOLING TIMING CHART FOR WHITE-RODGERS 50A55 AND HEATCRAFT HSI-2

INTEGRATED IGNITION CONTROL OPERATION

Troubleshooting Chart for 50A55 & HSI-2 Integrated Ignition Controls

Troubleshooting Chart for 50A55 & HSI-2 Integrated Ignition Controls

HEATING TIMING CHART FOR WHITE-RODGERS 50A52

RADIANT SENSE IGNITION CONTROL

COOLING TIMING CHART FOR WHITE-RODGERS 50A52