Amana GCCA Unit installation

GUCA & GCCA
Gas Fired Warm Air Furnace
®
User’s Information Manual
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.
You have purchased a high-efficiency, gas-fired, warm-air residential furnace. It is
designed to heat your home efficiently and safely. It is also designed to interface
with your cooling equipment and to assist in circulating conditioned air.
Your furnace functions are regulated by an integrated control module which
responds to your home thermostat. This module controls all aspects of operation,
and is designed to assure efficiency, reliability, comfort, and safety.
The GUCA/GCCA furnace has been designed with flexibility in mind. It can be
installed in an upright or horizontal position. It can use either indoor or outdoor air
for combustion purposes. Use of indoor air, referred to as non-direct vent (single
pipe), requires only a flue pipe; combustion air is drawn from indoors. Use of
outdoor air, referred to as direct vent (dual pipe), requires both a flue pipe and a
combustion air intake pipe.
Your furnace is built to provide many years of safe and dependable service,
providing it is properly installed and maintained. Take time to familiarize yourself
with the information concerning furnace installation, features, operation, and
maintenance contained within this manual.
Heating&Air Conditioning
®
Built Better Than It Has To Be
August 2000 Rev. 1
10318819
Contents
Important Note To The Owner ........................................................................... 3
Component Identification ........................................................................ 4
General Information ................................................................................. 5
Unit Location ...................................................................................................... 5
Unit Installation .................................................................................................. 5
Clearances and Accessibility ............................................................................. 6
Air Requirements ............................................................................................... 6
Combustion Air (Non-Direct Vent/Single Pipe) .................................................. 6
Combustion Air (Direct Vent/Dual Pipes) ........................................................... 7
Flue Pipe and Condensate Drainage ................................................................. 7
Indoor Humidity ........................................................................................... 7
For Propane (LP) Gas Installations Only ........................................................... 8
Operating Your Furnace .......................................................................... 9
Furnace Operation ............................................................................................. 9
Thermostat Functions ........................................................................................ 9
Integrated Control Module .......................................................................... 9
Gas Valve ...................................................................................................... 9
Igniter ............................................................................................................ 9
Blowers ......................................................................................................... 9
Starting Your Furnace ...................................................................................... 10
Shutting Down Your Furnace ........................................................................... 10
Safety Circuits......................................................................................... 11
Integrated Control Module ............................................................................... 11
Primary Limit .................................................................................................... 11
Auxiliary Limit ................................................................................................... 11
Rollout Limit ..................................................................................................... 11
Pressure Switches ........................................................................................... 11
Flame Sensor .................................................................................................. 11
Resetting From Lockout ................................................................................... 11
Routine Maintenance ............................................................................. 12
Annual Inspection ............................................................................................ 12
Filters .......................................................................................................... 12
Filter Removal ............................................................................................ 12
Filter Cleaning and/or Replacement ........................................................ 13
Troubleshooting / Before You Request a Service Call ....................... 14
Safety Labels ........................................................................................... 16
For Additional Information .................................................................... 17
THE INSTALLATION AND SERVICING OF THIS EQUIPMENT MUST BE PERFORMED BY
QUALIFIED, EXPERIENCED TECHNICIANS ONLY.
Due to policy of continual product improvement, the right is reserved to
change specifications and design without notice
2
WARNING
Should overheating occur, or the gas supply fail to shut off, shut off the manual gas valve to the furnace before shutting
off the electrical supply.
WARNING
To avoid death, personal injury or property damage, do not use this furnace if any part of the furnace has been under
water. Immediately call a qualified service technician to inspect the furnace and to replace any part of the control
system and any gas control having been under water.
Important Note To The Owner
It is important that you fill out the owner’s registration card and mail it today. This will assist Amana in contacting you
should any service or warranty information change in the future. When filling in the registration card, be sure to include
the Model, Manufacturing and Serial Numbers, plus the installation date. If the registration card cannot be located,
please call 1-877-254-4729 to register the furnace.
Your warranty certificate is also supplied with the unit. Read the warranty carefully and note what is covered. Keep the
warranty certificate in a safe place, so you can find it, if necessary.
Before using this manual, check the serial plate for proper model identification.
Installer - Affix this manual, the Installation Guide, and Specifications Sheet adjacent to the appliance.
Owner - Keep all product literature in a safe place for future reference.
RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION.
ATTENTION INSTALLING PERSONNEL
As a professional installer you have an obligation
to know the product better than the customer.
This includes all safety precautions and related
items.
Remember, it is your responsibility to install the
product safely and to know it well enough to be
able to instruct a customer in its safe use.
Safety is a matter of common sense...a matter of
thinking before acting. Most dealers have a list of
specific good safety practices...follow them.
Prior to actual installation, thoroughly familiarize
yourself with this Instruction Manual. Pay special
attention to all safety warnings. Often during
installation or repair it is possible to place
yourself in a position which is more hazardous
than when the unit is in operation.
The precautions listed in this Installation Manual
are intended as supplemental to existing
practices. However, if there is a direct conflict
between existing practices and the content of
this manual, the precautions listed here take
precedence.
Remember to leave this manual with the homeowner.
3
Component Identification
7
8
7
5
9 10
11
11
3
25
3
12
13
14 15
2
1
33
17
18
19
20
31
23
32
24
3
22
18
16
3
19
20
15
33
18
19
19
22
17
12
18
21
32
31
29
30
16
20
20
30
23
28
14
13
24
2 21
1
27
26
25
9
Upflow/Horizontal (GUCA Models)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
10
27
34
4
29
26
7
8
7
6
4
Counterflow/Horizontal (GCCA Models)
Gas Valve
Gas Line Entrance (Alternate)
Pressure Switch
Gas Manifold
Combustion Air Intake Connection
Hot Surface Igniter
Rollout Limit
Burners
Flame Sensor
Flue Pipe Connection
Flue Pipe
Combustion Air Intake (Alternate)
Primary Limit
Gas Line Entrance
Flue Pipe Connection (Alternate)
Rubber Elbow
Induced Draft Blower
Coil Front Cover Pressure Tap
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
4
BLOWER COMPARTMENT
6
Coil Front Cover Drain Tap
Drain Line Penetrations
Drain Trap
Capacitor
Electrical Connection Inlets (Alternate)
Integrated Control Module
(with fuse and diagnostic LED)
24 Volt Thermostat Connections
Transformer (40 VA)
Circulator Blower
Bottom Return Filter Retainer
Blower Door Interlock Switch
Junction Box
Electrical Connection Inlets
Auxiliary Limits
Coil Front Cover
Combustion Air Inlet Pipe
BURNER COMPARTMENT
BLOWER COMPARTMENT
BURNER COMPARTMENT
5
General Information
This furnace is built to provide many years of safe and dependable service, providing it is properly installed and
maintained. However, abuse and/or improper use can shorten the life of the furnace and create hazards for you, the
homeowner.
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 avoid possible equipment damage, personal injury, fire or death, the following instructions must be observed
regarding unit location, air requirements and operating procedures.
Unit Location
WARNING
1. The furnace area and the vicinity of any other gas appliances must be kept clear and free of combustible
materials, gasoline, and other flammable vapors and
liquids. Also, do not store or use flammable items
such as paint, varnish, or lacquer in the area.
To avoid personal injury or fire, minimum clearances
to combustible surfaces must be followed.
7. Make certain the required clearances for the furnace
are always maintained. These clearances are listed
on the furnace clearance label. If any question develops, contact the installer of the furnace, or another
qualified servicer.
2. Do not store or use chlorine or fluorine products
(bleaches, cements, strippers, aerosols) near the unit.
They can corrode the heat exchanger.
3. Do not use the furnace closet as storage for brooms,
mops, brushes and oily rags or cloths. The area must
be kept clear, clean and free of lint. Furnace must be
kept free and clear of exposed or loose insulation materials in the area of installation. Examine the furnace
area when the furnace or additional insulation is
added since some insulation materials may be combustible.
Unit Installation
Examine the furnace installation to determine the following:
1. The flue vent pipe is physically sound, sealed, and
well supported. The vent slopes upward to vent terminal so condensate drains back toward the furnace.
The vent shows no evidence of leaking or separation
at joints or fittings.
4. Make sure the furnace is always connected to an approved vent, in good condition, to carry combustion
products outdoors.
2. The return air duct connection is physically sound,
sealed to the furnace casing, and terminates outside
the space containing the furnace.
5. Familiarize yourself with the controls that shut off the
gas and electrical power to the furnace. If the furnace
is to be shut down at the end of the heating season,
turn off both the gas and electrical power. For safety,
always turn the gas and electrical power off before
performing service or maintenance on the furnace.
3. The physical support of the furnace is sound without
sagging, cracks, or gaps around the base so as to
provide a seal between the support and the base.
4. There are no obvious signs of deterioration of the furnace.
6. Establish a regular maintenance schedule to insure
efficient and safe operation of the furnace. The furnace should be checked at the beginning of each
heating and cooling season by a qualified service
technician.
5. Check for proper burner flame performance. Flame
should extend directly outward from burners without,
curling, floating, or lifting off.
5
General Information
Clearances and Accessibility
Carbon monoxide or “CO” is a colorless and odorless
gas produced when fuel is not burned completely or
when the flame does not receive sufficient oxygen.
Installations must adhere to the clearances to combustible materials for which this furnace has been design certified. The minimum clearance information for this
furnace is provided on the unit’s clearance label. These
clearances must be permanently maintained. In addition
to the required clearances to combustible materials, a
36-inch minimum for clearance servicing must be available in front of the unit. Unit positioning is referenced as
follows:
Be aware of these air starvation signals which
indicate conditions that may result in carbon monoxide or that carbon monoxide may be present:
1. Headaches-Nausea-Dizziness, Flu-Like Symptoms.
2. Excessive humidity-heavily frosted windows or a
moist “clammy” feeling in the home.
TOP
3. Smoke from a fireplace will not draw up the chimney.
TOP
SIDE
SIDE
4. Flue gases that will not draw up the appliance vent
pipe.
SIDE
Combustion Air (Non-Direct Vent/Single
Pipe)
BOTTOM
BOTTOM
Upflow
Counterflow
Horizontal
WARNING
Air Requirements
It is vitally important that the furnace have proper
venting. To prevent possible death or personal injury
due to asphyxiation, this furnace must never be
common vented with another gas fired appliance.
Any alteration to any venting system must be in
accordance with local and national codes, and the
manufacturer's instructions.
WARNING
To avoid death, personal injury or property damage,
enough fresh air for proper combustion and
ventilation of flue gases must be provided to this
furnace. Most homes require outside air to be
supplied into the furnace area.
In non-direct vent installations (single pipe), the air for
combustion and ventilation can typically be obtained from
the surrounding unconfined space or louvered closet
door. Observe the following precautions concerning air
availability:
Improved construction and additional insulation in homes
have reduced the heat loss and made these homes
much tighter around doors and windows so that air
infiltration is minimal. This creates a problem to supply
ventilation and/or combustion air for gas fired or other
fuel burning appliances. Any use of appliances that pull
air out of the house (clothes dryers, exhaust fans,
fireplaces, water heaters, non-direct vent furnaces, etc.)
increases this problem and appliances could be starving
for air.
• When a furnace is installed in a closet and the
closet door is louvered, DO NOT OBSTRUCT
LOUVERS. Louvers must be open and clear to
provide combustion air to the furnace.
• When a furnace is installed in a confined space
within a home and the air for combustion and ventilation enters the space through ducts from the outside, be sure to routinely check the entering and
outlet, grilled openings to verify that they are always
clear and clean.
If fuel-burning appliances are starved for air, the flue
gases which these appliances produce as they operate
may not vent outdoors properly, but remain in the home
instead. These flue gases may include carbon monoxide.
• Do not partition off a small area around the furnace
utilizing a non-louvered door. This could obstruct
the combustion air from reaching the furnace.
WARNING
• Do not allow the furnace’s air intake (top or side) to
become blocked.
• The combustion and ventilation air must never
come from a corrosive atmosphere.
Death or personal injury from asphyxiation can result
from exposure to carbon monoxide.
6
General Information
Provisions must be made to drain condensate from the
furnace and protect the condensate drain trap and drain
lines from freezing conditions. The drain trap and drain
lines must be kept clear of blockage.
Combustion Air (Direct Vent/Dual Pipes)
WARNING
Indoor Humidity
Relative humidity is the amount of water vapor in the air
relative to the amount the air can hold at the same
temperature. Example: At 40% relative humidity, the air
could hold 2 1/2 times as much moisture (2.5 x 40 =
100%) before becoming saturated.
It is vitally important that the furnace have proper
venting. To prevent possible death or personal injury
due to asphyxiation, this furnace must never be
common vented with another gas fired appliance.
Any alteration to any venting system must be in
accordance with local and national codes, and the
manufacturer's instructions.
The colder the air; the less moisture it can hold. As air is
warmed, its ability to hold moisture is increased.
Example: A winter day, outdoor temperature 10°F, and
relative humidity of 70%. If that air enters a home and is
warmed to 72°F the relative humidity will drop to 6%
(very dry) if no more moisture is added.
In direct vent installations (dual pipes), the air for combustion and ventilation is obtained from outdoors through
an air intake pipe. Observe the following precautions
concerning air availability:
Relative humidity is important to your health and home
as proper humidification helps reduce respiratory difficulties and helps improve the indoor air quality.
• To ensure proper furnace operation, both the air intake pipe and the flue pipe must never become obstructed.
A good relative humidity is one just high enough to barely
start condensation along the lower edges or lower
corners of the windows. More than that can be damaging.
• The combustion and ventilation air must never
come from a corrosive atmosphere.
Frequent fogging or excessive condensation on inside
windows indicates the indoor humidity level is too high
for outdoor weather conditions. Damage to the building
may result if the condition persists. (Condensation on
inside of storm windows indicates loose inside windows.
Adding weather-stripping to tighten inside windows
usually corrects this problem.)
Flue Pipe and Condensate Drainage
WARNING
To prevent possible death or personal injury due to
asphyxiation, Amana Condensing Gas Fired Warm
Air Furnaces must be Category IV vented.
The following table shows the recommended maximum
indoor humidity in relationship to the outdoor temperatures.
Temperature
(° F.)
+20°
+10°
0°
-10°
-20°
The venting of this furnace (Category IV venting) must
be both gas and water tight. For proper performance,
the size, length, number of elbows, and termination must
be in accordance with the specifications outlined in the
furnace installation guide. The flue system must slope
towards the furnace for proper condensate drainage.
The flue pipe and its termination must be kept clear of
blockage. For further information on Category IV venting, refer to the installation instructions accompanying
this product. If not included, ask your installing dealer or
distributor for this information.
Humidity
Table 1
7
35%
30%
25%
20%
15%
General Information
For Propane (LP) Gas Installations Only
For furnaces operating on propane gas, please review the following warnings before use.
WARNING
To avoid death, personal injury or property damage due to explosion or fire, install a gas detecting warning device.
Since the odorant in propane gas can be reduced by iron oxide (rust), a gas detecting warning device is the only
reliable method to detect propane gas leaks.
WARNING
If the gas furnace is installed in a basement, an excavated area or a confined space, it is strongly recommended to
contact a propane supplier to install a gas detecting warning device in case of a gas leak.
•
Since propane gas is heavier than air, 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.
WARNING
An undetected gas leak will create a danger of explosion or fire. If the presence of gas is suspected, follow the
instructions on the cover of this manual. Failure to do so could result in SERIOUS PERSONAL INJURY OR
DEATH.
8
Operating Your Furnace
WARNING
Furnace Operation
In the heating mode, gas is burned and the products of
combustion are drawn through a heat exchanger by an
induced draft blower. The flue gases are then exhausted
from your home through a flue pipe system. The
furnace’s circulator blower passes indoor air over the
heat exchanger and then through the conditioned space.
The furnace’s heat exchanger is actually two exchangers, a primary and a secondary, connected in series.
The primary heat exchanger is a tubular stainless steel
design built for exceptional durability and efficient heat
transfer. The secondary heat exchanger, sometimes
referred to as a recuperator coil, is a stainless steel tube
and aluminum fin arrangement designed to remove the
last remaining heat from the flue gases. The amount of
heat withdrawn from the flue gases is so great that the
gases are actually cooled to the point of condensing.
This furnace therefore produces condensate (water)
which must be directed to a drain. Furnaces of this type
are referred to as “condensing furnaces”.
Electrical components are contained in both
compartments. To avoid electrical shock, injury or
death, do not remove any internal compartment
covers. Contact a qualified servicer at once if an
abnormal condition is noticed.
Notice:
Do not use this furnace if any part has been under water.
Immediately call a qualified servicer to inspect the
furnace and to replace any part of the control system
and any gas control which has been under water.
Keep both doors in place except for inspection and
maintenance. An interlock switch prevents furnace
operation if the blower door is not in place.
Integrated Control Module
This furnace is equipped with an integrated control
module which regulates all furnace operations. The
control responds to input from the thermostat, initiates
and controls normal furnace operation, and monitors and
responds to all safety circuits. The integrated control
module is outfitted with a 3-amp fuse for electrical
protection.
Thermostat Functions
There are many types and styles of thermostats but the
operation is usually similar. BE SURE TO BECOME
FAMILIAR WITH YOUR THERMOSTAT. The simplest
type of thermostat only starts and stops the furnace to
maintain the desired room temperature. The most widely
used types will control both heating and cooling functions
and will have a Fan Switch with Auto and ON settings.
On Auto, the circulating air blower will cycle on/off with
the furnace but if switched to ON it will run continuously
regardless of whether or not heating or cooling is being
provided.
Gas Valve
The gas valve regulates gas flow to the burners in
response to input from the integrated control module.
Igniter
The furnace has an electronic ignition device which
lights the burners automatically, never try to light the
burners by hand.
Blowers
In addition, there are thermostats which automatically
switch from heating to cooling mode and those with night
set back capability. The night set back, or multiple set
back, type allows for a different temperature at night or
during the day when no one is at home. Programmable
thermostats will allow for more control and tailoring of the
heating and cooling functions. The level of this control
will depend on the type of thermostat applied.
Room Temperature
Thermostat
Cool/Heat
Temperature
Control Dials
Fan Switch
System
Switch
OFF
Fan
Switch
AUTO
COOL
AUTO
COOL
ON
HEAT
AUTO
HEAT
ON
OFF
ON
An induced draft blower is utilized to draw flue products
through the heat exchanger and exhaust them outdoors.
The circulator or main blower passes indoor air over the
heat exchanger and throughout the conditioned space.
Both blowers are permanently lubricated, no further
oiling is required.
Starting Your Furnace
Action
To put your furnace into operation, follow the steps listed
below.
None
System only cools, fan
cycles off and on.
System only cools, fan
runs all the time.
System only heats, fan
cycles off and on.
System only heats, fan
runs all the time.
No heating or cooling,
fan runs all the time.
1. Close the external manual gas shut-off valve.
2. Turn off the electrical power to the furnace.
3. Set the room thermostat to the lowest possible setting.
4. Remove the burner compartment door.
Cool/Heat
Switch
5. This furnace is equipped with an ignition device
which automatically lights the burner. Do not try to
light the burner by hand.
Typical Thermostat
6. Move the furnace’s gas valve ON/OFF switch to the
OFF position.
9
Operating Your Furnace
7. Wait five minutes to clear out any gas. Then smell
for gas, including near the floor as some types of gas
are heavier than air.
Shutting Down Your Furnace
To shut down your furnace into operation, follow the
steps listed below.
8. If you smell gas following the five minute waiting period in step 7, immediately follow the instructions on
the cover of this manual. If you do not smell gas after
five minutes, move the furnace’s gas valve ON/OFF
switch to the ON position.
1. Set the thermostat to the lowest setting.
2. Integrated control closes gas valve extinguishing
flame.
10. Open the external manual gas shut-off valve.
3. Induced draft blower is de-energized following a 15
second delay. The circulator blower is de-energized
following a 60, 90, 120, or 180 second delay period.
11. Turn on the electrical power to the furnace.
4. Remove the burner compartment door.
12. Adjust the thermostat to a setting above room temperature.
5. Move the furnace’s gas valve ON/OFF switch to the
OFF position.
13. After the burners are lit, set the thermostat to desired
temperature.
6. Close the external manual gas shut-off valve.
9. Replace the burner compartment door.
Gas Valve
On/Off
Selector
Switch
INLET
O
F
F
M
1
P
3
C
2
ON
Pressure Regulator
Inlet Pressure Tap
Adjustment
(Side of Valve)
(Under Cap Screw)
7. Replace the burner compartment door.
OUTLET
Outlet (Manifold)
Pressure Tap
(Side of Valve)
White-Rodgers
Model 36E22 or 36E23
(View Is Upside Down For Clarity)
10
Safety Circuits
A number of safety circuits are employed to ensure safe and proper furnace operation. These circuits serve to control
any potential safety hazards and, as inputs in the monitoring and diagnosis of abnormal function. These circuits are
continuously monitored by the integrated control module.
Integrated Control Module
The integrated control module is an electronic device
which regulates all furnace operations. Responding to
the thermostat, the module initiates and controls normal
furnace operation, and monitors and addresses all safety
circuits. If a potential safety concern is detected, the
module will take the necessary precautions and provide
diagnostic information through an LED displayed on the
module. See troubleshooting chart on page 14.
Blower
Deck
Primary Limit
The primary limit control is located on the partition panel
and monitors heat exchanger compartment temperatures. It is a normally closed (electrically), automatic reset, temperature activated sensor. This limit guards
against overheating as a result of insufficient conditioned
air passing over the heat exchanger.
Blower
Rollout Limits
Auxiliary Limit
Flame Sensor
Primary
Limit
Auxiliary Limit
The auxiliary limit control is located on or near the blower
deck and monitors heat exchanger compartment temperatures. It is a normally closed (electrically), manual
reset, temperature activated sensor. This limit guards
against overheating as a result of insufficient conditioned
air passing over the heat exchanger.
Pressure Switches
Rollout Limit
The rollout limit is a normally-closed (electrically),
manual-reset, temperature-activated sensor. It is
mounted on the burner/manifold assembly and monitors
the burner flame. If there is an improper draw of burner
flames into the heat exchanger, the rollout limit will detect
it and shutdown gas flowing to the burners.
Safety Circuits
Upflow Shown (Counterflow Similar)
Resetting From Lockout
Furnace lockout is characterized by a non-functioning
furnace (circulator blower may be running continuously)
providing a one flash diagnostic LED code. Lockout
results when a furnace is unable to achieve ignition after
three attempts, or when it has lost flame five times
during a single call for heat. If the furnace is in “lockout”,
it may be reset by any of the following methods:
Pressure Switches
The pressure switches are normally-open (closed during
operation), single-pole single-throw, negative air pressure
activated switches. They monitor the airflow (combustion
air and flue products) through the heat exchanger via
pressure taps located on the induced draft blower and the
coil front cover. These switches guard against insufficient
airflow (combustion air and flue products) through the
heat exchanger and blocked condensate drain conditions.
1. One hour automatic reset. Control will automatically
reset itself and attempt to resume normal operations
following a one hour lockout period.
2. Power interruption. Interrupt 115 volt power to the
furnace for between 0 and 20 seconds.
3. Thermostat cycle. Interrupt thermostat signal to the
furnace for between 0 and 20 seconds.
Flame Sensor
The flame sensor is a probe mounted to the burner/manifold assembly which uses the principle of flame rectification to determine the presence or absence of flame.
If the condition which originally caused the lockout still
exists, the control will return to lockout. Refer to the
“Troubleshooting” section for aid in determining the
cause. If your furnace frequently locks out, a problem
exists which must be corrected. Contact a qualified
servicer.
11
Routine Maintenance
If you perform maintenance on the furnace yourself, remember that certain mechanical and electrical knowledge, skills
and tools are required to perform maintenance on the furnace. Personal injury or death may result If you are not
properly trained. You should call your installing dealer or place of purchase if you are uncertain about your ability to
perform maintenance.
WARNING
To avoid death or personal injury due to electrical shock, disconnect the electrical power before performing any
maintenance.
Annual Inspection
Filters
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 insure that all furnace components are
in proper working order and that the heating system
functions appropriately. Particular attention should be
paid to the following items. Repair as necessary.
WARNING
To avoid death, personal injury or property damage,
disconnect electrical power before removing filters
never operate furnace without a filter installed. Dust
and lint will build up on internal parts resulting in loss
of efficiency, equipment damage and possible fire.
• Flue pipe system. Check for blockage and/or leakage. Check the outside termination and the connections at and internal to the furnace.
A return air filter is not supplied with this furnace; however, a means of filtering all of the return air must be
provided. Your installer will supply filters at the time of
installation. Become familiar with filter location and
procedures for removing, cleaning and replacing them.
• 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.
If you need assistance, contact the installer of your
furnace or another qualified servicer.
• Burners. Check for proper ignition, burner flame,
and flame sense. Flames should extend directly
outward from burners without curling, floating or lifting off.
Filters must be inspected, cleaned or changed every two
months or as required. As a homeowner, it your personal responsibility to keep air filters clean. Remember
that dirty filters are the most common cause of inadequate heating or cooling performance.
• Drainage system. Check for blockage and/or leakage. Check hose connections at furnace.
Filter Removal
• Wiring. Check electrical connections for tightness
and/or corrosion. Check wires for damage.
Filters are located either at the unit or in a central return
grille. Horizontal installations will always utilize a central
return grille location. If a filter is located at the unit, use
the following information to aid in filter removal.
• Filters. Check that filters are clean and in the
proper placement in the furnace or duct system.
Upflow Filters (Upright)
To remove a filter from the bottom of the blower compartment in an upright upflow installation:
1. Set thermostat to the OFF position or turn OFF electrical power to furnace.
2. Remove blower compartment door.
Check the burner flames for:
1. Good adjustment
2. Stable, soft and blue
3. Not curling, floating, or lifting off.
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.
Burner Flame
5. Replace filter and secure retainer opposite of removal.
12
Routine Maintenance
6. Replace blower compartment door and turn ON thermostat or electrical power to furnace.
Counterflow Filters (Upright)
To remove filters from the ductwork above an upright
counterflow installation:
To remove internal filter(s) from the retaining rails on the
side(s) of the blower compartment in an upright installation:
1. Set thermostat to the OFF position or turn OFF electrical power to furnace.
1. Set the thermostat to the OFF position or turn OFF
electrical power to furnace.
2. Remove access door in ductwork above furnace.
2. Remove the blower compartment door.
4. Replace filters opposite of removal. Replace access
door in ductwork.
3. Remove filters.
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.
5. Turn ON thermostat or electrical power to furnace.
Horizontal and Central Return Filters
To remove filter(s) from the central return grille installation:
4. Replace filter and blower compartment door opposite
of removal and turn ON thermostat or electrical
power.
1. Set thermostat to the OFF position or turn OFF electrical power to the furnace.
Front of Furnace
Front of Furnace
2. Remove filter(s) from the central grille location.
3. Replace filter(s) opposite removal.
4. Turn ON thermostat or electrical power to furnace.
Blower
Filter Cleaning and/or Replacement
Filter
Blower
Use a vacuum cleaner to clean out the blower compartment and the adjacent area of the return air duct
Disposable filters must be replaced with a filter or filters
of the same size as that which is removed. Filters must
comply with UL900 or CAN/ULC-S111 Standards.
Grab Here
And Lift
Permanent filters must be cleaned, washed, and dried as
specified by the filter manufacturer. Filters which use a
dust adhesive should be sprayed or oiled as recommended by the filter and adhesive manufacturers. If it
becomes necessary to replace a permanent filter, it must
be replaced with a filter or filters of the same size as that
which is removed. Filters must comply with UL900 or
CAN/ULC-S111 Standards.
a. Lift filter above bottom b. Tilt filter to clear rail.
rail
Front of Furnace
Front of Furnace
Blower
Blower
When reinstalling filters, be careful to maintain correct
airflow direction.
c. Lower filter below top d. Slide filter out.
rail.
Filter Removal Procedure
To remove filters from an external filter rack in an upright
upflow installation, follow the directions provided with the
external filter rack kit.
13
Troubleshooting / Before You Request a Service Call
If your furnace is not operating or is performing improperly, take time to perform the following checks before requesting service. A couple of simple checks may allow you to avoid a service call. If the following steps do not resolve the
problem, contact a qualified servicer for further troubleshooting and/or repairs. Do not attempt troubleshooting
beyond that which is outlined below. Do not attempt repairs yourself. Use the diagram on page 4 for parts reference.
If your furnace will not start, check the following (in sequence):
NOTE: If flashing, the integrated control module diagnostic LED flash code must be recorded prior to turning off the
power to the furnace or opening the blower compartment door. To determine the flash code, count the number of
flashes seen through the blower compartment door sight glass. Refer to the diagnostics chart for a description of the
LED flash codes and their possible causes.
•
•
•
•
Check thermostat for proper operation. Verify that it is set on HEAT and that temperature (above room temperature) setting is appropriate.
Check to see that the electrical disconnect at the furnace location is in the ON position. If the switch is in the
OFF position, switch it to the ON position to supply electrical power to the furnace.
Check fuse or circuit breaker in furnace electrical circuit. Replace as necessary.
Check to see that the manual gas shut-off valve external to the furnace is in the ON position. If the valve is in
the OFF position, turn the gas ON following the start up procedures outlined in the “Starting Your Furnace”
section.
NOTE: If flashing, record the integrated control module diagnostic LED flash code prior to power interruption. Turn off
furnace electrical power prior to proceeding.
•
•
•
•
Remove burner compartment door and check to see that gas valve ON/OFF switch is in the ON position. (See
figure on page 10) If the switch is in the OFF position, turn the gas ON following the start up procedures
outlined in the “Starting Your Furnace” section.
Remove blower compartment door and check to verify whether or not the manual reset auxiliary limit control
has tripped. The auxiliary limit control is located on or near the circulator blower. (See figure on page 4) If the
auxiliary limit control has tripped, a reset “click” will be heard when the red button on the back of the control is
pressed. Replace door. NOTE: Do not reset the auxiliary limit control more than once. If the control trips
again, follow the furnace shut down procedure outlined in the “Starting Your Furnace” section and contact a
qualified servicer.
Check for blockage at the termination(s) of flue pipe (and the combustion air intake pipe where present). Also
for blockage in the drain trap. Clear if possible. (See figure on page 4)
Check for blockage in the drain lines. If blockage is present, please contact a qualified servicer.
If you experience insufficient airflow, check the following (in sequence):
•
Check for dirty filter(s). This in the most common cause of improper furnace operation. Replace or clean filters
as necessary.
•
Check for blocked return air or supply air grilles throughout you home. Grilles may be blocked by furniture,
drapery, clothes, carpeting, etc. Clear any blockage.
14
Troubleshooting / Before You Request a Service Call
Symptoms of Abnormal
Operation
- Furnace fails to operate.
and
- Integrated control module diagnostic
LED provides no signal.
- Furnace fails to operate.
and
- Integrated control module diagnostic
LED is lit continuously.
- Furnace is not operating
and
- Integrated control module diagnostic
LED is flashing one flash.
- Furnace fails to operate.
and
- Integrated control module diagnostic
LED is flashing two flashes.
- Induced draft blower runs continuously
with no further furnace operation.
and
- Integrated control module diagnostic
LED is flashing three flashes.
- Circulator blower runs continuously
with no further furnace operation.
and
- Integrated control module diagnostic
LED is flashing four flashes.
- Circulator blower runs continuously
with no further furnace operation.
and
- Integrated control module diagnostic
LED is flashing five flashes.
- Furnace fails to operate.
and
- Integrated control module diagnostic
LED is flashing six flashes.
- Normal furnace operation.
but
- Integrated control module diagnostic
LED is flashing seven flashes.
- Furnace is not operating.
and
- Integrated control module diagnostic
LED is flashing eight flashes.
- Circulator blower running continuously
with no further operation.
and
- Integrated control module diagnostic
LED is flashing nine flashes.
- Induced draft and circulator blower run
continuously with no further
furnace operation.
and
- Integrated control module diagnostic
LED is flashing continuously.
Associated
LED Code
Probable Cause(s)
Corrective Action
(See Notes 1 & 2)
None
- No electrical power to furnace.
- Confirm that the external electrical disconnect switch is in the "ON" position.
If "OFF", switch to the "ON" position.
- Check for tripped or blown circuit breaker or fuse. Replace if necessary.
ON
Continuous
On
1
1 Flash
- Integrated control module has an
internal fault.
- Confirm that the external manual gas shut-off valve is in the "Open" position.
If "Closed", follow the start up procedure outlined in this manual when
moving the gas shut-off valve to the "Open" position.
- Check drain system for blockage. Clear if possible.
- No gas supply to furnace.
- Condensate drain blocked.
(See Note 3)
2
- Have servicer inspect furnace and replace faulty integrated control module if
necessary.
- Possible pressure switch malfunction.
- Have servicer inspect furnace and make necessary corrections.
- Blocked flue and/or inlet air pipe.
- Check flue and/or inlet air piping for blockage, especially at the outdoor
termination(s).
2 Flashes
3
1
3 Flashes
- Blocked drain system.
- Check drain system for blockage. Clear if possible
- Check filters. Repace or clean if necessary.
4
- Dirty filters or blocked return grilles.
4 Flashes
5
5 Flashes
6
6 Flashes
- Blocked flue and/or inlet air pipe has
caused flame rollout limit switch(es) to
be activated.
- Polarity of electrical power to furnace
or control module has been reversed.
- Check for furniture, curtains, etc. blocking return grilles. Correct if
necessary.
- Check flue and/or inlet air piping for blockage, especially at the outdoor
termination(s).
- Reset rollout limit switch(es) by depressing the red button on the back of the
switch(es). Only reset rollout limit switch(es) one time. If problem reoccurs,
have servicer inspect furnace and make neccessary corrections.
- Have servicer inspect furnace and make necessary corrections.
- Poor unit ground.
- Flame sensor is coated/oxidized.
7
7 Flashes
8
8 Flashes
(See Note 4)
- Flame sensor is incorrectly positioned
in burner flame
- Have servicer inspect furnace and make necessary corrections.
- Blocked flue and/or inlet pipe.
- Check flue and/or air inlet piping for blockage, especially at the outdoor
termination(s).
- Blocked drain system.
- Check drain system for blockage. Clear if possible
- Check filters. Replace or clean if necessary.
9
- Dirty fliters or blocked return grilles
9 Flashes
(See Note 3)
- Check for furniture, curtains, etc. blocking return
grilles. Correct if necessary.
C
- Malfunction in flame sense circuit.
- Have servicer inspect furnace and make necessary corrections.
Continuous
Flashing
1) LED flash code may be viewed through sight glass in blower compartment door.
2) LED flash code will cease if power to the control module is interrupted through the disconnect or furnace door switch.
3) Integrated control module will automatically attempt to reset from "lock out" (1 Flash) after one hour.
4) Integrated control module will automatically attempt to reset from "lock out" after 20 minutes.
15
16
M
1
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.
MISE EN MARCHE
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.
D. Ne pas se servir de cet appareil s'il a été plongé
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 levier 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.
QUE FAIRE S'IL Y A UNE ODEUR DE GAZ
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
B. AVANT DE LE FAIRE FONCTIONNER,
A.
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.
LIRE AVANT DE METTRE
EN MARCHELIRE
AVERTISSEMENT: Quiconque ne respecte pas á
WARNING: IMPROPER INSTALLATION, ADJUSTMENT, ALTER-
ATION, SERVICE OR MAINTAINANCE CAN CAUSE PROPERTY
DAMAGE, PERSONAL INJURY OR LOSS OF LIFE, EXPOSURE
TO SUSTANCES IN FUEL OR FROM FUEL COMBUSTION WHICH
CAN CAUSE DEATH OR SERIOUS ILLNESS, AND WHICH ARE
KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER
BIRTH DEFECTS, OR OTHER REPRODUCTIVE HARM. REFER
TO THE USER'S INFORMATION MANUAL PROVIDED WITH
THIS FURNACE. INSTALLATION AND SERVICE MUST BE
PERFORMED BY A QUALIFIED INSTALLER, SERVICE
AGENCY OR THE GAS SUPPLIER.
FOR YOUR SAFETY
DO NOT STORE OR USE GASOLINE OR OTHER
FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY
OF THIS OR ANY OTHER APPLIANCE.
SEE INSIDE SURFACE OF LOUVERED DOOR FOR
LIGHTING/OPERATING INSTRUCTIONS.
WARNING
RISK OF ELECTRIC SHOCK OR DEATH.
DISCONNECT THE REMOTE ELECTRIC POWER
SUPPLY OR SUPPLIES BEFORE SERVICING.
DANGER DE CHOC ÉLECTRIQUE OU DE
MORT. DÉBRANCHER TOUTE BOITE Á
FUSIBLES AVANT L'ENTRETIEN.
10435401
1. Set the thermostat to lowest setting.
2. Turn off all electric power to the appliance
if service is to be performed.
3. Push the gas control lever to "OFF" Position.
Do not force.
4. Replace control access panel.
TO TURN OFF GAS TO APPLIANCE
service technician or gas company.
3
2
P
C
LES INDICATIONS POUR L'ECLAIRAGE ET LE
SERVICE SE TROUVENT A LA SURFACE
INTERIEURE DE LA PORT A JALOUSIES.
11072707
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. Pousse le levier du contrôle du gaz à "OFF / ARRET"
position.
Ne pas forcer.
4. Remettre en place le panneau d'accès.
POUR COUPER L'ADMISSION
DE GAZ DE L'APPAREIL
1. ARRETÊR! Lisez les instructions de sécurité sur
1. STOP! Read the safety information above on
la portion supérieure de cette étiquette.
this label.
2. Set the thermostat to lowest setting.
. 2. Régler le thermostat à la température la plus basse
3. Couper l'alimentation électrique de l'appareil.
3. Turn off all power to the appliance.
4. Cet appareil ménager étant doté d'un système
4. This appliance is equipped with an ignition.
d'allumage automatique, ne pas essayer à
device which automatically lights the burner.
allumer le brûleur manuellement.
Do not try to light the burner by hand.
5. Pousse le levier du contrôle du gaz à "OFF/ ARRET"
5. Push the gas control lever to "OFF" Position.
position.
Do not force.
6. Attendre cinq (5) minutes pour laisser echapper tout le
6. Wait five (5) minutes to clear out any gas. Then
gaz. Renifler tout autour de l'appareil, y compris près du
smell for gas, including near the floor. If you
plancher, pour déceler une odeur de gaz. Si c'est le cas,
ROBINET A GAZ
then smell gas, STOP! Follow "B"
MANUEL, EN POS
ARRETER! Passer à l'étape B des instructions de sécuritié
in the safety. information above
"ON/MARCHE"
sur la portion supérieure de cette étiquette.
on this label if you don't smell
*
*
*
S'il n'y a pas d'odeur de gaz, passer à l'étape suivanté.
GAS
gas, go to next step.
INLET
7. Pousse le levier du contrôle du gaz à "ON/MARCHE"
O
7. Push gas control lever
*
F
F
position.
to "ON".
ON
*
8. Remettre en place le panneau d'accés.
8. Replace access panel.
ARRIVEE
9.
Mettre l'appareil sous tension.
*
*
9. Turn on all electric
DU GAZ
10.
Régler
le thermostat à la température desirée.
power to the appliance.
11. Si l'appareil ne se met pas en marche, suiyre les
10.Set thermostat to desired setting.
instructions intitulées. Comment coupler l'admission
MANUAL GAS
11.If the appliance will not operate,
de gaz de l'appereil et appeler un technicien
LEVER SHOWN
follow the instructions "To Turn
qualifié ou le fourrnisseur de gaz.
IN ON POSITION
Off Gas To Appliance" and call your
OPERATING INSTRUCTIONS
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.
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.
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.
WHAT TO DO IF YOU SMELL GAS
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.
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.
explosion may result causing property damage,
personal injury or loss of life.
FOR YOUR SAFETY
READ BEFORE OPERATING
WARNING: If you do not follow these instructions
Safety Labels
NOTE: If safety labels are missing or illegible, contact the installing dealer or Amana Customer Service Department
for ordering information.
COMPARTMENT MUST BE
CE COMPARTTIMENT DOIT RESTER
WARNING:THIS
CLOSED EXCEPT WHEN SERVICING AVERTISSEMENT: FERME, SAUF POUR L'ENTRETIEN
B13580-1LA
AVERTISSEMENT: UNE INSTALLATION, UN REGLAGE,
UNE MODIFICATION, UNE ENTRETIEN, OU UNE
MAINTAINANCE INCORRECTS PEUVENT ENTRAINER DES
DOMMAGES MATERIALS, DES LESIONS CORPORELLES OU LA
PERTE DE VIES HUMAINES. CONSULTER LE MANUEL DES
USAGER FOURNI AVEC CE GENERATEUR D'AIR CHAUD.
L'INSTALLATION ET L'ENTRETIEN DOIVENT ETRE
EFFECTUE'S PAR UN INSTALLATEUR QUALIFIE, UN
ORGANISME DE MAINTENANCE OU LE FOURNISSEUR DE GAZ.
NE PAS ENTREPOSER NI UTILISER DE L'ESSENCE
NI D'AUTRES VAPEURS OU LIQUIDES INFLAMMABLES
DANS LES VOISINAGES DE CET APPAREIL, NI DE
TOUT AUTRE APPAREIL.
AVERTISSEMENT
10232005
For Additional Information
Most questions can be answered by the local Amana dealer. Check with dealer first if needing any further information
regarding the operation, maintenance, or service of the furnace.
If you have any matters that are not resolved locally, or for more information on other heating and cooling products or
kitchen appliances offered by Amana is needed - please call:
CONSUMER INFORMATION LINE
AMANA TOLL FREE
1-877-254-4729 (U.S. only)
email us at: hac.consumer.affairs@amana.com
fax us at: (931) 438- 4362
(Not a technical assistance line for dealers.)
Outside the U.S., call 1-931-433-6101.
(Not a technical assistance line for dealers.)
Your telephone company will bill you for the call.
®
Ask a participating Amana dealer about Amana's extended service plan. It adds to the
strong warranty with additional parts and labor coverage.
TM
EXTENDED SERVICE PLAN
To obtain the proper labels, the Model, Manufacturing Number and Serial Number of
the unit must be supplied. These numbers are recorded on the nameplate of the
furnace. For convenience, record this information here:
MODEL NUMBER: _ _ _ _ _ _ _ _ _ _ _
MANUFACTURING NUMBER: P _ _ _ _ _ _ _F
SERIAL NUMBER: _ _ _ _ _ _ _ _ _ _
17