Amana S)8 manual

5151 San Felipe Suite 500 • Houston, TX 77056 www .goodmanmfg.com • www .amana-hac.com © 201 1 Goodman Manufacturing Company , L.P . C US ® A TTENTION INST ALLING PERSONNEL RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION. Installer: Affix all manuals adjacent to the unit. These furnaces comply with requirements em- bodied in the American Nationa[...]

2 T able of Content s A DDITIONAL S AFETY C ONSIDERA TIONS ...................................................................................................... 6 S HIPPING I NSPECTION ........................................................................................................................... 6 E LECTROST A TIC D ISCHARGE (ESD) P RE[...]

3 T able of Content s C IRCULA TING A IR AND F IL TERS .................................................................................................................... 22 D UCTWORK - A IR F LOW ...................................................................................................................... 22 C HECKING D UCT S T A TIC ....[...]

4 T able of Contents M AINTENANCE ......................................................................................................................................... 32 A NNUAL INSPECTION ........................................................................................................................... 33 F IL TERS ...................[...]

5 S AFETY P RECAUTIONS Adhere to the following warnings and cautions when installing, adjusting, altering, servicing, or operating the furnace. T o e nsure proper installation and operation, thoroughly read this manual for specifics pertaining to the installation and application of this product. T O  PREVEN T  PER SONAL  INJURY  OR  [...]

6 S AFETY P RECAUTIONS T O  PREVEN T  PER SONAL  INJURY  OR  DEATH  DUE  TO  ASPHYXIATIO N ,  THI S  FUR NAC E  MUST  BE  C ATEGORY  I  VE NTE D .  D O  NOT  VE NT  USI NG  C ATEGORY  II I  VE NTI NG . P RO VIS IO N S  MUST  BE  MADE  FOR  VE NTI NG  CO MB UST IO N [...]

7 P RODUCT A PPLICA TION • Air filters are installed in the system and maintained during construction, replaced as appropriate during construction, and upon completion of construction are replaced. • The input rate and temperature rise are set per the furnace rating plate. • 100% outside air is provided for combustion air requirements during [...]

8 L OCA TION R EQUIREMENTS AND C ONSIDERA TIONS A copy of the CAN/CSA B149 Installation Codes can also 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 c[...]

9 L OCA TION R EQUIREMENTS AND C ONSIDERA TIONS TOP B1- VEN T SI NG LE ( PLENUM) 1" 6" 1" 3" 0" 1" VENT SI DES FRONT BACK Top clearance for horizontal configuration - 1" I NSTALLATION P OSITIONS An upflow furnace may be installed in an upright position or horizontal on either the left or right side panel. Do not i[...]

10 C OMBUSTION & V ENTILA TION C A TEGORY I V ENTING A IR R EQUIREMENTS E XISTING F URNACE R EMOVAL 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[...]

11 E XTERIOR MASONRY C HIMNEYS - C A TEGORY I F URNACES O NL Y Code NFP A 54/ANSI Z223.1 or CAN/CSA B149 Installation Codes or applicable provisions of the local building codes for determining the combustion air requirements for the appliances. This furnace must use indoor air for combustion. It cannot be installed as a direct vent (i.e., sealed co[...]

12 E XTERIOR MASONRY C HIMNEYS - C A TEGORY I F URNACES O NL Y draft blower to properly orient the assembly . NOTE: If the pipe section is less than 18”, then attach it directly to the chimney top on 3 sides and feed it through the round cutout from the inside of the wrapper . 1 1. Reattach the induced draft blower using the (4) screws retained f[...]

13 E XTERIOR MASONRY C HIMNEYS - C A TEGORY I F URNACES O NL Y 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. Wall or Par apet 2' M in. 2' M in. 3' Min. Chimney 10&apos[...]

14 E XTERIOR MASONRY C HIMNEYS - C A TEGORY I F URNACES O NL Y 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 line[...]

15 E XTERIOR MASONRY C HIMNEYS - C A TEGORY I F URNACES O NL Y F IX 3 - R EBUILD THE C ROWN If the chimney crown is damaged, a qualified mason must re- pair it in accordance with nationally recognized building codes or standards. One such standard which may be referenced is the S tandard for Chimneys, Fireplaces, V ent s, and Solid Fuel Burning App[...]

16 E LECTRICAL C ONNECTIONS For sizing of flexible liners, see Note 22 and the tables in the National Fuel Gas Code NFP A 54/ANSI Z223.1 - latest edition and in the National S tandard of Canada, CAN/CSA B149.1 and CAN/CSA B149.2 - latest editions and amendments. T o install the liner , read and follow the liner manufacturer ’s in- structions and [...]

17 E LECTRICAL C ONNECTIONS A heat pump thermostat with two stages of heat is required to properly use a furnace in conjunction with a heat pump. Refer to the fossil fuel kit installation instructions for additional ther- mostat requirements. S trictly follow the wiring guidelines in the fossil fuel kit installa- tion instructions. All furnace conn[...]

18 G AS S UPPL Y AND P IPING 1. Install the field supplied relay on the control mount- ing panel near the furnace ignition control. The relay should be installed such that the motor leads will reach the relay contact terminals. 2. Connect the “Y2” (high stage cool) thermostat terminal to one coil terminal of the field supplied relay . Connect t[...]

19 G AS S UPPL Y AND P IPING 24 V AC H UMIDIFIER The yellow wire connected to the I.D. Blower pressure switch is powered anytime the pressure switch is closed and provides 24 V AC humidifier control. Remove the yellow wire and connect the supplied brown jumper wire to the pressure switch terminal. Reconnect the yellow wire to the “piggyback” te[...]

20 G AS S UPPL Y AND P IPING Contact your distributor for a tabular listing of appropriate manufacturer’s kits for propane gas and/or high altitude instal- lations. 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 . G AS P IPING C ONNECTIONS[...]

21 G AS S UPPL Y AND P IPING A ground joint union, drip leg, and manual shutoff valve must also be supplied by the installer . In some cases, the installer may also need to supply a transition piece from 1/2" to another pipe size. When the gas piping enters through the left side of the furnace, the installer must supply the following fittings [...]

22 C IRCULA TING A IR AND F IL TERS 200 PSIG Maximu m 5 t o 15 P SIG (2 0 PS IG Ma x. ) Con tin uous 11" W.C . Second Stage Regulator First Stage Regulator Propane Gas Installation (Typ.) P ROPANE G AS P IPING C HARTS 3/8" 1/2" 5/8" 3/4" 7/8" 1/2" 3/4" 10 730 1,700 3,200 5,300 8,300 3,200 7,500 20 500 1,100 2[...]

23 S TA R T - UP P ROCEDURE AND A DJUSTMENT nace and the cooling coil. This reading is usually taken by removing the “A” shaped block off plate from the end on the coil; drilling a test hole in it and reinstalling the block off plate. T ake a duct static reading at the test hole. T ape up the test hole after your test is complete. The negative [...]

24 S TA R T - UP P ROCEDURE AND A DJUSTMENT • Integrated ignition control monitors safety circuits continuously . • Furnace awaits call from thermostat. H EATING M ODE (M ODE DIP SWITCH IS SET TO “1 STG” POSITION ) The normal operational sequence in heating mode is as fol- lows: • R and W thermostat contacts close, initiating a call for h[...]

25 S TA R T - UP P ROCEDURE AND A DJUSTMENT 3. Set the room thermostat to the lowest possible setting. 4. Remove the burner compartment door . NOTE: This furnace is equipped with an ignition device which automatically lights the burner . Do not try to light the burner by hand. 5. White-Rodgers Model 36G22 or 36G54: Push the switch to the OFF positi[...]

26 S TA R T - UP P ROCEDURE AND A DJUSTMENT 4. Attach a hose and manometer to the outlet pressure barb fitting (Honeywell valve) or inlet pressure boss (White- Rodgers valve). 5. T urn ON the gas supply . 6. Turn On power and close thermostat “R” and “W” contacts to provide a call for heat. 7. Using a leak detection solution or soap suds, c[...]

27 S TA R T - UP P ROCEDURE AND A DJUSTMENT IN LET OUTLET Gas V al ve On/Off Selector Swi tch White-Rodgers Model 36G54 (Two-Stage) In let Pres sure Boss Low Fire Regulator Adj ust M a n o m e t e r M a n o m e t e r H o s e High Fi re Regulator Adj ust Regulator V ent Out let Pres sure Boss Open to Atmosphere O n / O f f S w i t c h H i g h F i r [...]

28 S TA R T - UP P ROCEDURE AND A DJUSTMENT Gas Line Gas Shutof f Val ve Gas Line To F u r n a c e Drip Leg Cap With Fitting Manom eter H ose Measuring Inlet Gas Pressure (Alt. Method) G AS M ANIFOLD P RESSURE M EASUREMENT AND A DJUSTMENT T O  PREVEN T  UNR ELI ABLE  OP ERA TI O N  OR  EQU IPMEN T  DAMAGE ,  THE  GAS  MAN[...]

29 S TA R T - UP P ROCEDURE AND A DJUSTMENT 3. Outlet pressure tap connections: a. Honeywell VR9205 valve: Remove the outlet pressure boss plug. Install an 1/8" NPT hose barb fitting into the outlet pressure tap. b. White-Rodgers 36G54 valve: Back outlet pressure test screw (inlet/outlet pressure boss) out one turn (counterclockwise, not more [...]

30 S TA R T - UP P ROCEDURE AND A DJUSTMENT SUPPL Y AIR RETURN AIR Temperature Rise Measurement 1. Operate furnace with burners firing approximately 15 minutes. 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 pos[...]

31 S TA R T - UP P ROCEDURE AND A DJUSTMENT Setting the Mode switch to “2 STG” allows the furnace to operate at the furnace’ s highest input AND at an input rate that is 75% of the highest input rate. For this mode of operation, the furnace operates at the low input rate for a pre-determined time period then steps to the high input rate. Oper[...]

32 O PERA TIONAL C HECKS & S AFETY C IRCUIT D ESCRIPTION R OLLOUT L IMITS The rollout limit controls are mounted on the burner/manifold assembly and monitor the burner flame. They are manual- reset, temperature sensors. This limit guards against burner flames not being properly drawn into the heat exchanger . P RESSURE S WITCHES The pressure sw[...]

33 T ROUBLESHOOTING & M AINTENANCE A NNUAL INSPECTION The furnace should be inspected by a qualified inst aller , or ser- vice agency at least once per year . This check should be per- formed 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 app[...]

34 T ROUBLESHOOTING & M AINTENANCE C LEANING (Q UALIFIED S ERVICER O NL Y ) 1. Shut off electric power and gas supply to the furnace. 2. Disconnect the rollout limit wires, flame sensor wire, and disconnect the igniter plug. L ABEL  ALL  WIRES  PRI OR  TO  DISCONNECT ION  WHEN  SERVICING  CO NTR OLS .  W IRING  ER [...]

35 C OMPONENT I DENTIFICA TION 1 Tubular Heat Exchanger 2 Pressure Switch 3 Flue Pipe Connection 4 Induced Draft Blower 5 Gas Line Entrance 6 Gas V alve 7 Rollout Limit 8 Junction Box 9 Wiring Harness Grommet 1 0 Gas Manifold 1 1 Inshot Burner 1 2 Transformer 1 3 Integrated Control Module 1 4 Blower Door Interlock Switch 1 5 Circulator Blower 1 6 G[...]

C OMPONENT I DENTIFICA TION 36 1 Tubular Heat Exchanger 2 Pressure Switch 3 Flue Pipe Connection 4 Induced Draft Blower 5 Gas Line Entrance 6 Gas V alve 7 Rollout Limit 8 Junction Box 9 Wiring Harness Grommet 1 0 Gas Manifold 1 1 Inshot Burner 1 2 Transformer 1 3 Integrated Control Module 1 4 Blower Door Interlock Switch 1 5 Circulator Blower 1 6 G[...]

37 1 Integrated control module will automatically attempt to reset from lockout after one hour . 2 LED Flash code will cease if power to the control module is interrupted through the disconnect or door switch. T ROUBLESHOOTING C HART • Furnace lockout due to an excessive number of ignition attempts. (3 total) 1 • Auxiliary Limit Open • Locate[...]

38 T ROUBLESHOOTING C HART Associated LED Code 2 2 LED Flash code will cease if power to the control module is interrupted through the disconnect or door switch. 4 4 FLASHES • Circulator blower runs continuously . No furnace operation. • Integrated control module diagnostic LED is flashing FOUR (4) flashes. 6 6 FLASHES 7 7 FLASHES • Furnace f[...]

39 T ROUBLESHOOTING C HART Associated LED Code 2 2 LED Flash code will cease if power to the control module is interrupted through the disconnect or door switch. • Induced draft blower runs continuously . No furnace operation. • Integrated control module diagnostic LED is flashing continuously . C CONTINUOUS • Polarity of 1 15 or 24 volt powe[...]

40 B LOWER P ERFORMANCE D ATA *M(H/S)8 To n s A C at 0.5" 0.6 0. 7 0.8 E S P CFM RI S E C FM RI S E CFM R IS E C FM RI S E CFM RI S E CFM C FM CFM H IG H 3 .0 15 21 - - -- 146 6 - -- - 1 414 - -- - 13 73 - - - - 1 29 8 - -- - 1 243 11 64 10 75 *M ( H/S) 8 040 3A *** M E D 2 .5 11 60 26 116 0 26 1 132 2 6 11 21 26 1 0 8 2 27 1 042 9 97 92 5 ( M[...]

41 B LOWER P ERFORMANCE D ATA *(D/H)S8 To ns AC at 0. 5" 0. 6 0.7 0. 8 ES P CF M RIS E CFM RI SE CF M RI S E CF M RIS E CF M RI S E CF M CF M CF M HI G H 3. 0 1 35 3 -- -- 12 90 -- - - 12 4 6 - - - - 1 19 9 2 5 11 49 2 6 1 11 6 1 11 6 1 09 9 G D S 8 0 4 0 3 A * * * M E D 2 . 5 1 1 8 32 51 1 1 32 71 0 9 82 71 0 5 22 81 0 3 92 9 1 0 0 6 1 0 1 2 [...]

42 GME8 B LOWER P ERFORMANCE D ATA To n s A C at 0 . 5" 0.6 0.7 0. 8 ES P CF M RIS E CF M RI SE CF M RI SE CF M RIS E CFM RI SE CF M CF M CF M T 1 - YE L LO W 1 .5 87 5 --- - 793 - - - - 7 36 -- -- 67 4 - - - - 592 - - - - 5 56 50 9 46 0 T 2 - R E D 2 .0 103 2 43 965 46 9 14 4 9 86 1 - --- 810 - - - - 7 56 71 2 65 9 T 3 - O R A N G E 2 . 5 1 2[...]

43 Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring. *(M, D, H)S8 W IRING D IAGRAM H I G H V O LTA G E ! D ISCONNE CT ALL PO WER BEFO RE SER VIC ING OR INSTALLING THIS UNIT . M ULTIPLE PO WER SOURCE S MA Y BE PRE SEN T . F AILU RE TO DO SO MA Y CAUSE PROP ER TY DAMAG E , PERSO NAL INJURY OR [...]

44 GME8 W IRING D IAGRAM H I G H V O LTA G E ! D ISCONNE CT ALL PO WER BEFO RE SER VIC ING OR INSTALLING THIS UNIT . M ULTIPLE PO WER SOURCE S MA Y BE PRE SEN T . F AILU RE TO DO SO MA Y CAUSE PROP ER TY DAMAG E , PERSO NAL INJURY OR DEATH . Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring. [...]

45 *(M,D)H8 W IRING D IAGRAM CAP BK(HI) AUXILIARY PROPER L Y PO LARIZED AND GROUNDED. SERVICING.WIRING TO UN IT M UST BE WARNING:DISCONNECT POWER B EFORE XFMR BK 115V 24V BR LIMITS WH(N) RD(LOW) OR(MEDLOW) BL(M ED) BLOWER CICULA TOR 24V THERMOST ATC ONNECTIONS RO2 (11) LIMIT GND (8) HUMIDIFIER XFMR (6) GND G C W Y TO MICRO R MVL (2) MVC (9) AUXILIA[...]

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48 Goodman Manufacturing Company , L.P . 5151 San Felipe, Suite 500, Houston, TX 77056 www .goodmanmfg.com © 2009-2010 Goodman Manufacturing Company , L.P .[...]