Amana GCI, Installation Instructions Manual

Page 1: ...en the unit is in operation Remember it is your responsibility to install the productsafelyandtoknowitwellenoughtobeable 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 The precautions listed in this Installation Manual areintendedassupplementaltoexistingpractices How...

Page 2: ...tructions are required call the dealer where the purchase was made To The Installer Before installing this unit please read this manual to familiarize yourself on the specific items which must be adhered to such as maximum external static pressure to unit air temperature rise minimum or maximum CFM motorspeedconnections andventing Thesefurnacesare designed for Category I venting only WARNING Topre...

Page 3: ... 1 and or CAN CSA B149 1 and CAN CSA B149 2 Installation Codes CAUTION This unit must not be used as a construction heater during the finishing phasesofconstructiononanewstructure 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 WARNING To prevent possible death personal injury or property ...

Page 4: ...el 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 in stalled 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 combustion air is obtained from the outside atmosphere and all flu...

Page 5: ...r 4000 BTU of the total input rating of all equipment in the enclosure Inlet Air Ventilation louvers for unheated crawl space Alternate air inlet Ventilation louvers each end of attic Figure 2 Equipment Located in Confined Spaces All Air from Outdoors Inlet Air from Ventilated Crawl Space and Outlet Air to Ventilated Attic See 5 3 3 b 2 When communicating with the outdoors through vertical ducts e...

Page 6: ...nt any ofthesefurnacesusingCategoryIIIventing 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 gas furnaces with induced draft blowers draw products of combustion through a heat exchanger allowing in some instances common venting with natural draft appli ances i e water...

Page 7: ...ed 90 degrees counterclockwise for Category I venting with the airflow horizontal left to right Figure 6 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 Nati...

Page 8: ...ions 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 chimn...

Page 9: ...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 If the chimney does not meet these termination require ments but all other requirements in the checklist can be met it may be possible for a mason t...

Page 10: ...e 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 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 u...

Page 11: ...liances vented outside the liner Alternatively thehomeownermayagreetodiscontinueuse ofthefireplace solidfuelappliance Ifso thetilelinermust 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 is...

Page 12: ...installed in accordance with the liner manufacturer s instructions Finally cap the chimney and terminate the liner in accor dance with the liner manufacturer s instructions VI Gas Supply and Piping GENERAL 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 require...

Page 13: ...nstallations 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 GAS PIPING CONNECTIONS General CAUTION Toavoidpossibleunsatisfactoryoperation orequipmentdamageduetounderfiringof equipment use the proper size of natural propane gas piping needed when running pipe from the meter tank to the furnace ...

Page 14: ...rs 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 Location of Manual Valve Installed Ahead of Ground Joint Pipe Union Height Required By Local Code Ground Joint Pipe Union To Be Installed Ahead Of Gas Valve Drip Leg Reducing Coupling 1 2 x 1 8 with 1...

Page 15: ...terior of the furnace Figure 18 Figure 18 Gas Inlet Through Left Side Counterflow A ground joint union drip leg and manual shutoff valve must also be supplied by the installer In some cases the installermayalsoneedtosupplyatransitionpiecefrom1 2 to another pipe size When the gas piping enters through the right side of the furnace the installer must supply the following fittings starting at the gas...

Page 16: ...00 1 300 2 200 3 300 1 300 3 100 80 260 610 1 200 1 900 2 900 1 200 2 600 100 220 540 1 000 1 700 2 600 1 000 2 300 125 200 490 900 1 400 2 300 900 2 100 150 190 430 830 1 300 2 100 830 1 900 175 170 400 780 1 200 1 900 770 1 700 200 160 380 730 1 100 1 800 720 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 Gas Pip...

Page 17: ...connect must be provided and sized in accordance with the unit maximum overcurrent protection This furnace has both W1 and W2 terminals The following figure shows connections for a heat only two stage system W2 W1 R G Y W2 W1 R C Y R B Y R B G W1 W2 Y C Furnace Control Furnace Control Remote Condensing Unit Heating Room Thermostat Heating Cooling Room Thermostat G W1 W2 Figure 21 Typical Field Wir...

Page 18: ...after the call for cooling ends This fan timing is not adjustable During normal heating operation the circulation fan will come on 37 seconds after the gas valve opens This timing is not adjustable Asshipped thecirculationfanwillremainonfor90seconds after the gas valve closes If desired this timing may be adjusted The adjustment pins or switches are near the low voltage terminal strip Figure 24 HE...

Page 19: ...r unit unless the damper is in the full heat or cool position When the furnace is installed without a cooling coil it is recommended that a removable access panel be provided in the outlet air duct This opening shall be accessible when the furnace is installed and shall be of such a size that the heat exchanger can be viewed for visual light inspection or such that a sampling probe can be inserted...

Page 20: ...ll run at heating 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 terminal G the blower will run at heating speed until the limit closes X Start Up Adjustments and Checks GENERAL OPERATION This furnace is equipped with an electronic ignition device to light the burners and an induce...

Page 21: ...aterials must be removed before the blower motor is operated ROLLOUT PROTECTION DEVICE If the flames from the burners are not properly drawn into the heat exchanger a protection device will open causing the gas valve to close In GUI furnaces installed horizon tal right to left airflow the device must be relocated Supply Air Return Air Figure 28 Right To Left Installation Supply Air Return Air Figu...

Page 22: ...EN CLOSED CLOSED OPEN 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 0 ign circ 0 15 60 90 120 or 180 IGNITER WARM UP PERIOD see note FIXED HEAT ON DELAY 30 SECONDS t t SECONDS Seconds 0 5 0 45 I...

Page 23: ...note of the number of flashes in sequence between pauses Next refer to the Troubleshooting Chart for an interpretation of the signals 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 NOTE This furnace is equipped with an ign...

Page 24: ...Position Inlet Pressure Tap Side of Valve INLET OUTLET Figure 35 Robertshaw Model 7222 O F F ON M P C 1 3 2 INLET Pressure Regulator Adjustment Under Cap Screw Inlet Pressure Tap Side of Valve Outlet Manifold Pressure Tap Side of Valve Gas Valve On Off Selector Switch OUTLET Figure 36 White Rodgers Model 36E22 Gas Line Gas Shutoff Valve Gas Line To Furnace Drip Leg Cap With Fitting Manometer Hose ...

Page 25: ...nutes Ensure all registers are open and all duct dampers are in their final fully or partially open posi tion 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 3 Subtract the return air temperature from the supply air temperature to determine the air temperature rise Al...

Page 26: ...oose or misconnected wiring Circulator blower runs continuously with no further furnace operation and Integrated control module diagnostic LED is flashing five flashes 5 Flashes Rollout limit circuit is open 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 Loose or misconnected wiring Furnace fails to...

Page 27: ...flashes 9 Flashes Furnace is not operating and Integrated control module diagnostic LED is flashing eight flashes 8 Flashes 7 Flashes Normal furnace operation but Integrated control module diagnostic LED is flashing seven flashes 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 ...

Page 28: ...ing the igniter element with bare fingers rough handling or vibration could damage the igniter resulting in prematurefailure Onlyaqualifiedservicer should ever handle the igniter 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 c...

Page 29: ...side of the blower Starting with the right filter push the filter into the plenum so that the bottom of the filter rests in the filter rack and the upper edge rests against the side of the plenum Repeat with the left filter Figure 40 Become familiar with filter location and procedures for removal cleaning and replacing them If help is needed contact the installer of the furnace or a qualified serv...

Page 30: ...t exchanger tubes can be cleaned using a round 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 spring cable Slowly rotate the cable with the drill and insert it into one of the primary heat exchanger tubes While reversing the drill work the cable in and out several times to obtain suff...

Page 31: ...unctional parts be sure to provide the furnace model manufacturing and serial numbers with the order 2 Although only functional parts are shown in the parts list all sheet metal parts doors etc may be ordered by description 3 Parts are available from your Amana distributor Gas Valve Blower Box Gasket Gas Orifice Natural Flame Rollout Switch Gas Orifice Propane Auxiliary Limit Burner Heat Exchanger...

Page 32: ...32 is a trademark of Maytag World wide N V and is used under license to Goodman Company L P All rights reserved ...