Maytag Amana ADSS8, Service Instructions Manual

Page 1: ...er service procedures or services performed by an unqualified person The material in this manual does not supercede manufacturer s installation and operation instructions is a registered trademark of Maytag Corporation or its related companies and is used under license All rights reserved Copyright 2013 2014 Goodman Manufacturing Company L P Goodman Amana Brand 80 Single Stage Gas Furnaces GMS8 AM...

Page 2: ...OMBUSTIBLE MATERIALS OR USE GASOLINE OR OTHER FLAMMABLE LIQUIDS OR VAPORS IN THE VICINITY OF THIS APPLIANCE TABLE OF CONTENTS WARNING HIGH VOLTAGE DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH IMPORTANTINFORMATION 2 3 PRODUCTIDENTIFICATION 4 9 ACCESSORIES 10 14 OPERATINGINSTRUC...

Page 3: ...arbon monoxide producing device continues to operate in the enclosed area Carbon monoxide emissions can be re circulated throughout the structure if the furnace or air handler is operating in any mode CO can cause serious illness including permanent brain damage or death To locate an authorized servicer please consult your telephone book or the dealer from whom you purchased this product For furth...

Page 4: ...nitial Release B 1st Revision Configuration M Upflow Horizontal Major Revision C Downflow Horizontal A Initial Release K Dedicated Upflow B 1st Revision D Dedicated Downflow Nox Gas Vale Motor N Natural Gas E Convertible 2 Stage High Efficiency X Low NOx H Convertible 2 Stage Single Speed S Single Stage Single Speed Cabinet Width A 14 AFUE B 17 5 97 97 AFUE C 21 80 80 AFUE D 24 5 MBTU h Maximum CF...

Page 5: ...entification of component parts used in manufacturing Please use these numbers when requesting service or parts information A D S S 8 0 0 6 0 3 B N A A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Brand Minor Revision A Amana A Initial Release B 1st Revision Configuration M Upflow Horizontal Major Revision C Downflow Horizontal A Initial Release K Dedicated Upflow B 1st Revision D Dedicated Downflow Nox Motor...

Page 6: ...at ex c hanger S tandard altitude rated to 5 500 ft Firing rate of 20 000 B TUH per burner 45 gas orific es F irs t rev with W hite Rodgers gas valve Chas s is widths 14 17 5 21 24 5 M O D E L M F G 8 0 G A S F U R N A C E S A D S S 8 A D S S 800403A XA A A D S S 800603A XA A A D S S 800804B XA A A D S S 801005C XA A A m ana B rand 80 gas furnac e 33 3 8 tall dedic ated dow nflow ins tallation Ind...

Page 7: ... furna c e 33 3 8 tall up flow ho riz on ta l right o f le ft ins ta lla tio n po s itio ns In du c e d draft G oo dm a n gray c ab in et a nd p an els M ulti s p ee d P S C m o to r 1 20 vo lt c a rb ide m ini Ig niter w ith in te grated c irc uit bo ard L eft o r rig ht s ide g as en try A lu m in iz e d s tee l tubu lar h ea t ex c ha ng er S tan da rd a ltitud e to 5 5 00 ft B re v firing rate...

Page 8: ...r blower compartment area of either side panel and provide filter retention as well as a location for attaching return air ductwork FTK04 FTK04 Furnace Twinning Kit This kit allows single stage 80 gas furnaces 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 sa...

Page 9: ... gas as shipped from the factory to propane gas requires replacing the burner orifices replacing gas valve regulator spring all single stage units and applying identification labels NOx screens must be removed when converting 80 furnaces to this LP kit MVK 01A MVK 02A N A Masonry Vent Kit For use with 80 AFUE 33 tall H and S model furnaces installed in the upflow position only and will only be use...

Page 10: ...ubbase 21 Propane Gas Conversion Ki t LP Low Pressure Shut Off Kit Twinning Kit High Altitude Orifices W P ressure Switch Masonry Vent Kit Masonry Vent Kit AMS80403A 1 2 AMS80603A 1 2 AMS80604B 1 2 AMS80804B 1 2 AMS80805C 1 2 AMS81005C 1 2 AMS81205D 1 2 AMS81405D 1 2 ADSS80403A 1 2 ADSS80603A 1 2 ADSS80804B 1 2 ADSS81005C 1 2 approved for this model not approved for this model AMANA BRAND S Model ...

Page 11: ...Switch High Altitude Orifices W Pressure Switch Masonry Vent Kit Masonry Vent Kit Sound Reduction Kit Sound Reduction Kit Sound Reduction Kit Sound Reduction Kit GMS80 403 A 1 2 3 4 GMS80 603 A 1 2 3 4 GMS80 604 B 1 2 3 4 GMS80 804 B 1 2 3 4 GMS80 805 C 1 2 3 4 GMS810 05 C 1 2 3 4 GMS812 05 D 1 5 4 GMS814 05 D 1 2 3 4 GDS8 040 3A 1 2 3 GDS8 060 3A 1 2 3 GDS8 080 4B 1 2 3 GDS8 100 5C 1 2 3 approved...

Page 12: ...SCREWS SLOTS IN FILTER CLEAR SCREWS ON UNIT FRONT OF UNIT RETURN AIR CUTOUT AREA LOWER EDGE SCREW FILTER RACK ASSEMBLY FACE FILTER OPENING TOWARDS FRONT OF UNIT UNIT SIDE PANEL BASE OF UNIT 80 Upflow Model Furnaces EFR01 EXTERNAL FILTER RACK KIT Used on Models ...

Page 13: ...G VALVE OUTPUT Q1 Y P2 4 K1 OT NO Y P2 9 CALL FOR 2ND STAGE COMPRESSOR Y2 1 0K G FURN P2 1 C OT C C SECOND STAGE COMPRESSOR OUTPUT G CALL FOR EMERGENCY HEAT W1 FURN W2 HP F1 3A OT NC 24VAC 2ND STAGE COMPRESSOR DEMAND OUTPUT W1 CALL FOR FURNACE HEAT 6 8K G STAT VDC P3 4 F U R N A C E P2 6 K2 ODT OUTDOOR THERMOSTAT Y R SECOND STAGE FURNACE DEMAND OUTPUT MICROPROCESSOR Y2 HP P1 5 CALL FOR 2ND STAGE F...

Page 14: ...S MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH 14 FURNACE TWINING KIT FTK04 UTEC Control Board 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 or 90 Single Stage Furnaces ...

Page 15: ...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 Do not try to light any appliance Do not touch any electric switch do not use any phone in your buildin...

Page 16: ... appliance if any part has been underwater or explosion technician Force or attempted repair may result in a fire hand don t try to repair it call a qualified service Never use tools If the lever will not push in or turn by C Use only your hand to push in or turn the gas control lever call the fire department If you cannot reach your gas supplier phone Follow the gas supplier s instructions do not...

Page 17: ...ancer birth defects or other reproductive harm are known to the This product contains fiberglass insulation State of California to product could expose California to cause known by the State of contains a chemical Fiberglass insulation cancer 0140F00688 Rev A call a qualified service technician will not operate don t try to repair it gas If you then smell gas STOP 8 Move the gas control switch or ...

Page 18: ... before removing a new control from its container Fol low Steps 1 through 3 if installing the control on a fur nace Return any old or new controls to their containers before touching any ungrounded object 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 or recreational vehicle applications This fur...

Page 19: ...o cated beneath the furnace between the supply air opening and the combustible floor Exposure to contaminated combustion air will result in safety and performance related problems Do not install the furnace where the combustion air is ex posed to the following substances chlorinated waxes or cleaners chlorine based swimming pool chemicals water softening chemicals deicing salts or chemicals carbon...

Page 20: ...riction leakage corrosion and other deficiencieswhichcouldcauseanunsafecondition c Insofaraspractical closeallbuildingdoorsandwindowsandall doorsbetweenthespaceinwhichtheappliance s connectedtothe 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...

Page 21: ...ation of exhaust fans kitchen ventilation systems clothes dryers and fireplaces shall be considered in determining the adequacy of a space to provide combustion air require ments 9 3 2 Indoor CombustionAir The required volume of indoor air shall be determined in accordance with the method in 9 3 2 1 or 9 3 2 2 except that where the air infiltration rate is known to be less than 0 40 ACH the method...

Page 22: ...attic Figure A 9 3 3 1 1 b All Combustion Air From Outdoors through Ventilated Attic 2 Where communicating with the outdoors through horizontal ducts each opening shall have a minimum free area of 1 in 2 2000 Btu hr 1100 min2 kW of total input rating of all appliances in the enclo sure See Figure A 9 3 3 1 2 Furnace Water Heater Chimney or Gas Vent NOTE The air duct openings must have a free area ...

Page 23: ...ir Ducts Combustion air ducts shall comply with 9 3 8 1 through 9 3 8 8 9 3 8 1 Ducts shall be constructed of galvanized steel or a material hav ing equivalent corrosion resistance strength and rigidity Exception Within dwellings units unobstructed stud and joist spaces shall not be prohibited from conveying combustion air provided that not more than one fireblock is removed 9 3 8 2 Ducts shall te...

Page 24: ... 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 Masonry Chimneys Wash Crown Clay Tile Size 8 x 8 x12 E...

Page 25: ...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 col lar If the chimney does not meet these termination require ments but all other requirements in the checklist can be met it may be pos...

Page 26: ...ix 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 f...

Page 27: ...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 refer enced 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 di...

Page 28: ...red 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 com pensate for the natural reduction in the density of both the gas fuel and the combustion air at higher alti...

Page 29: ...trol module As shipped the valve is configured for natural gas The valve is field convertible for use with propane gas by using the ap propriate propane gas conversion kit Taps for measuring the gas supply pressure and manifold pressure are provided on the valve NOTE The gas supply pressure on White Rodger J model gas valve used on single stage furnaces can be checked with a gas pressure test kit ...

Page 30: ...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 furnaces the installer must swap the alternate inlet hole plug with th...

Page 31: ... 16 35 72 1 211 187 103 217 409 834 1 275 80 13 29 62 104 155 89 185 346 724 1 066 100 11 26 55 90 138 78 162 307 630 976 125 10 24 48 81 122 69 146 275 567 866 150 9 21 43 72 109 63 132 252 511 787 200 8 19 39 66 100 54 112 209 439 665 250 8 17 36 60 93 48 100 185 390 590 Tubing Size O D Type L Nominal Pipe Size Schedule 40 Pipe or Tubing Length Feet Data in accordance with NFPA pamphlet No 54 Si...

Page 32: ... 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 siz...

Page 33: ...following drawing illus trates the typical field wiring for a heat only single stage system and a single stage heating single stage cooling sys tem Refer to the following figures for proper connections to the integrated control module Furnace Control Furnace Control Remote Condensing Unit Heating Room Thermostat Heating Cooling Room Thermostat W W Typical Field Wiring 24 VAC Control Circuit 1 Secu...

Page 34: ...ces with air delivery of less than 1800 CFM Use one side return or one bottom return ductwork connec tion Upflow furnaces with air delivery of 1800 CFM or higher Use two side returns or one side return and one bottom return connection Guide dimples locate the side and bottom return cutout lo cations Use a straight edge to scribe lines connecting the dimples Cut out the opening on these lines An un...

Page 35: ...el 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 NORMAL SEQUENCE OF OPERATION POWER UP 1 115 VAC power applied to furnace 2 Integrated ignition control module performs internal checks 3 Integrated ignition control module LED will light 4 Integrated ignition con...

Page 36: ...utdoor fan and compressor are de energized 8 Circulator blower is de energized following a fixed forty five 45 second cool off delay period Electronic air cleaner terminals are de energized 9 Furnace awaits next call from thermostat 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 2 Integrated control module ...

Page 37: ...re 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 within 5 minutes the control will go in...

Page 38: ...in pressure switch circuit Inspect pressure switch hose Repair if necessary Inspect flue and or inlet air piping for blockage proper length elbows and termination Check drain system Correct as necessary Correct pressure switch setpoint or contact motion Tighten or correct wiring connection Pressure switch hose blocked pinched or connected improperly Blocked flue and or inlet air pipe blocked drain...

Page 39: ...tails See rating plate for proper gas pressure 7 Flame sensor is coated oxidized Flame sensor incorrectly positioned in burner flame Lazy burner flame due to improper gas pressure or combustion air Induced draft blower and circulation blower runs continuously No furnace operation Integrated control module diagnostic LED is flashing FIVE 5 Flame sensed with no call for heat Correct short at flame s...

Page 40: ... OF UNMARKED TRANSFORMERS 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 So...

Page 41: ... proper furnace operation Remember that dirty filters are the most common cause of inadequate heating or cooling performance 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 ...

Page 42: ...ewer call backs HEATING PERFORMANCE TEST Before attempting to diagnose an operating fault run a heating performance test and apply the results to the Ser vice 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 mete...

Page 43: ...e 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 etc applied externally to the unit versus the motor speed tap direct drive or pulley ad justments of the motor and blower belt drive A properly operating unit must have the BTU per hour input and CFM of air within the...

Page 44: ... 160 400 20 45 90 180 360 900 46 78 157 391 21 43 86 171 343 857 47 19 38 76 153 383 22 41 82 164 327 818 48 75 150 375 23 39 78 157 313 783 49 147 367 24 37 75 150 300 750 50 18 36 72 144 360 25 36 72 144 288 720 51 141 355 26 34 69 138 277 692 52 69 138 346 27 33 67 133 265 667 53 17 34 136 340 28 32 64 129 257 643 54 67 133 333 29 31 62 124 248 621 55 131 327 30 30 60 120 240 600 56 16 32 64 12...

Page 45: ... Ignition Control Test Control S 313 Gas Valve or Gas Supply Shut Off Turn Valves to On Position S 317 Faulty Induced Draft Blower Test Induced Draft Motor S 303 Faulty Blower Motor PSC ECM Test Blower Motor PSC ECM S 16A B C Broken or Shorted Ignitor Test Ignitor S 308 Dirty Flame Sensor Low UA Clean Flame Sensor S 314 Stuck Gas Valve Replace Gas Valve S 304 Faulty Gas Valve Replace Gas Valve S 3...

Page 46: ...TURE RISE 50 S 300 CHECKING PRIMARY LIMIT CONTROL 50 S 301 CHECKINGAUXILIARYLIMITCONTROL 51 S 302 CHECKING FLAME ROLLOUT CONTROL 51 S 303 INDUCED DRAFT BLOWER MOTOR 52 S 304 CHECKING GAS VALVE REDUNDANT 52 S 305 CHECKING MAIN BURNERS 52 S 306 CHECKING ORIFICES 53 S 307 CHECKING GAS PRESSURE 53 S 308 CHECKING HOTSURFACE IGNITOR 55 S 309 CHECKING FOR FLASHBACK 56 S 310 CHECKING PRESSURE CONTROL 56 S...

Page 47: ... insulation of the same gauge or its equiva lent CHECKING THERMOSTAT WIRING AND ANTICIPATOR S 3A THERMOSTAT AND WIRING DISCONNECT ALL POWER BEFORE SERVICING 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 ...

Page 48: ...ock 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 trans former is inoperative Replace 7 After completing check and or replacement of trans former and check and or repair of control circuit re install blower compartment door ...

Page 49: ...ING WARNING S 200 CHECKING DUCT STATIC The maximum and minimum allowable external static pres sures 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 wi...

Page 50: ... 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 chang ing details Temperature rise is related to the BTUH output of the furnace and the amount of air CFM circu lated over the heat exch...

Page 51: ...SONAL INJURY OR DEATH VOLT OHM METER RED RESET BUTTON COLOR IDENTIFYING TAB Testing Auxiliary Limit Control 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 S 302 CHECKING FLAME ROLLOUT CONTROL A temperature activated manual reset control is mounted to...

Page 52: ...S MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH 1 Remove burner compartment door to gain access to the induced draft blower motor 2 Disconnect the motor wire leads from its connection point at the induced draft motor 3 Using a 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 p...

Page 53: ...zing is required a new orifice of the same physi cal size and angle with proper drill size opening should be installed A GAS STREAM B The length of Dimension A determines the angle of Gas Stream B DENT OR BURR GAS STREAM B A dent or burr will cause a severe deflection of the gas stream S 307 CHECKING GAS PRESSURE Gas Supply Pressure Measurement TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE T...

Page 54: ...Pressure Measurement and Ad justment n a c e 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 CAUTION NOTE Use apapter kit 0151K00000S to measure gas pressure on White Rodgers 36J22 gas valves Only small variations in gas pressure should be ...

Page 55: ...ssure Replace regulator cover screw i Turn off all electrical power and gas supply to the system j Remove the manometer hose from the hose barb fit ting or outlet pressure boss k Remove the 1 8 NPT hose barb fitting from the out let pressure tap Replace the outlet pressure boss plug and seal with a high quality thread sealer WARNING HIGH VOLTAGE DISCONNECT ALL ELECTRICAL POWER AND SHUT OFF GAS SUP...

Page 56: ...RE 2 Check burner for proper alignment and or replace burner 3 Improper orifice size check orifice for obstruction S 310 CHECKING PRESSURE SWITCH The pressure switch a safety device to prevent the combus tion cycle from occurring with inadequate venting caused by a restricted or blocked vent pipe on the 80 and 90 fur naces 1 Remove burner compartment door to gain access to pressure switch es 2 Rem...

Page 57: ...ut due to failure to sense flame TO AVOID THE RISK OF ELECTRICAL SHOCK WIRING TO THE UNIT MUST BE PROPERLY POLARIZED AND GROUNDED DISCONNECT POWER BEFORE PERFORMING SERVICE LISTED BELOW WARNING 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 re sistance between the neutral white...

Page 58: ...AL INJURY OR DEATH 1 Disconnect the orange flame sensor wire from the sen sor 2 Connect a micro amp meter in series with this wire and the sensor terminal 3 Place the unit into a heating cycle LINE VOLTAGE NOW PRESENT WARNING 4 As soon as flame is established a micro amp reading should be evident once proof of flame micro amp read ing is established the hot surface ignitor will be de energized 5 T...