Amana GCCA045AX30 Service Instructions Manual Download Page 73 | Manualshive

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SERVICING

73

Rev. 0

Reinstallation of New Heat Exchanger:

Note: Before installing new heat exchanger assembly, in-
spect gasket along inside rails. If the gasket needs replac-
ing, install the new pieces of gasket supplied with kit.

1. Slide new heat exchanger into cabinet and secure with

screws removed in Step 8 of removal procedures. Re-
install the permagum in the top and bottom corners be-
tween the heat exchanger and cabinet, that is used to
help seal the burner compartment area.

2. Next, reinstall top cover assembly to furnace cabinet

that was removed in Step 6 of removal procedures.

3. Reinstall the orifice shield and manifold assembly, pres-

sure switches and induced draft blower removed in Step
7 of removal procedures. Make sure wiring is placed
back in side clip and also reattach wires at manifold
with wire tires.

4. Reinstall inner vent/flue pipe (GUCA Only) with flue cou-

pling along with rubber elbow (Standard Vent/Flue Con-
nection) or rubber coupling (Alternate Vent/Flue Con-
nection) and attach to induced draft blower removed in
Step 5 of removal procedures.

5. Reconnect condensate drain lines to induced draft

blower and recuperator cover and then install conden-
sate drain trap removed in Step 4 of removal proce-
dures.

Note: The GCCA model furnace (Counterflow Installations)
can now be reinstalled into the installation.

6. Reconnect the attached ductwork along with combus-

tion air pipe (Direct Vent Only) and vent/flue pipe to fur-
nace removed in Step 3 of removal procedures. Also
reconnect the incoming electrical power lines (GCCA
Counterflow Installations).

7. Reinstall the inner gas supply piping and reconnect to

gas supply line removed in Step 2 of removal proce-
dures.

WARNING

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

WARNING

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

8. Turn on gas to furnace and check for leaks. If leaks are

found, repair and then reinstall burner compartment door
and blower compartment door.

9. Turn on electrical power and verify proper unit opera-

tion.

Note: Listed below are the complete unit checks that need
to be done after installation of a new heat exchanger as-
sembly:

1. Verify proper gas pressures (See

SERVICING section

S-12).

2. Verify proper duct static (See

SERVICING section S-

15).

3. Verify proper temperature rise (See

SERVICING sec-

tion

S-16).

4. Verify proper negative draw down from combustion

blower (See

SERVICING section S-17).

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Summary of Contents for GCCA045AX30

Page 1: ...fied HVAC technicians only Amana does not assume any responsibility for property damage or personal injury for improper service proce dures done by an unqualified person RS6610002 Revision 0 October 1998 A higher standard of comfort Heating n Air Conditioning Model and Manufacturing numbers listed on page 4 ...

Page 2: ...ications 14 15 Blower Performance Specifications 16 18 Combustion and Ventilation Air 19 28 Condensate Drain Lines and Drain Trap 29 32 Product Design 33 46 System Operation 47 51 PolarizationandPhasing 52 Scheduled Maintenance 53 54 Servicing 55 73 Wiring Diagrams 74 75 Schematics 76 78 ...

Page 3: ...OR SERVICE PROCEDURES IF YOU PERFORM SERVICE ON YOUR OWN PRODUCT YOU ASSUME RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROP ERTY DAMAGE WHICH MAY RESULT To locate an authorized servicer please consult your telephone book or the dealer from whom you purchased this product For further assistance please contact CONSUMER AFFAIRS DEPT OR 1 319 622 5511 AMANA HEATING AIR CONDITIONING CALL and ask for AMA...

Page 4: ...SSORY KITS FTK_ Furnace Twinning Kit HANG_ High Altitude Natural Gas Kit HALP_ High Altitude LP Kit HAPS_ High Altitude Pressure Switch Kit LPTK_ LP Conversion Kit Note See servicing section for available kits and usage ADDITIONAL FURNACE ACCESSORIES CFB_ Counterflow Floor Base EAC_ Electronic Air Cleaner EFR_ External Filter Rack Kit HCVK_ Horizontal Style Concentric Vent Kit MAC_ Media Air Clean...

Page 5: ...ply Type C Counterflow Horizontal U Upflow Horizontal Airflow Capability 30 3 0 Tons 35 3 5 Tons 40 4 0 Tons 50 5 0 Tons Nominal Input 045 46 000 Btuh 070 69 000 Btuh 090 92 000 Btuh 115 115 000 Btuh Model Family A Air Command 90 40 Height Design Series A First Series G U C A 045 A X 30 Furnace Type C Condensing 90 ...

Page 6: ...appliance does not have a pilot It is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand B BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor Do not try to light any appliance Do not touch any electric switch do not use any phone ...

Page 7: ... Straight pipe to reach gas valve POSITION SIDES FRONT REAR TOP BOTTOM FLUE Upflow 0 3 0 1 C 0 Horizontal 6 3 0 6 C 0 C If placed on combustible floor floor MUST be wood ONLY MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS INCHES All positioning is determined as installed unit is viewed from the front Cabinet Size Units A B C D 045__30 070__30 070__40 090__40 090__50 115__50 All dimensions are in inch...

Page 8: ...ed E Folded 045__30 070__30 070__40 090__40 090__50 115__50 Large 24 1 2 Small 16 1 2 Medium 20 1 2 19 15 12 3 8 13 1 2 15 All dimensions are in inches 23 20 3 8 21 1 2 23 19 16 3 8 17 1 2 POSITION SIDES FRONT REAR TOP BOTTOM FLUE Counterflow 0 3 0 1 NC 0 Horizontal 6 3 0 6 C 0 All positioning is determined as installed unit is viewed from the front C If placed on combustible floor floor MUST be w...

Page 9: ...or 23 Electrical Connection Inlets Alternate 24 Integrated Control Module with fuse and diagnostic LED 25 24 Volt Thermostat Connections 26 Transformer 40 VA 27 Circulator Blower 28 Bottom Return Filter Retainer 29 Blower Door Interlock Switch 30 Junction Box 31 Electrical Connection Inlets 32 Auxiliary Limit 33 Coil Front Cover 34 Combustion Air Inlet Pipe Upflow Horizontal GUCA Models Counterflo...

Page 10: ...C Uncased TXV A Coils CCF_F C Horiz A Coils CHF_TCC Horiz A Coils 45 000 16 1 2 1 1 2 3 70 000 16 1 2 2 3 1 2 70 000 20 1 2 2 1 2 4 90 000 20 1 2 2 1 2 4 90 000 24 1 2 3 5 115 000 24 1 2 3 5 CCF24FCC CCF30FCC CCF36FCC CCA30FDC CCA36FDC CCA42FDC CCA48FCC CCA48FSC CHA42TSC CCF24FDC CCF36FDC CCF42FCC CCF48FCC CCA18FCC CCA24FCC CCA30FCC CCA36FCC CCA42FCC CHA18TSC CHA24TSC CHA30TSC CHA36TSC CHA42TCC CH...

Page 11: ...50 24 1 2 23 3 4 23 18 9 16 All dimension are in inches Used On Models Floor Base Part Numbers Floor Opening Plenum Size Plenum Gasket 1 Min 3 4 F E Front View 3 4 Floor Floor Base Furnace Duct A B 4 7 16 Side View 3 4 Plenum Furnace Front 2 EXTERNAL FILTER RACK KIT 23 567 14 500 INTERNAL FILTER RETAINER SCREWS 80 MODELS ONLY BLOWER DECK SCREWS SLOTS IN FILTER CLEAR SCREWS ON UNIT INTERNAL FILTER ...

Page 12: ... 20 3 4 G 22 1 2 H 17 3 4 EAC5 SPECIFICATIONS DIMENSIONS All dimensions are in inches EAC5 ELECTRONIC AIR CLEANER Used On Models GUCA GCCA B C A D G E F H 30 2 1 8 3 1 2 MEDIA AIR CLEANER A C B E D MEDIA AIR CLEANER Used On Models GUCA GUCA CAPACITY 600 2000CFM MEDIA SERVICE LIFE 12 MO NOMINAL MEDIA LISTING UL CLASS 2 A 7 1 4 B 25 C 22 1 8 D 22 5 8 E 17 11 16 CFM INCHES W C 600 04 800 05 1000 09 1...

Page 13: ...nt Flue Pipe from Furnace Pipe to Furnace Combustion Air Intake Pipe Vent Flue Termination with Tee Wall Thickness 3 4 Minimum 13 3 4 Maximum Seal Penetration with Caulking Tee 12 Minimum Above Grade or Highest Anticipate Snow Level Inside Outside Vent Flue Termination Tee Pipe 2 to 4 Reducer Combustion Air Intake Pipe Seal Penetration with Flashing and Caulking Roof Thickness 3 4 Minimum 22 Maxim...

Page 14: ... 106 500 A F U E 92 0 92 0 92 0 92 0 92 0 92 0 Rated External Static WC 20 50 20 50 20 50 20 50 20 50 20 50 Temperature Rise F 35 65 35 65 35 65 35 65 35 65 35 65 ID Blower Pressure Switch Trip Point 0 37 0 37 0 37 0 37 0 37 0 37 Front Cover Pressure Switch Trip Point 0 37 0 37 0 37 0 37 0 37 0 37 Blower Wheel D x W 11 x 6 11 x 7 11 x 9 11 x 9 11 x 9 11 x 10 Blower Horsepower 1 3 1 2 1 2 1 2 3 4 3...

Page 15: ... 109 100 A F U E 92 0 92 0 92 0 92 0 92 0 92 0 Rated External Static WC 20 50 20 50 20 50 20 50 20 50 20 50 Temperature Rise F 35 65 35 65 35 65 40 70 35 65 40 70 ID Blower Pressure Switch Trip Point 0 37 0 37 0 37 0 37 0 37 0 37 Front Cover Pressure Switch Trip Point 0 37 0 37 0 37 0 37 0 37 0 37 Blower Wheel D x W 11 x 6 11 x 7 11 x 9 11 x 9 11 x 9 11 x 10 Blower Horsepower 1 3 1 2 1 2 1 2 3 4 3...

Page 16: ... 45 844 47 807 49 764 706 652 LOW 1 5 702 56 680 58 657 60 624 63 584 542 485 423 HIGH 3 5 1590 37 1550 38 1505 39 1454 41 1406 42 1343 1266 1194 GUCA070AX30 MED 3 0 1489 40 1450 41 1415 42 1370 43 1324 45 1261 1205 1130 MED LO MED LO 2 5 1251 47 1226 48 1205 49 1173 50 1135 52 1096 1037 975 LOW 2 0 1001 59 988 60 969 61 956 62 929 64 902 859 807 HIGH 4 0 1861 1823 1778 1721 1643 36 1581 1500 1387...

Page 17: ... 791 736 668 LOW 1 5 764 52 736 54 703 56 668 59 621 63 589 537 477 HIGH 3 5 1594 37 1541 38 1495 40 1426 41 1366 43 1300 1229 1155 GCCA070AX30 MED 3 0 1385 43 1338 44 1300 45 1245 47 1198 49 1138 1075 1008 MED HIGH MED LO 2 5 1164 51 1135 52 1105 53 1068 55 1027 58 982 931 873 LOW 2 0 982 60 957 62 924 64 891 859 819 777 724 HIGH 4 0 1911 1838 1762 1674 35 1590 37 1501 1407 1294 GCCA70AX40 MED 3 ...

Page 18: ...18 Rev 0 BLOWER PERFORMANCE SPECIFICATIONS ...

Page 19: ...de air shall be introduced c In addition to air needed for combustion process air shall be provided as required for cooling of equipment or material controlling dew point heating drying oxidation or dilution safety exhaust odor control and air for com pressors d In addition to air needed for combustion air shall be applied for ventilation including all air required for comfort and proper working c...

Page 20: ... and Outlet Air to Ventilated Attic See 5 3 3 b 2 When communicating with the outdoors through verti cal ducts each opening shall have a minimum free area of 1 square inch per 4 000 BTU per hour of total input rating of all equipment in the enclosure The following drawing illustrates the air opening specifications for equipment located in confined spaces all air from out doors through ventilated a...

Page 21: ... be connected to Type B BW or L vent or vent connector and must not be vented into any portion of a factory built or masonry chimney except when used as a pathway for PVC as described later in this sec tion Never common vent this appliance with another appli ance or use a vent which is used by a solid fuel appliance Do not use commercially available no hub connectors other than those shipped with ...

Page 22: ...ion All terminations must be located at least 12 inches above ground level or the anticipated snow level Vent terminations must terminate at least 3 feet above any forced air inlet located within 10 feet Note This provision does not apply to the combustion air intake termination of a direct vent application The vent termination of a non direct vent application must terminate at least 4 feet below ...

Page 23: ...lower compartment Note Because of probable ma terial conflicts do not use other commercially available no hub connectors The combustion air intake pipe can also be secured directly to the counterflow unit air intake pipe coupling Non Direct Vent Installations A minimum of one 90 elbow must be installed on the com bustion air intake coupling to guard against inadvertent blockage RUBBER COUPLING WIT...

Page 24: ... coupling to the induced draft blower Secure the coupling to the cabinet using the screws removed in step 1 or with field supplied 3 8 8 self drilling screws WARNING The rubber elbow is not designed to support a load When the rubber elbow is mounted externally to the furnace cabinet extreme care must be taken to ad equately support field supplied vent flue piping As damage can result in leaks caus...

Page 25: ...n addition to the vent flue pipe a single 90 elbow must be secured to the com Alternate Combustion Air Intake Location The alternate combustion air intake location is the large hole not in line with the induced draft blower outlet To use the alternate combustion air intake location refer to the following steps and the Alternate Combustion Air Intake Location figure Note Counterflow unit instructio...

Page 26: ... sealed tight with proper flashing such as is used with a plastic plumbing vent 12 Min To Roof Or Highest Anticipated Snow Level TEE Vertical Termination Single Pipe Horizontal vent flue pipe terminations should be as shown in the following figure Refer to Vent Flue Pipe and Com bustion Air Pipe Termination Locations section for details concerning location restrictions A 2 3 8 diameter wall pen et...

Page 27: ...installation The number of elbows tabulated represents the number of elbows and or tees in each Vent Flue Com bustion Air Intake pipe Elbows and or tees used in the terminations must be included when determining the num ber of elbows in the piping systems If the combustion air intake pipe is to be installed above a finished ceiling or other area where dripping of condensate will be objectionable i...

Page 28: ...f a direct vent furnace to be con centrically vented through a wall HCVK or roof VCVK These kits allow a single penetration to support termina tions for both the vent flue pipe and the combustion air in take pipe HCVK is designed for horizontal through the wall terminations while the VCVK is designed for vertical through the roof terminations The appropriate kit must be used for a given terminatio...

Page 29: ...installation the drain trap and drain connections must be located on the same side as the alternate vent flue outlet In horizontal installations the drain hoses will exit through the bottom down side of the unit with the drain trap sus pended beneath the furnace The field supplied drain sys tem must be in accordance with all local codes and the instructions in the following sections WARNING In upr...

Page 30: ... 16 5 045__30 8 inches 070__30 6 Insert short end of each Tube 2 through side panel grom met holes Secure tubes to Hose A and Hose B with hose clamps Note Ensure hoses and tubes maintain a downward slope for proper drainage and that they are not kinked or binding For details concerning mounting of the drain trap refer to Condensate Drain Lines and Drain Trap Upright Drain Trap Mounting section Alt...

Page 31: ...ide pressure tap to the right down side tap The pressure switch hose must be connected to the down side to guard against blocked drain condi tions Cut hose to appropriate length to minimize sag ging Plug left unused pressure tap with plug removed from right side 2 Secure Hose A to front cover drain tap with a hose clamp Route hose to rear right down side panel grom met holes HOSE A HOSE B GROMMETE...

Page 32: ...s with a 16 1 2 cabinet width cut 5 1 2 inches straight length from the long end of one Tube 2 For units with a 20 1 2 and 24 1 2 cabinet width cut 5 1 2 inches straight length from the long end of each Tube 2 7 Units with a 16 1 2 cabinet width Insert approximately one inch of cut Tube 2 through left side panel grommet hole and secure to Hose A with a hose clamp Insert uncut Tube 2 through remain...

Page 33: ...n step 2 Use caution not to recharge your body with static electricity i e do not move or shuffle your feet do not touch ungrounded objects etc If you come in contact with an ungrounded object repeat step 2 before touching control or wires 4 Discharge your body to ground before removing a new control from its container Follow steps 1 through 3 if installing the control on a furnace Return any old ...

Page 34: ...hed within the guidelines given Note The length of flue and or com bustion air piping can be a limiting factor in the loca tion of the furnace Locate the furnace so that the condensate can be piped at a downward slope between furnace and drain Do not locate the furnace or its condensate drainage system in any area subject to below freez ing temperatures without proper freeze protection Refer to th...

Page 35: ...with a total minimum free area of 0 25 square inches per 1 000 BTU hr of furnace input rating Refer to the PRODUCT IDENTI FICATION section pages 7 and 8 for minimum clearances to combustible materials dimensions One of the ventila tion openings must be within 12 inches of the top the other opening must be within 12 inches of the bottom of the con fined space In a typical construction the clearance...

Page 36: ...bserved during any of the above tests the common venting system must be corrected Corrections must be in accordance with the latest edition of the National Fuel Gas Code NFPA 54 ANSI Z223 1 and or CAN CGA B149 Installation Codes If resizing is required on any portion of the venting system use the appropriate table in Appendix G in the latest edition of the National Fuel Gas Code ANSI Z223 1 and or...

Page 37: ...ontal ap plications the connections can be made either through the top or bottom of the furnace Drain Pan A drain pan must be provided if the furnace is installed above a conditioned area The drain pan must cover the entire area under the furnace and air conditioning coil if appli cable Freeze Protection Refer to Horizontal Applications and Conditions Drain Trap and Lines section for details Furna...

Page 38: ...RNATE JUNCTION BOX LOCATION Junction Box Relocation 4 Verify that wires will not interfere with circulator blower operation filter removal or routine maintenance 5 Reinstall blower compartment door 6 Turn on electrical power and verify proper unit opera tion WARNING To avoid the risk of electrical shock injury or death the furnace must be electrically grounded in accor dance with local codes or in...

Page 39: ...ion kits required for alternate fuels and or high alti tude CAUTION To prevent unreliable operation or equipment damage the inlet gas supply pressure must be as specified on the unit rating plate with all other household gas fired appliances operating Inlet gas supply pressures must be maintained within the ranges specified below The supply pressure must be con stant and available with all other h...

Page 40: ...PSTREAM FROM GROUND JOINT PIPE UNION GROMMET IN STANDARD GAS LINE HOLE ALTERNATE GAS LINE LOCATION PLUG IN ALTERNATE GAS LINE HOLE HEIGHT REQUIRED BY LOCAL CODE GROUND JOINT PIPE UNION DRIP LEG MANIFOLD BURNERS GAS VALVE MANUAL SHUT OFF VALVE UPSTREAM FROM GROUND JOINT PIPE UNION DRIP LEG GROMMET IN STANDARD GAS LINE HOLE DRAIN TRAP ALTERNATE GAS LINE LOCATION MANIFOLD PLUG IN ALTERNATE GAS LINE H...

Page 41: ...he gas line installation must comply with local codes or in their absence with the latest edition of the National Fuel Gas Code NFPA 54 ANSI Z223 1 Natural Gas Capacity of Pipe In Cubic Feet of Gas Per Hour CFH Length of Nominal Black Pipe Size Pipe in Feet 1 2 3 4 1 1 1 4 1 1 2 10 132 278 520 1050 1600 20 92 190 350 730 1100 30 73 152 285 590 980 40 63 130 245 500 760 50 56 115 215 440 670 60 50 ...

Page 42: ...oved testing methods Note Never exceed specified pressures for testing Higher pressure may damage the gas valve and cause subsequent overfiring resulting in heat exchanger failure Disconnect this unit and shutoff valve from the gas supply piping system before pressure testing the supply piping sys tem with pressures in excess of 1 2 psig 3 48 kPa Isolate this unit from the gas supply piping system...

Page 43: ...t be installed in accordance with Stan dards of the National Board of Fire Underwriters for the Installation of Air Conditioning Warm Air Heating and Ven tilating Systems Pamphlets No 90A and 90B A closed return duct system must be used with the return duct connected to the furnace Supply and return con nections to the furnace may be made with flexible joints to reduce noise transmission To preven...

Page 44: ...ut___Air Flow Max CFM Horizontal Installations Minimum Recommended Size For Maximum CFM Qty Qty Disposable Permanent Upright Installations Depending on the installation and or customer preference differing filter arrangements can be applied Filters can be installed in the central return register the bottom of the blower compartment upflows a side panel external filter rack kit upflows or the ductw...

Page 45: ...t setting The integrated ignition control will close the gas valve and extinguish flame Following a 15 second delay the induced draft blower will be de energized After a 60 90 120 or 180 second delay period field selectable the circulator blower will be de energized 2 Remove the burner compartment door and move the furnace gas valve manual control to the OFF position 3 Close the manual gas shut of...

Page 46: ... Black Common Neutral White Circulator Blower Speeds Blower Heat Off Delay Timings The integrated control module provides a selectable heat off delay function The heat off delay period may be set to 60 90 120 180 seconds using the DIP switches or jumper provided on the control module The delay is factory shipped at 90 seconds but may be changed to suit the installation requirements and or homeowne...

Page 47: ...e de energized Circulator blower is de energized following a select able heat off delay period 60 90 120 or 180 sec onds Electronic air cleaner terminals are de ener gized Furnace awaits next call from thermostat Cooling Mode The normal operational sequence in cooling mode is as follows R and Y thermostat contacts close initiating a call for cool Integrated control module performs safety circuit c...

Page 48: ...ULE 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 TIMING CHART FOR NORMAL COOLING OPERATION Seconds 0 5 0 45 Indoor Fan Outdoor...

Page 49: ...or wires 4 Discharge your body to ground before removing a new control from its container Follow steps 1 through 3 if installing the control on a furnace Return any old or new controls to their containers before touching any un grounded object Diagnostic Chart WARNING To avoid electrical shock injury or death disconnect electrical power before performing any service or main tenance Refer to the tr...

Page 50: ...or blower Loose 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 Furna...

Page 51: ... switch set point and contact motion Check and correct wiring Symptoms of Abnormal Operation Associated LED Code See Note 2 Fault Description s Possible Causes Induced draft and circulator blower run continuously with no further furnace operation and Integrated control module diagnostic LED is flashing continuously Continuous Flashing Flame has been sensed with no call for heat Short to ground in ...

Page 52: ...TO SECONDARY 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...

Page 53: ...inadequate heating or cooling performance WARNING DISCONNECT THE ELECTRICAL POWER TO THE FUR NACE BEFORE REMOVING THE FILTER OR PER FORMING ANY OTHER MAINTENANCE 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 k...

Page 54: ... cable such as drain cleanout cable Attach a variable speed reversible drill to the other end of the cable Slowly rotate the cable with the drill and insert it into one of the heat exchanger tubes While reversing the drill work the cable in and out several times to obtain sufficient cleaning Repeat for each tube 9 Clean residue from furnace using a vacuum cleaner 10 Replace the parts removed in th...

Page 55: ...assume the local gas utility has stated that the calo rific value of the gas is 1025 BTU Multiplying the ninety 90 cubic feet by 1025 BTU gives us an input of 92 250 BTUH Checking the BTU input on the rating plate of the furnace being tested EXAMPLE GUCA090AX40 INPUT 92 000 BTU HR OUTPUT CAP 84 000 Should the figure you calculated not fall within five 5 per cent of the nameplate rating of the unit...

Page 56: ...50 100 200 400 1000 44 41 82 164 409 19 47 95 189 379 947 45 20 40 80 160 400 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 33...

Page 57: ...Off Turn Valves to On Position S 9 Faulty Induced Draft Blower Test Blower S 7 17 Broken or Shorted Igniter Test Igniter S 19 Dirty Flame Sensor Low uA Clean Flame Sensor S 21 Flame Sensor not in Flame Low uA Test Adjust Position of Flame Sensor S 21 Faulty Gas Valve Replace Gas Valve S 9 Open Auxiliary Limit Reset Control S 6 Improper Air Flow or Distribution Check Duct Static S 15 Cycling on Lim...

Page 58: ...t 62 S 9 Checking Gas Valve 62 63 S 10 Checking Main Burners 63 S 11 Checking Orifices 63 64 S 12 Checking Gas Pressure 64 65 S 13 Checking Delayed Ignition 65 S 14 Checking for Flashback 65 S 15 Checking Duct Static 66 S 16 Checking Temperature Rise 66 S 17 Checking Pressure Control 68 S 18 High Altitude Application USA 68 69 S 19 Checking Mini Igniter 69 S 20 Checking White Rodgers 50A55 288 or ...

Page 59: ...tat and Wiring WARNING Disconnect Electrical Power Supply 1 Remove 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 fur nace integrated control module terminals 3 Jumper terminals R to W on the integrated control mod ule With Power ON and Door Interlock Switch close...

Page 60: ...ccess to the thermostat low voltage wires located at the furnace integrated control module terminals 2 Remove the thermostat low voltage wires at the fur nace integrated control module terminals With Power On and Door Interlock Switch Closed WARNING LINE VOLTAGE NOW PRESENT 3 Use a voltmeter check voltage across terminals R and C Must read 24 VAC 4 No voltage indicates faulty transformer open fuse...

Page 61: ...ain access to the auxiliary limit control located in the furnace blower compartment area 2 Remove the wires from the auxiliary limit control termi nals 3 Use an ohmmeter test for continuity across the two terminals see auxiliary limit control figure below No reading indicates the control is open Push the red re set button test again if still open replace the control Color Identifing Tab Red Reset ...

Page 62: ...heck C a p a c i t o r VOLT OHM METER Testing Capacitor Resistance WARNING Disconnect Electrical Power Supply 1 Remove blower compartment door to gain access to capacitor 2 Discharge capacitor and remove wire leads 3 Set an ohmmeter on its highest ohm scale and connect the leads to the capacitor a Good Condition indicator swings to zero and slowly returns toward infinity b Shorted indicator swings...

Page 63: ...at exchanger 5 Turn on gas to furnace and check for leaks If leaks are found repair and then reinstall burner compartment door 6 Turn on electrical power and verify poper unit opera tion S 11 CHECKING ORIFICES A predetermined fixed gas orifice is used in all of these furnaces That is an orifice which has a fixed bore and po sition No resizing should be attempted until all factors are taken into co...

Page 64: ...piping drip leg as shown in the fol lowing two figures Note At either location a hose fitting must be installed prior to making the hose connection Manometer Hose O F F ON M P C 1 3 2 WR INLET OUTLET Pressure Regulator Adjustment Under Cap Screw Inlet Pressure Tap Side of Valve Outlet Manifold Pressure Tap Side of Valve Gas Valve Control ON Off Switch Manometer Open to Atmosphere Measuring Inlet G...

Page 65: ...ease the pressure or counterclockwise to decrease the pressure 7 Securely replace the regulator cap WARNING Disconnect Electrical Power and Shut Off Gas Supply 8 Disconnect manometer after turning off gas at manual shutoff valve Reinstall gas valve outlet pressure tap plug before turning on gas to furnace 9 Turn on gas to furnace and check for leaks If leaks are found repair and then reinstall bur...

Page 66: ...izi ng un it b e fo ret ou chi n gu ni t in te ri o r CUTAWAY OF DUCTWORK TO EXPOSE COIL RETURN AIR SUPPLY AIR INCLINED MANOMETER Checking Static Pressure S 16 CHECKING TEMPERATURE RISE The more air CFM being delivered through a given fur nace the less the rise will be so the less air CFM being delivered the greater the rise The temperature rise should be adjusted in accordance to a given furnace ...

Page 67: ...7 PROD 0 37 0 16 HAPS27 20197307 GUCA115AX50 GCCA115AX50 0 60 0 85 1 40 1 90 0 37 0 37 PROD 0 37 0 16 HAPS27 20197307 NEGATIVE PRESSURE COIL COVER NOT FIRING TYPICAL SEA LEVEL DATA NEGATIVE PRESSURE COIL COVER FIRING TYPICAL SEA LEVEL DATA Note Replacement pressure switch number is listed below high altitude kit number Note Minimum negative pressure required to activate the pressure switch is 0 52...

Page 68: ...e furnace for heating cycle The induced draft blower motor will begin to run The inclined manometer for the induced draft blower pressure switch should read approximately negative 0 60 to 1 00 w c and the in clined manometer for the coil cover pressure switch should read approximately negative 0 65 to 1 40 w c with no combustion Refer to the chart on page 67 for pressure switch usage and trip poin...

Page 69: ...nd hot wire connection to the line polarity or a high resistance connection in the neutral line may cause the control to lockout due to failure to sense flame WARNING To avoid the risk of electrical shock wiring to the unit must be properly polarized and grounded Disconnect power before performing service listed below The ground wire must run from the furnace all the way back to the electrical pan...

Page 70: ...me is reset back to the minimum time setting 6 After a call for heat begins check for 24 volts to the gas valve Voltage will be present only if proof of flame has been established Measure voltage from Pin 9 MV ter minal BR 13 wire to Pin 12 MV terminal GY 12 on the ignition control 12 Pin connector No voltage re place ignition control 7 If proof of flame was established 120 volts will be pro vided...

Page 71: ...alve The con trol is designed to open should a flame roll out accur An over firing condition or flame impingment on the heat shield may also cause the control to open To aid in identifying these controls color coded labels are attached to the back of these controls Refer to the follow ing chart for temperature settings color codes and the num ber of controls used on each unit Part Number 10 13 14 ...

Page 72: ...RNING Disconnect Electrical Power and Shut Off Gas Supply Note Save all components except existing heat ex changer and screws removed in the following procedures for reassembly 1 After electrical power and gas supply have been shut off remove the burner and blower compartment doors 2 Remove the gas supply piping from the unit In order to have proper clearance to remove the heat exchanger assembly ...

Page 73: ...e GCCA model furnace Counterflow Installations can now be reinstalled into the installation 6 Reconnect the attached ductwork along with combus tion air pipe Direct Vent Only and vent flue pipe to fur nace removed in Step 3 of removal procedures Also reconnect the incoming electrical power lines GCCA Counterflow Installations 7 Reinstall the inner gas supply piping and reconnect to gas supply line...

Page 74: ... P3 C2 R W Y G C TO MICRO FUSE 3 A INTEGRATED CONTROL MODULE 24V THERMOSTAT CONNECTIONS 24 VAC 40 VA TRANSFORMER 115 VAC FLAME SENSOR HUMIDIFIER ID BLWR INDOOR AIR CIRCULATION BLWR ELECTRONIC AIR CLEANER JUNCTION BOX WITH BLOWER COMPARTMENT DOOR SWITCH LINE H LINE N EAC H EAC N HEAT H CIRC N COOL H FP 2 IGN HUM H IND XFMR H XFMR N HOT SURFACE IGNITER HUM N C O O L H E A T INTEGRATED CONTROL MODULE...

Page 75: ... 34 WH 7 WH BK WH RD 2 VT 28 BR 13 GN GY 12 BU 14 OR ON OF F ON ON OF F OF F OF F BK 4 GN GND WARNING DISCONNECT POWER BEFORE SERVICING WIRING TO UNIT MUST BE PROPERLY POLARIZED AND GROUNDED GND TO 115 VAC 1Ø 60 HZ POWER SUPPLY WITH OVERCURRENT PROTE CTION DEVICE L N 4 IF HEATING AND COOLING BLOWER SPEEDS ARE NOT THE SAME DISCARD JUMPER BEFORE CONNECTING BLOWER LEADS UNUSED BLOWER LEADS MUST BE PL...

Page 76: ...ove refer to the appropriate wiring diagram for the unit being serviced 0005 3M K5 K2 HEAT COOL PARK PARK CIR NEU K8 GAS VALVE HIGH LIMIT AUX LIMIT PRESSURE SWITCH FLAME SENSOR PROBE IGNITOR FP IGN GND MV MV PS HLO HLI CIRCULATOR BLOWER XFMR HOT XFMR NEU 24 VAC TH RO1 RO2 R TR C Y G W COMPRESSOR CONTACTOR COIL THERMOSTAT R Y G W INDUCER IND ELECTRONIC AIR CLEANER HUMIDIFIER HUM NEU IND EAC EAU NEU...

Page 77: ... wiring is as shown above refer to the appropriate wiring diagram for the unit being serviced HEAT COOL PARK PARK CIR NEU GAS VALVE HIGH LIMIT AUX LIMIT PRESSURE SWITCH FLAME SENSOR PROBE IGNITER FP IGN GND MVC MV PS HLO HLI CIRCULATOR BLOWER XFMR HOT XFMR NEU 24 VAC TH RO1 RO2 R TR C Y G W COMPRESSOR CONTACTOR COIL THERMOSTAT R Y G W INDUCER IND ELECTRONIC AIR CLEANER HUMIDIFIER HUM NEU HUM EAC E...

Page 78: ...H DISCONNECT THE POWER BEFORE SERVICING WARNING SCHEMATICS 78 Rev 0 FURNACE TWINING KIT FTK03A This schematic is for reference only Not all wiring is as shown above refer to the appropriate wiring diagram for the unit being serviced Tape wire ends if not used ...

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