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40

T

ROUBLESHOOTING

 C

HART

Co

m

fo

r

tNet 

Therm

ost

at On

ly

 

Sym

ptom

s of A

bnor

m

al Opera

ti

on 

(Non-Com

m

unicating

 & Co

m

fo

r

tNet™ 

Therm

ost

at

 

D

ia

g

no

st

ic

/St

atus 

LED Codes

 

Fault De

scr

ipt

ion

 

Messa

ge 

Code 

P

o

ss

ib

le C

a

u

se

s

 

Correct

ive Action

s

 

No

tes

 & Ca

utio

ns

 

x

 

Ci

rcu

lato

b

lo

w

er ru

ns

 cont

inu

ou

sl

y

.  No

 

fur

nace opera

tion. 

x

 

Int

egr

ate

d c

o

ntr

o

l m

o

du

le L

E

D

 di

sp

lay

 

p

rovi

des

 

E3

 err

o

code. 

x

 

Com

fortNet 

therm

ostat “

C

all for Se

rvice” 

ico

n il

lum

ina

te

d

x

 

Com

fortN

et 

th

erm

ost

at sc

rolls “

C

heck 

Fur

nace” m

essa

ge. 

E3

 

x

 

Prim

ary

 li

m

it or 

au

xi

li

ary

 lim

it circu

it

 is 

op

en.

 

x

 

Ro

llo

ut

 li

m

it

 ci

rcui

is

 

op

en.

 

HIGH 

LIMIT 

OPEN 

E3

 

x

 

In

su

ffi

ci

en

t con

di

tio

ned

 ai

r ov

er 

th

h

eat

 ex

ch

an

g

er

.  B

loc

ke

d

 

filter

s, re

str

ic

tive 

duc

twor

k, 

im

proper 

ci

rc

u

lat

or b

low

er sp

ee

d, 

or fa

ile

d c

irc

ul

at

or b

lo

w

er m

o

tor. 

x

 

Flam

e rollout. 

x

 

Mis

al

igne

bur

ner

s,

 b

loc

ke

d f

lue 

an

d/

or a

ir i

n

le

pi

pe, 

or fa

ile

in

d

u

ce

d dr

aft 

bl

ow

er.

 

x

 

Loose or im

properly

 conne

cte

w

iri

ng. 

x

 

Chec

k f

il

ter

s an

duc

tw

or

k fo

bl

oc

ka

ge.

  Cle

an f

il

te

rs or 

rem

ove ob

st

ru

ct

io

n. 

x

 

Ch

eck

 ci

rcu

lato

r blower s

p

eed

 

an

d per

form

ance.  Correct 

spee

or re

place blower m

o

tor 

if 

nece

ss

ary

x

 

Chec

k b

u

rn

er

s f

o

r pr

op

er 

al

ign

m

en

t. 

x

 

Chec

k f

lue a

n

d ai

r i

n

le

t p

ip

ing 

fo

r blo

ck

ag

e, p

rop

er leng

th

elb

ow

s, a

n

d te

rm

inati

on.  C

o

rrec

as nece

ssa

ry

x

 

Chec

k i

n

d

u

ce

d

 dra

ft 

bl

ow

er f

o

prope

r per

form

ance.  Replace 

if 

nece

ss

ary

x

 

Tighte

or c

o

rrec

t wiring 

co

nne

ct

ion.

 

x

 

T

u

rn 

pow

er

 O

FF pr

io

r to 

repa

ir. 

x

 

See Spe

cif

ica

ti

o

n

 S

h

ee

ap

pl

ica

bl

e t

o

 y

our m

o

del 

for a

llowa

ble r

ise ra

nge 

an

d pr

o

p

er c

irc

ula

tor 

spe

ed.

 

x

 

See 

"V

en

t/F

lue P

ipe

"

 

se

ct

ion

 fo

r p

ipi

ng

 d

etai

ls

x

 

Ind

uc

ed draf

b

lo

w

er an

cir

cu

la

tor b

low

er

 

ru

ns

 co

nti

nuo

usl

y

.  

N

o

 fu

rn

ace op

erati

on

x

 

Int

egr

ate

d c

o

ntr

o

l m

o

du

le L

E

D

 di

sp

lay

 

p

rovi

des

 

E4

 err

o

code. 

x

 

Com

fortNet 

therm

ostat “

C

all for Se

rvice” 

ico

n il

lum

ina

te

d

x

 

Com

fortN

et 

th

erm

ost

at sc

rolls “

C

heck 

Fur

nace” m

essa

ge. 

E4

 

x

 

Flam

e sensed with no 

call for 

hea

t. 

IMPROPE

FLAME 

E4

 

x

 

Sh

ort

 t

o

 g

ro

und

 in

 fl

ame s

en

se 

circ

uit. 

x

 

Linger

ing bur

ner f

la

m

e. 

x

 

Slow

 c

lo

sin

g g

as 

va

lv

e.

 

x

 

Corre

ct 

shor

t at f

lam

e sens

or or 

in f

lam

e sensor wiring. 

x

 

Chec

k f

o

r linger

ing f

la

m

e. 

x

 

Veri

fy

 p

rop

er op

eratio

n

 o

f gas

 

val

ve. 

x

 

T

u

rn 

pow

er

 O

FF pr

io

r to 

repa

ir. 

x

 

No fur

nac

e opera

tion.

 

x

 

Int

egr

ate

d c

o

ntr

o

l m

o

du

le L

E

D

 di

sp

lay

 

p

rovi

des

 

E5

 err

o

code. 

x

 

Com

fortN

et th

erm

ost

at 

d

is

p

lay

“B

attery

 

Power”. 

E5

 

x

 

Op

en

 Fus

No

Di

sp

la

y

ed

 

No

Disp

la

y

ed

 

x

 

Sho

rt in low

 vo

lt

ag

w

iri

ng 

x

 

Locate 

and 

co

rre

ct short in low 

v

olt

age wi

ri

ng

 

x

 

T

u

rn 

pow

er

 O

FF pr

io

r to 

repa

ir. 

x

 

Replace f

u

se with 

3-a

m

p

 

aut

om

oti

ve ty

pe 

x

 

Norm

al furnace oper

at

ion.  

x

 

Int

egr

ate

d c

o

ntr

o

l m

o

du

le L

E

D

 di

sp

lay

 

p

rovi

des

 

E6

 err

o

code. 

E6

 

x

 

Flam

e sens

e m

icro am

si

g

n

al is low

 

WE

A

K

 

FLAME 

E6

 

x

 

F

la

m

e s

en

so

is

 co

at

ed

/ox

id

iz

ed

x

 

Flam

e sens

or 

inc

orr

ectly

 

po

si

ti

o

n

ed

 i

n

 bur

ner f

lam

e. 

x

 

Lazy

 burner f

lam

e due to 

im

proper 

ga

s pr

es

su

re

 or 

com

bus

tion air. 

x

 

Sand flam

e sensor if 

co

at

ed

/ox

id

ized

x

 

In

sp

ect

 fo

r prop

er 

se

ns

o

al

ign

m

en

t. 

x

 

Ch

eck

 inl

et

 ai

r p

ipi

ng 

fo

bl

oc

ka

ge,

 pr

o

p

er 

len

g

th,

 e

lb

o

w

s,

 

an

d term

ina

ti

o

n

x

 

Com

pare curr

ent gas 

pre

ss

ure 

to 

rati

ng

 pl

at

e.  Ad

jus

t as

 n

eed

ed

x

 

T

u

rn 

pow

er

 O

FF pr

io

r to 

repa

ir. 

x

 

Sand flam

e sensor with 

e

m

ery cloth. 

x

 

See "

V

ent/

Flu

e Pi

pe" 

se

ct

ion

 fo

r p

ipi

ng

 d

etai

ls

x

 

See rat

ing 

pl

ate f

o

pr

op

er 

gas pre

ssur

e.

 

x

 

Fur

nace 

fa

ils to opera

te. 

x

 

Int

egr

ate

d c

o

ntr

o

l m

o

du

le L

E

D

 di

sp

lay

 

p

rovi

des

 

E7

 err

o

code. 

x

 

Com

fortNet 

therm

ostat “

C

all for Se

rvice” 

ico

n il

lum

ina

te

d

x

 

Com

fortN

et 

th

erm

ost

at sc

rolls “

C

heck 

Fur

nace” m

essa

ge. 

E7

 

x

 

Pro

blem

 w

ith 

ig

ni

ter 

circ

uit. 

IGNITER 

FAULT 

E7

 

x

 

Im

pro

per

ly

 conne

cte

d i

g

n

it

er.

 

x

 

Sho

rte

d

 ig

ni

ter.

 

x

 

Po

or un

it

 groun

d

x

 

Ign

it

er re

lay

 faul

t o

n

 in

te

gra

te

co

ntr

o

l m

odule.

 

x

 

Chec

k a

nd c

o

rr

ect w

irin

g fr

om

 

in

te

gra

te

d co

n

tro

l m

odu

le 

to 

ig

n

iter. 

x

 

Repl

ace s

h

o

rt

ed

 ig

niter. 

x

 

Ch

eck

 an

d

 co

rrect

 uni

g

round

 

w

iri

ng. 

x

 

Ch

eck

 ign

it

er o

utp

ut

 fro

m

 

contr

ol.  Replace 

if necessary

x

 

T

u

rn 

pow

er

 O

FF pr

io

r to 

repa

ir. 

x

 

Replace ignite

with 

corre

ct re

placem

ent 

part. 

x

 

Replace c

o

ntr

o

l with 

corre

ct re

placem

ent 

part. 

Summary of Contents for DVC80603B

Page 1: ...s 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 are intended as...

Page 2: ...LEANOUT 13 CHECK 5 LINER CONDITION 13 CHECK 6 DILUTION AIR 13 CHECK 7 COMPLETE THE INSTALLATION 13 FIX 1 LINER TERMINATION 14 FIX 2 CHANGE VENTING ARRANGEMENTS 14 FIX 3 REBUILD THE CROWN 14 FIX 4 RELI...

Page 3: ...ATION 34 POWER UP 34 HEATING MODE 34 COOLING MODE 35 FAN ONLY MODE 35 OPERATIONAL CHECKS 35 SAFETY CIRCUIT DESCRIPTION 36 INTEGRATED CONTROL MODULE 36 PRIMARY LIMIT 36 AUXILIARY LIMIT 36 ROLLOUT LIMIT...

Page 4: ...AND IN SUCH CASE ALTERNATIVE HEAT SOURCES SHOULD BE UTILIZED WARNING TO PREVENT POSSIBLE PROPERTY DAMAGE PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK THE FURNACE MUST BE LOCATED TO PROTECT THE ELE...

Page 5: ...trol module to electrostatic discharge This procedure is applicable to both installed and non installed ungrounded furnaces 1 Disconnect all power to the furnace Do not touch the integrated control mo...

Page 6: ...els currently in pro ductioncanbeviewedatwww goodmanmfg comor www amana hac com If your model is not currently in production or does not appear on the website please contact your installing con tracto...

Page 7: ...hese pub lications are available from National Fire Protection Association Inc 1 Batterymarch Park Quincy MA 02269 NOTE Furnaces with NOx screens meet the California NOx emission standards and Califor...

Page 8: ...ing salts or chemicals carbon tetrachloride halogen type refrigerants cleaning solutions such as perchloroethylene printing inks paint removers varnishes hydrochloric acid cements and glues antistatic...

Page 9: ...ing 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 so they shall operate at maximum speed Do not operat...

Page 10: ...ap pliances i e water heaters All installations must be vented in accordance with National Fuel Gas Code NFPA54 ANSI Z223 1 latest edition In Canada the furnaces must be vented in ac cordance with the...

Page 11: ...t on the suitability of this type of venting In most situations the existing masonry chimneys will require a properly sized metallic liner POSSIBILITY OF PROPERTY DAMAGE PERSONAL INJURY OR DEATH DAMAG...

Page 12: ...clude fireplaces wood stoves coal fur naces and incinerators Proper Chimney Termination Check 1 Chimney channel free of solid and liquid fuel appliances Check 2 Change venting arrangements Fix 2 Crown...

Page 13: ...air will not be available the chimney must be relined Fix 4 CHECK 7 COMPLETE THE INSTALLATION If Checks 1 through 6 have been satisfactory and the liner is an acceptable size as determined by the tabl...

Page 14: ...or solid fuel appliances They are not suitable for use with gas fired appliances Flexible liners specifically intended and tested for gas applications are listed in the UL Gas and Oil Equipment Direc...

Page 15: ...N AFTER SERVICING CAUTION HIGH VOLTAGE TO AVOID THE RISK OF INJURY ELECTRICAL SHOCK OR DEATH THE FURNACE MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH LOCAL CODES OR IN THEIR ABSENCE WITH THE LATES...

Page 16: ...CODE WARNING To ensure proper unit grounding the ground wire should run from the furnace ground screw located inside the furnace junc tion box all the way back to the electrical panel NOTE Do not use...

Page 17: ...ermine the time to transition from low stage to high stage To use a single stage thermostat turn off power to the fur nace move the thermostat selection DIP switch to the OFF position Set the desired...

Page 18: ...inals for controlling power to an optional field supplied humidifier and or electronic air cleaner The accessory load specifications are as follows Humidifier 1 0 Amp maximum at 120 VAC Electronic Air...

Page 19: ...iring rate by changing orifices or increasing the manifold pressure This can cause poor combustion and equipment failure High altitude installations may require both a pressure switch and an orifice c...

Page 20: ...the furnace Use two pipe wrenches when making connection to the gas valve to keep it from turning The orientation of the gas valve on the manifold must be maintained as shipped from the factory Instal...

Page 21: ...AK 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 A...

Page 22: ...e blower from interfering with combustion air or draft when a cen tral return is used a connecting duct must be installed be tween the unit and the utility room wall A room closet or alcove must not b...

Page 23: ...or dirty filter Circulating air filters must be inspected monthly for dirt accumulation and replaced if necessary Failure to maintain clean filters can cause prema ture heat exchanger failure A new ho...

Page 24: ...losethemanualgasshutoffvalveexternaltothefurnace 4 Replace the burner compartment door GASSUPPLYPRESSUREMEASUREMENT CAUTION TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE THE INLET GAS SUPPLY PRE...

Page 25: ...The manifold pressure must be measured with the burners operating To measure and adjust the manifold pressure use the following procedure 1 Turn OFF gas to furnace at the manual gas shutoff valve exte...

Page 26: ...justment for details NOTE The final manifold pressure cannot vary by more than 0 3 w c from the specified setting Consult your local gas supplier if additional input rate adjustment is required 5 Repe...

Page 27: ...Acooling airflow of 990 CFM can be attained by setting the cooling speed to C and the adjustment to minus 4 Continuous fan speed in legacy mode is 25 of the furnace s maximum airflow capability For co...

Page 28: ...et System Airflow Consideration section for details DVC81005C DVC80805C DVC80603B MVC81005C MVC80805C MVC80604B To set airflow C 7 5 min 82 60 sec 100 A 60 sec 100 TAP 1 2 3 4 5 6 7 8 To set Comfort M...

Page 29: ...he dual 7 segment LED display In general lower heating speeds will reduce electrical consump tion lower operating sound levels of the blower and increase the outlet air temperature delivered to the ho...

Page 30: ...he CTK0 thermostat provides the airflow demand The thermostat may be configured for a low medium or high continuous fan speed The low medium and high fan speeds correspond to 25 50 and 75 respec tivel...

Page 31: ...ee tables below for listing of furnace submenus Touch the or _ to step through the list of submenus and view settings If a setting can be adjusted _ and keys will appear Use the _ or keys to adjust th...

Page 32: ...y repeated faults are shown a maximum of 3 times DIAGNOSTICS Submenu Item Indication for Display Only not User Modifiable Model Number MOD NUM Displays the furnace model number Serial Number SER NUM D...

Page 33: ...m CL TRM 10 to 10 in 2 increments default is 0 Selects the airflow trim amount for the non communicating compatible single stage AC unit Cool Airflow Profile CL PRFL A B C or D default is A Selects th...

Page 34: ...tions LED 2 Flashes Out of box reset Control power up Learn button depressed None None Off No power Communications error No power to furnace Open fuse Communications error Check fuses and circuit brea...

Page 35: ...balance of the heat off delay period 60 90 120 or 150 seconds Circulator blower and electronic air cleaner terminal is de energized Circulator blower ramps down to OFF during the 30 seconds following...

Page 36: ...and or blocked condensate drain condi tions FLAME SENSOR The flame sensor is a probe mounted to the burner manifold assembly which uses the principle of flame rectification to de termine the presence...

Page 37: ...ear 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 appropriately...

Page 38: ...ect the flue pipe system from the induced draft blower 4 Remove the induced draft blower and collector box cover 5 Clean the primary heat exchanger tubes using a wire brush attached to a length of hig...

Page 39: ...nse signal Sand sensor if coated and or oxidized x Check flue piping for blockage proper length elbows and termination x Verify proper induced draft blower performance x Turn power OFF prior to repair...

Page 40: ...l for heat IMPROPER FLAME E4 x Short to ground in flame sense circuit x Lingering burner flame x Slow closing gas valve x Correct short at flame sensor or in flame sensor wiring x Check for lingering...

Page 41: ...Repair replace if necessary x Inspect flue and or inlet air piping for blockage proper length elbows and termination Check drain system Correct as necessary x Check induced draft blower performance C...

Page 42: ...has lost communications with circulator blower motor MOTOR COMM b1 x Loose wiring connection at circulator motor control leads x Failed circulator blower motor x Failed integrated control module x Ti...

Page 43: ...et thermostat Call for Service icon illuminated x ComfortNet thermostat scrolls Check Furnace message b6 x Circulator blower motor shuts down for over or under voltage condition x Circulator blower mo...

Page 44: ...G CYCLE HIGH STAGE PRESSURE SWITCH STUCK OPEN REVERSED 115 VAC POLARITY DATA NOT YET ON NETWORK INVALID MEMORY CARD DATA BLOWER MOTOR NOT RUNNING BLOWER COMMUNICATION ERROR BLOWER HP MIS MATCH BLOWER...

Page 45: ...30 sec 50 7 5 min 82 30 sec 50 Select desired Comfort Mode profile see profiles above Set switches 5 and 6 to the appropriate ON OFF positions A OFF OFF OFF OFF OFF OFF OFF OFF Model Tap Low Stage Hig...

Page 46: ...CIRCULATOR BLOWER R 1 GND JUNCTION BOX SWITCH TEMP NEUTRAL 115kBTU MODELS BLOWER COMPARTMENT DOOR SWITCH OPEN WHEN DOOR OPEN C LINE BK 4 NEUTRAL POLARIZED AND C FS 2 PLUG CONNECTION DISCONNECT PU 3 I...

Page 47: ...47 THIS PAGE LEFT INTENTIONALLY BLANK...

Page 48: ...48 Goodman Manufacturing Company L P 5151 San Felipe Suite 500 Houston TX 77056 www goodmanmfg com 2011 2012 Goodman Manufacturing Company L P...

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