Goodman GMES8 U Series Guide
Service and Troubleshooting
Copyright © 2019-2020 Goodman Manufacturing Company, L.P.
RS6621006r2
June 2020
TABLE OF CONTENTS
IMPORTANT INFORMATION............................................. 2
PRODUCT IDENTIFICATION ............................................ 4
SYSTEM OPERATION....................................................... 6
SCHEDULED MAINTENANCE ........................................ 12
SERVICING...................................................................... 15
CHECKING VOLTAGE ...............................................16
CHECKING WIRING ...................................................16
CHECKNG THERMOSTAT, WIRING .........................16
CHECKING TRANSFORMER AND CONTROL
CIRCUIT.......................................................................16
CHECKING AIR CIRCULATOR BLOWER MOTOR .17
CHECKING DUCT STATIC.........................................17
CHECKING TEMPERATURE RISE ...........................18
CHECKING PRIMARY LIMIT CONTROL..................18
CHECKING AUXILIARY LIMIT CONTROL................19
INDUCED DRAFT BLOWER MOTOR .......................19
CECKING GAS VALVE (REDUNDANT) ....................19
CHECKING GAS PRESSURE ...................................20
CHECKING HOT SURFACE IGNITER ......................22
CHECKING PRESSURE TRANSDUCER .................22
CHECKING FOR DELAYED IGNITION.....................22
CHECKING INTERGRATED IGNITION CONTROL
BOARDS ......................................................................22
CHECKING FLAME SENSOR....................................23
TROUBLESHOOTING CHART ........................................ 24
WIRING DIAGRAMS........................................................ 27
Pride and workmanship go into every product to provide
our customers with quality products. It is possible, however,
that during its lifetime a product may require service.
Products should be serviced only by a qualied service
technician who is familiar with the safety procedures
required in the repair and who is equipped with the proper
tools, parts, testing instruments and the appropriate service
manual.
Cancer and Reproductive Harm -
www.P65Warnings.ca.gov
0140M00517-A
IMPORTANT INFORMATION
2
Pride and workmanship go into every product to provide our
customers with quality products. It is possible, however, that
during its lifetime a product may require service. Products
should be serviced only by a qualied service technician who
is familiar with the safety procedures required in the repair
and who is equipped with the proper tools, parts, testing in-
struments and the appropriate service manual.
OUTSIDE THE U.S., .
(Not a technical assistance line for dealers.) Your telephone company will bill you for the call.
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IMPORTANT INFORMATION
3
B10259-216
CO can cause serious illness including permanent brain
damage or death.
Advertencia especial para la instalación de calentadores ó manejadoras
de aire en áreas cerradas como estacionamientos ó cuartos de servicio.
B10259-216
El monóxido de carbono puede causar enfermedades severas
como daño cerebral permanente ó muerte.
Las emisiones de monóxido de carbono pueden circular a través
del aparato cuando se opera en cualquier modo.
B10259-216
RISQUE D'EMPOISONNEMENT AU MONOXYDE DE CARBONE
Cette ventilation est nécessaire pour éviter le danger d'intoxication
au CO pouvant survenir si un appareil produisant du monoxyde
de carbone continue de fonctionner au sein de la zone confinée.
PRODUCT IDENTIFICATION
4
The model and manufacturing number are used for positive identication of component parts used in manufacturing.
Please use these numbers when requesting service or parts information.
G M E S 8 0 0 6 0 3 A N A A
1 2 3 4 5 6 7 8 9 10 11 12 13
Brand Minor Revision
G - Goodman® A - Ini�al Release
V - GMC® B - 1st Revision
Configura�on
M - Upflow/Horizontal Major Revision
C - Counterflow/Horizontal A - Ini�al Release
B - 1st Revision
S - PSC Motor Nox
E - Constant Torque Motor/Mul�-Speed ECM N - Natural Gas
V - Variable Speed ECM X - Low NOx
U - Ultra-Low NOx
Gas Vale / Motor
S - Single Stage / Single Speed Cabinet Width
A - 14"
B - 17.5"
AFUE C - 21"
80 - 80% AFUE D - 24.5"
Maximum CFM
MBTU/h 3 - 1200 CFM
40 - 40,000 4 - 1600 CFM
60 - 60,000 5 - 2000 CFM
80 - 80,000
100 - 100,000
120 - 120,000
Goodman Furnace Nomenclature (13 Digits)
PRODUCT IDENTIFICATION
5
A C E 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 - Ini�al Release
B - 1st Revision
Configura�on
M - Upflow/Horizontal Major Revision
C - Downflow/Horizontal A - Ini�al Release
B - 1st Revision
Motor
V - Variable Speed/ComfortNet Nox
E - High Efficiency N - Natural Gas
S - Single SpeedX - Low NOx
U - Ultra-Low NOx
Gas Valve
M - Modula�ng Cabinet Width
C - 2 Stage A - 14"
S - Single Stage B - 17.5"
C - 21"
AFUE D - 24.5"
97 - 97% AFUE
80 - 80% AFUE Maximum CFM
3 - 1200 CFM
MBTU/h 4 - 1600 CFM
40 - 40,0005 - 2000 CFM
60 - 60,000
80 - 80,000
100 - 100,000
120 - 120,000
Amana Furnace Nomenclature (14 Digits)
The model and manufacturing number are used for positive identication of component parts used in manufacturing.
Please use these numbers when requesting service or parts information.
SYSTEM OPERATION
6
Please adhere to the following warnings and cautions when
installing, adjusting, altering, servicing, or operating the
furnace.
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Discharge your body’s static electricity before
touching unit. An electrostatic discharge can adversely
aect electrical components.
Use the following precautions during furnace installation
and servicing to protect the integrated control module from
damage. By putting the furnace, the control, and the per-
son at the same electrostatic potential, these steps will help
avoid exposing the integrated control module to electrostat-
ic discharge. This procedure is applicable to both installed
and uninstalled (ungrounded) furnaces.
1. Disconnect all power to the furnace. Do not touch the
integrated control module or any wire connected to
the control prior to discharging your body’s electro-
static charge to ground.
2. Firmly touch a clean, unpainted, metal surface of the
furnace near the control. Any tools held in a person’s
hand during grounding will be discharged.
3. Service integrated control module or connecting
wiring following the discharge process in Step 2. Use
caution not to recharge your body with static electrici-
ty; (i.e., do not move or shue 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 any static electricity from 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 ungrounded
object.
This product is designed for NATURAL GAS ONLY. This
product is designed for use as a residential home gas fur-
nace. It is designed or certied for use in mobile home,
trailer, or recreational vehicle applications.
To ensure proper installation, operation and servicing, thor-
oughly read the installation and service manuals for specif-
ics pertaining to the installation, servicing and application of
this product.
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To ensure proper furnace operation, install, operate,
maintain and service the furnace in accordance with the
installation, operation and service instructions, all local
building codes and ordinances. In their absence, follow
the latest edition of the National Fuel Gas Code (NFPA 54/
ANSI Z223.1), and/or CAN/CGA B149 Installation Codes,
local plumbing or waste water codes, and other applicable
codes.
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 calculated by an approved
method or in accordance with “ASHRAE Guide” or “Man-
ual J-Load Calculations” published by the Air Conditioning
Contractors of America.
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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 required for alternate fuels and/or high
altitude.
SYSTEM OPERATION
7
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Inlet gas supply pressures must be maintained within the
ranges specied below. The supply pressure must be constant
and available with all other household gas red appliances
operating. The minimum gas supply pressure must be
maintained to prevent unreliable ignition. The maximum must
not be exceeded to prevent unit overring.
Natural Gas Minimum: 4.5" w.c. Maximum: 10.0" w.c.
Propane Gas Minimum: 11.0" w.c. Maximum: 13.0" w.c.
This unit is equipped with a 24 volt gas valve controlled during
furnace operation by the integrated control module. Taps for
measuring the gas supply pressure and manifold pressure
are provided on the valve.
The gas valve has a manual ON/OFF control located on the
valve itself. This control may be set only to the “ON” or “OFF”
position. Refer to the Lighting Instructions Label section of this
manual or the installation instructions for use of this control
during start up and shut down periods.
To avoid possible unsatisfactory operation or
equipment damage due to underfiring of equipment,
use the proper size of natural gas piping needed when
running pipe from the meter to the furnace.
The gas piping supplying the furnace must be properly
sized based on the gas ow required, specic gravity of the
gas, and length of the run. The 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.
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 50 105 195 400 610
70 46 96 180 370 560
80 43 90 170 350 530
90 40 84 160 320 490
100 38 79 150 305 460
CFH =
(Pressure 0.5 psig or less and pressure drop of 0.3" W.C.; Based on 0.60 Specific
Gravity Gas)
BTUH Furnace Input
Heating Value of Gas (BTU/Cubic Foot)
Before placing unit in operation or upon completion of
servicing, leak test the unit and gas connections.
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Check for leaks using an approved chloride-free soap and
water solution, an electronic combustible gas detector, or
other approved testing methods.
Never exceed specied pressures for testing. Higher
pressure may damage the gas valve and cause subsequent
overring, resulting in heat exchanger failure. Disconnect
this unit and shuto valve from the gas supply piping system
before pressure testing the supply piping system with
pressures in excess of 1/2 psig (3.48 kPa). Isolate this unit
from the gas supply piping system by closing its external
manual gas shuto valve before pressure testing supply
piping system with test pressures equal to or less than 1/2
psig (3.48 kPa).
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SYSTEM OPERATION
8
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–
D
O NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND
LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.
–
S
S
•
D
O NOT TRY TO LIGHT ANY APPLIANCE.
•
D
O NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY
PHONE IN YOUR BUILDING.
•
I
MMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR’S
PHONE.
F
OLLOW THE GAS SUPPLIER’S INSTRUCTIONS.
•
I
F YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE
DEPARTMENT.
–
I
NSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER,
SERVICE AGENCY OR THE GAS SUPPLIER.
The furnace, as shipped, requires no change to run between
0-4500 feet. At all altitudes the air temperature rise must be
within the range listed on the Specication Sheet ap¬plicable
to your model for the fuel used. Manifold pressure adjustments
and combustion analysis are required for all installations
above 4500 ft. Refer to “Gas Supply Pressure Measurement”
section for instruction on how to properly measure and adjust
manifold “outlet” pressure. The furnace should operate for a
minimum of 15 minutes before taking a combustion sample.
Combustion samples should be taken from beyond the
furnace exhaust and must be within provided CO2% range.
See table below for recommended manifold pres¬sure
adjustments and proper CO2% range. Gas heating val¬ues
can vary; further pressure adjustment may be necessary to
ensure furnace operates within acceptable CO2 range.
2.4" w .c.
2.4" w .c.
2.4" w .c.
5.5 - 7.0
5.7 - 7.2
6.0 - 7.5
060
080
2.5" w .c.
2.5" w .c.
2.5" w .c.
MODEL
040
These ID plugs update the
furnace parameters to allow it to function properly at High
Altitude. ULN Single Speed 80% furnaces with serial numbers
2004 and after are approved for High Altitude installation
without the ID plug update. ULN 80% furnace with serial
numbers 2003 and prior will need this ID plug to operate at
High Altitude. You will still need to adjust manifold pressures
and CO2% as described above. See the table below for the
corresponding model number to ID Plug part number.
GMES800403AU 0130F00773 0130F00785
GMES800603BU 0130F00765 0130F00787
GMES800604BU 0130F00766 0130F00788
GMES800804BU 0130F00767 0130F00789
GMES800805CU 0130F00768 0130F00790
Goodman
Model
80% ULN ID Plugs
Not rated for high
altitude
80% ULN ID Plugs
Rated for altitude
up to 7500 ft
An optional kit is available (TSRK02) to provide
low and high cooling speeds to support operation of a two
stage cooling unit
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The wiring harness is an integral part of this furnace. Field
alteration to comply with electrical codes should not be
required. Wires are color coded for identication purposes.
Refer to the wiring diagram for wire routings. If any of the
original wire as supplied with the furnace must be replaced,
it must be replaced with wiring material having a temperature
rating of at least 105° C. Any replacement wiring must be
copper conductor.
Before proceeding with electrical connections, ensure that
the supply voltage, frequency, and phase correspond to
that specied on the unit rating plate. Power supply to the
furnace must be N.E.C. 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 sized in accordance with the maximum
SYSTEM OPERATION
9
overcurrent protection specied on the unit rating plate. An
electrical disconnect must be provided at the furnace location.
NOTE: Line polarity must be observed when making eld
connections.
Connect hot, neutral, and ground wires as shown in the wiring
diagram located on the unit’s blower door. Line polarity must
be observed when making eld connections. Line voltage
connections can be made through either the right or left side
panel.
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Wire routing must not interfere with circulator blower
operation, lter removal, or routine maintenance.
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Accessory wiring connections are to be made through the 1/4”
quick connect terminals provided on the furnace integrated
control module. The Humidier and Electronic Air Cleaner
hot and neutral terminals are identied as HUM and EAC. All
eld wiring must conform to applicable codes. Connections
should be made as shown below.
If it is necessary for the installer to supply additional line
voltage wiring to the inside of the furnace, the wiring must
conform to all local codes, and have a minimum temperature
rating of 105°C. All line voltage wire splices must be made
inside the furnace junction box.
The integrated control module humidier terminals (HUM)
are energized with 115 volts whenever the induced draft
blower is energized. The integrated control module electronic
air cleaner terminals (EAC) are energized with 115 volts
whenever the circulator blower is energized.
Low voltage connections can be made through either
the right or left side panel. Wire routing must not interfere
with circulator blower operation, lter removal, or routine
maintenance.
A 40 V.A. transformer and an integrated electronic control are
built into the furnace to allow use with most cooling equipment.
Consult the wiring diagram, located in the Technical Manual
or on the blower door for further details of 115 Volt and 24
Volt wiring.
The following drawing illustrates the typical eld wiring for
a heat only single stage system and a single stage heating/
single stage cooling system. Refer to the following gures for
proper connections to the integrated control module.
Furnace
Control Furnace
Control
Remote
Condensing
Unit
Heating
Room
Thermostat
Heating/Cooling
Room Thermostat
SYSTEM OPERATION
10
The single stage furnace control will energize the
circulator fan speed when the fan switch on the thermostat
is turned to the “ON” position.
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Connect the correct motor leads to the COOL, HEAT, and
PARK terminals. If the heating speed equals cooling speed,
use the jumper wire provided. All unused motor leads that
are not connected to “PARK” terminals on the control must
be taped to prevent shorts.
Duct systems and register sizes must be properly designed
for the C.F.M. and external static pressure rating of the
furnace. Ductwork should be designed in accordance with
the recommended methods of “Air Conditioning Contractors
of America” manual D.
A duct system should be installed in accordance with
Standards of the National Board of Fire Underwriters for
the Installation of Air Conditioning, Warm Air Heating and
Ventilating Systems, Pamphlets No. 90A and 90B.
A return air lter is not supplied with the furnace. The installer
or servicer must supply a means of ltering all of the return
air. Filter(s) shall comply with UL900 or CAN/ULC-S111
Standards.
Upflow / Horizontal
Models
Minimum Recommended Filter Size^
*0403A* 1 - 16 X 25 Side or 1 - 14 X 24 Bottom Return
*0603A* 1 - 16 X 25 Side or 1 - 14 X 24 Bottom Return
*0604B* 1 - 16 X 25 Side or Bottom Return
*0804B* 1 - 16 X 25 Side or Bottom Return
*0805C*
1 - 16 X 25 Side or Bottom Return¹
^ Larger filters may be used, filters may also be centrallylocated
¹ = us e 2 - 16 X 25 fi l ters a nd two si de returns or 20 X 25 fi l te r on bottom
return if furnace is connected to a cooling unit over 4 tons nominal capacity
Upow furnaces with air delivery of less than 1800 CFM:
Use one side return or one bottom return ductwork connection.
Upow furnaces with air delivery of 1800 CFM or higher:
Use two side returns or bottom return or combination of side/
bottom connection.
Guide dimples locate the side and bottom return cutout
locations. Use a straight edge to scribe lines connecting the
dimples. Cut out the opening on these lines. An undersized
opening will cause reduced airflow. For bottom return
connection, remove the bottom of the cabinet before setting
the furnace on the raised platform or return air duct.
A closed return duct system must be used, with the return
duct connected to the furnace. NOTE: Ductwork must never
be attached to the back of the furnace. Supply and return
connections to the furnace may be made with exible joints
to reduce noise transmission, if desired. If a central return is
used, a connecting duct must be installed between the unit
and the utility room wall so the blower will not interfere with
combustion air or draft. The room, closet, or alcove must not
be used as a return air chamber.
When the furnace is used in connection with a cooling unit,
the furnace should be installed in parallel with or on the
upstream side of the cooling unit to avoid condensation in
the heating element. With a parallel ow arrangement, the
dampers or other means used to control the ow of air must
be adequate to prevent chilled air from entering the furnace
and, if manually operated, must be equipped with means to
prevent operation of either unit unless the damper is in the
full heat or cool position.
When the furnace is heating, the temperature of the return
air entering the furnace must be between and .
Depending on the installation and/or customer preference,
diering lter arrangements can be applied. Filters can be
installed in the central return register and a side panel external
lter rack kit (upow lter kit # EFR01). As an alternative
a media air lter or electronic air cleaner can be used as
the requested lter. Refer to the following minimum lter
requirement charts for determination of the minimum lter
area to ensure proper unit performance.
The external lter rack kit is intended to provide a location
external to the furnace casing, for installation of a permanent
lter on upow model furnaces. The rack is designed to mount
over the indoor blower compartment area of either side panel,
and provide lter retention as well as a location for attaching
return air ductwork.
• 120 VAC power applied to furnace.
• Integrated ignition control performs internal checks.
• LED light will ash once at power up and then remain on.
• Integrated ignition control monitors safety circuit
continuously.
• Furnace awaits call from thermostat.
The normal operational sequence in heating mode is as
follows:
• R and W thermostat contacts close, initiating a call for
SYSTEM OPERATION
11
heat.
• Integrated control module performs safety circuit checks.
• The control operates
the inducer in a manner to verify the pressure sensor
null value and span operation are within specication.
If the system is operating correctly, this test takes only
a few seconds. If the system is not functioning properly,
the control times out after a maximum 90 seconds and
display the proper fault code.
• Induced draft blower is energized for 30 second
prepurge.
• Igniter warm up begins after 30 second prepurge expires.
• Gas valves open at end of igniter warm up period,
delivering gas to burners and establishing ame.
• Integrated control module monitors ame presence. Gas
valve will remain open only if ame is detected.
• Circulator blower is energized on high heat speed
following a xed 30 second blower on delay. Electronic
air cleaner terminals are energized with circulator blower.
• Furnace operates; integrated control module monitors
safety circuits continuously.
• R and W thermostat contacts open, completing the call
for heat.
• Gas valve closes, extinguishing ame.
• Induced draft blower is de-energized following a thirty
second post purge.
• HUM terminal is de-energized.
• Circulator blower continues running for selected heat o
delay period factory set at 120 seconds. If required this
can be changed in the eld.
• Electronic air cleaner is de-energized.
• Furnace awaits the next call from thermostat.
The normal operational sequence in cooling mode is as
follows:
• R, Y and G thermostat contacts close, initiating a call
for cool.
• Integrated control module performs safety circuit checks.
• Outdoor fan and compressor are energized.
• Circulator blower is energized on cool speed following a
xed six second on delay. If required this can be changed
in the eld to 45 seconds. Electronic air cleaner terminals
are energized with circulator blower.
• Furnace circulator blower and outdoor cooling unit
run, integrated control module monitors safety circuits
continuously.
• R, Y and G thermostat contacts open, completing the
call for cool.
• Outdoor fan and compressor are de-energized.
• Circulator blower is de-energized following a xed forty
rve second cool o delay period. Electronic air cleaner
terminals are de-energized.
• Furnace awaits the next call from thermostat.
The normal operational sequence in Fan Only Mode is as
follows:
• R and G thermostat contacts close, initiating a call for
fan.
• Integrated control module performs safety circuit checks.
• Circulator blower is energized on low heat speed.
Electronic air cleaner terminals are energized.
• Circulator blower runs, integrated control module
monitors safety circuits continuously.
Each 80% ULN model has a unique ID Plug that needs to
be installed into the board for your specic model number.
The ID plug will populate the board with the correct operating
parameters for each model and should be left in the board
once installed.:
Please see the table below for reference.
Part Number Goodman / Amana
0130F00773 *MES800403AUAA
0130F00765 *MES800603AUAA
0130F00766 *MES800604BUAA
0130F00767 *MES800804BUAA
0130F00768 *MES800805CUAA
The following procedure will ensure the proper operating
parameters are installed onto the board. Each model has a
unique ID PLUG that needs to be installed into the board for
your specic model number. Please see the instruction below.
1. 1.Select the appropriate ID plug for the installed
model number from the table above.
2. Attach the appropriate ID Plug for the installed model
number to the control board into the blue connector
as shown below. This will load the correct parame-
ters to the board. Failure to follow these instructions
will result in the board not functioning.
SCHEDULED MAINTENANCE
12
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The furnace should be inspected by a qualied 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 components are in proper working
order and that the heating system functions appropriately. Pay
particular attention to the following items. Repair or service
as necessary.
• Flue pipe system. Check for blockage and/or leakage.
Check the outside termination and the connections at
and internal to the furnace.
• Heat exchanger. Check for corrosion and/or buildup
within the heat exchanger passageways.
• Burners. Check for proper ignition and ame sense.
• Wiring. Verify that electrical connections are tight and
free from corrossion.
• Filters.
R R R R S S S
R RS RS SS
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Filters must be used with this furnace. Filters do not ship
with these furnaces but must be provided by the installer for
proper furnace operation.
Dirty lters are the most common cause on inadequate
heating or cooling performace.
Improper lter 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.
Filters in horizontal installations are located in the central
return register.
The bearings in the induced draft blower and circulator blower
motors are permanently lubricated by the manufacturer. No
further lubrication is required. Check motor windings for
accumulation of dust which may cause overheating. Clean
as necessary.
Under some conditions, the fuel or air supply can create a
nearly invisible coating on the ame sensor. This coating acts
as an insulator, causing a drop in the ame sensing signal. If
this occurs, a qualied servicer must carefully clean the ame
sensor with steel wool. After cleaning, the ame sensor output
should be as listed on the specication sheet.
The following is a must for every service technician and
service shop.
1. Dial type thermometers or thermocouple meter (option-
al) - to measure dry bulb temperature.
2. Amprobe - to measure amperage and voltage.
3. Volt-Ohm Meter - testing continuity, capacitors, and
motor windings.
4. Inclined Manometer - to measure static pressure, pres-
sure drop across coils, lters, and draft.
5. Water Manometer (12”) - to test gas inlet and manifold
pressure.
Other recording type instruments can be essential in solving
abnormal problems, however, in many instances they may
be rented from local sources.
Proper equipment promotes faster, more ecient service and
accurate repairs resulting in fewer call backs.
Before attempting to diagnose an operating fault code, run
a Heating Performance Test to determine if the heating
system is performing within 5% of the BTU input found on
the rating plate of the unit being tested. To conduct a heating
performance test, the BTU input to the unit must be calculated
(see Clocking a Gas Meter). Before clocking a gas meter,
contact your local utility to provide the caloric value (BTU
content) of the natural gas in the area.
It is also important to conrm the airow (CFM) is within the
temperature rise range (see Airow Data in spec sheet) and
external static pressure range (approximately 0.5” water
column). How-to instructions can be found in the service
manual under Checking External Static Pressure and
Checking Temperature Rise.
SCHEDULED MAINTENANCE
13
1. Turn o all gas appliances in the home.
2. Turn on the furnace. Ensure the furnace is operating at a 100% ring rate on 2 stage and modulating furnace product.
3. Once heating cycle is at a steady state (typically 15 minutes of operation), use a stopwatch to time how long it takes
the smallest unit of measure dial on the gas meter to make a full revolution. In Table 1, one cubic foot is selected. The
smallest unit of measure will vary depending on the gas meter.
CUBIC
FEET
11
One
In this example
we are using the
one cubic foot
dial on the gas
meter
TABLE 1
4. Using Table 2 below, nd the number of seconds it took for the dial to make a full revolution. To the right of that num-
ber of seconds and below the Size of Test Dial (selected in step 3 and shown in Table 1) will be the Cubic Feet per
Hour (CFH).
1/4
cu/ft
1/2
cu/ft
1
cu/ft
2
cu/ft
5
cu/ft
1/4
cu/ft
1/2
cu/ft
1
cu/ft
2
cu/ft
5
cu/ft
10 90 1803607201800 36 25 50 100200500
11 82 1643276551636 37 -- -- 97 195486
12 75 1503006001500 38 23 47 95 189474
13 69 1382775551385 39 -- -- 92 185462
14 64 1292575141286 40 22 45 90 180450
15 60 1202404801200 41 -- -- -- 176439
16 56 1132254501125 42 21 43 86 172429
17 53 1062124241059 43 -- -- -- 167419
18 50 1002004001000 44 -- 41 82 164409
19 47 95 189379947 45 20 40 80 160400
20 45 90 180360900 46 -- -- 78 157391
21 43 86 171343857 47 19 38 76 153383
22 41 82 164327818 48 -- -- 75 150375
23 39 78 157313783 49 -- -- -- 147367
24 37 75 150300750 50 18 36 72 144360
25 36 72 144288720 51 -- -- -- 141355
26 34 69 138277692 52 -- -- 69 138346
27 33 67 133265667 53 17 34 -- 136340
28 32 64 129257643 54 -- -- 67 133333
29 31 62 124248621 55 -- -- -- 131327
30 30 60 120240600 56 16 32 64 129321
31 -- -- 116232581 57 -- -- -- 126316
32 28 56 113225563 58 -- 31 62 124310
33 -- -- 109218545 59 -- -- -- 122305
34 26 53 106212529 60 15 30 60 120300
35 -- -- 103206514
GAS RATE -- CUBIC FEET PER HOUR
Secondsfo
r
One
Revolution
Size of Test Dial
Secondsfo
r
One
Revolution
Size of Test Dial
Locate 40 seconds for one
revoluon in the chart below
Then locate the 1 cu dial column and select the
corresponding CFH from the 40 seconds for one revoluon row
TABLE 2
SCHEDULED MAINTENANCE
14
5. Use this formula to verify the Cubic Feet per Hour (CFH) input determined in step 4 is correct:
(3600 x Gas Meter Dial Size) / Time (seconds) = Cubic Feet per Hour (CFH)
3600 is used as there are 60 seconds in
a minute and 60 minutes in an hour.
60x60=3600
6. Check with your local utility for actual BTU content (caloric value) of natural gas in the area (the average is 1025
BTU’s).
7. Use this formula to calculate the BTU/HR input (See BTU/HR Calculation Example):
8. Should the gure you calculated not fall within ve (5) percent of the nameplate rating of the unit, adjust the gas valve
pressure regulator or resize orices. To adjust the pressure regulator on the gas valve, turn downward (clockwise) to
increase pressure and input, and upward (counterclockwise) to decrease pressure and input. A properly operating unit
must have the BTU per hour input and CFM of air, within the limits shown to prevent short cycling of the equipment.
As the external static pressure goes up, the temperature rise will also increase. Consult the proper tables for tempera-
ture rise limitation.
The unit being tested takes 40 seconds for the 1 cubic foot dial to make one complete revolution. Using the chart, this
translates to 90 cubic feet per hour. Based upon the assumption that one cubic foot of natural gas has 1,025 BTU’s (Check
with your local utility for actual BTU content), the
90,000 BTU/HR
92,250 BTU/HR
This example is within the 5% tolerance input and does not need adjustment.
Always connect a manometer to the outlet tap at the
gas valve before adjusting the pressure regulator. In
no case should the final manifold pressure vary more
than plus or minus .2 inches water column from 3
inches water column for natural gas.
A properly operating unit must have the BTU per hour input and CFM of air, within the limits shown to prevent short cycling
of the equipment. As the external static pressure goes up, the temperature rise will also increase. Consult the proper tables
for temperature rise limitation.
SERVICING
15
29
1 Tubular Heat Exchanger
11 Transformer
Tubular Heat Exchanger
Pressure Sensor Assembly
Flue Pipe Connection
Gas Valve
Inducer
Gas Manifold Assembly
Grommet
Burner Assembly
Integrated
Control Module
Transformer
Blower Door
Interlock Switch
Circulator Blower
1
2
3
4
5
6
7
8
9
10
11
12
13
SERVICING
16
S
R RSR R
R R
R
SRS RS
R S S
RR RS JRR
1. Remove the burner door to gain entry to the Junction Box.
2. Remove cover from the Junction Box and gain access to
incoming power lines.
With Power ON:
RS
3. Using a voltmeter, measure the voltage across the hot
and neutral connections.
To energize the furnace, the Door Interlock Switch
must be engaged at this point.
4. No reading - indicates open wiring, open fuse, no pow-
er, or faulty Door Interlock Switch from unit to fused
disconnect service. Repair as needed.
5. With ample voltage at line voltage connectors, energize
the furnace blower motor by jumpering terminals R to
G on the integrated ignition control.
6. With the blower motor in operation, the voltage should
be 115 volts ± 10 percent.
7. If the reading falls below the minimum voltage, check
the line wire size. Long runs of undersized wire can
cause low voltage. If wire size is adequate, notify the
local power company of the condition.
8. After completing check and/or repair, replace Junction
Box cover and reinstall the service panel doors.
9. Turn on electrical power and verify proper unit opera-
tion.
S R RSR
1. Check wiring visually for signs of overheating, damaged
insulation and loose connections.
2. Use an ohmmeter to check continuity of any suspected
open wires.
3. If any wires must be replaced, replace with AWM, 105°C.
2/64 thick insulation of the same gauge or its equivalent.
S R RSR
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. Jumper terminals R to W on the integrated ignition control
With Power On (and Door Interlock Switch closed):
RS
4. Induced Draft Motor must run and pull in pressure
switch.
5. If the hot surface ignitor heats and at the end of the
ignitor warm-up period the gas valve opens and the
burners ignite, the trouble is in the thermostat or wiring.
6. With power o, check the continuity of the thermostat
and wiring. Repair or replace as necessary.
If checking the furnace in the air conditioning mode, pro-
ceed as follows.
7. With power o, Jumper terminals R to Y to G.
8. Turn on the power.
9. If the furnace blower motor starts and the condensing
unit runs, then the trouble is in the thermostat or wiring.
Repair or replace as necessary.
10. After completing check and/or repair of wiring and
check and/or replacement of thermostat, reinstall blow-
er compartment door.
11. Turn on electrical power and verify proper unit opera-
tion.
A step-down transformer 120 volt primary to 24 volt secondary,
40 VA (Heating and Cooling Models) supplies ample capacity
of power for either operation.
S
R RSR R
R R
R
SRS RS
R S S
RR RS JRR
1. Remove blower compartment door to gain access to
the thermostat low voltage wires located at the furnace
integrated control module.
SERVICING
17
2. Remove the thermostat low voltage wires at the furnace
integrated control module terminals.
With Power On (and Door Interlock Switch closed):
RS
3. Use a voltmeter, check voltage across terminals R and
C. Must read 24 VAC.
4. No voltage indicates faulty transformer, open fuse, bad
wiring, bad splice, or open door interlock switch.
5. Check transformer primary voltage at incoming line
voltage connections, fuse, splices, and blower door in-
terlock switch.
6. If line voltage is available to the primary side of trans-
former and not at secondary side, the transformer is
inoperative. Replace.
7. After completing check and/or replacement of trans-
former and check and/or repair of control circuit, rein-
stall blower compartment door.
8. Turn on electrical power and verify proper unit opera-
tion.
S R RSR
1. Remove blower compartment door to gain access to the
circulator blower motor and integrated ignition control.
2. Check for any obstruction that would keep the fan wheel
/ fan motor from turning.
3. Check wiring, the motor has two wiring harnesses, a main
harness and a control harness. The main power harness
has: White neutral wire connected to the NEUTRAL
terminal on the control board. Black wire connected to
the MOTOR terminal on the control board. Red wire
connected to the COM terminal, which is a female spade
connection next to the HEAT and COOL wires on the
control board. Green ground wire connected to cabinet
ground. The control power harness has: Blue wire
connected to HEAT on the control board. (Medium High
Speed)Red wire connected to RED on the control board.
(High Speed) Orange wire connected to FAN on the
control board. (Medium Speed) Black (Low Speed) and
Brown (Medium Low Speed) wires connected to PARK on
the control board. The multi-speed ECM motor requires
a line voltage power supply (black connected to MOTOR
and white connected to neutral on the control board) as
well as a signal on one of the speed taps. The signal to
the motor is a 24vAC signal to the speed tap. .
S R RSR
The maximum and minimum allowable external static
pressures are found in the specication 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 will result in insucient
air that can cause excessive temperature rise, resulting in
limit tripping, etc. Whereas not enough static may result in
motor overloading.
To determine proper air movement, proceed as follows:
1. With clean lters in the furnace, use a draft gauge (inclined
manometer) to measure the static pressure of the return
duct at the inlet of the furnace. (Negative Pressure)
2. Measure the static pressure of the supply duct. (Positive
Pressure)
3. Add the two (2) readings together for total external static
pressure.
Both readings may be taken simultaneously and read
directly on the manometer if so desired. If an air conditioner
coil or Electronic Air Cleaner is used in conjunction with the
furnace, the readings must also include theses components,
as shown in the following drawing.
4. Consult proper tables for the quantity of air.
If the total external static pressure exceeds the minimum
or maximum allowable statics, check for closed dampers,
registers, undersized and/or oversized poorly laid out duct
work.
.
SERVICING
18
The more air (CFM) being delivered through a given furnace,
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 specifications and its
external static pressure. An incorrect temperature rise may
result in condensing in or overheating of the heat exchanger.
An airow and temperature rise table is provided in the blower
performance specication section. Determine and adjust
temperature rise as follows:
1. Operate furnace with burners ring for approximately ten
minutes. Check BTU input to furnace - do not exceed
input rating stamped on rating plate. Ensure all registers
are open and all duct dampers are in their nal (fully or
partially open) position.
2. Place thermometers in the return and supply ducts as
close to the furnace as possible. Thermometers must not
be inuenced by radiant heat by being able to “see” the
heat exchanger.
SUPPLY
AIR
RETURN
AIR
3. Subtract the return air temperature from the supply air
temperature to determine the air temperature rise. Allow
adequate time for thermometer readings to stabilize.
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 changing details.
Temperature rise is related to the BTUH output of the
furnace and the amount of air (CFM) circulated over the
heat exchanger. Measure motor current draw to determine
that the motor is not overloaded during adjustments.
All use a nonadjustable, automatic reset, bi-metal type limit
control.
Style 1 drawing illustrates the Primary Limit used on the 80%
furnaces.
S
R RSR R
R R
R
SRS RS
R S S
RR RS JRR
1. Remove burner compartment door to gain access to
the primary limit.
2. Remove low voltage wires at limit control terminals.
3. With an ohmmeter, test between these two terminals
as shown in the following drawing. The ohmmeter
should read continuous unless heat exchanger tem-
perature is above limit control setting. If not as above,
replace the control.
COLOR
IDENTIFYING
TAB
SERVICING
19
S R RSR R
S S R SRS
RS R S SRR
RS JRR
RED
RESET
BUTTON
COLOR
IDENTIFYING
SS R RS XR R
S S Q SRR
SR XR R
RS
S
R RSR R
S S
R SRS
RS
R S SRR
RS JRR
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 probe in turn to each lead.
If the windings do not test continuous or a reading is
obtained to ground, replace the motor.
5. If the windings have a continuity reading, reconnect
wires. Turn power on to the furnace and turn the
thermostat on in the heating mode. Check voltage for
115V at the induced draft motor terminals during the tri-
al for ignition. If you have 115V and the motor does not
run, replace the induced draft motor.
6. After completing check and/or replacement of induced
draft motor, reinstall burner compartment door.
7. Turn on electrical power and verify proper unit opera-
tion.
A combination redundant operator type gas valve which
provides all manual and automatic control functions required
for gas red heating equipment is used.
The valve provides control of main burner gas ow, pressure
regulation, and 100 percent safety shut-o.
S R RSR
Single stage gas valves should be tested on the furnance with
24 VAC connected to the gas valve and manometers reading
supply line and manifold pressures.
SERVICING
20
S S R R S
Orices should be treated with care in order to prevent
damage. They should be removed and installed with a box-
end wrench in order to prevent distortion. In no instance
should an orice be peened over and redrilled. This will
change the angle or deflection of the vacuum effect or
entraining of primary air, which will make it dicult to adjust
the ame properly. This same problem can occur if an orice
spud of a dierent length is substituted.
S S R R S
R R R R Q
S S RSSRS S S
R R S S R S
R
Gas inlet and manifold pressures should be checked and
adjusted in accordance to the type of fuel being consumed.
The line pressure supplied to the gas valve must be within the
range specied below. The supply pressure can be measured
at the gas valve inlet pressure tap or at a hose tting installed
in the gas piping drip leg. The supply pressure must be
measured with the burners operating. To measure the gas
supply pressure, use the following procedure.
S R R S S S
1. After turning o gas to furnace at the manual gas shuto
valve external to the furnace, remove burner compartment
door to gain access to the gas valve.
2. Connect a calibrated water manometer (or appropriate
gas pressure gauge) at either the gas valve inlet pressure
tap or the gas piping drip leg as shown in the following
gures. Refer to Measuring Gas Pressure: Single Stage
Valves gure for single stage valve inlet pressure tap
connections.
At either location, a hose tting must be installed prior
to making the hose connection.
Use apapter kit #0151K00000S to measure gas
pressure on White-Rodgers 36J22 gas valves.
.
3. Turn ON the gas and electrical power supply and operate
the furnace and all other gas consuming appliances on
the same gas supply line.
4. Measure furnace gas supply pressure with burners ring.
Supply pressure must be within the range specied in the
following table.
Minimum: 4.5" w.c. Maximum: 10.0" w.c.
If supply pressure differs from above, make necessary
adjustments to pressure regulator, gas piping size, etc., and/
or consult with local gas utility.
S
R R S S
S RSR R S S
R SRS RS
R
S SRR RS JRR
5. Disconnect manometer after turning o gas at manual
shuto valve. Reinstall plug before turning on gas to
furnace.
6. Turn OFF any unnecessary gas appliances started in step
3.
7. Turn on gas to furnace and check for leaks. If leaks are
found, repair and then reinstall burner compartment door.
This manual suits for next models
11
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