Amana AMVM97 Service Instructions Manual
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Amana AMVM97 Service Instructions Manual

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Service Instructions

97% Modulating Gas Furnaces
34.5" Chassis ACVM, AMVM, GCVM, GMVM
& Accessories
RS6612009r1
This manual is to be used by qualified, professionally trained HVAC technicians only. Goodman does
not assume any responsibility for property damage or personal injury due to improper service
November 2014
procedures or services performed by an unqualified person.
is a registered trademark of Maytag Corporation or its related companies and is used under license to Goodman Company, L.P., Houston, TX. All rights reserved.
Copyright © 2014 Goodman Company, L.P.
1

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  • Page 1: Service Instructions

    Service Instructions 97% Modulating Gas Furnaces 34.5" Chassis ACVM, AMVM, GCVM, GMVM & Accessories RS6612009r1 This manual is to be used by qualified, professionally trained HVAC technicians only. Goodman does not assume any responsibility for property damage or personal injury due to improper service November 2014 procedures or services performed by an unqualified person.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS IMPORTANT INFORMATION ...... 2-4 OPERATIONAL CHECKS ...... 49 - 51 PRODUCT IDENTIFICATION ....5 - 8 MAINTENANCE ........52 ACCESSORIES ........9 - 11 SERVICING TABLE OF CONTENTS ....53 LIGHTING INSTRUCTIONS ......12 SERVICING ........54 - 60 PRODUCT DESIGN ......

  • Page 3: Important Information

    IMPORTANT INFORMATION 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 INFORMATION LINE CONSUMER INFORMATION LINE AMANA BRAND PRODUCTS GOODMAN BRAND PRODUCTS ® ®...
  • Page 4 IMPORTANT INFORMATION CO can cause serious illness including permanent brain damage or death. B10259-216 Advertencia especial para la instalación de calentadores ó manejadoras de aire en áreas cerradas como estacionamientos ó cuartos de servicio. Las emisiones de monóxido de carbono pueden circular a través del aparato cuando se opera en cualquier modo.

  • Page 5: Product Identification

    PRODUCT IDENTIFICATION PRODUCT FURNACE TYPE TYPE: MAJOR V: Variable-Speed G: Goodman ® REVISION Brand CABINET A: Initial Release A: Amana ® WIDTH Brand B: 17-1/2" C: 21" D: 24-1/2" MINOR REVISION A: Initial Release NOMINAL INPUT 060: 60,000 Btuh 080: 80,000 Btuh...
  • Page 6 PRODUCT IDENTIFICATION MODEL: AMVM97 MODEL: ACVM97 REV AA REV AA Equipm ent Type Amana Brand Residential Gas Furnace Equipment Type Amana Brand Residential Gas Furnace Heating Stages Modulating (35% - 100% of rated input) Heating Stages Modulating (35% - 100% of rated input)
  • Page 7 USB plug allowing dealers the ability to insert pre-programmed operating parameters and dealer information by use of an online data entry system. Communicating Thermostat Kit- Digitally communicating touchscreen thermostat from Honeywell. Designed for use with compatible Amana® Brand or Goodman® Brand Air Handlers or Furnaces and outdoor split AC or CTK03A* CTK03A* Heat Pump units.
  • Page 8 DESCRIPTION DCVK-20 Concentric Vent Kit. For use with Amana® Brand Modulating furnace models. This kit is designed to allow (CVENT-2) terminations of a direct vent furnace to be "concentrically" vented through a wall or roof. This kit allows a single penetration to support terminations for both the vent/flue and the combustion air intake pipe.

  • Page 9: Accessories

    ACCESSORIES 97% Mod Furnace Accessories *MVM970603BN** *MVM970803BN** *MVM970804CN** *MVM971005CN** *MVM971205DN** *CVM970603BN** *CVM970803BN** *CVM970804CN** *CVM971005CN** *MVM970603BN** *MVM970803BN** *MVM970804CN** *MVM971005CN** *MVM971205DN** *CVM970603BN** *CVM970803BN** *CVM970804CN** *CVM971005CN**...
  • Page 10 ACCESSORIES EXTERNAL FILTER RACK (EFR02) Used on 97% Upflow Modulating Furnaces SLOTS IN FILTER CLEAR SCREWS ON UNIT BLOWER DECK SCREWS UNIT SIDE PANEL FRONT OF UNIT FILTER RACK ASSEMBLY (FACE FILTER OPENING BASE TOWARDS FRONT OF UNIT OF UNIT) RETURN AIR CUTOUT AREA LOWER EDGE...
  • Page 11 ACCESSORIES LPM-09 LP CONVERSION KIT SIDE WALL VENT KIT (0170K00000S) This furnace is factory equipped to operate on Natural Gas This side wall only vent kit #0170K00000S is to be used but may be field converted to operate on LP gas. To con- with 2”...

  • Page 12: Lighting Instructions

    LIGHTING INSTRUCTIONS FOR YOUR SAFETY LIRE AVANT DE METTRE READ BEFORE OPERATING EN MARCHELIRE WARNING: AVERTISSEMENT: If you do not follow these instructions Quiconque ne respecte pas à Exactly, a fire or explosion may result causing property la lettre les instructions dans le presént manuel damage, personal injury or loss of life.

  • Page 13: Product Design

    PRODUCT DESIGN Adhere to the following warnings and cautions when in- stalling, adjusting, altering, servicing, or operating the WARNING furnace. To ensure proper installation and operation, O PREVENT POSSIBLE PROPERTY DAMAGE PERSONAL INJURY OR thoroughly read this manual for specifics pertaining to the DEATH DUE TO ELECTRICAL SHOCK THE FURNACE MUST BE LOCATED TO installation and application of this product.

  • Page 14: General Information

    The modulating furnace is part of the Goodman® brand & ing following the discharge process in step 2. Use Amana® brand family of communicating ready products. caution not to recharge your body with static elec- The furnace may be used with conventional single or multi- tricity;...
  • Page 15 This furnace may be used as a construction site heater ONLY 1. Modulating furnace alone if all of the following conditions are met: 2. Modulating furnace with Goodman® brand / Amana® • The vent system is permanently installed per these in- brand communicating split A/C or H/P unit (no sepa- stallation instructions.
  • Page 16 PRODUCT DESIGN National Fire Protection Association • A special accessory subbase must be used for upright counterflow unit installations over any combustible ma- 1 Batterymarch Park terial (including wood). Refer to subbase instructions Quincy, MA 02269 for installation details. (NOTE: A subbase will not be CSA International required if an air conditioning coil is located beneath the furnace between the supply air opening and the combus-...
  • Page 17 The primary heat exchanger is a tubular type constructed provided in the LP kit. of high quality steel (409 stainless steel for Amana Brand, ECM Motor aluminized for Goodman) the heat exchanger assembly con-...
  • Page 18 PRODUCT DESIGN This voltage to the IBD will vary between furnace models • Terminate a call for gas heat. and is dependant on what percentage of maximum fire is • When the modulating furnace is installed with a com- being called for. The power wires are colored red, white, municating thermostat and a non-communicating a/ and black.
  • Page 19 PRODUCT DESIGN WARNING T O P T O P O PREVENT POSSIBLE EQUIPMENT DAMAGE PROPERTY DAMAGE PERSONAL INJURY OR DEATH THE FOLLOWING BULLET POINTS MUST BE S ID E S ID E S ID E OBSERVED WHEN INSTALLING THIS UNIT B O T T O M WARNING B O T TO M...

  • Page 20: Installation Positions

    PRODUCT DESIGN If this furnace is to be installed in the same space with other gas appliances, such as a water heater, ensure there is an Insert flange. Cut 2 ½” long. adequate supply of combustion and ventilation air for the other appliances.
  • Page 21 PRODUCT DESIGN Propane Gas/High Altitude Installations ONNECTIONS Return duct must not be connected to the back of any fur- nace. Up flow furnaces installed vertically may have return WARNING air duct connections on either side or the furnace bottom. When airflow requirements are greater than 1,800 CFM for OSSIBLE PROPERTY DAMAGE PERSONAL INJURY OR DEATH MAY heating or cooling, both sides or a bottom return must be...
  • Page 22 PRODUCT DESIGN PREFERRED *MVM97/*CVM97 Direct Vent (2 - Pipe) and Non-Direct Vent (1- Pipe) (1) (2) Maximum Allowable Length of Vent/Flue Pipe & Combustion Air Pipe (ft) (3) (5) Unit Number of Elbows Pipe Size Input (in.) (Btu) 60,000 or 2 1/2 80,000 or 2 1/2 80,000...
  • Page 23 PRODUCT DESIGN DIRECT VENT TERMINAL CLEARANCES Canadian Installations U.S. Installations Canadian Installations U.S. Installations Clearance to service 3 ft. (91 cm). A= Clearance above grade, 12 in. (30 cm) 12 in. (30 cm) regulator vent outlet. veranda, porch, deck or balcony.
  • Page 24 PRODUCT DESIGN Condensate Drain Lines & Drain Trap Electrical Connections A condensing gas furnace achieves its high level of efficiency by extracting heat from the products of combustion to the point WARNING where condensation takes place. The condensate must be col- HIGH VOLTAGE ! lected in the furnace drain trap and routed to an appropri- ate drain location in compliance with local and national codes.

  • Page 25: Operation

    OPERATION Line voltage connections can be made through either the right 115 V ONNECTIONS or left side panel. The furnace is shipped configured for a Before proceeding with electrical connections, ensure that the right side electrical connection. To make electrical connec- supply voltage, frequency, and phase correspond to that speci- tions through the opposite side of the furnace, the junction fied on the unit rating plate.
  • Page 26 OPERATION When installed with a non-communicating thermostat, the IMPORTANT NOTE furnace integrated control module provides terminals for both “W1” and “W2”, and “Y1” and “Y2” thermostat connections. O APPLY A SINGLE STAGE EATING HERMOSTAT THE THERMOSTAT This allows the furnace to support the following system applica- MUST SELECTOR SWITCH ON THE NTEGRATED...
  • Page 27 OPERATION 1. Humidification Options are ON / OFF with the CTK03. OSSIL PPLICATIONS When “On” is selected, the humidification relay on the This furnace can be used in conjunction with a heat pump in a furnace control board will function during a heat call if a fossil fuel application.

  • Page 28: Gas Supply And Piping

    OPERATION All field wiring must conform to applicable codes. Connections should be made as shown in the following figure. CAUTION O PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE 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 in the following table.
  • Page 29 OPERATION • Tighten all joints securely. Natural Gas Capacity of Pipe In Cubic Feet of Gas Per Hour (CFH) • Connect the furnace to the building piping by one of Length of Nominal Black Pipe Size the following methods: Pipe in Feet 1/2"...
  • Page 30 OPERATION ROPANE ANKS AND IPING Sizing Between First and Second Stage Regulator* Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting. Capacities in 1,000 BTU/hour. Pipe or Nominal Pipe Size WARNING Tubing Tubing Size, O.D. Type L Schedule 40 Length Feet...
  • Page 31 OPERATION If the total external static pressure exceeds the maximum A closed return duct system must be used, with the return duct listed on the furnace rating plate, check for closed damp- connected to the furnace. NOTE: Ductwork must never be at- ers, registers, undersized and/or oversized poorly laid out tached to the back of the furnace.

  • Page 32: Startup Procedure

    OPERATION AIR FLOW CENTRAL RETURN CUT USING TIN SNIPS GRILLE PRESS OUT BY HAND SIDE RETURN EXTERNAL FILTER RACK KIT (EITHER SIDE) CUT FOUR CORNERS AFTER REMOVING SHEET METAL SCRIBE LINES OUTLINING DUCT FLANGES Duct Flange Cut Outs Possible Upright Upflow When a cooling coil is installed with the furnace, it must be installed in the supply air to avoid condensation from occuring in the heat exchanger.
  • Page 33 OPERATION After a successful Light Off Sequence and expiration of the Upon power up, all segments in the dual seven segment display will illuminate briefly and then display ON, indicat- Ignition Stabilization Period: ing the furnace is standing by & ready to receive commands •...
  • Page 34 OPERATION Call for 2nd-Stage Heat satisfied; Call for 1st-Stage Heat remains. • The IFC remains at the current firing rate until the 10 MINS. 1st-Stage call for heat is satisfied. 8 MINS. CTK01 T EATING PERATION WITH HERMOSTAT OMMUNI IGNITION (80%) CATING •...
  • Page 35 OPERATION UPPLY RESSURE EASUREMENT 1. Turn OFF gas to furnace at the manual gas shutoff valve external to the furnace. CAUTION 2. Connect a calibrated water manometer (or appropri- O PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE ate gas pressure gauge) at either the gas valve inlet INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT pressure boss or the gas piping drip leg.
  • Page 36 OPERATION URNACE ANIFOLD RESSURES Gas Line NATURAL GAS L.P. GAS Shutoff .5" WC 1.2" WC Valve .9" WC 2.5" WC 1.25" WC 3.7" WC 1.70" WC 5.0" WC Gas Line To Furnace 2.20" WC 6.5" WC 2.80" WC 8.0" WC 100% 3.50"...
  • Page 37 OPERATION 3. Subtract the return air temperature from the supply NPUT EASUREMENT ATURAL air temperature to determine the air temperature The gas input rate to the furnace must never be greater than rise. Allow adequate time for thermometer readings that specified on the unit rating plate. To measure natural gas to stabilize.
  • Page 38 OPERATION Example: The airflow being delivered is 1225 CFM. The dis- play indicates 12. If the airflow being delivered is 1275, the • Profile A provides only an OFF delay of one (1) minute at display indicates 13. 100% of the cooling demand airflow. 1.
  • Page 39 OPERATION In general lower heating speeds will: reduce electrical consump- Switch 14 Selects compressor setup for cooling. Factory tion, lower operating sound levels of the blower, and increase position is OFF. This is the correct position for a single the outlet air temperature delivered to the home. The speeds stage condensing unit.
  • Page 40 DIP Switches...
  • Page 41 OPERATION In continuous fan mode, the CTK0* thermostat provides the UTDOOR NDOOR IRING airflow demand. The CTK02**, CTK03 and CTK04 thermo- Two wires can be utilized between the indoor and outdoor units. stats may be configured for one of threecontinuous fan speed For this wiring scheme, only the data lines, 1 and 2, are needed settings allow for 25%, 50% or 75% airflow, based on the between the indoor and outdoor units.
  • Page 42 OPERATION • Close the humidifier relay contacts OOLING PERATION WITH A OMMUNICATING HERMOSTAT AND • Energize the circulator at the circulation speed (G ONVENTIONAL INGLE TAGE speed) unless the circulator is commanded to a dif- • The call for cooling will be communicated via the ferent speed by a heat demand.
  • Page 43 OPERATION The ComfortNet system is a system that includes a ComfortNet 100% Low heat compatible furnace and air conditioner or heat pump with a High Stage Model Stage Heat CFM for Cool CTK0* thermostat. A valid ComfortNet system could also be a Cool *CFM 2 stage...
  • Page 44 OPERATION 100% (Max) CTK0* 4-Position Connectors Closed Thermostat from CTK0* Thermostat Kit ComfortNet Compatible 2 R C W1 W2 Y1 Furnace Integrated RPM 2 Control Module Closed 35% (Minimum) Non-ComfortNet Compatible Single Stage AC RPM 1 System Wiring between Furnace and Non-Communicating Compatible Single Stage Air Conditioner Time Inducer Calibration Routine...
  • Page 45 OPERATION Beginning from the moment the pressure switch is tem fault occurring and the IFC recognizing the fault sensed closed and lasting until the ignition source is has occurred. This time varies depending on the spe- energized. cific fault. • Inter-purge Time: The period of time intended to •...
  • Page 46 OPERATION Ignition Recycles: stopped and the circulator will adjust to the speed requested by the heating sequence. When flame is established during Trial for Ignition, and then lost: If the limit switch circuit opens in any mode, other than • The gas valve is de-energized.
  • Page 47 ECM Motor An Emerson® UltraTech® four wire indoor fan motor pro- vides supply air to the conditioned space. This is the same motor used on Goodman & Amana previous generation com- municating furnaces. The ECM motor consists of two sections;...

  • Page 48: Service And Operation

    SERVICE & OPERATION -EZ™ D ® SING MERSON LTRACHECK IAGNOSTIC Green LED Orange Power Button Emerson Ultracheck-EZ™ Diagnostic Tool ® • Turn off power to the furnace being serviced and verify with a volt meter • Disconnect the 4 wire communication cable from the motor control unit (end bell) •...

  • Page 49: Operational Checks

    OPERATIONAL CHECKS LED Status Indication Possible Causes Corrective Action(s) • Normal condition • None • None 2 Flashes • Out-of-box reset • Control power up • None Communications • Learn button depressed Rapid Flashing • Normal network traffic • Control is “talking” on •...
  • Page 50 OPERATIONAL CHECKS 5. If the furnace is installed as a one pipe system; make 3. Insert the memory card in the slot on the control board. sure the surrounding area and structure are adequate 4. Power the system back up and allow a few minutes for to provide combustion air the network to establish communication between all de- vices.
  • Page 51 OPERATIONAL CHECKS Troubleshooting WARNING HIGH VOLTAGE ! O AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK DISCONNECT ELECTRICAL POWER BEFORE PERFORMING ANY SERVICE OR MAINTENANCE Refer to the Troubleshooting Codes for assistance in determin- ing the source of unit operational problems. The dual 7-seg- ment LED display will display an error code that may contain a letter and number.

  • Page 52: Maintenance

    MAINTENANCE not be yellow). They should extend directly outward from the Maintenance burners without curling, floating, or lifting off. Flames must not impinge on the sides of the heat exchanger firing tubes. WARNING NDUCED RAFT AND IRCULATOR LOWERS The bearings in the induced draft blower and circulator blower O AVOID ELECTRICAL SHOCK INJURY OR DEATH motors are permanently lubricated by the manufacturer.

  • Page 53: Servicing Table Of Contents

    SERVICING SERVICING CHECKING VOLTAGE ........54 S-305 CHECKING MAIN BURNERS ......57 CHECKING WIRING ........54 S-306 CHECKING ORIFICES ........57 S-3A THERMOSTAT AND WIRING ......54 S-307 CHECKING GAS PRESSURE ......57 S-3B HEATING ANTICIPATOR/ CYLCE RATE ....55 S-308 CHECKING HOT SURFACE IGNITOR ....

  • Page 54: Checking Voltage

    SERVICING S-1 CHECKING VOLTAGE 3. If any wires must be replaced, replace with AWM, 105°C. 2/64 thick insulation of the same gauge or its equiva- lent. WARNING CHECKING THERMOSTAT, WIRING HIGH VOLTAGE ISCONNECT POWER BEFORE SERVICING OR AND ANTICIPATOR CHANGING ANY ELECTRICAL WIRING. ULTIPLE POWER SOURCES MAY BE PRESENT.

  • Page 55: S-3B Heating Anticipator/ Cylce Rate

    SERVICING S-300 CHECKING PRIMARY LIMIT CONTROL S-3B HEATING ANTICIPATOR/ CYLCE RATE All modulating furnaces use a nonadjustable, automatic Older heating thermostats may have an adjustable antici- reset, bi-metal type limit control. The primary limit con- pator. This is a wire wound adjustable heater which is en- trol is located on the front panel of the furnace between ergized during the "ON"...

  • Page 56: Checking Flame Rollout Control

    SERVICING S-303 INDUCED DRAFT BLOWER MOTOR Induced Draft Blower (IDB) All modulating furnace models use a three phase induced draft blower to draw flue gases through the heat exchanger. AUXILIARY LIMIT The inducer uses ball bearings and is permanently CONTROL lubricated.

  • Page 57: Checking Main Burners

    S-306 CHECKING ORIFICES the range specified below. The supply pressure can be mea- A fixed gas orifice is used in all Goodman brand & Amana sured at the gas valve inlet pressure tap or at a hose fit- ® ®...

  • Page 58: Checking Hot Surface Ignitor

    SERVICING wards the front of the furnace. Manifold pressure for natu- GAS LINE ral gas is pre-set to be between 3.2” WC to 3.8”WC. If the furnace has been converted to LP gas, the manifold pres- GAS SHUTOFF VALVE sure will be 9.7”WC to 10.3”W. Manifold Gas Pressure GAS LINE Natural Gas...

  • Page 59: High Altitude Application

    SERVICING S-313 CHECKING INTEGRATED IGNITION CON- 3. Using a VOM check from common terminal to NO (Nor- mally Open) - should read open. TROL BOARDS If switch reads as above proceed to Step 4, otherwise NOTE: Failure to earth ground the furnace, reversing the replace control.

  • Page 60: Checking Flame Sensor

    SERVICING S-314 CHECKING FLAME SENSOR Flame signal is continuously monitored by the IFC. The A flame sensing device is used in conjunction with the ig- flame rod, flame rod wire, and proper grounding are all nition control module to prove combustion. If proof of flame critical to proving the presence of flame.

  • Page 61: Troubleshooting

    Troubleshooting...
  • Page 62 Troubleshooting...
  • Page 63 Troubleshooting...
  • Page 64 Troubleshooting...
  • Page 65 Troubleshooting...

  • Page 66: Status Codes

    Status Codes NO POWER NORMAL OPERATION INDICATES AIRFLOW, FOLLOWED BY CFM BLOWER MOTOR NOT RUNNING BLOWER COMMUNICATION ERROR BLOWER HP MIS-MATCH BLOWER MOTOR OPERATING IN POWER, TEMPERATURE, OR SPEED LIMIT BLOWER MOTOR CURRENT TRIP OR LOST ROTOR BLOWER MOTOR LOCKED ROTOR BLOWER OVER/UNDER VOLTAGE TRIP OR OVER TEMPERATURE TRIP INCOMPLETE PARAMETERS SENT TO MOTOR LOW INDOOR AIRFLOW...

  • Page 67: Wiring Diagram

    Wiring Diagram *MVM97_A*, *CVM97_A* DOOR JUNCTION BOX INDUCTOR COIL INDOOR CIRCULATOR LINE ELECTRONIC 3Ø ID NEUTRAL HUMIDIFIER OPTIONAL NEUTRAL DIAGNOSTIC LED'S FUSE 3A TRANSFORMER 24 VAC LIMIT CONTROL CONTROLS LOW FIRE SWITCH LOUT LIMIT CONTROLS DEHUM (10) PRESS. VALVE SWITCH GND (4) INDOOR RX (2)

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