Goodman Mfg CVC9/95 manual

5151 San Felipe Suite 500 Houston, TX 77056 www .goodmanmfg.com • www .amana-hac.com © 2009-2010 Goodman Manufacturing Company , L.P . I NST ALLA TION I NSTRUCTIONS FOR *CVC9/95 & *MVC95 - T WO -S T AGE G AS F URNACE IO-341E 12/10 (T ype FSP CA TEGOR Y IV Direct or Non Direct V ent Air Furnace) These furnaces comply with requirements em- bod[...]

2 S HIPPING I NSPECTION ........................................................................................................................... 6 E LECTROST A TIC D ISCHARGE (ESD) P RECAUTIONS ..................................................................................... 6 T O T HE I NST ALLER ............................................[...]

3 1 15 V OL T L INE C ONNECTION OF A CCESSORIES ( H UMIDIFIER AND E LECTRONIC A IR C LEANER ) ............................. 29 24 V OL T H UMIDIFIER ......................................................................................................................... 30 G AS S UPPL Y AND P IPING ..................................................[...]

4 G OOD MA N  WILL  NOT  BE  RE SPO NSI BL E  FOR  ANY  INJURY  OR  PROP ERTY  DAMAGE  ARISING  FROM  IMPROPER  SERVIC E  OR  SERVIC E  PROC EDURE S .  I F  YOU  INST ALL  OR  PERF ORM  SERVIC E  ON  THI S  UNIT ,  YOU  ASSUME  RE SPO NSI BI LITY  FOR  ANY [...]

5 S AFETY P RECAUTIONS Adhere to the following warnings and cautions when installing, adjusting, altering, servicing, or operating the furnace. T o e nsure proper installation and operation, thoroughly read this manual for specifics pertaining to the installation and application of this product. T O  PREVEN T  POSSIB L E  PROP ERTY  DAM[...]

6 P RODUCT D ESCRIPTION & A PPLICA TION S HIPPING I NSPECTION All units are securely packed in shipping containers tested ac- cording to International Safe T ransit Association specifications. The carton must be checked upon arrival for external damage. If damage is found, a request for inspection by carrier’s agent must be made in writing im[...]

7 P RODUCT D ESCRIPTION & A PPLICA TION T O  PREVEN T  PROP ER TY  DAMAGE ,  PER SONAL  INJURY  OR  DEATH  DUE  TO  FIRE ,  DO  NOT  INST ALL  THI S  FUR NACE  IN  A  MOBILE  HOME ,  TR AIL ER ,  OR  RE CREA TIO NAL  VE HICLE . W ARNI NG P RODUCT D ESCRIPTION F EATURES This fu[...]

8 L OCA TION R EQUIREMENTS & C ONSIDERA TIONS A copy of the National Fuel Gas Code (NFP A 54/ANSI Z223.1) can be obtained from any of the following: American National Standards Institute 1430 Broadway New Y ork, NY 10018 National Fire Protection Association 1 Batterymarch Park Quincy , MA 02269 CSA International 8501 East Pleasant V alley Cleve[...]

9 L OCA TION R EQUIREMENTS & C ONSIDERA TIONS • If the furnace is used in connection with a cooling coil unit, install the furnace upstream or in parallel with the cooling coil unit. Premature heat exchanger failure will result if the cooling unit is placed ahead of the furnace. • If the furnace is installed in a residential garage, positio[...]

10 C OMBUSTION & V ENTILA TION A IR R EQUIREMENTS • Unconditioned areas behind the thermostat, such as an outside wall. Consult the instructions packaged with the thermostat for mounting instructions and further precautions. C OMBUSTION & V ENTILA TION A IR R EQUIREMENTS T O  AVOID  PROP ERT Y  DAMAGE ,  PER SONAL  INJURY ?[...]

11 H ORIZONT AL A PPLICA TIONS & C ONSIDERA TIONS H ORIZONT AL A PPLICA TIONS & C ONSIDERA TIONS Horizontal applications, in particular , may dictate many of the installation’s specifics such as airflow direction, ductwork connec- tions, flue and combustion air pipe connections, etc. The basic application of this furnace as a horizontal f[...]

12 P ROP ANE G AS /H IGH A L TITUDE I NST ALLA TIONS A LTERNATE E LECTRICAL AND G AS L INE C ONNECTIONS This furnace has provisions allowing for electrical and gas line con- nections through either side panel. In horizontal applications the connections can be made either through the “top” or “bottom” of the furnace. D RAIN P AN A drain pan [...]

13 V ENT /F LUE P IPE & C OMBUSTION A IR P IPE T O  AVOID  BOD ILY  INJURY ,  FIRE  OR  EXPLO SION ,  SOL VENT  CEME NT S  MUST  BE  KE PT  AWA Y  FROM  ALL  IGNITION  SOUR CES  ( I . E .,  SPAR KS ,  OP EN  FLA MES ,  AND  EX CE SSIV E  HEAT )  AS  THE Y  ARE  CO [...]

14 V ENT /F LUE P IPE & C OMBUSTION A IR P IPE vicing. Combustion Air and V ent piping should be routed in a man- ner to avoid contact with refrigerant lines, metering devices, con- densate drain lines, etc. If necessary , clearances may be in- creased by utilizing two 45 deg. Long-Sweep Elbows and creat- ing an “S” joint to provide additio[...]

15 V ENT /F LUE P IPE & C OMBUSTION A IR P IPE RUBBER COU PLING WIT H WORM GEAR C LAMPS RUBBE R COUPLINGS WITH WOR M GEAR CL AMPS COMBUSTION AIR PI P E ( DIREC T VENT ONLY) COMBUSTION AIR PIPE (DI RECT VENT ONL Y) VENT/FLUE PIPE VENT/FLUE PIPE 90 PVC ELBOW ( NON-DIRECT VENT ) 90 PVC ELBOW ( NON- DIRE CT V ENT ) Standar d Connections OR OR UPFL [...]

16 V ENT /F LUE P IPE & C OMBUSTION A IR P IPE 8. Upflow and Counterflow units . For horizontal installations , externally secure the field- supplied vent/flue pipe directly to the vent/flue coupling using a PVC or ABS coupling or elbow . A LTERNATE C OMBUSTION A IR I NTAKE L OCATION The alternate combustion air intake location consists of a la[...]

17 V ENT /F LUE P IPE & C OMBUSTION A IR P IPE N ON -D IRECT V ENT (S INGLE P IPE ) P IPING Non-direct vent installations require only a vent/flue pipe. The vent pipe can be run horizontally with an exit through the side of the building or run vertically with an exit through the roof of the building. The vent can also be run through an existing[...]

18 V ENT /F LUE P IPE & C OMBUSTION A IR P IPE In a basement installation, the vent/flue pipe can be run between joist spaces. If the vent pipe must go below a joist and then up into the last joist space to penetrate the header , two 45° elbows should be used to reach the header rather than two 90° elbows. TEE (OPT IO NAL) 12 " M i n T o[...]

19 V ENT /F LUE P IPE & C OMBUSTION A IR P IPE 1 23456 78 S t a n d a r d2 o r 2 1 / 2 7 16 86 56 2 5 95 65 35 0 A l t e r n a t e 2 o r 2 1 / 2 5 85 55 24 9 4 64 3 4 03 7 2 o r 2 1 / 2 4 94 64 34 0 3 73 43 12 8 3 7 16 86 56 2 5 95 65 35 0 2 o r 2 1 / 2 3 63 33 02 7 2 42 11 81 5 3 5 75 45 14 8 4 54 23 93 6 S t a n d a r d 3 7 16 86 56 2 5 95 65[...]

20 V ENT /F LUE P IPE & C OMBUSTION A IR P IPE 24" MAX 3" MIN 24" MAX A IR INT A KE 12” MIN SCRE EN 12" MIN. TO ROOF OR HIGHEST ANT ICIP A TED SNO W LEV EL 90º ME DIUM RADIUS ELBOW Alternate Horizontal Vent Termination (Dual Pipe) SUP PORT STRAPS V ENT/ FLUE TEE 12" MIN . A BOVE HIGHEST ANTICIP A TED SNO W LEV EL 12&[...]

21 C ONDENSA TE D RAIN L INES & D RAIN T RAP C ONDENSA TE D RAIN L INES & D RAIN T RAP A condensing gas furnace achieves its high level of efficiency by extracting almost all of the heat from the products of combustion and cooling them to the point where condensation takes place. The condensate which is generated must be piped to an appropr[...]

22 C ONDENSA TE D RAIN L INES & D RAIN T RAP U PRIGHT I NSTALLATIONS -T RAP ON R IGHT S IDE In a upright installation drain hoses are connected to drain ports on the rubber elbow and the recuperator coil front cover . The drain lines are then routed through the right side panel and into the drain trap secured to the outside of the cabinet. NOTE[...]

23 C ONDENSA TE D RAIN L INES & D RAIN T RAP A LTERNATE V ENT /F LUE D RAIN H OSE C ONNECTIONS Upright installations using the alternate vent/flue outlet will require “right-side only” drain hoses to be connected as follows. Refer to Vent/Flue Pipe and Combustion Air Pipe for details on alternate vent/flue pipe connection . 1. Remove the ru[...]

24 C ONDENSA TE D RAIN L INES & D RAIN T RAP U PRIGHT I NSTALLATIONS -T RAP ON L EFT S IDE NOTE: For left side trap installation, grommets must be moved to the left side of the furnace and the plugs installed on the right side of the furnace. 1. Remove the rubber plug/cap from the left side drain port on the front cover . 2. Secure Hose A to fr[...]

25 C ONDENSA TE D RAIN L INES & D RAIN T RAP U PRIGHT D RAIN T RAP M OUNTING (L EFT OR R IGHT S IDE P ANEL ) 1. Insert drain tubes into drain trap and position the drain trap against the side panel. NOTE: Drain tubes must reach the bottom of the drain trap. 2. Secure drain trap to side panel at the mounting holes (dimples or crosshairs on count[...]

26 C ONDENSA TE D RAIN L INES & D RAIN T RAP L EFT S IDE D OWN Horizontal installations with the left side panel down will require drain hoses to be connected to the left side front cover drain port and the side drain port on the rubber elbow . 1 . Remove the rubber plug/cap from the front cover left (down) side drain port. 2. Relocate the fron[...]

27 E LECTRICAL C ONNECTIONS E LECTRICAL C ONNECTIONS HIG H  VO L T AG E  ! T O  AVOID  THE  RIS K  OF  ELECT RI CAL  SHOCK ,  WIRING  TO  THE  UNIT  MUST  BE  POL ARIZE D  AND  GROUN DED . W ARNI NG HIG H  VO L T AG E  ! T O  AVOID  PER SONAL  INJURY  OR  DEATH  DUE  TO ?[...]

28 E LECTRICAL C ONNECTIONS 1 . Measure resistance between the neutral (white) connection and one of the burners. 2. Resistance should measure 10 ohms or less. This furnace is equipped with a blower door interlock switch which interrupts unit voltage when the blower door is opened for servicing. Do not defeat this switch. 24 V OLT T HERMOSTAT W IRI[...]

29 E LECTRICAL C ONNECTIONS T o use a single-stage thermost at, turn of f power to the furnace, move the thermostat selection DIP switch to the OFF position. Set the desired transition time by setting the transition delay DIP switch to the desired ON/OFF position. Turn power back on. Refer to the following figure. 3 4 Thermostat Stag e D elay Move [...]

30 G AS S UPPL Y AND P IPING Accessories Wiring 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 mo[...]

31 G AS S UPPL Y AND P IPING Contact your distributor for a tabular listing of appropriate manufacturer’s kits for propane gas and/or high altitude installa- tions. The indicated kits must be used to insure safe and proper furnace operation. All conversions must be performed by a quali- fied installer , or service agency . G AS V ALVE This unit i[...]

32 G AS S UPPL Y AND P IPING MANUAL SHUT OF F VAL VE (UP ST REAM FROM PIPE UNION) GRO MME T IN STA NDARD GAS LINE HOLE GAS LINE PL U G I N GAS LINE HOLE HEIGHT REQUIRED BY LO CA L CO DE PIPE UNION DRIP LEG MA N IFOLD BURNE RS GA S V A LV E HO RI ZO NT A L [U P FL OW M OD E L] MA NUAL SHUT - OF F V AL VE (U PST REAM FR OM GRO UND JO INT PI P E U NIO[...]

33 G AS S UPPL Y AND P IPING D IRECT /S TANDARD I NLET P IPING E DGES  OF  SHEET  META L  HOLES  MAY  BE  SHARP .  U SE  GLOVES  AS  A  PRE CAUT ION  WHEN  RE MOV IN G  HOLE  PLUGS . W ARNI NG When gas piping enters directly to the gas valve through the stan- dard inlet hole, the installer must supply[...]

34 G AS S UPPL Y AND P IPING 3/8" 1/2" 5/8" 3/4" 7/8" 1/2" 3/4" 10 730 1,700 3,200 5,300 8,300 3,200 7,500 20 500 1,100 220 3,700 5,800 2,200 4,200 30 400 920 2,000 2,900 4,700 1,800 4,000 40 370 850 1,700 2,700 4,100 1,600 3,700 50 330 770 1,500 2,400 3,700 1,500 3,400 60 300 700 1,300 2,200 3,300 1,300 3,100 80 [...]

35 C IRCULA TING A IR & F IL TERS 4. Consult proper tables for the quantity of air . If the total external static pressure exceeds the maximum listed on the furnace rating plate, check for closed dampers, registers, undersized and/or oversized poorly laid out duct work. Checking Static Pressure (80% Furnace Shown, 90% Similar) B OTTOM R ETURN A[...]

36 S T ARTUP P ROCEDURE & A DJUSTMENT 600 80 0 100 0 12 00 1 400 160 0 20 00 045 3__ X A 37 6* 38 4 4 80 576 --- -- - -- - 07 0 4 __ XA --- --- 62 7 * 6 2 7* 67 2 768 --- 090 5__ X A - -- - -- - - - 83 6* 8 36 * 836 * 960 115 5__ X A - -- - -- - - - 94 0* 9 40 * 940 * 960 600 80 0 100 0 12 00 1 400 160 0 20 00 070 4__ X A 071 4 __ X A --- --- 3[...]

37 S T ARTUP P ROCEDURE & A DJUSTMENT H EAT A NTICIPATOR S ETTING The heat anticipator in the room thermostat must be correctly adjusted to obtain the proper number of cycles per hour and to prevent “overshooting” of the setting. Set the heat anticipator set- ting to 0.7 amps. Follow the thermostat manufacturer’s instruc- tions on how to [...]

38 S T ARTUP P ROCEDURE & A DJUSTMENT Honeywell Model VR9205 (Two-Stage) i M a n o m e t e r M a n o m e t e r H o s e Com mon T e rmina l(C) Hig h Fi re Coi l T erminal ( HI ) Low Fire Coil T erminal ( LO ) Inlet Pressure T ap 1/8 NPT O p e n t o A t m o s p h e r e Outlet Pressure T ap 1/8 NPT Honeywell Model VR9205 Connected to Manometer 1. [...]

39 S T ARTUP P ROCEDURE & A DJUSTMENT 9. Close thermostat “R” and “W2” contacts to provide a call for high stage heat. 1 0. Remove regulator cover screw from the high (HI) outlet pressure regulator adjust tower and turn screw clockwise to increase pressure or counterclockwise to decrease pressure. Replace regulator cover screw . 1 1. Tu[...]

40 S T ARTUP P ROCEDURE & A DJUSTMENT RISE = SU PP LY AIR RET URN AIR HEA T EX CHA NGER RADIA TIO N "L INE OF S IGHT " T RETURN T SUPPLY T SU PPL Y - T RETURN Temperature Rise Measurement C IRCULATOR B LOWER S PEEDS T O  AVOID  PER SONAL  INJURY  OR  DEATH  DUE  TO  ELECT RI CAL  SHOCK ,  TU RN  OF F ?[...]

41 S T ARTUP P ROCEDURE & A DJUSTMENT • Profile B ramps up to full cooling demand airflow by first stepping up to 50% of the full demand for 30 seconds. The motor then ramps to 100% of the required airflow . A one (1) minute OFF delay at 100% of the cooling airflow is provided. 50% CFM 1/2 min 100% CFM 100% CFM 1 min OFF OFF • Profile C ram[...]

42 COMFORTNET™ SYSTEM 7. Select the heating speed for your model from the heating speed chart in the S pecification Sheet. The adjust setting (already established by the cooling speed selection) determines which set of speeds are available. The selected speed must provide a temperature rise within the rise range listed with the particular model. [...]

43 COMFORTNET™ SYSTEM demand and transmits the demand along with a fan request to the indoor unit. The indoor unit then sends the demand to the ECM motor . The table below lists the various ComfortNet™ systems, the operating mode, and airflow demand source. Sy s t em S y st em O pe r a t i n g Mo d e Air f l ow De ma nd S ourc e Co o l i ng A i[...]

44 COMFORTNET™ SYSTEM 12 R C 12 RC CTK01AA Thermostat CT™ Compatible Furnace Integrated Control Modul e CT™ Compatible AC/HP I ntegra t ed Control M odule 40V A Transformer (include d in CTK01 AA ki t) 208/230 V AC 24 V AC 12 R C System Wiring using Two-Wires between Furnace and AC/HP and Four-Wires between Furnace and Thermostat CT C OMPATIB[...]

45 COMFORTNET™ SYSTEM F URNACE A DVANCED F EATURES M ENUS S ubm e nu I t em I ndi ca t i on ( f o r D i s pl a y On l y ; not U s e r Mod i f i able) N umber of Heat S tages (HT S TG ) Disp l ay s t he num ber of fur n ac e heat in g st ag es I nput Rat e (B T U/ HR ) Disp l ay s t he f urnac e i nput rat e i n kB t u/h r M ot or HP ( 1/2, ¾ , o[...]

46 COMFORTNET™ SYSTEM S u bmenu I tem User M o d i fi ab l e Op ti o n s Co m m ents C oo l Airf l ow ( CL CFM ) 18, 24, 30, 36, 42, 48, or 60, def aul t is 1 8 S el ects the ai r flow for t he non - CT c om patibl e s i ngl e s t age A C uni t C oo l A i rf low T rim (C L T RM ) -10% to +10% in 2% increm ent s , default i s 0% S el ects t he air[...]

47 N ORMAL S EQUENCE OF O PERA TION S YSTEM T ROUBLESHOOTING NOTE: Refer to the instructions accompanying the CT compatible outdoor AC/HP unit for troubleshooting information. Refer to the T roubleshooting Chart in the Appendix for a listing of possible furnace error codes, possible causes and corrective actions. N ORMAL S EQUENCE OF O PERA TION P [...]

48 O PERA TIONAL C HECKS & S AFETY C IRCUIT D ESCRIPTION • Integrated control module performs safety circuit checks. • Induced draft blower is energized on high speed for a 15- second prepurge. Humidifier terminal is energized with induced draft blower . • Induced draft blower steps to low speed following prepurge. Low stage pressure swit[...]

49 T ROUBLESHOOTING & M AINTENANCE O PERA TIONAL C HECKS The burner flames should be inspected with the burner compart- ment door installed. Flames should be stable, quiet, soft, and blue (dust may cause orange tips but they must not be yellow). Flames should extend directly outward from the burners without curling, floating, or lifting off. Fl[...]

50 T ROUBLESHOOTING & M AINTENANCE R ESETTING F ROM L OCKOUT Furnace lockout results when a furnace is unable to achieve igni- tion after three attempts during a single call for heat. It is charac- terized by a non-functioning furnace and a E 0 code displayed on the dual 7-segment display . If the furnace is in “lockout”, it will (or can be[...]

51 M ISCELLANEOUS C ONDENSATE T RAP AND D RAIN S YSTEM (Q UALIFIED S ERVICER O NLY ) Annually inspect the drain tubes, drain trap, and field-supplied drain line for proper condensate drainage. Check drain system for hose connection tightness, blockage, and leaks. Clean or repair as necessary . F LAME S ENSOR (Q UALIFIED S ERVICER O NLY ) Under some[...]

D IP S WITCHES 52 123456789 1 0 9 0 s e con d s O F F O F F --- --- --- --- --- --- --- --- 12 0 secon d s O N O F F --- --- --- --- --- --- --- --- 150 s ec onds * O F F ON - -- - -- - -- -- - -- - - -- - -- -- - 18 0 secon d s O N O N --- --- --- --- --- --- --- --- 1- S t a g e T -s t at --- --- OF F --- --- --- --- --- --- --- 2-Stage T -St at [...]

T ROUBLESHOOTING C HART 53 ComfortNet™ Thermostat Only Symptoms of Abnor mal Operation (Leg acy & ComfortNet™ Thermostat ) Diagnostic/St atus LED Codes Fault Description Message Code Possible Cau ses Corrective Actions Notes & Cautions x Furnace fails to operate x Integrated c ontrol m odule LED display provides n o signal. x ComfortNet[...]

T ROUBLESHOOTING C HART 54 ComfortNet™ Thermostat Only Symptoms of Abnor mal Operation (Legacy & Com fortNet™ Thermostat) Diagnostic/St atus LED Codes Fault Description Message Code Possible Cau ses Corrective Actions Notes & Cautions x Circulator blower runs continuously. No furnace operation. x Integrated c ontrol m odule LED display [...]

T ROUBLESHOOTING C HART 55 ComfortNet™ Thermostat Only Symptoms of Abnor mal Operation (Legacy & Com fortNet™ Thermostat) Diagnostic/St atus LED Codes Fault Description Message Code Possible Cau ses Corrective Actions Notes & Cautions x Furnace fails to opera te on high stage; furnace operates nor mally on low stage. x Integrated c ontr[...]

T ROUBLESHOOTING C HART 56 ComfortNet™ Thermostat Only Symptoms of Abnor mal Operation (Legacy & Com fortNet™ Thermostat) Diagnostic /Status LED Codes Fault Description Message Code Possible Cau ses Corrective Actions Notes & Cautions x Operation different than expected or no operation. x Integrated c ontrol m odule LED display provides[...]

T ROUBLESHOOTING C HART 57 ComfortNet™ Thermostat Only Symptoms of Abnor mal Operation (Legacy & Com fortNet™ Thermostat) Diagnostic /Status LED Codes Fault Description Message Code Possible Cau ses Corrective Actions Notes & Cautions x Furnace fails to operate. x Integrated c ontrol m odule LED display provides b 4 error code. x Comfor[...]

S T A TUS C ODES 58 C 2 O P H I b 0 d 4 C 1 b 2 E 4 H I INTERNA L CONTROL F AUL T /NO P O W ER NORMAL OPERAT ION LOCKOUT DUE TO EXCESSIVE RETRIE S LOW S T AGE P RESSUE SWI TCH S TUCK CL OS ED A T S T A RT OF H E A TING CYCLE LOW ST AGE PRSSURE SWIT CH S TUCK OPEN OPEN HIG H LIMI T SW I TCH FLAME D E TECTED WHEN N O FLAME SHOULD BE PRESENT OPEN F US[...]

W IRING D IAGRAM 59 NO FUSE 3 A 1. SET HE A T ANT IC IPAT OR ON RO OM TH ERM OSTAT AT 0.7 AMP S. YL MA NU AL RE S ET AUX ILIAR Y LI MIT CONTR OL PK WA R NING:DISCO NNECT TO MICR O ID 40 V A TRANSF ORM ER PU GY N NEUTRAL BL WIRING T O UNIT 10 DE HU M 3 O NO PK DIA GNO STIC LE D' S BR 4. UNIT M U ST BE PERM A NENTLY GROU ND ED AND CONFO R M TO N[...]

W IRING D IAGRAM 60 HIGH VOL T AGE! Disconnect ALL power befor e s ervicing or i nstalling t his unit . Multiple power sources m ay b e present. Fai lure to do so may cause property damage, p ersonal injury or death. Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring. *CVC9_AB, *MVC95_AB TO +V[...]