Goodman Mfg CVM96 manual

5151 San Felipe Suite 500 Houston, TX 77056 www .goodmanmfg.com • www .amana-hac.com © 2011 Goodman Manufacturing Company , L.P . I NST ALLA TION I NSTRUCTIONS FOR *MVM96 & *CVM96 M ODULA TING G AS F URNACE IO-406 6/11 (T ype FSP CA TEGOR Y IV Direct or Non Direct V ent Air Furnace) These furnaces comply with requirements em- bodied in the A[...]

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

3 GAS SUPPL Y AND PIPING .......................................................................................................... .................... 29 H IGH A L TITUDE D ERA TE .................................................................................................................................. 2 9 P ROP ANE G AS C ONVERSION ......[...]

4 G OOD MA N  WILL  NOT  BE  RE SP O N SIB L E  FOR  ANY  INJURY  OR  PROP E RTY  DAMAGE  ARISING  FROM  IMPROPER  SERVIC E  OR  SERVIC E  PROC EDU RES .  I F  YOU  INST ALL  OR  PERF ORM  SERVIC E  ON  THI S  UNIT ,  YOU  ASSUME  RE SP O N SIB I LI TY  FOR ?[...]

5 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 LE  PROP E RTY  DAMAGE ,  PER SONAL ?[...]

6 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 immediately . The furnace must be carefully [...]

7 T O  PREVEN T  PROP ERTY  DAMAGE ,  PER SONAL  INJURY  OR  DEATH  DUE  TO  FIRE ,  DO  NOT  INST A LL  THI S  FUR NAC E  IN  A  MOBILE  HOME ,  TR AI LE R ,  OR  RE CR EAT IO N AL  VE HICL E . W ARNING P RODUCT D ESCRIPTION F EATURES This furnace is a part of the ComfortNet™ f[...]

8 • All furnace operating conditions (including ignition, input rate, temperature rise and venting) are verified according to these installation instructions. NOTE: The Commonwealth of Massachusetts requires that the following additional requirements must also be met: • Gas furnaces must be installed by a licensed plumber or gas fitter . • A [...]

9 deicing salts or chemicals carbon tetrachloride halogen type refrigerants cleaning solutions (such as perchloroethylene) printing inks paint removers varnishes hydrochloric acid cements and glues antistatic fabric softeners for clothes dryers and masonry acid washing materials • Seal off a non-direct vent furnace if it is installed near an area[...]

10 C OMBUSTION & V ENTILA TION A IR R EQUIREMENTS T O  AVOID  PROP E RT Y  DAMAGE ,  PER SONAL  INJURY  OR  DEAT H ,  SU FFICI ENT  FRES H  AIR  FOR  PROP E R  CO MB U ST ION  AND  V ENTILATION  OF  FLUE  GASES  MUST  BE  SUPPL IE D .  M OS T  HOMES  RE Q UIR E  OU TSI D[...]

11 Horizontal Furnace F URNACE S USPENSION If suspending the furnace from rafters or joists, use 3/8" threaded rod and 2”x2”x1/8” angle iron as shown in the following diagram. The length of rod will depend on the application and the clearances necessary . If the furnace is installed in a crawl space it must be suspended from the floor jo[...]

12 Recommended Installation Positions NOTE: Alternate “vertical” piping connections can not be used when an upflow furnace is installed with supply air discharging to the right, or when a counterflow furnace is installed with supply air discharging to the left. In either case, use the standard flue and combustion air piping connections. A LTERN[...]

13 It is the responsibility of the installer to follow the manufacturers’ recommendations and to verify that all vent/flue piping and connec- tors are compatible with furnace flue products. Additionally , it is the responsibility of the installer to ensure that all piping and con- nections possess adequate structural integrity and support to pre-[...]

14 V ENT /F LUE P IPE V ent/flue pipe can be secured to the vent/flue coupling using the rubber coupling and worm gear hose clamps provided with this furnace (see “S tandard Connections” figure). The rubber coupling allows separation of the vent/flue pipe from the furnace during ser- vicing. Combustion Air and V ent piping should be routed in a[...]

15 N ON -D IRECT V ENT I NSTALLATIONS A minimum of one 90° elbow should be installed on the combus- tion air intake “coupling” to guard against inadvertent blockage. RUBBER COU PLI NG WIT H WOR M GEAR C LAM PS RUBBE R COUPLINGS WITH W OR M GEAR CL AMPS COMBUSTION AIR PI PE ( D IR ECT VEN T ONLY) COMBUSTION AIR PIPE (DI REC T VEN T O NL Y) VENT[...]

16 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 large, unobstructed hole (alternate vent connectio[...]

17 6. For direct vent installations , secure field-supplied combustion air intake pipe directly to the air intake coupling. NOTE: A PVC coupling or elbow is required on counterflow units. 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 throu[...]

18 I n 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. 12 " M in T o R oof Or Highest Anticipat ed Snow Le vel Vertical Termination ([...]

19 1 234 56 78 2 or 2 1/ 2 4 9 4 6 43 4 0 37 3 4 3 1 28 3 7 1 6 86 56 25 95 6 5 35 0 2 or 2 1/ 2 3 6 3 3 30 2 7 24 2 1 1 8 15 3 5 7 5 45 14 84 54 2 3 93 6 2 or 2 1/ 2 6 1 5 8 55 5 2 49 4 6 4 3 40 3 7 1 6 86 56 25 95 6 5 35 0 2 or 2 1/ 2 4 8 4 5 42 3 9 36 3 3 3 0 27 3 5 7 5 45 14 84 54 2 3 93 6 S t a n d a r d 3 7 1 6 86 56 25 95 6 5 35 0 Al te r na[...]

20 Alternate Vent Termination Above Anticipated Snow Level (Dual Pipe) In a basement installation, the pipes may be run between the joist spaces. If the pipes must go below the 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. V ENT /I NTAKE T ERMINA[...]

21 S TANDARD R IGHT OR L EFT S IDE D RAIN H OSE C ONNECTIONS All installations positions require the use of the drain trap, hoses, tubes, and clamps. The following quantity of hoses, tubes, and hose clamps are provided with the unit. DRAIN TRAP QTY : 1 GREEN HOSE CLAMPS QTY : 3 SIL V ER HOSE CLAMP QTY : 1 TUB E 2 QTY : 2 TUB E 1 QTY : 1 HOSE B QTY [...]

22 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 rubber plug/cap from the right-side drain port [...]

23 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 front cover drain port with a red hose clamp. Ro[...]

24 H ORIZONTAL I NSTALLATIONS R IGHT S IDE D OWN Horizontal installations with the right side down require that the drain hoses be connected to the right side front cover drain port and the rubber elbow drain port. NOTE: On counterflow models, relocation of the front cover pressure switch hose is required. Make connections as follows: 1. Remove the[...]

25 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 front cover pressure switch hose connection from the right side (as [...]

26 E LECTRICAL C ONNECTIONS HIG H  VOLT A G E  ! T O  AVOID  THE  RIS K  OF  ELECT RICAL  SHOCK ,  WIRING  TO  THE  UNIT  MUST  BE  POL ARIZE D  AND  GROUN DED . W ARNING HIG H  VOLT A G E  ! T O  AVOID  PER SONA L  INJURY  OR  DEATH  DUE  TO  ELECT RICAL  SHOCK , ?[...]

27 T o ensure proper unit grounding, the ground wire should run from the furnace ground screw located inside the furnace junction box all the way back to the electrical panel. NOTE: Do not use gas piping as an electrical ground. T o confirm proper unit grounding, turn off the electrical power and perform the following check. 1 . Measure resistance [...]

28 W1 W2 Y2 Fur nace Integra ted Control M odule Remote Condensin g Unit (T wo-Stage Cooling) Dehumidis tat [Optiona l] Y2 NEU W1 W2 Y2 Thermostat - Two-Stage Heating with Two-Stage Cooling S ET  DIP  SWIT CH  #14  TO  ON  PO SI TI ON  WHEN  USING  A  2 ‐ ST A GE  COO LIN G  THERMO STAT . IMPORT ANT N OTE Therm[...]

29 A UX OUT AUX IN L1 NEUTRAL 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 furnace c[...]

30 G AS V ALVE This unit is equipped with a 24 volt gas valve which modulates by pneumatic linkage to the combustion air blower T a p s for mea- suring the gas supply pressure and manifold pressure are provided on the valve. This is a non-convertible gas valve equipped for natural gas. The gas valve has a manual ON/OFF control located on the valve [...]

31 MANUAL SH UT O F F VALVE (UP ST REAM FROM PIPE UNION) GRO M M E T IN S T ANDA RD GAS LI NE HOLE G AS L IN E PLUG IN G AS L IN E HOLE HEI GHT REQUIRED BY L O CAL CODE PIPE UNION DRIP L EG MA N IFOLD BURNE RS G AS VAL VE HO RI ZO NTAL [UP FL O W M O D E L] MA N U AL SH U T -OF F V AL VE (UPSTREAM FR OM GROUND J OI N T P IP E UN I ON) DR IP L E G G[...]

32 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 M OV IN G  HOLE  PLUGS . W ARNING When gas piping enters directly to the gas valve through the stan- dard inlet hole, the installer must supply straight pipe with a grou[...]

33 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 80 260 610 1,200 1,900 2,900 [...]

34 Checking Static Pressure (80% Furnace Shown, 90% Similar) B OTTOM R ETURN A IR O PENING [U PFLOW M ODELS ] The bottom return air opening on upflow models utilizes a “lance and cut” method to remove sheet metal from the duct opening in the base pan. T o remove, simply press out the lanced sections by hand to expose the metal strips retaining [...]

35 6 00 800 1 000 120 0 14 00 1 600 200 0 06 03 __X A --- -- - 5 64* 564 * 672 76 8 08 05 __X A --- -- - -- - 752 * 75 2* 76 8 9 60 1 005 __X A 1 155 __X A -- - --- - -- 940 * 94 0* 9 40* 9 60 6 00 800 1 000 120 0 14 00 1 600 200 0 0 604 __X A --- -- - 6 41* 641 * 672 76 8 - -- 0 805 __X A 1 005 __X A -- - --- - -- 854 * 85 4* 8 54* 9 60 Inp ut Ai [...]

36 • After 2 minutes, the IFC increases to 57% at a rate of 1% per second • After 10 total minutes, the IFC increases to 78% at a rate of 1% per second. • After 20 total minutes, the IFC increases to 100% at a rate of 1% per second for the remainder of the call for heat. • The circulator is adjusted to the appropriate CFM, corresponding to [...]

37 • If the differential is equal to or less than 2 degrees, the IFC will follow the conventional 2-S tage algorithm, equivalent to a W1 request and be reflected in the Heat Current Demand S tatus %. • If the heat differential is greater than 2 degrees, the IFC will follow the conventional 2-S tage algorithm, equivalent to a W2 request and be r[...]

38 AT M O S P H E R E PO RT DIRECTIO N FLO W PS CON NECTI ON Honeywell Model VR9205R Outle t Pressure Ta p 1/8 N PT Inl et Pres sure Ta p 1/8 NPT 2-PI N POW ER CONNECTOR i M a n o m e t e r M a n o m e t e r H o s e O p e n t o A t m o s p h e r e Honeywell Model VR9205R Connected to Manometer 1. Turn OFF gas to furnace at the manual gas shutoff va[...]

39 3 . Outlet pressure tap connections: Remove the outlet pressure boss plug. Install an 1/8" NPT hose barb fitting into the outlet pressure tap. 4 . Attach a hose and manometer to the outlet pressure barb fitting. 5 . T urn ON the gas supply . 6 . Turn on power and close thermostat “R” and “W1” contacts to provide a call for low stage[...]

40 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 Startup Procedure and Adjustment -Circulator Blower Speeds for speed changing details. RISE = SU PP L Y AIR RET UR N AIR HEA T EXCH ANGE R RADIA TION "L INE OF SI[...]

41 • Profile A provides only an OFF delay of one (1) minute at 100% of the cooling demand airflow . OFF 100% CFM 100% CFM 1 min OFF • 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 co[...]

42 B LOWER H EAT O FF D ELAY T IMINGS The integrated control module provides a selectable heat off delay function. The heat off delay period may be set to 90, 120, 150, 180 seconds using the DIP switches or jumper provided on the control module. The delay is factory shipped at 150 seconds but may be changed to suit the installation requirements and[...]

43 For example, assume the system is an air conditioner matched with a furnace. With a call for low stage cooling, the air conditioner will calculate the system’s low stage cooling airflow demand. The air conditioner will then send a fan request along with the low stage cooling airflow de- mand to the furnace. Once received, the furnace will send[...]

44 123456 789 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 A O FF O FF - -- - -- -- - -- - -- - --- --- - -- - -- -- - -- - - - - --- -- - - -- - -- B O N O F F - - -- - -- - -- - -- - -- - - - - -- - -- - -- - -- - -- - -- - - - - -- - -- - - C O F F O N - - -- - -- - -- - -- - -- - - - - -- - -- - -- - -- - -- - -- - - - - -- - -- - - D ON ON - - -- - -- [...]

45 F OSSIL F UEL A PPLICATIONS This furnace can be used in conjunction with a ComfortNet™ compatible heat pump in a fossil fuel application. A fossil fuel application refers to a combined gas furnace and heat pump in- stallation which uses an outdoor temperature sensor to determine the most cost efficient means of heating (heat pump or gas fur- n[...]

46 F URNACE A DVANCED F EATURES M ENUS Subm e nu Ite m Ind ic ati on ( for D is pl a y On ly ; no t U s e r Mo difi ab le ) Nu m ber of H eat S ta ge s (HT S TG ) Dis p lay s t he num be r o f f u r n ac e h eat i n g sta ges In p u t R a te ( B T U /H R ) D i spl a y s th e f u r n a c e i np u t r a te i n k B tu /h r M ot o r HP ( 1/ 2 , ¾, o r[...]

47 T HERMOSTAT M ENU If this furnace is installed with a communicating compatible heat pump, the system is recognized as a dual fuel system. The balance point temperature should be set via the thermostat ad- vanced menu. Navigate to the THERMOST A T menu. Press the INST ALLER CONFIG key . Navigate to the SETUP menu and press the INST ALLER CONFIG b[...]

48 F AULT C LEAR S EQUENCE : • Only allowed in standby mode, while display is showing ON. • Hold fault recall push-button for 5-10 seconds (until display starts flashing “—”) and then release. • All faults in the history will have been cleared, and display returns to ON. • If you hold the button for longer than 10 seconds, the display[...]

49 If the last call for heat was a call for high heat, the air circulating motor will run on the high heating speed for thirty (30) seconds and then switch to the low heating speed for the balance of the heat off delay period (60, 90, 120 or 150 seconds). • Circulator blower and electronic air cleaner terminal is de- energized. • Circulator blo[...]

50 P RESSURE S WITCHES The pressure switches are normally-open (closed during opera- tion) negative air pressure-activated switches. They monitor the airflow (combustion air and flue products) through the heat ex- changer via pressure taps located on the induced draft blower and the coil front cover . These switches guard against insufficient air- [...]

51 A NNUAL I NSPECTION The furnace should be inspected by a qualified 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 fur- nace components are in proper working order and that the heating system functions appropriately . Pay particular attention [...]

52 B EFORE L EA VING AN I NST ALLA TION • Cycle the furnace with the thermostat at least three times. V erify cooling and fan only operation. • Review the Owner’s Manual with the homeowner and discuss proper furnace operation and maintenance. • Leave literature packet near furnace. R EP AIR AND R EPLACEMENT P ARTS • When ordering any of t[...]

53 T ROUBLESHOOTING C ODES ComfortNet Thermostat Only Symptoms of Abnor mal Operation (Non-communicat ing & 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 dis play provides n o signal. x C[...]

54 T ROUBLESHOOTING C ODES ComfortNet Thermostat Only Symptoms of A bnormal Operation (Non-communicat ing & 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[...]

55 T ROUBLESHOOTING C ODES ComfortNet Thermostat Only Symptoms of Abnor mal Operation (Non-comm unicating & 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 Integrat[...]

56 T ROUBLESHOOTING C ODES ComfortNetThermostat Only Symptoms of Abnor mal Operation (Non-communicat ing & Com fortNet™ Thermostat) Diagnostic/St atus 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 dis play[...]

57 T ROUBLESHOOTING C ODES ComfortNet Thermostat Only Symptoms of Abnor mal Operation (Non-communicat ing & 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 dis play provides b 4 error code[...]

58 S T A TUS C ODES E 4 IN T E RN AL C O NTR OL FA ULT/N O P OW ER NO RMA L OP ER A T I ON LOCKOUT DUE T O EX C ESSIVE RE TR IES LOW ST A GE P RESSUE SWI T CH STUCK CLOS ED A T STAR T OF HE A TING CYCLE LOW ST A GE P RSSURE SWI TCH S TUCK OPEN OP EN HIGH LI MI T SW IT C H FLAME DETECTED W HEN NO F LAME SHOUL D BE PRESENT OPE N FUSE LOW FL AME SIGN [...]

59 HIGH VOL TAGE! Disconnect ALL pow er be fore s ervicing or inst alling thi s unit. Multiple power sources m ay be present. Fai lur e to do so may cause property damage, p er sonal injury or de ath. Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring. *MVM96_A*, *CVM96_A* W IRING D IAGRAM OP [...]

60 5151 San Felipe Suite 500 Houston, TX 77056 www .goodmanmfg.com • www .amana-hac.com © 2011 Goodman Manufacturing Company , L.P .[...]