Goodman CVC9/95 manual

5151 San Felipe Suite 500 Houston, TX 77056 www .goodmanmfg.com • www .amana-hac.com © 2009-2011 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-341F 5/11 (T ype FSP CA TEGOR Y IV Direct or Non Direct V ent Air Furnace) These furnaces comply with requirements em- bodi[...]

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

3 Gas Supply and Piping .......................................................................................................... .......................... 3 0 H IGH A L TITUDE D ERA TE ....................................................................................................................................... 3 0 P ROP ANE G AS C ONVER[...]

4 G OOD MA N  WILL  NOT  BE  RE SP O NSI B LE  FOR  ANY  INJURY  OR  PROP E RTY  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 SP O NSI B IL IT Y  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 AIL ER ,  OR  RE CR EATI O N AL  VE HICL E . W ARNING P RODUCT D ESCRIPTION F EATURES This furnace is a part of the ComfortNet™ fa[...]

8 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 Cleveland, OH 44131 The rated heating capacity of the[...]

9 • 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, position the furnace so that the burners and ignition s[...]

10 • Concealed hot or cold water pipes, or chimneys. • 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 E RT Y  DAMAGE ,  PER SONAL  INJURY[...]

11 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 furnace differs only slightly from an upright instal[...]

12 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 must be provided if the furnace is installed above[...]

13 T O  AVOID  BOD ILY  INJURY ,  FIRE  OR  EXPLO SION ,  SOL VENT  CEME NT S  MUST  BE  KE P T  AWA Y  FROM  ALL  IGNITION  SOUR CES  ( I . E .,  SPAR KS ,  OP EN  FLA MES ,  AND  EX CESSIV E  HEAT )  AS  THE Y  ARE  CO MB U STIBL E  LIQUIDS .  A VO ID  BR EA[...]

14 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 additional space at connection loca- tions. This joint [...]

15 RUBBER COU PLING WIT H WOR M GEAR C LAM PS RUBBE R COUPLINGS WITH W ORM GEAR CL AMPS COMBUSTION AIR PI PE ( D IR ECT VENT O NL Y) COMBUSTION AIR PIPE (DI REC T VE N T ON LY) VENT/FLUE PIPE VENT/FLUE PIPE 90 PVC ELBOW ( NON-DIRECT VENT ) 90 PVC ELBOW ( NON- DIRE CT V ENT ) Standar d Conn ecti on s OR OR UPFL OW CO UNT ERF LOW A LTERNATE F URNACE [...]

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 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 unused chimney; however , it must extend a mini[...]

18 V ENT /F LUE P IPE T ERMINATIONS The vent/flue pipe may terminate vertically , as through a roof, or horizontally , as through an outside wall. V ertical vent/flue pipe terminations should be as shown in the fol- lowing figure. Refer to Vent/Flue Pipe and Combustion Air Pipe - T ermination Locations for details concerning location restrictions. [...]

19 If the combustion air intake pipe is to be installed above a finished ceiling or other area where dripping of condensate will be objec- tionable, insulation of the combustion air pipe may be required. Use 1/2” thick closed cell foam insulation such as Armaflex™ or Insultube™ where required. V ENT /F LUE AND C OMBUSTION A IR P IPE T ERMINAT[...]

20 24" MAX 3" MIN 24" MAX A IR INT A KE 12” MIN SCREEN (OPTIONAL) 90 º ME DI UM RADIUS ELBOWS 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" MIN . ABOV E HIGHEST ANT ICIP ATED SNO W LEV EL 90° or 45° MEDIU[...]

21 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 appropri- ate drain location. In upright installation[...]

22 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: Refer to Alternate Vent/Flue Hose Connection[...]

23 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 o[...]

24 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[...]

25 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 counterflow models) located below the grommet drain[...]

26 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 front cover pressure switch hose connection from t[...]

27 E LECTRICAL C ONNECTIONS HIG H  VO L T 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  VO L T A G E  ! T O  AVOID  PER SONAL  INJURY  OR  DEATH  DUE  TO  ELECT RICAL  SHOCK [...]

28 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 IRING W IRE  RO U TIN G ?[...]

29 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 el ay Move to the ON positi on to s[...]

30 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 module humidifier terminals [...]

31 Consult the furnace S pecification Sheet for a listing of appropri- ate kits. 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 is equipped with a 24 volt gas valve controlled during furnace operation by the integra[...]

32 MANUAL SHU T O FF VALVE (UP ST R EA M FROM PI PE UNION) GRO M ME T IN STA NDA RD GAS L INE HO LE G AS L IN E PL U G I N G AS L IN E HOLE HEI G HT REQ UIR ED BY LO CA L CODE PIPE UNION DRI P L EG MA NIFOLD BURNERS G AS VALVE HORI ZONTAL [UP FL O W M OD EL] MA NU AL S H UT - OF F V A L VE (UPSTR EAM FR OM GROU N D J OI NT PI PE U N IO N ) DR IP LE[...]

33 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 MO V 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[...]

34 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 [...]

35 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 [...]

36 600 80 0 100 0 12 00 1 400 160 0 20 00 045 3__ XA 37 6* 38 4 4 80 576 - -- -- - - -- 07 0 4 _ _ XA --- --- 62 7 * 6 2 7 * 67 2 768 --- 090 5__ XA -- - --- - -- 83 6* 8 36* 836 * 960 115 5__ XA -- - --- - -- 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 --- --- 32 0 * 32 0 * 33 6 384 --- 090 5__ X A 091 5 _[...]

37 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 adjust the heat anticipator setting. D [...]

38 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 rm inal (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. Turn OFF gas to furnace at the manual gas shutoff valve external to the fur[...]

39 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. Turn off all electrical power and gas sup[...]

40 RISE = SU PP LY AIR RET UR N AIR HEA T EXCH A NGE R RADIA TION "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 RICAL  SHOCK ,  TU RN  OF F  POWE R  TO  THE  FUR NAC E ?[...]

41 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 cooling airflow is provided. 50% CFM 1/2 min 100% CFM 100% CFM 1 min OFF OFF • Profile C ramps up t[...]

42 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. Example: The *MVC9507[...]

43 Sy st em S y st em O p e r a ti n g Mo d e Ai r f l ow De ma nd So ur c e Co o l i ng A i r Co nd it io n er H eat i n g F ur na ce C on ti nuo us F a n T he r m osta t C oo lin g H ea t P u mp H e at Pum p H e ati ng On l y He at P u m p A u x il ia ry H e ati n g F ur na c e C on ti nuo us F a n T he r m osta t Co ol i ng F ur na ce H eat i n [...]

44 12 R C 12 RC CTK0 *AA Th er most at Comfor tNet Compatible Furnace Int egrated Contr ol Mo dul e Comfor tNet Compati ble AC/H P Int egra ted Contr ol Mo dul e 40V A Tra nsf or mer (included i n CTK0*AA kit) 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 C OMFORT N[...]

45 F URNACE A DVANCED F EATURES M ENUS S ubm e nu I t em I ndi c a t i on ( f o r D i s pl ay On ly; not Us er Mod if i able) N um ber of Heat S tages (HT STG ) Disp l ay s t he number of fur nace heating st ag es I n put Rat e (B T U/ HR ) Disp l ay s t he furnac e i npu t rat e i n kB t u /h r M ot or H P ( 1/2, ¾ , or 1 M T R H P ) Disp l ay s [...]

46 T HERMOSTAT M ENU If this furnace is installed with a c ommunicating 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 [...]

47 S YSTEM T ROUBLESHOOTING NOTE: Refer to the instructions accompanying the ComfortNet compatible outdoor AC/HP unit for troubleshooting information. Refer to the Troubleshooting Chart in the back of this manual fo r a listing of possible furnace error codes, possible causes and corrective actions. N ORMAL S EQUENCE OF O PERA TION P OWER U P The n[...]

48 • 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 switch contacts are closed. • Igniter warm up begins upon st[...]

49 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. Flames must not impinge on the sides o[...]

50 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 E E E E 0 0 0 0 0 code displayed on the dual 7-segment display . If the furnace is in “lockout”, it will (or can be) reset in any of th[...]

51 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 conditions, th[...]

52 123456789 1 0 9 0 s econ d s O F F OF F --- --- --- --- --- --- --- --- 12 0 seco n ds O N O F F --- --- --- --- --- --- --- --- 150 s ec onds * OF F ON -- - - - - - - - -- - - - - - - - - - - -- - 18 0 seco n ds O N O N --- --- --- --- --- --- --- --- 1- S t a g e T -s ta t --- --- O F F --- --- - -- - -- -- - -- - --- 2-Stage T - St at -- - - [...]

53 T ROUBLESHOOTING C HART ComfortNet Thermostat Only Symptoms of Abnor mal Operation (Non-Communicating & 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 n o signal. x Com[...]

54 T ROUBLESHOOTING C HART ComfortNet Thermostat Only Symptoms of Abnor mal Operation (Non-Communicating & ComfortNet™ Thermostat Diagnostic /Status 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 di[...]

55 T ROUBLESHOOTING C HART ComfortNet Thermostat On ly Symptoms of A bnormal Operation (Non-Communicating & ComfortNet™ Thermostat Diagnostic /Status LED Codes Fault Description Message Code Possible C auses Corrective Actions Notes & Cautio ns x Furnace fails to operate on high stage; furnace operates normally on low stage. x Integrated [...]

56 T ROUBLESHOOTING C HART ComfortNetThermostat Only Symptoms of A bnormal Operation (Non-Communicating & 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 pr[...]

57 T ROUBLESHOOTING C HART ComfortNet Thermostat On ly Symptoms of A bnormal Operation (Non-Communicating & ComfortNet™ Thermostat Diagnostic /Status LED Codes Fault Description Message Code Possible Cau ses Corrective Actions Notes & Ca utions x Furnace fails to operate. x Integrated c ontrol m odule LED display provides b 4 error code. [...]

58 S T A TUS C ODES C 2 H I b 0 d 4 C 1 b 2 E 4 H I INT ERNAL CONTROL F AUL T/NO POW ER N O RMAL OP E R ATIO N LOCKOUT DUE T O EXCESSIVE RETRIES LOW S T A GE PRESSUR E SWI T CH STUCK C LOSED A T ST A RT OF HEA TIN G CY CLE LOW S T A GE PRESSURE SWI T CH STUCK O PEN OPE N HI GH LIM IT S WI T CH FLAME DETECTED WHEN N O FLAM E SHOULD BE PRESEN T OPEN [...]

59 NO FUSE 3 A 1. SE T HE A T ANTI CIPATOR ON R OO M T HE RM O STAT AT 0 .7 AMP S . YL MA NU A L RE S ET AUX I LIAR Y LI MIT CONTR OL PK WA R NING:DISCO NNECT TO MICR O ID 40 V A TRANSF ORMER PU GY N NEUTRAL BL WIRING T O UNIT 10 DE HU M 3 O NO PK DIA G NO STIC LE D' S BR 4. UNIT M UST BE PERMANENTLY GROUNDED AND CONFO RM TO N.E .C . A ND LOCA[...]

60 HIGH VOL T AGE! Disconnect ALL power be f ore s ervicing or i nstalling t his unit . Multiple power sources m ay be present. Fai lure to do so may cause property damage, p er sonal injur y or de ath. 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 +VDC TO MICRO TO[...]