Goodman MVM96 Installation Instructions Manual

Modulating gas furnace

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Technical manual (23 pages)

Installation instructions manual (60 pages)

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Page 1 *MVM96 & *CVM96 NSTALLATION NSTRUCTIONS FOR ODULATING URNACE (Type FSP CATEGORY IV Direct or Non Direct Vent Air Furnace) Installer: Affix all manuals adjacent to the unit. These furnaces comply with requirements em- bodied in the American National Standard / Na- ®...
Page 2: Table Of Contents
TABLE OF CONTENTS ............................6 HIPPING NSPECTION (ESD) P ....................6 LECTROSTATIC ISCHARGE RECAUTIONS ............................6 NSTALLER ................6 MPORTANT OTE TO THE WNER REGARDING RODUCT ARRANTY PRODUCT DESCRIPTION ..........................7 ..............................7 EATURES PRODUCT APPLICATION ..........................7 LOCATION REQUIREMENTS & CONSIDERATIONS ..................8 ........................
Page 3 GAS SUPPLY AND PIPING ..........................29 ..........................29 LTITUDE ERATE ........................... 29 ROPANE ONVERSION ..........................30 IPING ONNECTIONS ........................32 ROPANE ANKS AND IPING CIRCULATING AIR & FILTERS........................33 ..........................33 UCT WORK ..........................33 HECKING TATIC ] .................... 34 OTTOM ETURN PENING...
Page 4: Wiring Diagram
TROUBLESHOOTING ............................. 50 (ESD) P ....................50 LECTROSTATIC ISCHARGE RECAUTIONS ............................50 IAGNOSTIC HART ..........................50 ESETTING OCKOUT MAINTENANCE ..............................50 ............................51 NNUAL NSPECTION ............................... 51 ILTERS ..............................51 URNERS ...................... 51 NDUCED RAFT AND IRCULATOR LOWERS ) ..............51 ONDENSATE RAP AND RAIN...
Page 5 Adhere to the following warnings and cautions when installing, adjusting, altering, servicing, or operating the furnace. To ensure proper installation and operation, thoroughly read this manual for specifics pertaining to the installation and application of this product. WARNING WARNING ...
Page 6: Shipping Inspection
4. Discharge your body to ground before removing a new HIPPING NSPECTION control from its container. Follow steps 1 through 3 if All units are securely packed in shipping containers tested ac- installing the control on a furnace. Return any old or new cording to International Safe Transit Association specifications.
Page 7: Product Description
In such applications, the furnace must be installed with the follow- WARNING ing stipulations: • It must be installed per the installation instructions , PREVENT PROPERTY DAMAGE PERSONAL INJURY DEATH , ...
Page 8: Location Requirements & Considerations
• All furnace operating conditions (including ignition, input WARNING rate, temperature rise and venting) are verified according to these installation instructions. , OSSIBLE PROPERTY DAMAGE PERSONAL INJURY DEATH , , , , , ...
Page 9: Clearances And Accessibility
deicing salts or chemicals LEARANCES AND CCESSIBILITY carbon tetrachloride Installations must adhere to the clearances to combustible mate- halogen type refrigerants rials to which this furnace has been design certified. The minimum cleaning solutions (such as perchloroethylene) clearance information for this furnace is provided on the unit’s clear- printing inks ance label.
Page 10: Thermostat Location
3. As far as practical, close all building doors and win- & V OMBUSTION ENTILATION EQUIREMENTS dows and all doors between the space in which the appliance(s) connected to the venting system are lo- WARNING cated and other spaces of the building. ...
Page 11: Furnace Suspension
EVELING Leveling ensures proper condensate drainage from the heat ex- changer and induced draft blower. For proper flue pipe drainage, the furnace must be level lengthwise from end to end. The furnace should also be level from back to front or have a slight tilt with the access doors downhill (approximately 3/4 inches) from the back panel.
Page 12: Alternate Electrical And Gas Line Connections
Pr essure Manifo ld Pressure Altitude Orifice Switch Hig h Stage Low Stage Change Natural None 3.5" w.c. 1" w.c. None 0-7000 Propane LPKMOD** *** 10.0" w.c . 2.6" w.c. None 1.25MM NOTE: In Canada, gas furnaces are only certified to 4500 feet. Except 115,000 BT U: #43 Except 115,000 BT U: #55 Furnace Model...
Page 13: Dual Certification : Non -Direct /Direct Vent
It is the responsibility of the installer to follow the manufacturers’ ROPER LUE AND OMBUSTION IPING RACTICES recommendations and to verify that all vent/flue piping and connec- Adhere to these instructions to ensure safe and proper furnace tors are compatible with furnace flue products. Additionally, it is performance.
Page 14: Canadian Venting Requirements
• A vent termination shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the Vent/flue pipe can be secured to the vent/flue coupling using the operation of regulators, relief valves, or other equipment.
Page 15: Alternate Furnace Connections
3. Upflow and Counterflow units. IRECT NSTALLATIONS Remove the vent/flue pipe from the furnace. A minimum of one 90° elbow should be installed on the combus- 4. Cut the vent/flue pipe 3.75 inches from the flanged end of tion air intake “coupling” to guard against inadvertent blockage. the pipe (see “Vent/Flue Pipe Cuts”...
Page 16 8. Upflow and Counterflow units. 3. Remove plastic plug from alternate combustion air intake location. Relocate and install plug in standard air intake For horizontal installations, externally secure the field- location (basepan). Plug the remaining hole in the blower supplied vent/flue pipe directly to the vent/flue coupling using deck with the plastic plug included in the drain kit bag.
Page 17: Non -Direct Vent (Single Pipe ) Piping
6. For direct vent installations, secure field-supplied COUNTERFLOW combustion air intake pipe directly to the air intake coupling. Non-Direct Vent (Single Pipe) (1)(2) NOTE: A PVC coupling or elbow is required on counterflow Maximum Allowable Length of Vent/Flue Pipe (ft) units.
Page 18: Irect Ent Ual Ipe Iping
In a basement installation, the vent/flue pipe can be run between IRECT IPING joist spaces. If the vent pipe must go below a joist and then up into The inlet air screens provided in the installation instruction packet the last joist space to penetrate the header, two 45° elbows should are available for the installer to use in the inlet of the combustion air be used to reach the header rather than two 90°...
Page 19 Horizontal terminations should be as shown in the following figure. COUNTERFLOW Refer to Vent/Flue Pipe and Combustion Pipe - Termination Loca- Direct Vent (Dual Pipe) Maximum Allowable Length* (ft) of Vent/Flue & Combustion Air Intake Pipe tion for location restrictions. A 2 3/8” diameter wall penetration is (1)(2)(3)(5) Number of Elbows Unit Input...
Page 20: Vent /Intake Terminations For Installation Of Multiple Direct Vent Furnaces
This kit is to be used with 2” or 3” direct vent systems. The vent kit must terminate outside the structure and may be installed with the intake and exhaust pipes located side-by-side or with one pipe above the other. This kit is NOT intended for use with single pipe (indirect vent) installations.
Page 21: S R L S D H C
TANDARD IGHT OR RAIN ONNECTIONS PRIGHT NSTALLATIONS RAP ON IGHT All installations positions require the use of the drain trap, hoses, In a upright installation drain hoses are connected to drain ports on tubes, and clamps. The following quantity of hoses, tubes, and the rubber elbow and the recuperator coil front cover.
Page 22 4. Cut 1/4 inch from the end of the drain port on the externally LTERNATE RAIN ONNECTIONS mounted rubber elbow. Discard cut portion. Upright installations using the alternate vent/flue outlet will require 5. Insert Tube 1 into rubber elbow drain port and secure with a “right-side only”...
Page 23: Upright Installations -Trap On Left Side
5. Cut “X” inches from the long end of Hose B and discard. PRIGHT NSTALLATIONS RAP ON Refer to table for appropriate length to cut. Secure NOTE: For left side trap installation, grommets must be moved remaining hose to Tube 1 with a green hose clamp. Route to the left side of the furnace and the plugs installed on the right other end of Hose B to front left side panel grommet hole.
Page 24: Horizontal Installations
2. Secure Hose A to front cover drain tap with a red hose ORIZONTAL NSTALLATIONS clamp. Route hose to rear right (down) side panel grommet IGHT holes. 3. Cut 1/4 inch from the end of the drain port on the rubber Horizontal installations with the right side down require that the elbow and discard.
Page 25 Horizontal installations with the left side panel down will require 7. Insert approximately one inch of each Tube 2 through left drain hoses to be connected to the left side front cover drain port side panel grommet hole. Secure tubes to Hose A and and the side drain port on the rubber elbow.
Page 26: Electrical Connections
Line polarity must be observed when making field connections. LECTRICAL ONNECTIONS Line voltage connections can be made through either the right or left side panel. The furnace is shipped configured for a right side WARNING (left side for counterflows) electrical connection with the junction HIGH VOLTAGE ! box located inside the burner compartment.
Page 27: Volt Thermostat Wiring
To ensure proper unit grounding, the ground wire should run from IMPORTANT NOTE the furnace ground screw located inside the furnace junction box all the way back to the electrical panel. NOTE: Do not use gas “R” ...
Page 28: Single -Stage Heating Thermostat Application
Once the switch is set, the dehumidify function is enabled during a combination call for cooling (T-Stat) and dehumidification (DEHUM- Stat). Refer to the dip switch chart in the back section of this manual. Furnace Integrated Control Module OSSIL PPLICATIONS Dehumidistat This furnace can be used in conjunction with a heat pump in a [Optional]...
Page 29: Volt Humidifier
CAUTION , PREVENT UNRELIABLE OPERATION EQUIPMENT DAMAGE INLET SUPPLY PRESSURE MUST SPECIFIED UNIT RATING PLATE WITH...
Page 30: Gas Piping Connections
The following stipulations apply when connecting gas piping. Re- ALVE fer to Gas Piping Connections figure for typical gas line connec- This unit is equipped with a 24 volt gas valve which modulates by tions to the furnace. pneumatic linkage to the combustion air blower Taps for mea- •...
Page 31 GAS VALVE MANUAL MANIFOLD BURNERS SHUT OFF VALVE (UPSTREAM FROM GAS LINE PIPE UNION) PLUG IN PLUG IN ALTERNATE GAS LINE GAS LINE HEIGHT REQUIRED HOLE HOLE BY LOCAL CODE GROMMET IN STANDARD GAS LINE HOLE GAS VALVE PIPE UNION DRIP LEG DRIP LEG BURNERS...
Page 32: Ropane As Anks And Iping
IRECT TANDARD NLET IPING ROPANE ANKS AND IPING WARNING WARNING , FURNACE INSTALLED BASEMENT EXCAVATED . U DGES SHEET METAL HOLES SHARP GLOVES...
Page 33: Circulating Air & Filters
A closed return duct system must be used, with the return duct Sizing Between First and Second Stage Regulator* connected to the furnace. NOTE: Ductwork must never be at- Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting. Capacities in 1,000 BTU/hour.
Page 34: Bottom Return Air Opening [Upflow Models ]
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 flow arrangement, the dampers or other means used to control the flow 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...
Page 35: Upright Installations
FILTER UPFLOW ACCESS COOLING AIRFLOW REQUIREMENT (CFM) DOOR 1000 1200 1400 1600 2000 0603__XA 564* 564* RETURN 0805__XA 752* 752* CENTRAL DUCT RETURN 1005__XA GRILLE 940* 940* 940* FILTER 1155__XA SUPPORT BRACKET COUNTERFLOW (Field Supplied) COOLING AIRFLOW REQUIREMENT (CFM) 1000 1200 1400 1600...
Page 36: Hermostat Octk01Aa T (C )
• After 2 minutes, the IFC increases to 57% at a rate Call for 2nd-Stage Heat - Thermostat contacts close R to W1 of 1% per second and W2. • After 10 total minutes, the IFC increases to 78% at a After a successful Light Off Sequence and expiration of the rate of 1% per second.
Page 37: Heating Octk02Aatk02Aa T (M Ctk02Aa )
• If the differential is equal to or less than 2 degrees, URNACE TARTUP the IFC will follow the conventional 2-Stage algorithm, 1. Close the manual gas shutoff valve external to the furnace. equivalent to a W1 request and be reflected in the 2.
Page 38: Gas Manifold Pressure Measurement
the normal firing rate sequence at a rate of 100% for 5 ATMOSPHERE CONNECTION minutes or until the end of the call for heat. The display PORT will show the normal “Hi” while the control is firing at 100%. If the Fault Recall Push-Button has not been pressed within 5 seconds of displaying “Ft”...
Page 39: Gas Input Rate Measurement (Natural Gas Only )
3. Outlet pressure tap connections: Remove the outlet NPUT EASUREMENT ATURAL pressure boss plug. Install an 1/8" NPT hose barb fitting The gas input rate to the furnace must never be greater than that into the outlet pressure tap. specified on the unit rating plate. To measure natural gas input 4.
Page 40: Circulator Blower Speeds
4. Adjust temperature rise by adjusting the circulator blower The cooling system manufacturer’s instructions must be checked speed. Increase blower speed to reduce temperature rise. for required air flow. Any electronic air cleaners or other devices Decrease blower speed to increase temperature rise. Refer may require specific air flows, consult installation instructions of to Startup Procedure and Adjustment -Circulator Blower those devices for requirements.
Page 41 • Profile A provides only an OFF delay of one (1) minute at High High 100% of the cooling demand airflow. Model Stage Stage Stage Stage Cool Cool Heat Heat 1220 100% CFM 100% CFM 1340 *CVM960604CX* 1150 1040 1460 1 min 1470 1120...
Page 42: Blower Heat Off Delay Timings
Two-way digital communications is accomplished using only two LOWER ELAY IMINGS wires. The thermostat and subsystem controls are powered with The integrated control module provides a selectable heat off delay 24 VAC. Thus, a maximum of 4 wires between the equipment and function.
Page 43 In continuous fan mode, the CTK0*AA thermostat provides For example, assume the system is an air conditioner the airflow demand. The thermostat may be configured for matched with a furnace. With a call for low stage cooling, one of threecontinuous fan speed settings allow for 25%, 50% the air conditioner will calculate the system’s low stage or 75% airflow, based on the furnaces’...
Page 44: Dip Switches
WITCHES...
Page 45: Fossil Fuel Applications
NOTE: Use of the CTK0*AA transformer is recommended if OSSIL PPLICATIONS installing a dual fuel/fossil fuel system. Failure to use the This furnace can be used in conjunction with a ComfortNet™ transformer in the outdoor unit could result in over loading of the compatible heat pump in a fossil fuel application.
Page 46: F A F M
URNACE DVANCED EATURES ENUS CONFIGURATION Submenu Item Indication (for Display Only; not User Modifiable) Number of Heat Stages (HT STG) Displays the number of furnace heating stages Input Rate (BTU/HR) Displays the furnace input rate in kBtu/hr Motor HP (1/2, ¾, or 1 MTR HP) Displays the furnace indoor blower motor horsepower DIAGNOSTICS Submenu Item...
Page 47: Network Troubleshooting
NON-COMM (APPLIES ONLY TO A COMMUNICATING COMPATIBLE FURNACE MATCHED WITH A NON-COMMUNICATING COMPATIBLE SINGLE STAGE AIR CONDITIONER) Submenu Item User Modifiable Options Comments Cool Airflow (CL CFM) 18, 24, 30, 36, 42, 48, or 60, default Selects the airflow for the non- is 18 communicating compatible single stage AC unit...
Page 48: Fault Clear Sequence
LED Status Indication Possible Causes Corrective Action(s) Notes & Cautions • Normal condition • None • None • None 1 Flash • Communications Failure • Communications Failure • Depress Learn Button • Depress once quickly for a • Verify that pull up, pull power-up reset down and bias dip •...
Page 49: Cooling Mode
If the last call for heat was a call for high heat, the air PERATIONAL HECKS circulating motor will run on the high heating speed for thirty (30) seconds and then switch to the low heating speed for The burner flames should be inspected with the burner compart- the balance of the heat off delay period (60, 90, 120 or 150 ment door installed.
Page 50: Pressure Switches
RESSURE WITCHES IAGNOSTIC HART The pressure switches are normally-open (closed during opera- WARNING tion) negative air pressure-activated switches. They monitor the HIGH VOLTAGE ! airflow (combustion air and flue products) through the heat ex- changer via pressure taps located on the induced draft blower and ...
Page 51: Annual Inspection
ORIZONTAL ILTER EMOVAL NNUAL NSPECTION The furnace should be inspected by a qualified installer, or service Filters in horizontal installations are located in the central return agency at least once per year. This check should be performed at register or the ductwork near the furnace. the beginning of the heating season.
Page 52: Before Leaving An Installation
Functional Parts List- EFORE EAVING AN NSTALLATION Gas Valve Blower Motor • Cycle the furnace with the thermostat at least three times. Gas Manifold Blower Wheel Verify cooling and fan only operation. Natural Gas Orifice Blower Mounting Bracket • Propane Gas Orifice Blower Cutoff Review the Owner’s Manual with the homeowner and Igniter...
Page 53: Troubleshooting Codes
ROUBLESHOOTING ODES...
Page 54 ROUBLESHOOTING ODES...
Page 55 ROUBLESHOOTING ODES...
Page 56 ROUBLESHOOTING ODES...
Page 57 ROUBLESHOOTING ODES...
Page 58: Status Codes
TATUS ODES INTERNAL CONTROL FAULT/NO POWER NORMAL OPERATION LOCKOUT DUE TO EXCESSIVE RETRIES LOW STAGE PRESSUE SWITCH STUCK CLOSED AT START OF HEATING CYCLE LOW STAGE PRSSURE SWITCH STUCK OPEN OPEN HIGH LIMIT SWITCH FLAME DETECTED WHEN NO FLAME SHOULD BE PRESENT OPEN FUSE LOW FLAME SIGNAL IGNITER FAULT OR IMPROPER GROUNDING...
Page 59: Wiring Diagram
*MVM96_A*, *CVM96_A* IRING IAGRAM TO 115VA C/1 Ø /60 HZ PO W ER SUPPLY W ITH OVERCURRENT PROTECTION DEVICE DIS CO NNE CT POW ER BEFORE SERVICING W IRING TO UNIT MUST BE PROP ERLY POLARIZE D A ND O PTIONAL O PTIO NAL D EH UM FR ONT COVER...
Page 60 5151 San Felipe Suite 500 Houston, TX 77056 www.goodmanmfg.com • www.amana-hac.com © 2011 Goodman Manufacturing Company, L.P.

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Goodman MVM96 Installation Instructions Manual

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