Goodman GCH95 Installation Instructions Manual
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Goodman GCH95 Installation Instructions Manual

Goodman GCH95 Installation Instructions Manual

Gas-fired warm air furnace
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G
(Type FSP CATEGORY IV Direct or Non Direct Vent Air Furnace)
ATTENTION INSTALLING PERSONNEL
As a professional installer you have an obligation to know the product better than the customer. This includes all safety
Prior to actual installation, thoroughly familiarize yourself with this Instruction Manual. Pay special attention to all safety
warnings. Often during installation or repair it is possible to place yourself in a position which is more hazardous than
Remember, it is your responsibility to install the product safely and to know it well enough to be able to instruct a customer
Safety is a matter of common sense...a matter of thinking before acting. Most dealers have a list of specific good safety
The precautions listed in this Installation Manual are intended as supplemental to existing practices. However, if there is
a direct conflict between existing practices and the content of this manual, the precautions listed here take precedence.
IO-299G
11/09
GMH95/GCH95/GCH9
-F
W
AS
IRED
I
NSTALLATION
Installer: Affix all manuals adjacent to the unit.
These furnaces comply with requirements
embodied in the American National Stan-
dard / National Standard of Canada ANSI
Z21.47·CSA-2.3 Gas Fired Central Fur-
naces.
RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION.
precautions and related items.
when the unit is in operation.
practices...follow them.
NOTE: Please contact your distributor or our website
for the applicable Specification Sheet referred to in this manual.
Goodman Manufacturing Company, L.P.
5151 San Felipe, Suite 500, Houston, TX 77056
www.goodmanmfg.com
2006-2009 Goodman Manufacturing Company, L.P.
©
A
F
ARM
IR
I
NSTRUCTIONS
in its safe use.
URNACE
®
C
US

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  • Page 1 GMH95/GCH95/GCH9 IRED URNACE NSTALLATION NSTRUCTIONS Installer: Affix all manuals adjacent to the unit. (Type FSP CATEGORY IV Direct or Non Direct Vent Air Furnace) These furnaces comply with requirements embodied in the American National Stan- ® dard / National Standard of Canada ANSI Z21.47·CSA-2.3 Gas Fired Central Fur-...

  • Page 2: Table Of Contents

    Table of Contents ................4 MPORTANT OTE TO THE WNER REGARDING RODUCT ARRANTY I. Component Identification ............................... 5 II. Safety ....................................6 (ESD) P ....................6 LECTROSTATIC ISCHARGE RECAUTIONS III. Product Application ..............................6 IV. Location Requirements & Considerations ......................... 7 .................................
  • Page 3 Table of Contents ..........................30 ORIZONTAL NSTALLATIONS XIV. Startup Procedure & Adjustment ..........................30 ..........................30 NTICIPATOR ETTING ............................30 RAIN RIMING ............................30 URNACE OPERATION ......................31 UPPLY RESSURE EASUREMENT .................. 32 ANIFOLD RESSURE EASUREMENT AND DJUSTMENT ) ..................32 NPUT EASUREMENT ATURAL...

  • Page 4: I N O P W

    HIPPING NSPECTION WARNING All units are securely packed in shipping containers tested accord- ing to International Safe Transit Association specifications. The car- F THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED ton must be checked upon arrival for external damage. If damage is EXACTLY A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY found, a request for inspection by carrier’s agent must be made in...

  • Page 5: Component Identification

    I. COMPONENT IDENTIFICATION Upflow/Horizontal Counterflow/Horizontal Gas Valve 22 Blower Door Interlock Switch Gas Line Entrance (Alternate) 23 Capacitor Pressure Switch 24 Integrated Control Module Gas Manifold (with fuse and diagnostic LED) Combustion Air Intake Connection / “Coupling” 25 24-Volt Thermostat Connections Hot Surface Igniter 26 Transformer (40 VA) Rollout Limit...

  • Page 6: Safety

    II. SAFETY or shuffle your feet, do not touch ungrounded objects, etc.). If you come in contact with an ungrounded object, repeat Please adhere to the following warnings and cautions when in- step 2 before touching control or wires. stalling, adjusting, altering, servicing, or operating the furnace. 4.

  • Page 7: Location Requirements & Considerations

    • 100% outside air is provided for combustion air The rated heating capacity of the furnace should be greater than or requirements during construction. Temporary ducting can equal to the total heat loss of the area to be heated. The total heat be used.

  • Page 8: Clearances And Accessibility

    the furnace where the combustion air is exposed to the of 0.25 square inches per 1,000 BTU/hr of furnace input rating. Refer to the Specification Sheet applicable to your model for mini- following substances: mum clearances to combustible surfaces. One of the ventilation chlorinated waxes or cleaners openings must be within 12 inches of the top;...

  • Page 9: Thermostat Location

    House depressurization can cause back drafting or improper com- f. After it has been determined that each appliance connected to the bustion of gas-fired appliances, thereby exposing building occu- venting system properly vents when tested as outlined above, re- pants to gas combustion products that could include carbon mon- turn doors, windows, exhaust fans, fireplace dampers and any other oxide.
  • Page 10 Space, Unconfined. Equipment Located in Confined Spaces; All Air from Outdoors— For purposes of this Code, a space whose volume is not less than 50 Inlet Air from Ventilated Crawl Space and Outlet Air to Ventilated Attic. See 5.3.3-b cubic feet per 1,000 BTU per hour of the aggregate input rating of all appliances installed in that space.

  • Page 11: Installation Positions

    NOTE: The single opening must have VII. HORIZONTAL APPLICATIONS & CONSIDERATIONS a free area of not less than one Chimney or Gas Vent square inch per 3000 BTU of ENERAL the total input rating of all equip- ment in the enclosure, but not less than Horizontal applications, in particular, may dictate many of the the sum of the areas of all vent connectors in the confined space.

  • Page 12: Alternate Electrical And Gas Line Connections

    furnace on the ground or allow it to be exposed to water. Refer to Section IV, Location Requirements and Considerations - Furnace Suspension for further details. VIII. PROPANE GAS /HIGH ALTITUDE INSTALLATIONS WARNING OSSIBLE PROPERTY DAMAGE PERSONAL INJURY OR DEATH MAY OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INSTALLED APPROPRIATE KITS MUST BE APPLIED TO ENSURE SAFE AND PROPER FURNACE OPERATION...

  • Page 13: Dual Certification : Non -Direct /Direct Vent

    described later in this section. Never common vent this appliance the performance of the furnace and must be carefully sized. All with another appliance or use a vent which is used by a solid fuel piping must be installed in accordance with local codes and these appliance.

  • Page 14: Canadian Venting Requirements

    NOTE: In Canada, the Canadian Fuel Gas Code takes precedence NOTE: For non-direct vent installations, a minimum of one 90° over the preceding termination restrictions. elbow should be installed on the combustion air intake coupling to guard against inadvertent blockage. ANADIAN ENTING EQUIREMENTS...

  • Page 15: Non -Direct Vent (Single Pipe ) Piping

    1. Remove and save the four screws securing the vent/flue using a worm gear hose clamp. NOTE: Use of the alternate vent/flue location for upright installations, requires the drain coupling to the furnace top panel. trap be installed on the same side of the unit as the flue Counterflow units.

  • Page 16: Direct Vent (Dual Pipe ) Piping

    Although non-direct vent installations do not require a combus- tion air intake pipe, a minimum of one 90° elbow should be at- tached to the furnace’s combustion air intake if: an upright instal- 12 " Min To lation uses the standard intake location. This elbow will guard Roof Or Highest Anticipated against inadvertent blockage of the air intake.
  • Page 17 For details concerning connection of pipes to the furnace, refer to Horizontal terminations should be as shown in the following fig- the Section IX, Vent/Flue Pipe and Combustion Pipe - Standard ure. Refer to Section IX, Vent/Flue Pipe and Combustion Pipe - Furnace Connections or Alternate Furnace Connections.

  • Page 18: Vent /Intake Terminations For Installation Of Multiple Direct Vent Furnaces

    X. CONDENSATE DRAIN LINES & DRAIN TRAP 90° Vent Medium Radius A condensing gas furnace achieves its high level of efficiency by Elbow extracting almost all of the heat from the products of combustion and cooling them to the point where condensation takes place. 12”...
  • Page 19 In a upright installation drain hoses are connected to drain ports 4. Insert Tube 1 into rubber elbow drain port and secure with silver hose clamp. Angle tube outward toward front of on the rubber elbow and the recuperator coil front cover. The drain furnace.
  • Page 20 5. Insert Tube 1 into rubber elbow drain port and secure with a LTERNATE RAIN ONNECTIONS silver hose clamp. Angle tube toward trap. Upright installations using the alternate vent/flue outlet will require 6. Cut 17 3/4 inches from the long end of Hose B and discard. “right-side only”...
  • Page 21 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 remaining NOTE: For left side trap installation, grommets must be moved to hose to Tube 1 with a green hose clamp. Route other end the left side of the furnace and the plugs installed on the right side of Hose B to front left side panel grommet hole.

  • Page 22: Orizontal Nstallations

    Make connections as follows: "X" Length to Cut From Long 1. Remove the rubber plug from right side of the front cover Cabinet Width Models End of Hose B drain port. (inches) (kBTU_Tons) (inches) Counterflow furnaces 17 1/2 45_30 Relocate the front cover pressure switch hose connection from the left side pressure tap to the right (down) side tap.
  • Page 23 5. Secure the short end of Hose B to rubber elbow side drain port using a green hose clamp. NOTE: For left side drainage, Horizontal installations with the left side panel down will require route hose to far left (down) side panel grommet holes. drain hoses to be connected to the left side front cover drain port NOTE: Horizontal left side connections (when using new and the side drain port on the rubber elbow.

  • Page 24: Electrical Connections

    XI. ELECTRICAL CONNECTIONS Line polarity must be observed when making field connections. Line voltage connections can be made through either the right or left side panel. The furnace is shipped configured for a left side WARNING (right side for counterflows) electrical connection with the junction box located inside the burner compartment.

  • Page 25: 115 Volt Line Connection Of Accessories (Electronic Air Cleaner )

    24 V UMIDIFIER The yellow wire connected to the I.D. Blower pressure switch is powered anytime the pressure switch is closed and provides 24 VAC humidifier control. Remove the yellow wire and connect the supplied brown jumper wire to the pressure switch terminal. Re- connect the yellow wire to the “piggyback”...

  • Page 26: General

    A different pressure switch may be required at high altitude regard- Natural Gas Capacity of Pipe less of the BTU/ft content of the fuel used. Contact your distributor In Cubic Feet of Gas Per Hour (CFH) Length of Nominal Black Pipe Size for a tabular listing of appropriate altitude ranges and correspond- Pipe in Feet 1/2"...
  • Page 27 • • Connect the furnace to the building piping by one of the Protect connectors and semi-rigid tubing against physical following methods: and thermal damage when installed. Ensure aluminum- alloy tubing and connectors are coated to protect against – Rigid metallic pipe and fittings. external corrosion when in contact with masonry, plaster, or –...

  • Page 28: Ropane As Anks And Iping

    ROPANE ANKS AND IPING WARNING WARNING DGES OF SHEET METAL HOLES MAY BE SHARP SE GLOVES AS A PRECAUTION WHEN REMOVING HOLE PLUGS F THE GAS FURNACE IS INSTALLED IN A BASEMENT AN EXCAVATED AREA OR A CONFINED SPACE IT IS STRONGLY RECOMMENDED TO IRECT TANDARD NLET...

  • Page 29: Circulating Air & Filters

    When the furnace is installed without a cooling coil, it is recom- Sizing Between First and Second Stage Regulator* Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting. mended that a removable access panel be provided in the outlet Capacities in 1,000 BTU/hour.

  • Page 30: Upright Installations

    ORIZONTAL NSTALLATIONS COO LING AIRFLO W REQ UIREM ENT (CFM ) Filters must be installed in either the central return register or in the 1000 1200 1400 1600 2000 return air duct work. 0453BXA 194* 194* XIV. STARTUP PROCEDURE & ADJUSTMENT 0703BXA 324* 324*...

  • Page 31: Gas Supply Pressure Measurement

    High Fire URNACE HUTDOWN Regulator Regulator 1. Set the thermostat to the lowest setting. The integrated Adjust Vent control will close the gas valve and extinguish flame. Following a 15 second delay, the induced draft blower will be de-energized. After a 100 or 150 second delay period (field selectable), the circulator blower will be de-energized.

  • Page 32: Gas Manifold Pressure Measurement And Adjustment

    If supply pressure differs from table, make the necessary adjust- 8. Remove regulator cover screw from the low (LO) outlet ments to pressure regulator, gas piping size, etc., and/or consult pressure regulator adjust tower and turn screw clockwise with local gas utility. to increase pressure or counterclockwise to decrease 5.

  • Page 33: Temperature Rise

    This furnace is equipped with a multi-speed circulator blower. This Installation’s seconds per cubic foot: 34 sec/ ft blower provides ease in adjusting blower speeds. The Specifica- Conversion Factor (hours to seconds): 3600 sec/hr tion Sheet applicable to your model provides an airflow table, show- Input = (Htg.

  • Page 34: (Mdip S "2 Stg" )

    If the furnace is operating in high-stage heating mode when • Circulator blower is energized on high heat speed following the thermostat contacts open, the circulator blower remains a fixed thirty second blower on delay. Electronic air cleaner at high heat speed for thirty seconds. The circulator blower terminals are energized with circulator blower.

  • Page 35: Safety Circuit Description

    XVIII. TROUBLESHOOTING (ESD) P LECTROSTATIC ISCHARGE RECAUTIONS NOTE: Discharge body’s static electricity before touching unit. An electrostatic discharge can adversely affect electrical components. Check the burner flames for: Use the following precautions during furnace installation and ser- 1. Good adjustment vicing to protect the integrated control module from damage.

  • Page 36: Maintenance

    1. Automatic reset. The integrated control module will ILTERS automatically reset itself and attempt to resume normal operations following a one hour lockout period. CAUTION 2. Manual power interruption. Interrupt 115 volt power to the furnace for 1 - 20 seconds. O ENSURE PROPER UNIT PERFORMANCE ADHERE TO THE FILTER 3.

  • Page 37: Condensate Trap And Drain System (Qualified Servicer Only )

    11. Turn on electrical power and gas to furnace. Check for ONDENSATE RAP AND RAIN YSTEM UALIFIED ERVICER leaks and proper unit operation. 12. Severe heat exchanger fouling is an indication of an Annually inspect the drain tubes, drain trap, and field-supplied drain operational problem.

  • Page 38: Troubleshooting Chart

    TROUBLESHOOTING CHART Associated Associated Symptoms of Abnormal Fault Description(s) Possible Causes Fault Description(s) Possible Causes Corrective Action Cautions and Notes Operation LED Code LED Code • Furnace fails to operate. NONE • No 115 volt power to • Manual disconnect switch •...
  • Page 39 TROUBLESHOOTING CHART Fault Associated Symptoms of Cautions Corrective Action Possible Causes Description(s) LED Code Abnormal Operation & Notes • Check primary limit. • Insufficient conditioned air • Turn power OFF • Circulator blower runs • Primary limit Replace if necessary. over the heat exchanger.

  • Page 40: Blower Performance Data

    BLOWER PERFORMANCE DATA GMH95 BLOWER PERFORMANCE (CFM & Temperature Rise vs. External Static Pressure) EXTERNAL STATIC PRESSURE (Inches Water Column) Tons AC Model Motor at 0.5" Heating Speed Speed As Shipped CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM CFM CFM 1352 1318 1260...
  • Page 41 BLOWER PERFORMANCE DATA GCH95 BLOWER PERFORMANCE (CFM & Temperature Rise vs. External Static Pressure) EXTERNAL STATIC PRESSURE (Inches Water Column) Tons AC Model Motor at 0.5" Heating Speed Speed As Shipped CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM CFM CFM...
  • Page 42 WIRING DIAGRAM GMH95 & GCH9 STAGE DELAY MODE HEAT DELAY NOTE 6 COOL-H 6. TO RECALL THE LAST 5 FAULTS, MOST RECEN T TO LEAST RECENT, DEPRESS SWITCH FOR MORE THAN 2 SECONDS WHILE IN STANDBY (NO THERMOSTAT INPUTS) Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.
  • Page 43 WIRING DIAGRAM GCH95 STAGE DELAY MODE HEAT DELAY NOTE 6 COOL-H 6. TO RECALL THE LAST 5 FAULT S, MOST RECENT TO LEAST RE CENT, DEPR ESS SWITCH FOR MORE THAN 2 SECONDS WHILE IN STANDBY (NO THERMOSTAT INPUTS) Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.
  • Page 44 Goodman Manufacturing Company, L.P. 5151 San Felipe, Suite 500, Houston, TX 77056 www.goodmanmfg.com 2006-2009 Goodman Manufacturing Company, L.P. ©...

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