Goodman *CVC96 Installation Instructions Manual
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Goodman *CVC96 Installation Instructions Manual

Goodman *cvc96; *mvc96 two-stage gas furnace
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I
NSTALLATION
*CVC96 & *MVC96
T
-S
WO
TAGE
(Type FSP CATEGORY IV Direct
or Non Direct Vent Air Furnace)
These furnaces comply with requirements em-
bodied in the American National Standard / Na-
tional Standard of Canada ANSI Z21.47·CSA-2.3
Gas Fired Central Furnaces.
s a professional installer you have an obligation to know
A
the product better than the customer. This includes all safety
precautions and related items.
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 when the unit is in operation.
Remember, it is your responsibility to install the product
safely and to know it well enough to be able to instruct a
customer in its safe use.
Safety is a matter of common sense...a matter of thinking
before acting. Most dealers have a list of specific good
safety practices...follow them.
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.
RECOGNIZE THIS SYMBOL
AS A SAFETY PRECAUTION.
NOTE: Please contact your distributor or our website for
*
the applicable Specification Sheet referred to in this manual.
IOG-2008A
12/14
I
NSTRUCTIONS FOR
G
F
AS
URNACE
Installer:
Affix all manuals
adjacent to the unit.
5151 San Felipe Suite 500
Houston, TX 77056
www.goodmanmfg.com • www.amana-hac.com
© 2014 Goodman Manufacturing Company, L.P .
is a registered trademark of Maytag Corporation or its related companies and is used under license. All rights reserved.

TABLE OF CONTENTS

SAFETY CONSIDERATIONS .................................... 3
......................................... 4
........................................... 4
PRODUCT DESCRIPTION ....................................... 4
F
................................................... 4
PRODUCT APPLICATION ....................................... 5
....................................... 9
INSTALLATION POSITIONS .................................... 9
........................................ 10
...................................... 10
.................................................. 10
V
................................................. 11
......................................... 11
D
C
V
LUE AND
V
V
........................................... 14
V
V
T
V
V
....................................... 19
...................................... 20
U
I
S
R
WITH
IGHT
U
PFLOW MODEL INSTALLED HORIZONTALLY WITH LEFT SIDE DOWN
C
M
I
OUNTERFLOW
ODEL
................. 4
................................ 7
.................................. 7
................ 9
.............. 10
C
A
C
IR
ONNECTIONS
C
............ 11
ONNECTIONS
-D
/D
V
.............. 12
............................ 12
..................................... 13
............................ 14
............................ 14
V
...............14
..................... 16
F
I
NSTALLATION
V
.................... 19
.............................. 19
................................ 19
V
....................... 20
................................... 20
.................................... 20
............................... 21
V
.................. 22
NSTALLED
.... 10
.... 13
. 21

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Summary of Contents for Goodman *CVC96

  • Page 1: Table Of Contents

    ERTICALLY 5151 San Felipe Suite 500 Houston, TX 77056 IOG-2008A www.goodmanmfg.com • www.amana-hac.com 12/14 © 2014 Goodman Manufacturing Company, L.P . is a registered trademark of Maytag Corporation or its related companies and is used under license. All rights reserved.
  • Page 2 ........22 ........42 RAIN XITING OSSIL PPLICATIONS ........22 CTK0* WIRING ..........42 RAIN XITING IGHT ....43 OUNTERFLOW ODEL NSTALLED ORIZONTALLY OMFORT YSTEM DVANCED EATURES ....... 22 ......44 WITH IGHT URNACE DVANCED EATURES ENUS ......... 46 OUNTERFLOW ODEL NSTALLED ORIZONTALLY...

  • Page 3: Safety Considerations

    AFETY ONSIDERATIONS WARNING Adhere to the following warnings and cautions when install- O PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER ing, adjusting, altering, servicing, or operating the furnace. INSTALLATION ADJUSTMENT ALTERATION SERVICE OR MAINTENANCE To ensure proper installation and operation, thoroughly read REFER TO THIS MANUAL OR ADDITIONAL ASSISTANCE OR this manual for specifics pertaining to the installation and...

  • Page 4: Shipping Inspection

    RISQUE D'EMPOISONNEMENT AU MONOXYDE DE CARBONE Advertencia especial para la instalación de calentadores ó manejadoras de aire en áreas cerradas como estacionamientos ó cuartos de servicio. Cette ventilation est nécessaire pour éviter le danger d'intoxication Las emisiones de monóxido de carbono pueden circular a través au CO pouvant survenir si un appareil produisant du monoxyde del aparato cuando se opera en cualquier modo.

  • Page 5: Product Description

    1. Disconnect all power to the furnace. Do not touch the integrated control module or any wire connected to the control prior to discharging your body’s electrostatic charge to ground. 2. Firmly touch a clean, unpainted, metal surface of the furnaces near the control. Any tools held in a person’s hand during grounding will be discharged.

  • Page 6: Location Requirements & Considerations

    • A return air temperature range between 60ºF (16ºC) and 80ºF (27ºC) is maintained. • Air filters are installed in the system and maintained during construction replaced as appropriate during construction, and upon completion of construction. • The input rate and temperature rise are set per the furnace rating plate. •...
  • Page 7 accomplished within the guidelines given. NOTE: The length of flue and/or combustion air piping can be a limiting factor in the location of the furnace. • Locate the furnace so condensate flows downwards to the drain. Do not locate the furnace or its condensate drainage system in any area subject to below freezing temperatures without proper freeze protection.

  • Page 8: Clearances And Accessibility

    • Counterflow Installation over a combustible floor. If installation over a combustible floor *M96VC MINIMUM CLEARANCES TO COM BUSTIBLE MATERIALS becomes necessary, use an accessory subbase (INCHES) (see Specification Sheet applicable for your POSITION* SIDES REAR FRONT BOTTOM FLUE model for details.) A special accessory subbase must be used for upright counterflow unit Upflow 0"...

  • Page 9: Thermostat Location

    1. Seal any unused openings in the venting system. 2. Inspect the venting system for proper size and horizontal pitch, as required by the National Fuel Gas Code, ANSI Z223.1 or the Natural Gas and Propane Installation Code, CSA B149.1-05 and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.

  • Page 10: Installation Positions

    NSTALLATION OSITIONS This furnace may be installed in an upright position or horizontal on either the left or right side panel. Do not install this furnace on its back. For upright upflow furnaces, return air ductwork may be attached to the side panel(s) and/or basepan. For horizontal upflow furnaces, return air ductwork must be attached to the basepan.

  • Page 11: Alternate Electrical And Gas Line

    When using the horizontal alternate vent configuration, you must use the RF000142 vent drain kit. See following illustration. Figure 3B Alternate Vent/Flue Location Figure 3A Figure 3C LTERNATE LECTRICAL AND ONNECTIONS Recommended Installation Positions This furnace has provisions allowing for electrical and gas line connections through either side panel.

  • Page 12: Vent/Flue Pipe & Combustion Air Pipe

    & C OMBUSTION WARNING WARNING PON COMPLETION OF THE FURNACE INSTALLATION CAREFULLY AILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN BODILY INSPECT THE ENTIRE FLUE SYSTEM BOTH INSIDE AND OUTSIDE OF THE INJURY OR DEATH AREFULLY READ AND FOLLOW ALL INSTRUCTIONS FURNACE TO ASSURE IT IS PROPERLY SEALED EAKS IN THE FLUE GIVEN IN THIS SECTION...

  • Page 13: Proper Vent /F

    All 90° elbows must be medium radius (1/4 bend DWV) or long radius (Long sweep 1/4 bend DWV) types conforming to ASTM D3311. A medium radius (1/4 bend DWV) elbow measures 3 1/16” minimum from the plane of one opening to the center line of the other opening for 2”...

  • Page 14: Canadian Venting Requirements

    • The vent termination of a direct vent application must terminate at least 12 inches from any opening through which flue gases may enter a building (door, window, or gravity air inlet). • The vent termination of vent pipe run vertically through a roof must terminate at least 12 inches above the roof line (or the anticipated snow level) and be at least 12 inches from any vertical wall (including any anticipated snow build up).

  • Page 15: Alternate Vent/Flue Location

    COMBUSTION AIR INTAKE OPTION: The RF000142 coupling can be secured directly to the furnace intake coupling if conden- sation is a concern. If the RF000142 is used on the combustion air inlet, it must be installed with the arrow pointing up. It should be noted, the combustion air will actually be moving in a direction opposite of the arrow on the RF000142 coupling.

  • Page 16: Non -Direct Vent (Single Pipe ) Piping

    IRECT INGLE IPING CAUTION Non-direct vent installations require only a vent/flue pipe. The E SURE NOT TO DAMAGE INTERNAL WIRING OR OTHER COMPONENTS vent pipe can be run horizontally with an exit through the side of WHEN REINSTALLING COUPLING AND SCREWS the building or run vertically with an exit through the roof of the building.
  • Page 17 DOWN VENTING UPFLOW MODEL FURNACES ONLY Use alternate vent & combination air locations 6’ MAX. Vent Pipe Combustion Air Pipe Both Pipes Terminated Outside Structure Field Supplied Drain Tee on Vent Pipe 1/4” per foot min. slope Condensate trapped to prevent flue gas from escaping and routed to field supplied condensate disposal All piping and fittings must be joined per material manufacturer’s specifications...
  • Page 18 IRECT IPING 12" MIN. Direct vent installations require both a combustion air intake and a vent/ flue pipe. The pipes may be run horizontally and exit through the side of the VENT/FLUE TEE ( OPTIONAL) building or run vertically and exit through the roof of the building. The 45°...

  • Page 19: Vent /I

    Vent and intake clearance to ground or anticipated snow level = 12” min. NTAKE ERMINATIONS NSTALLATION OF ULTIPLE IRECT 3”MIN URNACES 24”MAX If more than one direct vent furnace is to be installed vertically through 12” MIN SEPARATION a common roof top, maintain the same minimum clearances be- tween the exhaust vent and air intake terminations of adjacent units 3”...

  • Page 20: Field Supplied Drain

    IELD UPPLIED RAIN Drain the furnace and air conditioning coil if applicable, in com- pliance with code requirements. In horizontal or counterflow in- stallations, a field installed rubber coupling will allow the drain trap to be removed for cleaning. The drain trap must be primed before initial furnace start up.
  • Page 21 4. Remove the two plugs from the right side of the cabinet and install them in the blower deck. 5. (Draining the Vent Elbow ) Locate hose #5 and cut it at line “C”. Install the cut end of hose #5 from outside the cabinet through the cabinet drain hole nearest the top.

  • Page 22: Ertically

    OUNTER ODEL NSTALLED ERTICALLY The furnace drain may exit the right or left side of the furnace cabi- net (left side preferred) Trap and factory installed hoses remain as shipped if the drain will exit the left side of the cabinet. Draining from the right side requires re-location of the trap to outside the cabinet.

  • Page 23: Electrical Connections

    OUNTERFLOW ODEL NSTALLED ORIZONTALLY WITH Minimum 5 ½" clearance is required for the drain trap beneath the furnace. 1. Remove hose clamps and hoses from trap. 2. Remove trap. 3. Remove plugs from left side of cabinet and install in blower deck. Hose #4 4.

  • Page 24: Junction Box Relocation

    must be sized in accordance with the maximum overcurrent protection specified on the unit rating plate. An electrical disconnect must be provided at the furnace location. Connect hot, neutral, and ground wires as shown in the wiring diagram located on the unit’s blower door. For direct vent applications, the cabinet opening to the junction box must be sealed air tight using either an UL approved bushing such as Heyco Liquid Tight or by applying non-reactive UL approved sealant to bushing.

  • Page 25: Single -Stage Heating Thermostat

    NOTE: For single stage cooling applications, a jumper may be required between Y1 and Y2 at the furnace control in order to achieve the desired single stage cooling airflow. Use of ramping profiles and dehumidification features require a jumper between Y1 and O. NOTE: Thermostat “R”...

  • Page 26: Ossil Uel Pplications

    coil. For proper function, a dehumidistat applied to this furnace must operate on 24 VAC and utilize a switch which opens on humidity rise. Refer to the “Thermostat Wiring Diagrams” figure for additional wiring details. (See Figure 33) To install/connect a dehumidistat: 1.
  • Page 27 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 single humidifier terminal (HUM) is energized with 115 volts whenever the induced draft blower is ener- gized.

  • Page 28: Gas Supply And Piping

    UXILIARY LARM WITCH The control is equipped with a 24VAC Auxiliary Alarm Input (12 inch purple / white wire attached to pin 6 of 15 pin connector) which can be utilized with communicating mode setups (typically used for condensate switch wiring but could be used with compatible C0 sensors or Fire Alarms).

  • Page 29: Gas Piping Connections

    ALVE This unit is equipped with a 24 volt gas valve controlled during furnace operation by the integrated control module. As shipped, the valve is configured for natural gas. The valve is field convertible for use with propane gas by replacing the regulator spring with a propane gas spring from an appropriate manufacturer’s propane gas conversion kit.
  • Page 30 – Semi-rigid metallic tubing and metallic fittings. Manual Shut Off Valve Alternate Manifold Burners Gas Line (upstream from Aluminum alloy tubing must not be used in exterior ground joint Location locations. In order to seal the grommet cabinet pipe union) penetration, rigid pipe must be used to reach the outside of the cabinet.

  • Page 31: Propane Gas Tanks And Piping

    IPING HECKS Before placing unit in operation, leak test the unit and gas connec- tions. WARNING Check for leaks using an approved chloride-free soap and water O AVOID THE POSSIBILITY OF EXPLOSION OR FIRE NEVER USE A MATCH solution, an electronic combustible gas detector, or other approved OR OPEN FLAME TO TEST FOR LEAKS testing methods.

  • Page 32: Circulating Air & Filters

    Sizing Between Second or Second Stage Regulator & Appliance* Sizing Between First and Second Stage Regulator* Maximum Propane Capacities listed are based on 1/2" W.C. pressure drop at 11" W.C. setting Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting. Capacities in 1,000 BT U/hour.

  • Page 33: Ottom Eturn Ir Pening

    NOTE: Both readings may be taken simultaneously and read directly on the manometer if so desired. If an air conditioner coil or Elec- tronic Air Cleaner is used in conjunction with the furnace, the read- ings must also include theses components, as shown in the following drawing.

  • Page 34: Startup Procedure & Adjustment

    Filter Sizing Chart PRIGHT NSTALLATIONS Model Minimum Filter Size Depending on the installation and/or customer preference, differing filter ar- 20 X 24 *M96VC0403BN** rangements can be applied. Filters can be installed in the central return register 20 X 25 or a side panel external filter rack kit (upflows). As an alternative a media air *M96VC0603BN** filter or electronic air cleaner can be used as the requested filter.

  • Page 35: Gas Supply Pressure Measurement

    URNACE TARTUP 1. Close the manual gas shutoff valve external to the furnace. 2. Turn off the electrical power to the furnace. 3. Set the room thermostat to the lowest possible setting. 4. Remove the burner compartment door. NOTE: This furnace is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand. 5.
  • Page 36 Open to Atmosphere High Fire Regulator Outlet Adjust Regulator Pressure Boss Vent Low Fire Regulator Adjust White-Rodgers Model 36J54 (Two-Stage) Inlet Pressure Figure 45A Boss Common Terminal(C) White-Rodgers Model 36J54 Connected to Manometer Figure 45B High Fire Common Regulator Regulator Terminal(C) Adjust Vent...

  • Page 37: Gas Manifold Pressurem

    If supply pressure differs from table, make the necessary adjustments to pres- sure regulator, gas piping size, etc., and/or consult with local gas utility. Gas Line 5. Turn OFF gas to furnace at the manual shutoff valve and disconnect manometer. Reinstall plug before turning on gas to furnace. Shutoff Valve 6.

  • Page 38: Temperature Rise

    2. While the furnace is operating at high fire rate, time and record one complete revolution of the gas meter dial, measuring the smallest quantity, usually the dial that indicates 1/2 cu. ft. per revolution. You will use this number to calculate the quantity of gas in cubic ft.
  • Page 39 Example: Cooling Capacity of 30,000 BTU/hr. 30,000/12,000 = 2.5 Tons 2. Determine the proper air flow for the cooling system. Most cooling systems are designed to work with air flows between 350 and 450 CFM per ton. Most manufacturers recommend an air flow of about 400 CFM per ton. Example: 2.5 tons X 400 CFM per ton = 1000 CFM The cooling system manufacturer’s instructions must be checked for required air flow.
  • Page 40 Sw itch Bank: S3 Sw itch Bank: S3 DIP Sw itch No. DIP Sw itch No. Adjust Taps Cooling Speed Taps + 5%* - 5% + 10% - 10% (*Indicates factory setting) (*Indicates factory setting) NOTE: To enable adjustments • Profile D ramps up to 50% of the demand for 1/2 minute, then ramps to 85% of the full cooling demand airflow and operates there for approximately 7 1/2 minutes.

  • Page 41: Blower Heat Off Delay Timings

    7. Select the heating speed for your model from the heating speed chart in the Specification 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.

  • Page 42: Ctk0* Wiring

    and transmits the demand along with a fan request to the indoor System Airflow Dem and System unit. The indoor unit then sends the demand to the ECM motor. Operating M ode Source The table below lists the various ComfortNet systems, the operat- Cooling Air Conditioner ing mode, and airflow demand source.

  • Page 43: Comfort Net System Advancedf

    NOTE: Use of a transformer is CTK0* Thermostat recommended if installing a dual fuel/ fossil fuel system with a CTK01* or ComfortNet Compatible CTK02*. Failure to use the transformer Furnace Integrated in the outdoor unit could result in over Control Module loading of the furnace transformer.

  • Page 44: Furnace Advanced Features Menus

    URNACE DVANCED EATURES ENUS (accessed through the communicating thermostat) C ONFIGUR ATION Subm e nu Ite m Indica tion (for Displa y Only; not Use r M odifia ble ) Number of Heat Stages (HT STG) Display s the number of furnace heating stages Input Rate (BTU/HR) Display s the furnace input rate in kBtu/hr Motor HP (1/2, ¾...
  • Page 45 SET-UP Submenu Item User Modifiable Options Comments -10% to +10% in 2% increments, Trims the heating airflow by the selected Heat Airflow Trim (HT TRM) default is 0% amount. 5, 10, 15, 20, 25, or 30 seconds, Heat ON Delay (HT ON Selects the indoor blower heat ON delay default is 30 seconds 30, 60, 90, 120, 150, or 180 seconds,...

  • Page 46: Thermostat Menu

    HERMOSTAT 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. IAGNOSTICS Accessing the furnace’s diagnostics menu provides ready access to the last six faults detected by the furnace. Faults are stored most recent to least recent.

  • Page 47: Normal Sequence Of Operation

    YSTEM 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 for a listing of possible furnace error codes, possible causes and corrective actions. ORMAL EQUENCE OF PERATION...

  • Page 48: Operational Checks

    • Outdoor fan and compressor are energized to their appropriate speed. • Circulator blower is energized on the appropriate cool speed at the level and time determined by the selected ramping profile. Electronic air cleaner terminal is energized with circulator blower. •...

  • Page 49: Pressure Switches

    RESSURE WITCHES The pressure switches are normally-open (closed during operation) negative air pressure-activated switches. They monitor the airflow (combustion air and flue products) through the heat exchanger via pressure taps located on the induced draft blower and the coil front cover. These switches guard against insufficient airflow (combustion air and flue products) through the heat exchanger and/or blocked condensate drain conditions.

  • Page 50: Filters

    • Flue pipe system. Check for blockage and/or leakage. Check the outside termination and the connections at and internal to the furnace. • Heat exchanger. Check for corrosion and/or buildup within the heat exchanger passageways. • Burners. Check for proper ignition, burner flame, and flame sense. •...

  • Page 51: Flue Passages

    ASSAGES UALIFIED ERVICER The heat exchanger flue passageways should be inspected at the beginning of each heating season. EFORE EAVING AN NSTALLATION • Cycle the furnace with the thermostat at least three times. Verify cooling and fan only operation. • Review the Owner’s Manual with the homeowner and discuss proper furnace operation and maintenance.

  • Page 52: Dip Switches

    WITCHES Dip Switch Switch Bank Purpose Function Heating Off Delay 2 Stage Stat 2 Stage Stat Thermostat Setup 1 Stg Stat 5 min delay 1 Stg Stat auto delay Cooling Airflow Add 5% Minus 5% Trim Add 10% Minus 10% Ramping Profile Heating Airflow Disabled...

  • Page 53: Status Codes

    TATUS ODES INTERNAL CONTROL FAULT/NO POWER NORMAL OPERATION LOCKOUT DUE TO EXCESSIVE RETRIES LOW STAGE PRESSURE SWITCH STUCK CLOSED AT START OF HEATING CYCLE LOW STAGE PRESSURE 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 54: Troubleshooting Chart

    ROUBLESHOOTING HART ComfortNet™ Symptoms of Abnormal Diagnostic/ Thermostat Only Operation (Legacy & Status LED Fault Description Possible Causes Corrective Actions Notes & Cautions ComfortNet™ Thermostat) Codes Message Code • Furnace fails to operate None • No 115 power to INTERNAL •...
  • Page 55 ROUBLESHOOTING HART Symptoms of Abnormal ComfortNet™ Diagnostic/ Operation (Legacy Thermostat Only Status LED Fault Description Possible Causes Corrective Actions Notes & Cautions & ComfortNet™ Codes Message Code Thermostat) • Induced draft blower • Low stage PS1 OPEN • Pressure switch hose •...
  • Page 56 ROUBLESHOOTING HART Symptoms of Abnormal ComfortNet™ Diagnostic/ Operation (Legacy Thermostat Only Status LED Fault Description Possible Causes Corrective Actions Notes & Cautions & ComfortNet™ Codes Message Code Thermostat) • Furnace fails to operate. • Problem with IGNITER • Improperly connected •...
  • Page 57 ROUBLESHOOTING HART ComfortNet™ Symptoms of Abnormal Diagnostic/ Thermostat Only Operation (Legacy Status LED Fault Description Possible Causes Corrective Actions Notes & Cautions & ComfortNet™ Codes Message Code Thermostat) • Operation different than • Invalid memory INVALID MC • Shared data set on •...
  • Page 58 ROUBLESHOOTING HART ComfortNet™ Symptoms of Abnormal Diagnostic/ Thermostat Only Operation (Legacy Status LED Fault Description Possible Causes Corrective Actions Notes & Cautions & ComfortNet™ Codes Message Code Thermostat) • Circulator blower MOTOR • Turn power OFF prior • Furnace fails to operate. motor senses TRIPS to repair...

  • Page 59: Wiring Diagram

    IRING IAGRAM Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring.

  • Page 60: Special Instructions For Products Installed

    PECIAL NSTRUCTIONS FOR RODUCTS NSTALLED IN THE TATE OF ASSACHUSETTS For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termi- VENT/FLUE nation is less than seven (7) feet above finished grade in the area...

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