Installation Instructions for *CVC96*BA & *MVC96*BA Two-Stage Gas Furnace (Type FSP CATEGORY IV Direct or Non Direct Vent Air Furnace) (Type FSP CATÉGORIE IV Direct ou four á air soufflé non direct) These furnaces comply with requirements embodied in the American National Standard/National Standard of Canada ANSI Z21.47•CSA-2.3 Gas Fired Central Furnaces. Installer: Affix all manuals adjacent to the unit.
Safety Circuit Description...............................................44 Troubleshooting..............................................................45 Maintenance....................................................................46 Filters...............................................................................46 Before Leaving an Installation.......................................46 Repair and Replacement Parts......................................47 Menu Options................................
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. Las emisiones de monóxido de carbono pueden circular a través del aparato cuando se opera en cualquier modo. CO can cause serious illness including permanent brain damage or death.
Shipping Inspection All units are securely packed in shipping containers tested according to International Safe Transit 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. WARNING If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
Product Application NOTE: This furnace may be used as a construction site heater ONLY if all of the following conditions are met: • The vent system is permanently installed per these installation instructions. • A room thermostat is used to control the furnace. Fixed jumpers that provide continuous heating CANNOT be used and can cause long term equipment damage. Bi-metal thermostats, or any thermostat affected by vibration must not be used during construction.
A copy of the National Fuel Gas Code (NFPA 54/ANSI Z223.1) can be obtained from any of the following: American National Standards Institute 25 West 43rd Street, 4th Floor New York, NY 10036 National Fire Protection Association 1 Batterymarch Park Quincy, MA 02169-7471 • CSA International 8501 East Pleasant Valley Independence, OH 44131 The rated heating capacity of the furnace should be greater than or equal to the total heat loss of the area to be heated.
• Isolate a non-direct vent furnace if it is installed near an area frequently contaminated by any of the above substances. This protects the non-direct vent furnace from airborne contaminants. To ensure that the enclosed non-direct vent furnace has an adequate supply of combustion air, vent from a nearby uncontaminated room or from outdoors. Refer to the Combustion and Ventilation Air Requirements for details.
6. Follow the lighting instructions. Place the appliance being inspected in operation. Adjust thermostat so appliance shall operate continuously. 7. Test for spillage from draft hood appliances at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle. 8. If improper venting is observed during any of the above tests, the venting system must be corrected in accordance with the National Fuel Gas Code ANSI Z223.
Most homes will require outside air be supplied to the furnace area by means of ventilation grilles or ducts connecting directly to the outdoors or spaces open to the outdoors such as attics or crawl spaces. WARNING CARBON MONOXIDE POISONING HAZARD INSTALLATION POSITIONS Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death.
Front Cover Pressure Switch Tube Location When a furnace is installed horizontally with left side down the front cover pressure switch tube must be re-located to the lower port of the collector box cover. 1. Remove tube from front cover pressure switch and collector box cover. 2. Remove rubber plug from bottom collector box port and install on top collector box port. 3. Locate 24” x 1/4” tube in bag assembly. 4. Install one end on front cover pressure switch. 5.
Freeze Protection Refer to Horizontal Applications and Conditions - Drain Trap and Lines. WARNING Possible property damage, personal injury or death may occur if the correct conversion kits are not installed. The appropriate kits must be applied to ensure safe and proper furnace opearation. All conversions must be performed by a qualified installer or service agency.
NOTE: Requirement does not apply to the combustion air pipe. As an alternative to PVC pipe, primer, solvent cement, and fittings, ABS materials which are in compliance with the following specifications may be used. Two-or-three-inch ABS Schedule 40 pipe must meet ASTM D1527 and, if used in Canada, must be CSA listed. Solvent cement for ABS to ABS joints must meet ASTM D2235 and, if used in Canada, must be CSA listed. The solvent cement for the PVC to ABS transition joint must meet ASTM D3138.
Termination Locations ACCEPTABLE Non-Direct Vent & Direct Vent Vent/Flue Terminations Non-Direct Vent Vent/Flue Termination No Terminations Above Walkway TRANSITION NO LESS THAN 45 DEGREES TO HORIZONTAL PLANE TO AVOID CREATING A WATER TRAP IN VENT PIPING.
Vent/Flue Pipe The vent pipe outlet is sized to accept 2” pipe. Secure vent/flue pipe directly into the furnace fitting with the appropriate glue. Alternately, a small section of 2” pipe may be glued in the furnace socket and a rubber coupling installed to allow removal for future service. Combustion Air and Vent piping should be routed in a manner to avoid contact with refrigerant lines, metering devices, condensate drain lines, etc.
Insert flange. Cut 2 ½” long. RF000142 Figure 9 Figure 10 *MVC96/*CVC96 Direct Vent (2 - Pipe) and Non-Direct Vent (1- Pipe) Maximum Allowable Length of Vent/Flue Pipe & Combustion Air Pipe (ft) MODEL *M V96C0403BN *M VC960603BN *M VC960803BN *M VC960804CN *M VC961005CN *M VC961005DN *M VC961205DN *CVC960403BN *CVC960603BN *CVC960804CN *CVC961005CN *CVC961205DN Pipe Size (4) (in.
Figure 11 WARNING The rubber elbow is not designed to support a load. When the rubber elbow is mounted externally to the furnace cabinet, extreme care must be taken to adequately support field- Non-Direct Vent Installations A minimum of one 90° elbow should be installed on the combustion air intake “coupling” to guard against inadvertent blockage. supplied vent/flue piping, as damage can result in leaks causing bodily injury or death due to exposure to flue gases, including carbon monoxide.
Alternate Combustion Air Provision (Upflow / Horizontal models only) When using the alternate venting location, either in a horizontal left side down installation or a vertical installation using down – venting, an alternate combustion air opening can be used. A locating dimple is located on the right side of the furnace cabinet. The locating dimple is 1 7/8” measured from the front edge of the cabinet in line with the knock out. To use the alternate combustion air location: 1.
6” MAX 4” MIN ELBOWS STRAIGHT 12" MIN. TO GRADE OR HIGHEST ANTICIPATED SNOW LEVEL Standard Horizontal Terminations (Dual Pipe) Figure 13 Figure 16 Direct Vent (Dual Pipe) Piping DOWN VENTING UPFLOW MODEL FURNACES ONLY 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 building or run vertically and exit through the roof of the building.
The vent/flue and combustion air pipes may terminate vertically, as through a roof, or horizontally, as through an outside wall. VENT/FLUE TEE Vent/Intake Terminations For Installation of Multiple Direct Vent Furnaces If more than one direct vent furnace is to be installed vertically through a common roof top, maintain the same minimum clearances between the exhaust vent and air intake terminations of adjacent units as with the exhaust vent and air intake terminations of a single unit.
2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes. c. MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED.
NOTE: In vertical installations, air conditioning coil condensate may drain into the furnace trap as long as there is a trap between the coil and the furnace trap and the drain pipe is not terminating #2 #1 below the water level of the furnace trap. #3 General Drain Information All furnace models come with a factory installed drain trap. For vertical installations, the trap will remain in the factory position except for a counterflow when the installer desires the drain to exit the right side.
Acceptable area for drain hole. Side Cut-Out 12” Hose #11 3” Hose #2 Right side shown. Figure 25 Figure 23 1. Remove the clamps from both ends of the drain hoses. 2. Remove the two screws holding the drain trap to the blower deck. 3. Remove the trap and two hoses from the blower deck 4. Remove the two plugs from the right side of the cabinet and install them in the blower deck. 5.
14. Refer to Field Supplied Drain section for instructions on field supplied / installed drain on outlet of furnace trap. Upflow Model Installed Horizontally With Left Side Down - Alternate * Also see the Front Cover Pressure Switch Tube Location. Insert flange. Cut 2 ½” long. RF000142 Hose #6 Hose #5 Hose #11 Figure 26 1. Remove the clamps from the two drain tubes on the trap. 2. Remove the two screws holding the drain trap to the blower deck. 3. Remove the trap and hoses from the blower deck . 4.
Drain Exiting Right Side Hose #4 x 3 Hose #5 Figure 29 1. Remove hose clamps and hoses from trap. 2. Remove trap. 3. (Draining the Vent Elbow) Insert the non-grommet end hose #10 into the cabinet back drain hole. Insert a coupling into the drip leg of the vent-drain elbow and secure with a silver clamp. Secure hose #10 on ventdrain elbowbarb fitting with a silver clamp. 4.
Counterflow Model Installed Horizontally with Right Side Down Minimum 5 ½” clearance is required for the drain trap beneath the furnace. Counterflow Model Installed Horizontally with Left Side Down * Also see Front Cover Pressure Switch Tube Location on page 9. NOTE: For horizontal installations, some of the required hoses are found in the factory-installed hose assemblies. Remove the hose clamps to obtain the respective hoses needed for installation, and install per the following directions.
12. Insert 100º elbow in hose #5 and secure with a red clamp. 13. Locate hose #4 and cut a cut off a 4” straight section and discard the radius end. 14. Connect the 4” straight section of hose #4 to the 100º elbow and the PVC pipe and secure with red clamps. 15. Connect the hoses to the trap inlets and secure with silver clamps, drain trap outlet must point to the original bottom of the furnace. 16. Using the two sheet metal screws provided in the cabinet, secure the trap to the furnace. 17.
The gas piping supplying the furnace must be properly sized based on the gas flow required, specific gravity of the gas, and length of the run. The gas line installation must comply with local codes, or in their absence, with the latest edition of the National Fuel Gas Code, NFPA 54/ANSI Z223.1 or CAN/CSA B149.1-15. This unit is configured for natural gas. The appropriate manufacturer’s propane gas conversion kit, must be applied for propane gas installations.
• Connect the furnace to the building piping by one of Manual Shut Off Valve (upstream from ground joint pipe union) the following methods: – – • • Alternate Gas Line Location Rigid metallic pipe and fittings. Semi-rigid metallic tubing and metallic fittings. Aluminum alloy tubing must not be used in exterior locations. In order to seal the grommet cabinet penetration, rigid pipe must be used to reach the outside of the cabinet. A semi-rigid connector to the gas piping may be used from there.
Propane Gas Tanks and Piping Manual Shut Off Valve (upstream from ground joint pipe union) WARNING If the gas furnace is installed in a basement, an excavated area or confined space, it is strongly recommended to contact a propane supplier to install a gas detecting warning device in case of a gas leak. • Since propane gas is heavier than air, any leaking gas can settle in any low areas or confined spaces. • Propane gas odorant may fade, making gas undetectable except with a warning device.
Complete information regarding tank sizing for vaporiza tion, recommended regulator settings, and pipe sizing is available from most regulator manufacturers and propane gas suppliers. Total external static refers to everything external to the furnace cabinet. Cooling coils, filters, ducts, grilles, registers must all be considered when reading your total external static pressure. The supply duct pressure must be read between the furnace and the cooling coil.
Bottom Return Air Opening [Upflow Models] 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. To remove, simply press out the lanced sections by hand to expose the metal strips retaining the sheet metal over the duct opening. Using tin snips, cut the metal strips and remove the sheet metal covering the duct opening. In the corners of the opening, cut the sheet metal along the scribe lines to free the duct flanges.
Upright Installations Depending on the installation and/or customer preference, differing filter arrangements can be applied. Filters can be installed in the central return register or a side panel external filter rack kit (upflows). As an alternative a media air filter or electronic air cleaner can be used as the requested filter. Consider installing an air cleaner with deep-pleated media filter at the time of furnace installation.
locations. WARNING AIR FLOW High voltage! To avoid personal injury or death due to electrical shock, disconnect SIDE RETURN EXTERNAL FILTER RACK KIT (EITHER SIDE) electrical power before servicing or changing any electrical wiring. FILTER FILTER CENTRAL RETURN GRILLE CAUTION Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.
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 right side electrical connection with the junction box located inside the burner compartment (blower compartment for downflows).
This furnace is Bluetooth ready and functions with the CoolCloud HVAC phone application designed to improve the contractor’s setup / diagnostic experience. Users can see specific model information, review active diagnostic error codes, observe system status during operation, make system menu adjustments, add site visit notes and run system testing of all operational modes (heat / cool / fan) directly from the phone.
1. Allow the system to remain Idle for 5 minutes. 2. Turn the system verification test on either by using the phone application, or by entering the SUt menu through the furnace push buttons. 3. Wait for the test to complete. 1. Use the wiring diagrams below to connect low voltage thermostat wires. NOTE: When installing the furnace with a non “O” terminal “O” terminal on the non communicating heat pump. See Figure 23 for single stage and Figure 24 for the two stage diagrams.
NOTE: For two stage non-communicating outdoor units, system will stage airflow automatically for low stage operation. INDOOR BOARD TERMINAL CONNECTIONS 1 2 C 24 VAC Thermostat Heat Pump R R R C C Optional C G Optional G Y Y Y Optional INDOOR BOARD TERMINAL CONNECTIONS 1 R R C Optional C G Optional G Y Y Y2 Tonnage Selection Airflow 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2 2.1 2.2 400 440 480 520 560 600 640 680 720 760 800 840 880 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3 3.1 3.2 3.3 3.
24 VAC Thermostat Indoor Board Terminal Connections R R C G Optional Optional The terminal can be configured to enable dehumidification when the input is energized or de-energized. When using an external dehumidistat, connect it between the R and DH terminals. If the humidistat closes on humidity rise or the thermostat energizes this terminal when dehumidification is required, set the control board “dHL” (Dehum Logic) menu setting to “HI” using the push buttons or CoolCloud HVAC phone application.
Accessories Accessory Control (Ventilators) If an external humidifier, dehumidifier or ventilator is installed, it may require airflow from the HVAC system to function accordingly. 1. Make sure the installed 24VAC thermostat is capable of controlling the accessory or accessories. 2. Connect the appropriate accessory control wires to the accessory devices from the thermostat (see thermostat manual for connection and setup instructions). 3.
STARTUP PROCEDURE & ADJUSTMENT • Profile D (4) 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. The motor then steps up to the full demand airflow. Profile D has a 1/2 minute at 50% airflow OFF delay. OFF Furnace must have a 115 VAC power supply properly connected and grounded. Proper polarity must be maintained for correct operation.
8. Replace the burner compartment door. 9. Open the manual gas shutoff valve external to the furnace. 10. Turn on the electrical power to the furnace. 11. Adjust the thermostat to a setting above room temperature. 12. After the burners are lit, set the thermostat to desired temperature. CAUTION To prevent unreliable operation or equipment damage, the inlet gas supply pressure must be as specified on the unit rating plate with all other household gas fired appliances operating. Furnace Shutdown 1.
Only small variations in gas pressure should be made by adjusting the gas valve pressure regulator. The manifold pressure must be measured with the burners operating. To measure and adjust the manifold pressure, use the following procedure. 1. Turn OFF gas to furnace at the manual gas shutoff valve external to the furnace. 2. Turn off all electrical power to the system. 3.
3. If the 1/2 cu. ft. dial was used, multiply your number by two. EXAMPLE: If it takes23 seconds to complete one revolution of the 1/2 ft. dial (23 x 2 = 46). SUPPLY AIR This tells us that at this rate, it would take 46 seconds to consume one cu. ft. of gas. 3600 / 46 = 78. This tells us that in one hour, the furnace would consume 78 cu. ft. of gas. The typical value range for 1 cu. ft. of natural gas is around 1000 BTU. Check with your gas utility, if possible.
Operational Checks The burner flames should be inspected with the burner compartment 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 of the heat exchanger firing tubes. • Igniter warm up begins upon Inducer draft blower step to low speed and presence of closed low stage pressure switch contacts.
Flame Sensor The flame sensor is a probe mounted to the burner/ manifold assembly which uses the principle of flame rectification to determine the presence or absence of flame. Diagnostic Chart WARNING High voltage! To avoid personal injury or death due to electrical shock, disconnect electrical power BEFORE performing any service or maintenance. Refer to the Troubleshooting Chart in the back of this manual for assistance in determining the source of unit operational problems.
MAINTENANCE Induced Draft and Circulator Blowers Annual Inspection CAUTION WARNING To ensure proper unit performance, adhere to the filter sizes given in the recommended To avoid electrical shock, injury or death, disconnect electrical power before performing any maintenance. If you must handle the igniter, handle with care. Touching the igniter element with bare fingers, minimum filter size table or specification sheet applicable to your model.
REPAIR AND REPLACEMENT PARTS • When ordering any of the listed functional parts, be • • sure to provide the furnace model, manufacturing, and serial numbers with the order. Although only functional parts are shown in the parts list, all sheet metal parts, doors, etc. may be ordered by description. Parts are available from your distributor.
Menu Options LED Display St tt CAP CP CdL Menu Description LED Display Enable or disable inverter boost operation. (compressor speed may increase when this feature is on) (inverter only) Boost mode will operate above this selected temperature. On = boost mode always on (default = 105°F) (inverter only) Cooling Airflow Profile setting (default = profile D shown as 4) Heat Pump compressor lockout temperature. Furnace will act as primary heat source below this temperature.
Status Codes LED Display Description of System Status 1AC Compressor Cooling, Low Stage (non-communicating units) 2AC Compressor Cooling, High Stage (non-communicating units) 1AC Compressor Heat, Low Stage (non-communicating units) 2AC Compressor Heat, High Stage (non-communicating units) AC Compressor Cooling, Single-Stage (single stage non-comm.
Troubleshooting Chart Symptom LED Status d0 IdL None Corrective Actions Equipment lacks shared data Populate shared data set using memory card Normal operation None No 115 power to furnace or no 24 volt power to integrated control module Furnace fails to operate Integrated control module LED display provides no signal Fault Description Blown fuse or tripped circuit breaker Restore high voltage power to furnace and integrated control module. Replace non-functional integrated control module.
Troubleshooting Chart Symptom LED Status Fault Description Corrective Actions Check filters for blockage, clean filters or remove obstruction Furnace operates at reduced performance or operates on low stage when high stage is expected E9 Airflow is lower than demanded Check ductwork for blockage, remove obstruction and verify all registers are fully open Verify ductwork is appropriately sized for system, resize and/or replace ductwork if necessary Furnace fails to operate E10 Grounding fault Poor
Troubleshooting Chart Symptom LED Status Fault Description Flame sensed with no call for heat Induced draft blower and circulator blower runs continuously EE Short to ground in flame sense circuit Lingering burner flame No furnace operation Corrective Actions Correct short at flame sensor or in flame sensor wiring Check for lingering or lazy flame Verify proper operation of gas valve Slow closing gas valve No furnace operation Normal furnace operation Furnace fails to operate Furnace fails to o
Troubleshooting Chart Symptom LED Status Fault Description Corrective Actions Check filters and ductwork for blockage, clean filters or remove obstruction Furnace fails to operate EED Aux limit switch open (blower compartment) Check circulator blower speed and performance, correct speed or replace blower motor if necessary Tighten or correct wiring connection Furnace fails to operate EEF Aux switch (condensate switch) open 53 Check evaporator drain pan, trap, piping
Wiring Diagrams HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. GN GND OR GY 2 1 YL HIGH FIRE PRESSURE SWITCH OR LOW FIRE PRESSURE SWITCH C NO OPT. HUM.
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