INSTALLATION INSTRUCTIONS FOR *CVC96 & *MVC96 TWO-STAGE GAS FURNACE ONLY PERSONNEL THAT HAVE BEEN TRAINED TO INSTALL, ADJUST, SERVICE OR REPAIR ( HEREINAFTER, “SERVICE”) THE EQUIPMENT SPECIFIED IN THIS MANUAL SHOULD SERVICE THE EQUIPMENT.
BLOWER HEAT OFF DELAY TIMINGS .............................. 40 COMFORTNET™ SYSTEM................................................40 OVERVIEW ..................................................... 40 AIRFLOW CONSIDERATION ........................................ 40 FOSSIL FUEL APPLICATIONS ....................................... 41 SIDE WALL VENT KIT .................................................. 18 CONDENSATE DRAIN LINES & DRAIN TRAP .........................19 GENERAL DRAIN INFORMATION ..............
SAFETY CONSIDERATIONS WARNING 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. TO PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE, REFER TO THIS MANUAL.
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.
• TO THE INSTALLER Before installing this unit, please read this manual thoroughly to familiarize yourself with specific items which must be adhered to, including but not limited to: unit maximum external static pressure, gas pressures, BTU input rating, proper electrical connections, circulating air temperature rise, minimum or maximum CFM, and motor speed connections.
To ensure proper furnace operation, install, operate and maintain the furnace in accordance with these installation and operation instructions, all local building codes and ordinances. In their absence, follow the latest edition of the National Fuel Gas Code (NFPA 54/ANSI Z223.1), and/or CAN/CSA B149.1-15 Installation Codes, local plumbing or waste water codes, and other applicable codes. A copy of the National Fuel Gas Code (NFPA 54/ANSI Z223.
• • • • • • • 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. 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.
9. After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous conditions of use. input rating. Refer to Specification Sheet applicable to your model for minimum clearances to combustible surfaces.
FRONT COVER PRESSURE SWITCH TUBE LOCATION If this furnace is to be installed in the same space with other gas appliances, such as a water heater, ensure there is an adequate supply of combustion and ventilation air for the other appliances. Refer to the latest edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1 or CAN/CSA B149.1-15 Installation Codes or applicable provisions of the local building codes for determining the combustion air requirements for the appliances.
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 OPERATION. ALL CONVERSIONS MUST BE PERFORMED BY A QUALIFIED INSTALLER OR SERVICE AGENCY.
MATERIALS AND JOINING METHODS takes place. Because of the relatively low flue gas temperature and water condensation requirements, PVC or ABS are typically used venting and intake pipe materials. In Canada ABS is not an approved vent pipe material but it is permissable to use as combustion air pipe material. Two-three-inch nominal diameter PVC Schedule 40 pipe meeting ASTM D1785, PVC primer meeting ASTM F656, and PVC solvent cement meeting ASTM D2564 specifications must be used.
Piping must be adequately secured and supported to prohibit sagging, joint separation, and/or detachment from the furnace. Horizontal runs of vent/flue piping must be supported every three to five feet and must maintain a 1/4 inch per foot downward slope, back towards the furnace, to properly return condensate to the furnace’s drain system. Allowances should be made for minor expansion and contraction due to temperature variations.
• • • • • The vent termination of a non-direct vent application must terminate at least 4 feet below, 4 feet horizontally from, or 1 foot above any door, window, or gravity air inlet into any building. 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).
VENT-DRAIN Figure 9B NOTE: For non-direct vent installations, a minimum of one 90° elbow should be installed on the combustion air intake coupling to guard against inadvertent blockage. WARNING COMBUSTION AIR PIPE THE RUBBER ELBOW IS NOT DESIGNED TO SUPPORT A LOAD.
4. Remove plastic plug in line with the inducer outlet 5. Install cut end of the flanged section and connect to inducer with rubber coupling supplied with furnace. 6. Install screws removed in step 1 securing flange to cabinet. NON-DIRECT VENT (SINGLE PIPE) PIPING 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.
DOWN VENTING UPFLOW MODEL FURNACES ONLY Use alternate vent & combination air locations 6’ MAX. Vent Pipe r Floo Combustion Air Pipe Both Pipes Terminated Outside Structure Field Supplied Drain Tee on Vent Pipe 1/4” per foot min. slope ce lspa w a r /C ent m e s Ba 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 to prevent separation and flue gas leaks.
VENT/FLUE PIPE TERMINATIONS 12" MIN. 6” MAX VENT/FLUE TEE (OPTIONAL) or 45° ELBOW TURNED DOWN or 90° ELBOW TURNED DOWN 4” MIN 90º OR 45° ELBOW 12" MIN. ABOVE HIGHEST ANTICIPATED SNOW LEVEL 12" MIN.
VENT/INTAKE TERMINATIONS FOR INSTALLATION OF MULTIPLE DIRECT VENT FURNACES 90° ELBOWS 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.
CONDENSATE DRAIN LINES & DRAIN TRAP box to prevent air conditioning condensate from backing up into the furnace if the common drain was blocked. A condensing gas furnace achieves its high level of efficiency by extracting heat from the products of combustion to the point where condensation takes place. The condensate must be collected in the furnace drain trap and routed to an appropriate drain location in compliance with local and national codes.
UPFLOW MODEL INSTALLED HORIZONTALLY DOWN WITH RIGHT SIDE Minimum 5 ½" clearance is required for the drain trap beneath the furnace. Hose #1 Hose #2 45 degree barb-pipe adapter 45 degree barb-pipe adapter Hose #11 Hose #2 Figure 24 Installer selects right or left side drain and installs this hose accordingly. 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.
UPFLOW MODEL INSTALLED HORIZONTALLY WITH LEFT SIDE DOWN - ALTERNATE * Also see Front Cover Pressure Switch Tube Location on page 9. Insert flange. Cut 2 ½” long. RF000142 Hose #6 Hose #5 Hose #11 Figure 25 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. Remove the two plugs from the left side of the cabinet and install them in the blower deck. 5.
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. (Draining the Collector Box) Insert non-grommet end of hose #9 into the cabinet front drain hole and secure on collector box drain port with a silver clamp. 5.
4. (Draining the Vent Elbow) Insert the straight barbed coupling into the vent – drain elbow drip leg and secure with a red clamp. 5. From outside the cabinet, insert the non-grommet end of hose #8 into the front cabinet drain hole and secure on the vent - drain elbow barb fitting using a red clamp. 6. Using the two sheet metal screws provided in the cabinet, secure the trap to the furnace. 7.
115 VOLT LINE CONNECTIONS 3. Relocate junction box and associated plugs and grommets to opposite side panel. Secure with screws removed in step 2. Before proceeding with electrical connections, ensure that the supply voltage, frequency, and phase correspond to that specified on the unit rating plate. Power supply to the furnace must be NEC Class 1, and must comply with all applicable codes.
To use a single-stage thermostat, turn off 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.
Once the switch is set, the dehumidify function is enabled during a combination call for cooling (T-Stat) and dehumidification (DEHUM-Stat). FOSSIL FUEL APPLICATIONS This furnace can be used in conjunction with a heat pump in a fossil fuel application. A fossil fuel application refers to a combined gas furnace and heat pump installation which uses an outdoor temperature sensor to determine the most cost efficient means of heating (heat pump or gas furnace).
HUM-IN and HUM-OUT. Similar to the HUM terminal, when utilizing legacy connections, this relay will be closed during normal heating operation. HUM IN must be powered with the desired voltage (24 vac from the R terminal or 115 vac from L1 terminal). The internal relay will close during a call for heat. Also, the control can provide additional humidification features when wired to a communicating thermostat (1, 2, R, C connections).
GAS PIPING CONNECTIONS amount of air into the burner. This may cause incomplete combustion, flashback, and possible yellow tipping. Natural Gas Capacity of Pipe In Cubic Feet of Gas Per Hour (CFH) Nominal Black Pipe Size In some areas the gas supplier may artificially derate the gas in an effort to compensate for the effects of altitude. If the gas is artificially derated, the appropriate orifice size must be determined based upon the BTU/ft3 content of the derated gas and the altitude.
• Always use a back-up wrench when making the connection • Alternate Gas Line Location to the gas valve to keep it from turning. The orientation of the gas valve on the manifold must be maintained as shipped from the factory. Maximum torque for the gas valve connection is 375 in-lbs; excessive over-tightening may damage the gas valve. Install a manual shutoff valve between the gas meter and unit within six feet of the unit.
Disconnect this unit and shutoff valve from the gas supply piping system before pressure testing the supply piping system with pressures in excess of 1/2 psig (3.48 kPa). Manual Shut Off Valve (upstream from ground joint pipe union) Isolate this unit from the gas supply piping system by closing its external manual gas shutoff valve before pressure testing supply piping system with test pressures equal to or less than 1/2 psig (3.48 kPA).
Complete information regarding tank sizing for vaporization, recommended regulator settings, and pipe sizing is available from most regulator manufacturers and propane gas suppliers. To determine total external duct static pressure, proceed as follows; 1. With clean filters in the furnace, use a draft gauge (inclined manometer) to measure the static pressure of the return duct at the inlet of the furnace.
FILTERS - READ THIS SECTION BEFORE INSTALLING THE RETURN AIR DUCT WORK CUT USING TIN SNIPS PRESS OUT BY HAND CUT FOUR CORNERS AFTER REMOVING SHEET METAL SCRIBE LINES OUTLINING DUCT FLANGES Duct Flange Cut Outs Figure 43 Filters must be used with this furnace. Discuss filter maintenance with the building owner. Filters do not ship with this furnace, but must be provided, sized and installed externally by the installer. Filters must comply with UL900 or CAN/ULCS111 standards.
Clean Comfort™ brand MERV 11 air cleaners have 5¼” media filters and are available in the following configurations. Consult your distributor for information on our complete line of IAQ Clean Comfort™ products. The following figure shows possible filter locations.
5. Move the furnace gas valve manual control to the OFF position. 6. Wait five minutes then smell for gas. Be sure check near the floor as some types of gas are heavier than air. 7. If you smell gas after five minutes, immediately follow the safety instructions in the Safety Considerations on page 3 of this manual. If you do not smell gas after five minutes, move the furnace gas valve manual control to the ON position. 8. Replace the burner compartment door. 9.
6. During test mode, if both push buttons are pressed for greater than 1 second, the display will blank to indicate push buttons are pressed. If both push buttons are released within 5 seconds, the test mode will terminate and the system will return to normal operation. Otherwise, the test mode will continue uninterrupted. Common Terminal(C) High Fire Coil Terminal (HI) Manometer Hose Open to Atmosphere Low Fire Coil Terminal (LO) i 7.
6. Turn on power and close thermostat “R” and “W1” contacts to provide a call for low stage heat. 7. Measure the gas manifold pressure with burners firing. Adjust manifold pressure using the Manifold Gas Pressure table shown below. 8. Remove regulator cover screw from the low (LO) outlet pressure regulator adjust tower and turn screw clockwise to increase pressure or counterclockwise to decrease pressure. Replace regulator cover screw. 9.
This tells us that in one hour, the furnace would consume 78 cu. ft. of gas. Using a leak detection The typical value range for 1 cu. ft. of natural gas is around 1000 BTU. Check with your gas utility, if possible. In this example, the furnace is consuming 78,000 BTUH. Gas Line Gas Shutoff Valve NOTE: The final manifold pressure cannot vary by more than ± 0.3” w.c. for Natural and + 0.5” for LP from the specified setting. Consult your local gas supplier if additional input rate adjustment is required.
CIRCULATOR BLOWER SPEEDS The cooling system manufacturer’s instructions must be checked for required air flow. Any electronic air cleaners or other devices may require specific air flows, consult installation instructions of those devices for requirements. WARNING TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK, TURN OFF POWER TO THE FURNACE BEFORE CHANGING SPEED TAPS. 3.
• Profile A provides only an OFF delay of one (1) minute at 100% of the cooling demand airflow. Model 100% CFM 100% CFM OFF OFF *MVC960403BN* 1 min Figure 50 • 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.
In general lower heating speeds will: reduce electrical consumption, lower operating sound levels of the blower, and increase the outlet air temperature delivered to the home. The speeds available allow the blower performance to be optimized for the particular homeowner’s needs. In a ComfortNet system, the indoor unit, outdoor unit, and thermostat comprising a ComfortNet system “communicate” digitally with one another, creating a two-way communications path.
demand and transmits the demand along with a fan request to the indoor unit. The indoor unit then sends the demand to the ECM motor. The table below lists the various ComfortNet systems, the operating mode, and airflow demand source. For example, assume the system is an air conditioner matched with a furnace. With a call for low stage cooling, the air conditioner will calculate the system’s low stage cooling airflow demand.
COMFORTNET™ COMPATIBLE FURNACE WITH NON-COMFORTNET COMPATIBLE SINGLE-STAGE AIR CONDITIONER Four wires are required between the furnace and thermostat. Two wires are required between the furnace control and single stage air conditioner. For this system configuration, the “Y1” terminal on the integrated furnace control becomes an output rather than an input. The “Y1” connection to the outdoor unit is made using both 4-position thermostat connectors in the CTK0* kit.
Furnace Advanced Features Menus (accessed through the communicating thermostat) SET-UP Subm e nu Ite m Heat Airflow Trim (HT TRM) Heat ON Delay (HT ON Use r Modifia ble Options -10% to +10% in 2% increments, default is 0% 5, 10, 15, 20, 25, or 30 seconds, default is 30 seconds Com m e nts Trims the heating airflow by the selected amount.
SET-UP Subm e nu Ite m Heat Airflow Trim (HT TRM) Heat ON Delay (HT ON Use r Modifia ble Options -10% to +10% in 2% increments, default is 0% 5, 10, 15, 20, 25, or 30 seconds, default is 30 seconds Com m e nts Trims the heating airflow by the selected amount.
THERMOSTAT MENU The ComfortNet™ system is a fully communicating system, and thus, constitutes a network. Occasionally the need to troubleshoot the network may arise. The integrated furnace control has some on-board tools that may be used to troubleshoot the network. These tools are: red communications LED, green receive (Rx) LED, and learn button. • Red communications LED - Indicates the status of the network. The table below indicates the LED status and the corresponding potential problem.
• • All faults in the history will have been cleared, and display returns to ON. If the button is held for longer than 10 seconds, the display will return to ON and the faults will not be cleared. • NORMAL SEQUENCE OF OPERATION POWER UP • The normal power up sequence is as follows: • 115 VAC power applied to furnace. • Integrated control module performs internal checks. • Integrated control module displays 8 8 on dual 7segment display LED’s.
• • • AUXILIARY LIMIT Furnace is now operating on the specified stage called for by the two-stage thermostat. Furnace runs, integrated control module monitors safety circuits continuously. If the two-stage thermostat changes the call from low heat to high heat, the integrated control module will immediately switch the induced draft blower, gas valve, and circulator blower to their high stage settings.
MAINTENANCE 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 furnace away from the control. Any tools held in a person’s hand during grounding will be discharged. 3. Service integrated control module or connecting wiring following the discharge process in step 2.
HORIZONTAL UNIT FILTER REMOVAL FLUE PASSAGES (QUALIFIED SERVICER ONLY) Filters in horizontal installations are located in the central return register or the ductwork near the furnace. The heat exchanger flue passageways should be inspected at the beginning of each heating season. To remove: 1. Turn OFF electrical power to furnace. 2. Remove filter(s) from the central return register or ductwork. 3. Replace filter(s) by reversing the procedure for removal. 4. Turn ON electrical power to furnace.
DIP SWITCHES Switch Bank Dip Switch Purpose Function 90 Off Off Heating Off 120 On Off Delay 150 Off On 180 On On S1 Thermostat Setup Cooling Airflow S3 1 2 Ramping Profile S4 Heating Airflow Dehum Trim S5 Continuous Fan 4 2 Stage Stat On On 1 Stg Stat 5 min delay Off Off 1 Stg Stat auto delay Off On Off Off Minus 5% On Off Add 10% Off On Minus 10% On On A Off Off B On Off C Off On D On On 25% Off Off 50% On Off 75% Off On 100% On On A Off
STATUS CODES INTERNAL CONTROL FAULT/NO POWER O n 0 NORMAL OPERATION LOCKOUT DUE TO EXCESSIVE RETRIES E 1 E 2 LOW STAGE PRESSURE SWITCH STUCK CLOSED AT START OF HEATING CYCLE E E E E OPEN HIGH LIMIT SWITCH 3 4 5 6 LOW STAGE PRESSURE SWITCH STUCK OPEN FLAME DETECTED WHEN NO FLAME SHOULD BE PRESENT OPEN FUSE LOW FLAME SIGNAL E 7 IGNITER FAULT OR IMPROPER GROUNDING E 8 HIGH STAGE PRESSURE SWITCH STUCK CLOSED AT START OF HEATING CYCLE E E E d d b b b b b HIGH STAGE PRESSURE SWITCH STUCK OPEN 9 A
TROUBLESHOOTING CHART Symptoms of Abnormal Diagnostic/ Operation (Legacy & Status LED ComfortNet™ Thermostat) Codes Fault Description ComfortNet™ Thermostat Only Message Code INTERNAL FAULT EE Possible Causes Corrective Actions Notes & Cautions • Manual disconnect switch OFF, door switch open or 24 volt wire improperly connected or loose • Blown fuse or circuit breaker • Integrated control module has an internal fault • Assure 115 and 24 volt power to furnace and integrated control module.
TROUBLESHOOTING CHART Symptoms of Abnormal Operation (Legacy & ComfortNet™ Thermostat) Diagnostic/ Status LED Codes Fault Description ComfortNet™ Thermostat Only Message Code Possible Causes Corrective Actions Notes & Cautions • Induced draft blower runs continuously with no further furnace operation. • Integrated control module LED display provides E2 error code. • ComfortNet™ thermostat “Call for Service” icon illuminated. • ComfortNet™ thermostat scrolls “Check Furnace” message.
TROUBLESHOOTING CHART Symptoms of Abnormal Operation (Legacy & ComfortNet™ Thermostat) Diagnostic/ Status LED Codes Fault Description ComfortNet™ Thermostat Only Possible Causes Message Code IGNITER FAULT E7 • Improperly connected igniter. • Shorted igniter. • Poor unit ground. • Igniter relay fault on integrated control module. Corrective Actions • Check and correct wiring from integrated control module to igniter. • Replace shorted igniter. • Check and correct unit ground wiring.
TROUBLESHOOTING CHART Symptoms of Abnormal Diagnostic/ Operation (Legacy Status LED Fault Description & ComfortNet™ Codes Thermostat) ComfortNet™ Thermostat Only Message Code Possible Causes Corrective Actions Notes & Cautions • Operation different than expected or no operation. • Integrated control module LED display provides d4 error code. • ComfortNet™ thermostat “Call for Service” icon illuminated. • ComfortNet™ thermostat scrolls “Check Furnace” message. d4 • Invalid memory card data.
TROUBLESHOOTING CHART Symptoms of Abnormal Diagnostic/ Operation (Legacy Status LED Fault Description & ComfortNet™ Codes Thermostat) • Furnace fails to operate. • Integrated control module LED display provides b4 error code. • ComfortNet™ thermostat “Call for Service” icon illuminated. • ComfortNet™ thermostat scrolls “Check Furnace” message. b4 • Furnace fails to operate. • Integrated control module LED display provides b5 error code. • ComfortNet™ thermostat “Call for Service” icon illuminated.
WIRING DIAGRAM TO 115 VAC/ 1 Ø /60 HZ POWER SUPPLY WITH OVERCURRENT PROTECTION DEVICE GND HI 3 C 2 PM C NO NO FLAME SENSOR C GY FRONT COVER PRESSURE SWITCH AUTO RESET PRIMARY LIMIT CONTROL PU 1 9 4 5 6 1 2 3 WH/PU T-STAT 24 VAC 115 VAC GY GY FUSE FLAME SENSOR 115 VAC TO +VDC TH (4) 24 VAC AUTO RESET PRIMARY AUTO RESET AUXILIARY LIMIT LIMIT CONTROL CONTROLS HLO (10) Y1 PSO (7) W1 NO W2 Y2 TO MICRO HIGH FIRE PRESS.
SPECIAL INSTRUCTIONS FOR PRODUCTS INSTALLED IN THE STATE OF MASSACHUSETTS 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 termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied: V
THIS PAGE LEFT BLANK INTENTIONALLY.
CUSTOMER FEEDBACK We are very interested in all product comments. Please fill out the feedback form on one of the following links: Goodman® Brand Products: (http://www.goodmanmfg.com/about/contact-us). Amana® Brand Products: (http://www.amana-hac.com/about-us/contact-us). You can also scan the QR code on the right for the product brand you purchased to be directed to the feedback page. PRODUCT REGISTRATION Thank you for your recent purchase.
