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Service Manual - Alpine Home Air Products

1. e 4110100040040 Bari 5 ld z EA Minus 1096 0 Trim Adjust 90 Seconds 120 Seconds 150 Seconds 180 Seconds 1 Stage Stat 2 Stage Stat Compressor 2 Stage Compressor Db ON EE __ O Trim Adjust NIE Plusto Continuous T Stat Heat Compressor Pull Down Indicates factory setting Communicating thermostats are used only with Bias Pull Up Pull Down dip switches Not applicable OPERATION In continuous fan mode the CTKO thermostat provides the airflow demand The CTK02 CTK03 and 4 thermo stats may be configured for one of threecontinuous fan speed settings allow for 25 50 or 75 airflow based on the furnaces maximum airflow capability During continuous fan operation the thermostat sends a fan request along with the continuous fan demand to the furnace The fur nace in turn sends the demand to the ECM motor The ECM motor deliversthe requested continuous fan airflow FossiL FUEL APPLICATIONS This furnace can be used in conjunction with ComfortNet compatible heat pump in fossil fuel application A fossil fuel application refers to a combined gas furnace and heat pump installation which uses an
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5. INDOOR AIR BLOWER CIRCULATOR 6 COMPARTMENT BLWR DOOR SWITCH OPEN WHEN i ol INTEGRATED INTROL CIRCULATOR BLOWER INDUCTOR COIL MODULE SOME MODELS NOTES LOW VOLTAGE FIELD 1 SET HEAT ANTICIPATOR ON ROOM THERMOSTAT AT 0 7 AMPS COLOR CODES MANUFACTURER S SPECIFIED REPLACEMENT PARTS MUST LOW VOLTAGE 24V USED WHEN SERVICING BROW IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE BET FURNACE MUST BE REPLACED IT MUST BE REPLACED WITH OV CRAY WIRING MATERIAL HAVING A TEMPERATURE RATING OF AT DEED HI VOLTAGE FIELD LEAST 105 USE COPPER CONDUCTORS ONLY RI UNIT MUST BE PERMANENTLY GROUNDED AND CONFORM TO YL YELLOW OR ORANGE JUNCTION N E C AND LOCAL CODES PU PURPLE IGNITER TO RECALL THE LAST 10 FAULTS MOST RECENT TO LEAST TERMINAL RECENT DEPRESS SWITCH FOR MORE THAN 2 SECONDS GR GREEN WHILE IN STANDBY NO THERMOSTAT INPUTS ERBEACK INTERNAL TO SWITCH PRESSURE INTEGRATED CONTROL OVERCURRENT 0140F02013 A PLUG CONNECTION PROT DEVICE FIELD GND HI VOLTAGE 115V FIELD SPLICE SWITCH TEMP Wiring is subject to change Always refer to the wiring diagram on the unit for the most up to date wiring 67
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8. 1 e SMAS 10 VEISOUN SN HOJUON ay uo 4 8 1 uonrpuoo Jopun epoo 10119 94 medar SI 9IBUINJ QUI 0 MOT SITOA 10 10 UMOP sjnus ox3uoo 0 Joud 440 19MOd UML e ja JYI e3ej oA OV USIH 94 YOLOW 10 0 JOMOT e 54 0 s rej ooeumnq K1essooou 10 y eSessour ed juourooe do1 J030UI pU 3jeus 15945 S 0JoS jejsourreq 3 1991109 UJIM OOUM oov dow e 1 JII Pereurumqr ed 1 Kiessooou sduuvoq 99IAIoS 1991109 e 4 1 1 71 oArnnoosuoo 2p09 10119 Gq soprAo1d pue suononnsqo Sursnoq YOLOY OI HEIS 03 1 _ Kejds p 0 Jord 440 1o od UML e 10 1 12940 ur 90 sq Q2 JOJOUI
9. 55 530 CHECKING FLAME ROLLOUT 56 5 313 INDUCED DRAFT BLOWER 56 CHECKING MODULATING GAS VALVE 56 314 CHECKING INDUCTOR 2 56 CHECKING MAIN BURNERS 57 CHECKING ORIFICES usan ettet 57 CHECKING GAS PRESSURE 57 CHECKING HOT SURFACE 58 CHECKING FOR FLASHBACK 58 CHECKING PRESSURE CONTROL 58 HIGH ALTITUDE APPLICATION 59 CHECKING FOR DELAYED IGNITION 59 CHECKING INTEGRATED IGNITION CONTROL BOARDS tinte Pe t n etes 59 CHECKING FLAME SENSOR 60 53 SERVICING S 1 CHECKING VOLTAGE warnine HIGH VOLTAGE Disconnect ALL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH 1 Remove the blower door to gain entry to the J unction Box 2 Remove cover from the J unction Box and gain access to incoming power lines With Power ON WARNING 3 Using a voltmeter measure the voltage across the hot and neutral connections Line voltage should measure 115 10 Measure from black hot to ground should also read 115 volts 10 Measuring from white neu tral to ground should read 0 volts NO
10. Modulating Furnace Pneumatic Tubing Diagram Upflow Model Shown For representation only Actual unit may vary in appearance S 311 HIGH ALTITUDE APPLICATION Modulating furnaces are approved up to 10 000 ft al titude No kit or changes are needed S 312 CHECKING FOR DELAYED IGNITION Delayed ignition is a delay in lighting a combustible mix ture of gas and air which has accumulated in the combus tion chamber When the mixture does ignite it may explode and or rollout causing burning in the burner venturi If delayed ignition should occur the following should be checked 1 Improper gas pressure adjust to proper pressure See S 307 CHECKING GAS PRESSURE 2 Improper burner positioning burners should be in locating slots level front to rear and left to right 3 Carry over lighter tube or cross lighter obstructed clean 4 Main burner orifice s deformed or out of alignment to burner replace S 313 CHECKING TROL BOARDS NOTE Failure to earth ground the furnace reversing the neutral and hot wire connection to the line polarity or a high resistance connection in the neutral line may cause the control to lockout due to failure to sense flame INTEGRATED IGNITION CON To AVOID THE RISK OF ELECTRICAL SHOCK WIRING TO THE UNIT MUST BE PROPERLY POLARIZED AND GROUNDED DISCONNECT POWER BEFORE PERFORMING SERVICE LISTED BELOW The ground wire must run from the furnace all the way back to the electrica
11. Piping must be adequately secured and supported to prohibit sagging joint separation and or detachment from the fur nace Horizontal runs of vent flue piping must be supported every three to five feet and must maintain 1 4 inch per foot downward slope back towards the furnace to properly return condensate to the furnace s drain system 21 PRODUCT DESIGN PREFERRED TRANSITION MADE IN VERTICAL SECTION OF PIPE ACCEPTABLE oe e 2 NS TRANSITION NO LESS 45 DEGREES HORIZONTAL PLANE TO AVOID CREATING WATER TRAP IN VENT PIPING NO TRANSITION ON HORIZONTAL PLANE THIS CREATES WATER TRAP AND RESTRICTS GASES 22 MVM97 CVM97 Direct Vent 2 Pipe and Non Direct Vent 1 Pipe Maximum Allowable Length of Vent Flue Pipe amp Combustion Air Pipe ft gue 3 5 Unit Pipe Size Number of Elbows 1 2 3 4 5 6 7 8 Btu Hy 60 000 2 250 245 240 235 230 225 220 215 210 or2 1 2 2 80 000 250 245 240 235 230 225 220 215 210 or2 1 2 80 000 3 250 243 236 229 222 215 208 201 194 2 100 000 90 85 80 75 70 65 60 55 50 or2 1 2 100 000 3 250 243 236 229 222 215 208 201 194 2 120 000 75 70 65 60 55 50 45 40 35 or2 1 2 120 000 3 220 213 206 199 192 185 178 171 164 Maximum allow
12. D 24 1 2 MINOR REVISION NOMINAL INPUT A Initial Release 060 60 000 Btuh 080 80 000 Btuh 100 100 000 Btuh 120 120 000 Btuh ADDITIONAL FEATURES SUPPLY TYPE N Natural Gas M Upflow Horizontal X Low NOx C Downflow Horizontal AFUE 97 97 AIRFLOW CAPABILITY 0 5 ESP 3 1200 4 1600 5 2000 COMMUNICATION FEATURE M Modulating Furnace 4 Wire Communication Ready PRODUCT MODEL 7 Equiprrent Heating Stages Cooling Stages Control Type Blower Motor Type 7 Installation Positions BTUH Input Range X 1000 A C Capable Tons Cabinet Hight Cabinet Width Heating 100 Firing Rate ECM Motor H P Draft Inducer Gas Valve 24 Heating Inputs 24 Cooling Inputs Primary Heat Exchanger Accessory Terminals Gas Line Entry Revision Attributes MODEL 97 Equiprrent Type Cooling Stages Control Type Blower Motor Type 97 Installation Positions BTUH Input Range 1000 A C Capable Tons Cabinet Hight Cabinet Width Heating 100 Firing Rate ECM Motor HP Draft Inducer Gas Valve 24 Heating I nputs 24 VAC Cooling I nputs Primary Heat Exchanger Accessory Terminals Gas Line Entry Revision Attributes IDENTIFICATION REV AA Amana Brand Residential Gas Furnace Modulating 35 100 of rated input Two ClimateTalk or Conventional 24 Volt 4 Wire Variable Speed ECM 0603BN
13. DCVK 30 are also known as CVENT 2 amp 3 10 See the section in this manual under Vent Flue and Com bustion Air Pipe Terminations for more information or consult the Installation and Operating Instructions 10 619 Vent Maintain 12 18 for Canada minimum KR dos above highest anticipated snow level Maximum of 24 above roof gt fo Combustion Air il Roof Boot Flashing Field Supplied pn 2555950 Support Field Supplied 45 Elbow L 1 ___ Field Supplied Vent gt 4 Combustion Air LO DCVK Vertical Installation ACCESSORIES SIDE WALL VENT KIT 0170K000005 This side wall only vent kit 0170 000005 is to be used with 2 3 vent systems This kit is NOT intended for use with single pipe non direct vent installations The vent kit must terminate outside the structure and may be installed with the intake and exhaust pipes located side by side or with one pipe above the other See the section in this manual under Vent Flue and Com bustion Air Pipe Terminations for more information or consult the Installation Instructions 10 635 SIDE WALL VENT KIT 0170K00001S This side wall only vent kit 0170K00001S is to be used with 2 vent systems This kit is NOT intended for use with single pipe non direct vent installations The vent kit must terminate outside the structure and may be installed with the inta
14. modulating counter flow furnace PRODUCT IDENTIFICATION MODEL N A DESCRIPTION Fossil Fuel Kit The AFE18 60A control is designed for use where the indoor coil is located above downstream of a gas orfossil fuel furnace when used with a heat pump It will operate with single and two stage heat pumps and single and two stage furnaces The AFE18 60A control will turn the heat pump unit off when the furnace is turned on An anti short cycle feature initiates a 3 minute timed off delay when the compressor goes off P1251305F P1251306F P1251307F P1251308F N A Media Air Cleaner For use with current architectural grey Goodman and Amana Brand 96 variable speed modulating furnace models The Amana AMU and Goodman GMU Media Air Cleaner is a high efficiency air filtration device designed to remove dirt dust pollen and other microscopic particles from the air passing through it Flexible performance range up to 2 000 CFM capacity The air cleaner should be installed in the system so that all the system air is circulated through the air cleaner The air cleaner will only remove the airborne contaminants delivered to it Maximum performance is obtained when the system blower is setfor continuous operation Carbon filters optional are available P1251301F P1251302F P1251303F P1251304F Electronic Air Cleaner For use with current architectural grey Goodman and Amana Brand 96 variable speed modulating furn
15. 0803BN O804CN 100504 1205DN UF Hor UR UF Hor L R UF Hor UR UF Hor L R UF 21 60 28 80 28 80 35 100 42 120 15 3 15 3 2 4 2 5 2 5 34 5 34 5 34 5 34 5 34 5 17 5 17 5 21 21 24 5 1059 1316 1337 1870 1940 3 Variable Speed 24 VAC Modulates by Pneurratic signal W1 W2 Y1 Y2 Stainless Steel EAC terminal HUM IN HUM OUT terminals Left or Right First revision of 34 5 modulating up flow furnace REVAA Goodman Brand Residential Gas Furnace Modulating 35 100 of rated input Two ClimateTalk or Conventional 24 Volt 4 Wire Variable Speed ECM 060384 080384 O804CN 1005041 1205DN UF Hor UR UF L R UF Hor UR UF Hor L R UF Hor 21 60 28 80 28 80 35 100 42 120 15 3 15 3 2 4 2 5 2 5 34 5 34 5 34 5 34 5 34 5 17 5 17 5 21 21 24 5 1059 1316 1337 1870 1940 3 Variable Speed 24 VAC Modulates by Pneumatic signal W1 W2 Y1 Y2 Alurrinized Steel EAC terminal HUM IN HUM OUT terminals Left or Right First revision of 34 5 modulating up flow furnace MODEL ACVM97 Equipment Type Heating Stages Cooling Stages Control Type Blower Motor Type ACVM97 Installation Positions BTUH Input Range X 1000 A C Capable Tons Cabinet Hight Cabinet Width Heating 100 Firing Rate ECM Motor H P Draft Inducer Gas Valve 24 VAC Heating Inputs 24 Cooling 1 nputs Primary Heat Exchanger Accessory Terminals Gas Line Entry Revision Attributes MODEL
16. 25 12 CIRCUIT CONNECTOR INTEGRATED FURNACE CONTROL AUX OUT LC AUX INLO AUX REMOVE FACTORY INSTALLED JUMPER TO USE WITH FLOAT SWITCH Accessories Wiring If it is necessary for the installer to supply additional line volt age wiring to the inside of the furnace the wiring must con form to all local codes and have a minimum temperature rating of 105 All line voltage wire splices must be made inside the furnace j unction box The integrated furnace control HUM dry contacts are closed whenever the inducer is energized in a non communicating installation When used with a CTK02 CTK03 or 4 communicating thermostat the HUM terminals are closed whenever there is a call for humidity The integrated control module electronic air cleaner terminals EAC are energized with 115 volts whenever the circulator blower is energized 24 HUMIDIFIER 24 volt humidifier can be powered by feeding one of the HUM terminals with a field installed wire from the termi nal or by connecting to the NO side of the low fire pressure switch Gas Supply and Piping The furnace rating plate includesthe approved furnace gas in put rating and gas types The furnace must be equipped to operate on the type of gas applied This includes any conver sion kits required for alternate fuels and or high altitude 28 caution TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE THE INLET GAS SU
17. 9 and 10 appropriately Refer to the DIP switch chart for switch positions and their corresponding taps Verify CFM by notingthe number displayed on the dual 7 segment LED display 6 The multi speed circulator blower also offers several custom ON OFF ramping profiles These profiles may be used to enhance cooling performance and increase comfort level The ramping profiles are selected us ing DIP switches 7 and 8 Refer to the following fig ure for switch positions and their corresponding taps Refer to the bullet points below for a description of each ramping profile Verify CFM by noting the num ber displayed on the dual 7 segment LED display 38 Profile A provides only an OFF delay of one 1 minute at 100 of the cooling demand airflow 100 4 100 CFM OFF OFF Cooling Demand ja 1 min Profile Brampsupto 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 pro vided 100 100 OFF 1min 50 OFF 4 1 2 ooling Demand Profile C ramps up to 85 of the full cooling demand air flow and operates there for approximately 7 1 2 minutes The motor then steps up tothe full demand airflow Profile C also has a one 1 minute 100
18. ACCESSIBILITY MVM97 MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS INCHES If placed on combustible floor floor MUST be wood only NOTES For servicing or cleaning a 24 front clearance is required Unit connections electrical flue and drain necessitate greater clearances than the minimum clearances listed above In all cases accessibility clearance must take precedence over clearances from the enclosure where accessibility clearances are greater CVM97 MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS INCHES FRONT POSITION Counterflow SIDES REAR BOTTOM NC FLUE Horizontal C If placed on combustible floor floor MUST be wood only NC For installation on non combustible floors only A combustible subbase must be used for installations on combustible flooring NOTES For servicing or cleaning a 24 front clearance is required Unit connections electrical flue and drain may necessitate greater clearances than the minimum clearances listed above In all cases accessibility clearance must take precedence over clearances from the enclosure where accessibility clearances are greater Installations must adhere to the clearances to combustible ma terials to which this furnace has been design certified The minimum clearance information for this furnace is provided on the unit s clearance label These clearances must be perma nently maintained Cle
19. AIR BE SUPPLIED INTO THE FURNACE AREA Improved construction and additional insulation in buildings have reduced heat loss by reducing air infiltration and escape around doors and windows These changes have helped in reducing heating cooling costs but have created a problem supplying combustion and ventilation air for gas fired and other fuel burning appliances Appliances that pull air out of the house clothes dryers exhaust fans fireplaces etc increase the problem by starving appliances for air House depressurization can cause back drafting or improper combustion of gas fired appliances thereby exposing building occupantsto gas combustion productsthat could include car bon monoxide 19 PRODUCT DESIGN 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 Installation Codes or applicable provisions of the local building codes for determining the combustion air requirements for the appli ances Most homes will require outside air be supplied to the furnace area by means of ventilation grilles or ducts connecting di rectly to the outdoors or spaces open to the outdoors such as attics or crawl spaces Installation Positions MVM97 models may be installed up flow or horizontally with
20. Furnace Components Heat Exchanger Assembly The primary heat exchanger is a tubular type constructed of high quality steel 409 stainless steel for Amana Brand aluminized for Goodman the heat exchanger assembly con sists of primary and secondary sections crimped together on a back transition plate The secondary heat exchanger is a single pass coil consisting of AL29 4C stainless steel tubes and aluminum fins These stainless steel tubes are expanded on to the aluminum fins to enhance heat trans fer Each tube in the secondary heat exchanger contains an internal turbulator to effectively scrub heat from the flue gases The primary and secondary heat exchanger sec tions are joined by a 441 stainless steel header plate Flue gas condensation takes place in the secondary heat ex changer as latent heat is transferred from the flue gasesto heat the conditioned space Burners Burners have been redesigned for 34 5 chassis furnaces Overall length and width dimensions remain the same as 40 model burners The burners used 34 5 models have burner head insert with larger diameter center hole and a larger number of surrounding holes New 34 5 Burner Depending on the size of the furnace each furnace will have from three to six inshot burners Burners are precisely con structed of aluminized steel and designed to provide proper ignition and flame stability Gas Manifold Assembly Each gas manifold isfitted with the appropriate number of 345
21. IOMMI e 5q 0 JO JOJUI 99BUIMJ JO oSexoo q Bessou SHIOMJONP SIO JPM SOS poxoo q suonrpuoo 8 quanno 8 sosuos uoor segexoo q J9MO Q e 9914195 10 E YEISOULIOY 39 NDHOJUIO 10 JO jo eSexoo q epoo 10119 q soprAo1d medos pue uiojs s 519151891 5 118 u ppns onbzoj Jo poeds ur 10101 JO 550 Y 95195 empour o33uoo 01 1008 440 Jomod UML e JOIE SIY YOoyO uoppns EULIOUGY F4 YOLOW 1 JOMOTG e 0 2180 9 9 0 Y E 0 0 eurrouq y 65 Status Codes NO POWER On NORMAL OPERATION INDICATES AIRFLOW FOLLOWED bo MOTOR NOT RUNNING b1 BLOWER COMMUNICATION ERROR b2 BLOWER MIS MATCH b3 BLOWER MOTOR OPERATING IN POWER TEMPERATURE OR SPEED LIMIT b4 BLOWER MOTOR CURRENT TRIP OR LOST ROTOR b5 BLOWER MOTOR LOCKED ROTOR bG BLOWER OVER UNDER VOLTA
22. Installation Code 2 In accordance with the current ANSI 2223 1 NFPA 54 National Fuel Gas Code t Avent shall not terminate directly above a sidewalk or paved driveway that is located between two single fanily dwellings and serves both dwellings Permitted only if veranda porch deck or balcony is fully open on a minimum of two sides beneath the floor For clearances not specified in ANSI 2223 1 NFPA 54 or CSA B149 1 the following statement shall be included Clearance in accordance wtih local installation codes and the requirements of the gas supplier and the manufacturer s installation instruction OTHER THAN DIRECT VENT TERMINAL CLEARANCES Canadian Installations 1 U S Installations 2 A Clearance above grade 12 in 30 cm 12 in 30 cm veranda porch deck or balcony See 1 24 6 i 9 b B Clearance to window or 6 in 15 cm for appliances 4 ft 1 2 m below or to side of door that may be opened C Clearance to permanently closed window D Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet 61 cm from the center line of the terminal E Clearance to unventilated soffit F Clearance to outside comer G Clearance to inside corner H Clearance to each side of center line extended above meter regulator assembly 10 000 Btuh 3 kW 12 in 30 cm for appliances gt 10 000 Btuh 3 kW and 100 000 Btuh 30 kW 36 in 91 cm for
23. MAY BE EXPOSED TO FREEZING TEM PERATURES AND WILL BE VACANT ANY HYDRONIC COIL UNITS SHOULD BE DRAINED AS WELL AND IN SUCH CASE ALTERNATIVE HEAT SOURCES SHOULD BE UTILIZED A WARNING TO PREVENT POSSIBLE PROPERTY DAMAGE PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK THE FURNACE MUST BE LOCATED TO PROTECT THE ELECTRICAL COMPONENTS FROM WATER DANGER PELIGRO CARBON MONOXIDE POISONING HAZARD Special Warning for Installation of Furnace or Air Handling Units in Enclosed Areas such as Garages Utility Rooms or Parking Areas Carbon monoxide producing devices such as an automobile space heater gas water heater etc should not be operated in enclosed areas such as unventilated garages utility rooms or parking areas because of the danger of carbon monoxide CO poisoning resulting from the exhaust emissions If a furnace or air handler is installed in an enclosed area such as a garage utility room or parking area and a carbon monoxide producing device is operated therein there must be adequate direct outside ventilation This ventilation is necessary to avoid the danger of CO poisoning which can occur if a carbon monoxide producing device continues to operate in the enclosed area Carbon monoxide emissions can be re circulated throughout the structure if the furnace or air handler is operating in any mode CO can cause serious illness including permanent brain damage or death B10259 216 RIESGO DE INTOXICACION POR M
24. MODULE AND MOTOR CAN THEN BE INSPECTED SEPARATELY The motor contains three windings of equal resistance 10 Resistance between windings is generally less than 10 ohms and will vary between models To take this read ing the ohm meter leads are placed in the wiring harness previously disconnected from the internal control unit con nector Inspect capacitors inside the control unit for bulging or swol len caps The end bell should be replaced if components appear swollen or bulging A functioning control unit should have a phase to phase resistance of greater than 100K be tween any two pins A separated control unit is shown be low To take this reading the ohm meter leads are placed in the end bell socket and not in the wiring harness 3 Wire Motor to Control Harness SS 3 Pin Connector sI amp e Y e UN a g Motor a Be ET Connector 7 gt A EE PUN Beyond basic visual checks and voltage resistance checks the Emerson ECM motor may be tested with an Emerson UltraCheck EZ diagnostic tool Goodman Part UTT 01 Thistool will test the motor windings and also the commu nicating module of the motor 47 SERVICE amp OPERATION Usinc THE Emerson ULTRACHECK EZ DiacNosric 48 Emerson Ultracheck EZ Diagnostic Tool Turn off power to the furnace being serviced and verify with a volt meter Disconnect the 4 wire communication cab
25. OFF delay 859 CFM 100 CFM 100 OFF 7 1 2 min 1 min __ Cooling Demand gt Profile Drampsup to 50 of the demand for 1 2 minute then ramps to 85 of the full cooling demand airflow and operatesthere for approximately 7 1 2 minutes The mo tor then steps up to the full demand airflow Profile D has a 1 2 minute at 50 airflow OFF delay 85 OFF 2 i 7 1 2 min Cooling Demand 100 CFM 50 CFM OFF 1 2 min 7 Select the heating speed for your model from the heating speed chart in the Specification Sheet The adjust set ting already established by the cooling speed selection determines which set of speeds available The selected speed must provide a temperature rise within the rise range listed with the particular model 8 Select the desired heating speed tap by positioning switches 3 and 4 appropriately Refer to figure above Verify CFM by noting the number displayed on the dual 7 segment LED display OPERATION In general lower heating speeds will reduce electrical consump tion 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 DIP SwitcHes There are 18 DIP switches on the modulating furnace IFC Switches are located in 3 rows ea
26. Repair or service as neces sary e Flue pipe system Check for blockage and or leakage Check the outside termination and the connections at and internal to the furnace e Heat exchanger Check for corrosion and or buildup within the heat exchanger passageways e Burners Check for proper ignition burner flame and flame signal e Drainage system Check for blockage and or leakage Check hose connections at and internal to furnace e Wiring Check electrical connections for tightness and or corrosion Check wires for damage Filters FILTERS TO ENSURE PROPER UNIT PERFORMANCE ADHERE TO THE FILTER SIZES GIVEN IN THE RECOMMENDED M INIMUM FILTER SIZE TABLE OR SPECIFICATION SHEET APPLICABLE TO YOUR MODEL FILTER MAINTENANCE Improper filter maintenance isthe most common cause of inad equate heating or cooling performance Filters should be cleaned permanent or replaced disposable every two months or as required BURNERS Visually inspect the burner flames periodically duringthe heat ing season Turn on the furnace at the thermostat and allow several minutes for flamesto stabilize since any dislodged dust will alter the flames normal appearance Flames should be stable quiet soft and blue dust may cause orange tips but they must 52 not be yellow They should extend directly outward from the burners without curling floating or lifting off Flames must not impinge on the sides o
27. 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 This furnace is shipped from the factory configured for natural gas up to 10 000 ft altitude Propane conversions require the proper LP kit to compensate for the energy content dif ference between natural and propane gas LP kits include an L P gas valve and a set of gas orifices Although the gas valve is ready to use with L P gas be sure not to remove the tape from the regulator screws Do not change or adjust the gas valve regulator springs High Low Switch amuse ones Stage Stage Change Natural pr 0 10 000 LPM 09 NOTE In Canada gas furnaces are only certified to 4500 feet M anifold Pressure Pressure Vent Flue Pipe amp Combustion Air Pipe WARNING FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN BODILY INJURY OR DEATH CAREFULLY READ AND FOLLOW ALL INSTRUCTIONS GIVEN IN THIS SECTION Proper VENT FLUE AND Air PIPING PRACTICES Adhere to these instructions to ensure safe and proper furnace performance The length diameter and number of elbows of the vent flue pipe and combustion air pipe when applicable affects the performance of the furnace and must be carefully sized All piping must be installed in accordance with local codes and the insttaltion manual shipped with the furnace
28. a communicating touchscreen thermostat and sub base 230V 24V 40va transformer terminal blocks 2 wire jumpers mounting screws installation manual and homeowner guide CTKO1BA CTKO2 CTKO3A CTKO4A Communicating Thermostat Kit Digitally communicating touchscreen thermostat a necessary part of any communicating system Designed for use with compatible Amana Brand Goodman Brand Air Handlers or Furnaces and outdoor split AC or Heat Pump units This thermostat supports up to three stages of heat two stages of cooling dual fuel applications dehumidification filter maintenance reminders outdoor temperature display and advanced menus including diagnostics The 1 kit includes a communicating touchscreen thermostat and sub base terminal blocks 2 mounting screws installation manual and homeowner guide Communicating Thermostat Kit Digitally communicating thermostat a necessary part of any communicating system Designed for use with compatible Brand or Goodman Brand Air Handlers or Furnaces and outdoor split AC or Heat Pump units The CTK02 thermostat features full color high definition display advanced programming options including humidification control amp heat and cool maximum temperature settings a USB plug allowing dealers the abilityto insert pre programmed operating parameters and dealer information by use of an online data entry system Communicating Thermostat Kit Digitally
29. appliances gt 100 000 Btuh 30 kW 3 ft 91 cm within a height 15 ft 4 5 m above the meter regulator assembly opening 1 ft 300 m above opening Canadian Installations U S Installations ft 91 om g l Clearance to sevice regulator vent outlet 6 in 15 for appliances 10 000 Btuh 3 kW 12 in 30 cm for appliances gt 10 000 Btuh 3kW and 100 000 Btuh 30 kW 36 in 91 cm for appliances gt 100 000 Btuh 30 kW 4 ft 1 2 m below or to side of opening 1 ft 300 m above opening J Clearance to nonmechanical air supply inlet to building or the combustion air inlet to any other appliance K Clearance to a mechanical ft 1 83 m 3 ft 91 cm above if within air supply inlet 10 ft 3 m horizontally L Clearance above paved sidewalk or ft 2 13m t 7 ft 2 13m paved driveway located on public property M Clearance under veranda porch 12 in 30 cm deck or balcony 1 In accordance with the current CSA B149 1 Natural Gas and Propane Installation Code 2 In accordance with the current ANS Z223 1 NFPA 54 National Fuel Gas Code t A vent shall not terminate directly above a sidewalk or paveable driveway that is located between two single family dwellings and serves both dwelling Permitted only if veranda porch deck or balcony is fully open on a minimum of two sides beneath the floor For clearances not specified in ANSI Z223 1 NFPA 54 CSA B
30. communicating touchscreen thermostat from Honeywell Designed for use with compatible Amana Brand or Goodman Brand Air Handlers or Furnaces and outdoor split AC or Heat Pump units The thermostat features full color high definition display can be used with RedLINK wireless accessories Communicating Thermostat Kit Digitally communicating touchscreen thermostat from Honeywell Designed for use with compatible Amana Brand or Goodman Brand Air Handlers or Furnaces and outdoor split AC or Heat Pump units The 4 thermostat features full color high definition display can be used with RedLINK wireless accessories Split system inverter capable PRODUCT IDENTIFICATION MODEL DESCRIPTION Concentric Vent Kit For use with Brand Modulating furnace models This kitis designed to allow terminations of a direct vent furnace to be concentrically vented through a wall or roof This kit allows a single N A penetration to support terminations for both the vent lue and the combustion air intake pipe The DCVK 20 2 and DCVK 30 3 kits are certified for models listed above See specification sheets on future models for use of the vent kit Dehumidistat For use with Goodman amp Amana Brand two stage variable speed modulating furnace models Wall mounted 24 volt humidity control available as a Dehumidistat used to reduce the airflow in the air conditioning mode when necessaryto lower the humidity
31. fire is being called for The power wires are colored red white and black green colored ground wire is also present Hot Surface Igniter Modulating furnaces use a 115 volt silicon nitride hot sur face igniter This 15 the familiar and reliable 0131F00008S igniter with 17 second warm up time At room temperature the igniter has a resistance range of 37 68 ohms The 5 1 is connected electrically to the IFC by a 3 16 push on connection Gas Valve Modulating furnaces use a 24 VAC pneumatically operated gas valve by Honeywell The valve is energized by the inte grated furnace control on a call for heat wired in series through the front cover pressure switch The firing rate per centage is determined by the negative pressure created by the operation of the draft inducer The gas valve is factory set and non adjustable in the field Do not remove the seal covering the regulator screws or attempt to adjust ei ther of the regulator screws Inductor Coil Wired in series with 34 and 1 HP ECM motors the inductor coil conditions the power supply to the motor smoothing out spikes and electrical noise With voltage applied to one side of the inductor coil the output voltage to the motor should be the same as incoming voltage Integrated Furnace Control IFC The IFC is the main control center for the furnace It has many functions including e Receiving commands from the thermostat for heat ing and cooling continuous fan opera
32. furnace from physical damage by ve hicles PRODUCT DESIGN e Ifthe furnace isinstalled horizontally ensure the access doors are not on the up top or down bottom side of the furnace connect thisfurnaceto a chimney flue that serves a separate appliance designed to burn solid fuel e On Counterflow Installations the air conditioning coil must be downstream on the supply positive side of the furnace heat exchanger e Counterflow Installation over a noncombustible floor Before settingthe furnace over the plenum opening en surethe surface around the opening is smooth and level A tight seal should be made between the furnace base and floor by using a silicone rubber caulking compound or cement grout e Counterflow Installation over a combustible floor If in stallation over a combustible floor becomes necessary use an accessory subbase see Specification Sheet ap plicable for your model for details A special accessory subbase must be used for upright counterflow unit in stallations over any combustible material including wood Refer to subbase instructions for installation details Follow the instructions with the subbase for proper in stallation Do not install the furnace directly on carpeting tile or other combustible material other than wood flooring NOTE The subbase will not be required if an air condi tioning coil is installed between the supply air opening onthe furnace and the floor
33. gas and electrical power supply and oper ate the furnace and all other gas consuming appliances on the same gas supply line 4 Measure furnace gas supply pressure with burners fir ing Supply pressure must be within the range speci fied in the following table To test manifold pressure the furnace must be put into field test mode to bring the furnace up to 100 input 5 Disconnect manometer after turning off gas at manual shutoff valve Reinstall plug before turning on gas to furnace 6 Turn OFF any unnecessary gas appliances started in step 3 7 Turn on gasto furnace and check for leaks If leaks are found repair and then reinstall burner compartment door 8 Turn on electrical power and verify proper unit opera tion The gas valve is factory set and non adjustable in the field Do not remove the seal covering the regulator screws or attempt to adjust either of the regulator screws Even though the modulating gas valve is non adjustable in the field gas industry procedure dictates that the installing servicing technician should know that the appliance is op erating as designed before leaving newly installed or ser viced equipment The gas valve is equipped with 1 8 NPT fittings to access both the inlet and manifold gas pres sures To do a manifold gas pressure check the furnace can be operated in field test mode This mode will quickly bringthe furnace up to high fire To enter field test mode during a call for
34. heat press the fault recall button twice within a five second period when the dual seven segment displays show Ft pressthe fault recall button again to en ter field test mode The furnace will stay in field test for five minutes or until the call for heat is satisfied Gas valve orientation must be such that the switch is facing out to 58 wards the front of the furnace Manifold pressure for natu ral gasis pre set to be between 3 2 WCto 3 8 WC If the furnace has been converted to LP gas the manifold pres sure will be 9 7 WC to 10 3 W Manifold Gas Pressure 3 5 w c S 308 CHECKING HOT SURFACE IGNITOR Modulating furnaces use a 115 volt silicon nitride hot sur face igniter This is the familiar and reliable 0131F00008S igniter with 17 second warm up time At room tempera ture the igniter has a resistance range of 37 68 ohms The 5 1 isconnected electrically to the IFC by a 3 16 push on connection S 309 CHECKING FOR FLASHBACK Flashback will also cause burning in the burner venturi but is caused by the burning speed being greater than the gas air flow velocity coming from a burner port Flashback may occur at the moment of ignition after a burner heats up or when the burner turns off The latter is known as extinction pop Since the end results of flashback and delayed ignition can be the same burning in the burner venturi a definite at tempt should be made to determine which has occurred If fla
35. in an occupied home to prevent dew build up associated with high humidity levels This control features moisture sensitive nylon element and also provides positive ON OFF settings for manual operation The control is a normally closed switch that opens humidity rise causing the blower to switch to a lower speed to control the humidity within the structure External Filter Rack Kit For use with Goodman and Amana Brand 97 upflow variable speed MVM34 5 NA modulating gas furnaces This kit is intended to provide a location external to the furnace casing for installation of a permanent filter The rack is mounted over the indoor air blower compartment area of either side panel and provide filter retention as well as a location for attaching return air ductwork Side Wall Only Concentric Vent Kit For use with 96 modulating furnace models This kitis to be used with NA 2 3 vent systems The vent kit must terminate outside the structure This kitis NOT intended for use with single pipe indirect vent installations Side Wall Only Concentric Vent Kit For use with 96 modulating furnace models This kitis to be used with NA 2 vent systems The vent kit must terminate outside the structure This kit is NOT intended for use with single pipe indirect vent installation LP Gas Low Pressure Kit Designed for application on Goodman and Amana Brand s 80 and 90 single N A stage two stage and modulating fu
36. is equipped with an ignition 4 Cet appareil menager etant dote d un systeme device which automatically lights the burner d allumage automatique ne pas essayer Do not try to light the burner by hand allumer le br leur manuellement 5 Push the gas control leverto OFF Position 5 Pousse le levier du contrOle du gaz OFF ARRET Do not force position 6 Wait five 5 minutes to clear out any gas Then 6 Attendre cinq 5 minutes pour laisser echapper tout le smell for gas including near the floor If you gaz Renifler tout autour de l appareil compris pr s du plancher pour d celer une odeur de gaz Si c est le cas ROBINET A GAZ ARR TEZ Passer l etape des instructions de securite MANUEL EN POS sur la portion superieure de cette etiquette ON MARCHE S il n y a pas d odeur de gaz passer l et pe suivante then smell gas STOP Follow B in the safety information above on this label if you don t smell gas go to next step GAS E 7 Push gas control lever INLET 7 Pousse le levier du contr le du gaz to position 8 Replace access panel gt 8 Remettre en place le panneau d acc s 9 Turn on all electric ARRIVEE 9 Mettre l appareil sous tension 10 R gler le thermostat a la temp rature d sir e power to the appliance DU GAZ 11 Si l appareil ne se met pas en marche suivre les 10 Set thermostat to desired setting 11 If the appliance will not oper
37. outdoor temperature sensor to deter mine the most cost efficient means of heating heat pump or gas furnace When used with the thermostat the furnace heat pump system is automatically configured asa fossil fuel system The balance point temperature may be adjusted via the thermostat advanced user menus see CTKO instructions for additional information CTKO WirinG NOTE Refer to Electrical Connections for 115 volt line connections to the furnace NOTE Aremovable plug connector is provided with the control to make thermostat wire connections This plug may be removed wire connections made to the plug and replaced Multiple wires imust be twisted together prior to inserting into the plug connector Failure to do so may result in intermittent operation Typical 18 AWG thermostat wire may be used to wire the sys tem components One hundred 100 feet is the maximum length of wire between indoor unit and outdoor unit or be tween indoor unit and thermostat Wire runs over 100 feet require larger gauge wire Four Wire AND OUTDOOR WIRING Typical ComfortNet wiring will consist of four wires between the indoor unit and outdoor unit and between the indoor unit and thermostat The required wires are a data lines 1 and 2 b thermostat R 24 VAC hot and C 24 VAC common CTKO 1 2 R Thermostat ComfortNet Compatible Furnace Integrated Control Module ComfortNe
38. side bottom Flexible joints may be used for supply and return connections to reduce noise transmission To prevent the blower from interfering with com bustion air or draft when a central return is used a connecting duct must be installed between the unit and the utility room wall Never use a room closet or alcove asa return air cham ber Duct STATIC Refer to your furnace rating plate for the maximum ESP external duct static rating Total external static refers to everything external to the furnace cabinet Cooling coils filters ducts grilles regis ters must all be considered when reading your total exter nal static pressure The supply duct pressure must be read between the furnace and the cooling coil This reading is usually taken by removing the A shaped block off plate from the end on the coil drilling a test hole in it and rein stalling the block off plate Take a duct static reading at the test hole Tape up the test hole after your test is com plete The negative pressure must be read between the filter and the furnace blower Too much external static pressure will result in insufficient air that can cause excessive temperature rise This can cause limit switch tripping and heat exchanger failure To determine total external duct static pressure proceed as follows 1 With clean filters in the furnace use a draft gauge in clined manometer to measure the static pressure of the re
39. the scribe lines to free the duct flanges Using the scribe line along the duct flange as a guide unfold the duct flanges around the perimeter of the opening using a pair of seamer pliers or seamer tongs NOTE Airflow area will be reduced by approximately 18 if duct flanges are not unfolded This could cause perfor mance issues and noise issues WARNING EDGES OF SHEET METAL HOLES MAY BE SHARP USE GLOVES AS PRECAUTION WHEN REMOVING SHEET METAL FROM RETURN AIR OPENINGS 31 OPERATION CUT FOUR CORNERS AFTER REMOVING SHEET METAL SCRIBE LINES OUTLINING DUCT FLANGES Duct Flange Cut Outs When a cooling coil isinstalled with the furnace it must be installed in the supply air to avoid condensation from occuring in the heat exchanger When the furnace is installed without a cooling coil it is recom mended that a removable access panel be provided in the out let air duct This opening shall be accessible when the furnace is installed and shall be of such a size that the heat exchanger can be viewed for visual light inspection or such that a sam pling probe can be inserted into the airstream The access panel must be made to prevent air leaks when the furnace is in operation When the furnace is heating the temperature of the return air entering the furnace must be between 55 F and 100 F Fitters Reap THis SECTION BEFORE INSTALLING THE RETURN Air Duct work Filters must be used with this furnace Discuss filt
40. the fur nace integrated control module terminals 2 Remove the thermostat low voltage wires at the fur nace control panel terminal board 3 Jumper terminals R to W on the integrated ignition control With Power On and Door Interlock Switch closed NOTE For this test DIP switch 13 must be in OFF posi tion LINE VOLTAGE NOW PRESENT 4 Induced Draft Motor must run and pull in pressure switch 5 If the hot surface ignitor heats and at the end of the ignitor warm up period the gas valve opens and the burners ignite the trouble is in the thermostat or wiring 6 With power off check the continuity of the thermo stat and wiring Repair or replace as necessary If checking the furnace in the air conditioning mode proceed as follows 7 With power off Jumper terminals R to Y or Y1 or Y2 for two stage models to G 8 Turn on the power 9 Ifthe furnace blower motor starts and the condens ing unit runs then the trouble is in the thermostat or wiring Repair or replace as necessary 10 After completing check and or repair of wiring and check and or replacement of thermostat reinstall blower compartment door 11 Turn on electrical power and verify proper unit opera tion SERVICING S 3B HEATING ANTICIPATOR CYLCE RATE Older heating thermostats may have an adjustable antici pator Thisis a wire wound adjustable heater which is en ergized during the ON cycle to help prevent overheating of the con
41. time of installation Amemory chip is not required when an indi vidual control board or motor is replaced Amemory chip is only required when all communicating com ponents have been replaced with service parts containing no shared data If either an existing control board or ECM motor needed to be replaced the service part would upload the necessary data from the remaining communicating com ponent Ina fully communicating system this would include the communicating thermostat and communicating outdoor unit control board as the necessary data is stored in all com municating devices A furnace void of shared data will not function in a legacy or afully communicating installation The furnace display would show d0 indicating that there is no shared data the furnace control board If it is ever necessary to use a memory chip the specific memory chip for your furnace number must be used To use a memory chip 1 Power down all HVAC equipment in the system 2 Aswhen handling any electronic components discharge any static electricity you may be carrying by touching grounded metal 50 Insert the memory card in the slot on the control board 4 Powerthe system back up and allow a few minutes for the network to establish communication between all de vices 5 Furnace control board will display OP or ON depend ing on board part number 6 Check operation 7 Memory chip can be left on the control boa
42. 149 1 the following statement shall be included Clearance in accordance wtih local installation codes and the requirements of the gas supplier and the manufacturer s installation instruction PRODUCT DESIGN Condensate Drain Lines amp Drain Trap 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 col lected in the furnace drain trap and routed to an appropri ate drain location in compliance with local and national codes Follow the bulletslisted below when installingthe drain system Refer to the following sections for specific details concerning furnace drain trap installation and drain hose hook ups e Thedraintrap supplied with the furnace must be used e Thedraintrap must be primed at time of installation e The drain line between furnace and drain location must meet local and nation codes e Thedrain line between furnace and drain location must maintain a 1 4 inch per foot downward slope toward the drain Donottrapthe drain line in any other location than at the drain trap supplied with the furnace e Ifthe drain line is routed through an area which may see temperatures near or below freezing precautions must be taken to prevent condensate from freezing within the drain line e lfanair conditioning coil is installed with the furnace a common drain may be used An open tee mus
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45. 8599 only happens during low stage cooling operation The dehumidifica tion feature is not active during high stage cool The and 04 be set up to overcool the home in order to reach the RH set point NOTE In non communicating installations with a condens ing unit DIP switch 14 must be checked and set to match a single or two stage condensing unit Factory setting is OFF single stage 24 DenuMipisTAT WIRING The optional usage of a dehumidistat allows the furnace s circu lator blower to operate at a slightly lower speed 85 of desired speed during a combined thermostat call for cooling and dehu midistat call for dehumidification Thiscan be done through an independent dehumidistat or through a thermostat s DEHUM terminal if available This lower blower speed enhances dehu midification of the conditioned air as it passes through the AC coil For proper function a dehumidistat applied to thisfurnace 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 To install connect a dehumidistat 1 Turn OFF power to furnace 2 Secure one dehumidistat lead to the terminal marked DEHUM on the furnace integrated control module 3 Secure the other dehumidistat lead to the terminal marked R on the furnace integrated control module 4 Secure the dehumidistat ground wire typically the green
46. 87 103 217 409 834 1275 13 29 62 104 155 89 185 346 724 1 066 too 11 26 55 90 138 78 162 307 630 976 _125 to 24 48 81 122 69 146 275 567 866 150 9 21 43 72 109 63 132 252 511 787 200 e 19 39 66 100 54 112 209 439 66 250 8 17 36 es 48 too 185 390 590 in accordance with NFPA pamphlet 54 Tubing Size O D Type L Propane Gas Piping Chart II Circulating Air amp Filters Duct work Air Flow WARNING NEVER ALLOW THE PRODUCTS OF COMBUSTION INCLUDING CARBON MONOXIDE TO ENTER THE RETURN DUCT WORK OR CIRCULATION AIR SUPPLY Duct systems and register sizes must be properly designed for the CFM and external static pressure rating of the furnace De sign the ductwork in accordance with the recommended meth ods of Air Conditioning Contractors of America Manual D Install the duct system in accordance with Standards of the Na tional Board of Fire Underwriters for the Installation of Air Con ditioning Warm Air Heating and Ventilating Systems Pamphlets No 90A and 90B OPERATION closed return duct system must be used with the return duct connected to the furnace NOTE Ductwork must never be at tached to the back of the furnace For upflow installations requiring 1800 CFM or more use either two side returns or bottom return or a combination of
47. 9Q 6 1U9A 9UJUSIUOD Svs SYSV 02 MAOG aZ 9140119913 uZ NN NWY 5100001010 NERO DIS DUNI LOS VO9 08133V 5504 50000040710 5 ESSERE Joquinn Sis 8 8 5 5 5 5 Jaquinn uonduoseg uonduoseg 82 85 1 IPPON s RE OUT 2 0 9 22222299 ACCESSORIES EXTERNAL FILTER RACK EFRO2 Used on 97 Upflow Modulating Furnaces UNIT SIDE PANEL 0 FRONT OF UNIT OF UNIT RETURN AIR CUTOUT AREA SLOTS IN FILTER CLEAR SCREWS ON UNIT BLOWER DECK SCREWS FILTER RACK ASSEMBLY FACE FILTER OPENING TOWARDS FRONT OF UNIT LOWER EDGE SCREW CONCENTRIC VENT CONVERSION KIT DCVK 20 amp DCVK 30 CVENT 2 amp CVENT 3 The DCVK 20 2 or the DCVK 30 3 is a concentric vent kit approved with furnaces listed in this manual This concentric vent kit allows for vertical or horizontal vent termination The illustrations give a brief view of the kit and its application Combustion Air A Strap Vent Field Supplied IN y gt d P vent 7 to Y maximum Nas Elbow 7 Combustion Air Field Supplied 7 DCVK Horizontal Installation DCVK 20 amp
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49. AL NEUTRAL Q31VH93INI death TOHLNO9 93493934 HOT SURFACE IGNITER YOU m p EMA HOSN3S NEUTRAL Injury or DIAGNOSTIC LED S En 40 VA FUSESA_ n 5 TRANSFORMER 24 VAC AUTO RESET PRIMARY AUTO RESET AUXILIARY LIMIT LIMIT CONTROL d CONTROLS VA OF Sdvitoo 8 5 1 SdvL T In oO In MOON G31V49431NI DNILLWINGOW LOW FIRE PRESS SWITCH S3HOLIMS gt o 2 5 3 5 gt a 8 5 c o a gt o 5 a o E damage personal WARNING Disconnect ALL power before serv HIGH FIRE PRESS SWITCH MANUAL RESET ROLLOUT LIMIT CONTROLS TO m 9 m 1 51 02 TO NMOQ Tina I rina 11 2 55770 9 3 NSNOILO3NNOO LYLSOWHAHL Are 24 THERMOSTAT CONNECTIONS AUX N E C CLASS 2 WIRE ECM MTR 10 FRONT COVER HARNESS o PRESS GND 4 SWITCH 9 GND
50. DUCT DAMAGE PERSONAL INJURY OR DEATH GOODMAN WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES IF YOU INSTALL OR PERFORM SERVICE ON THIS UNIT YOU ASSUME RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROPERTY DAMAGE WHICH MAY RESULT MANY JURISDICTIONS REQUIRE A LICENSE TO INSTALL OR SERVICE HEATING AND AIR CONDITIONING EQUIPMENT A warnine 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 IMPORTANT INFORMATION THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE PERSONAL INJURY OR LOSS OF LIFE DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE WHAT TODO IF YOU SMELL GAS e DO NOT TRY TO LIGHT ANY APPLIANCE DO NOT TOUCH ANY ELECTRICAL SWITCH DO NOT USE ANY PHONE IN YOUR BUILDING IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR S PHONE FOLLOW THE GAS SUPPLIER S INSTRUCTIONS F YOU CANNOT REACH YOUR GAS SUPPLIER CALL THE FIRE DEPARTMENT INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER SERVICE AGENCY OR THE GAS SUPPLIER SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF TURN OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE FURNACE BEFORE TURNING
51. G THERMOSTAT DIP SWITCH 13 MUST BE SET TO ON POSITION THIS IS ALSO THE CORRECT SETTING FOR A NON COMMUNICATING 2 STAGE THERM OSTAT TO USE CTKO2 MODULATING THERMOSTAT CHECK TO MAKE SURE DIP SWITCH 13 IS IN THE OFF POSITION FACTORY POSITION THIS IS ALSO THE CORRECT POSITION WHEN USING A NON COM MUNICATING SINGLE STAGE THERM OSTAT OPERATION When installed with a non communicating thermostat the furnace integrated control module provides terminals both W1 and W2 and Y1 and Y2 thermostat connections Thisallowsthe furnace to support the following system applica tions Two Stage Heating Only Two Stage Heating with Single Stage Cooling and Two Stage Heating with Two Stage Cool ing Refer to the following figures for proper connections to the integrated control module Low voltage connections can be made through either the right or left side panel Thermostat wiring entrance holes are located inthe blower compartment The following figure shows connec tions for a heat cool system This furnace is equipped with a 40 VA transformer to facilitate use with most cooling equipment Consult the wiring diagram located on the blower compartment door for further details of 115 Volt and 24 Volt wiring NOTE Use of ramping profiles requires a jumper between Yl and 0 IMPORTANT NOTE THERMOSTAT R REQUIRED IF OUTDOOR UNIT IS EQUIPPED WITH A COMFORT ALERT MODULE OR IF T
52. GCVM97 Equipment Type Heating Stages Cooling Stages Control Type Blower Motor Type GCVM97 Installation Positions REV AA Amana Brand Residential Gas Furnace Modulating 35 100 of rated input Two ClimateT alk or Conventional 24 Volt 4 Wire Variable Speed ECM 0603BN 0803BN 0804CN 1005CN CF Hor UR CF HorL R CF Hor UR Hor 21 60 28 80 28 80 35 100 15 3 1 5 3 2 4 2 5 34 5 34 5 34 5 34 5 17 5 17 5 21 21 950 1146 1325 1779 3 Variable Speed 24 VAC Modulates by Pneumatic signal W1 W2 Y1 Y2 Stainless Steel EAC terminal HUM IN HUM OUT terminals Left or Right First revision of 34 5 modulating counter flow furnace REV AA Goodman Brand Residential Gas Furnace Modulating 35 100 of rated input Two ClimateT alk or Conventional 24 Volt 4 Wire Variable Speed ECM 0603BN 0803BN 0804CN 1005CN CF Hor L R CF Hor L R CF Hor L R CF Hor BTUH Input Range X 1000 21 60 28 80 28 80 35 100 Capable Tons 15 3 15 3 2 4 2 5 Cabinet Hight 34 5 34 5 34 5 34 5 Cabinet Width 17 5 17 5 21 21 Heating CFM 100 Firing Rate 950 1146 1325 1779 ECM Motor H P Draft Inducer 3 Variable Speed Gas Valve 24 VAC Modulates by Pneumatic signal 24 VAC Heating Inputs W1 W2 24 VAC Cooling Inputs Y1 Y2 Primary Heat Exchanger Aluminized Steel Accessory Terminals EAC terminal HUM IN HUM OUT terminals Gas Line Entry Left or Right Revision Attributes First revision of 34 5
53. GE TRIP OR OVER TEMPERATURE TRIP b7 INCOMPLETE PARAMETERS SENT TO MOTOR bg INDOOR AIRFLOW CLIMATETALK COMPRESSOR COOLING CONVENTIONAL COMPRESSOR COOLING WHEN 1 STAGE COMPRESSOR IS SET UP C1 STAGE COOL C2 HIGHSTAGE COOL CLIMATETALK COMPRESSOR COOLING WITH DEHUMIFICATION CONVENTIONAL d COMPRESSOR COOLING WITH DEHUMIDIFICATION WHEN 1 STAGE COMPRESSOR IS SET UP dO DATA NOT YET ON NETWORK CONVENTIONAL 1 STAGE COMPRESSOR COOLING WITH DEHUMIDIFICATION WHEN 2 STAGE COMPRESSOR IS SET UP az CONVENTIONAL 2 STAGE COMPRESSOR COOLING WITH DEHUMIDIFICATION WHEN 2 STAGE COMPRESSOR IS SET UP d4 INVALID MEMORY CARD DATA DEFROST DEMAND EO LOCKOUT DUE TO EXCESSIVE RETRIES OR RECYCLES STAGE PRESSURE SWITCH STUCK CLOSED AT START OF HEATING CYCLE E2 STAGE PRESSURE SWITCH STUCK OPEN OPEN HIGH LIMIT SWITCH E4 FLAME DETECTED WHEN NO FLAME SHOULD BE PRESENT OPEN FUSE EG LOW FLAME SIGNAL E7 IGNITER FAULT OR IMPROPER GROUNDING E8 STAGE PRESSURE SWITCH STUCK CLOSED AT START OF HEATING CYCLE E9 STAGE PRESSURE SWITCH STUCK OPEN EA REVERSED 115 VAC POLARITY EC INDUCER MOTOR OVERCURRENT FAULT Ed ROLLOUT SWITCH OPEN EF AUXILIARY INPUT OPEN CONTINUOUS FAN Ft FIELD TEST MODE H INDICATES GAS HEAT FOLLOWED BY PERCENTAGE OF DEMAND HI HIGH HEAT 100 IF INTERNAL FAULT p CLIMATETALK COMPRESSOR HEATING CONVENTIONAL COMPRESSOR HEATING WHEN 1 STAGE COMPRESSOR IS SET U
54. Gas Minimum 11 0 w c If supply pressure differs from table make the necessary ad justments to pressure regulator gas piping size etc and or consult with local gas utility 5 Turn OFF gasto furnace at the manual shutoff valve and disconnect manometer Reinstall plug before turning on gasto furnace 6 Turn OFF any unnecessary gas appliances stated in step 3 Maximum 13 0 w c 35 OPERATION Gas Line Gas Shutoff Valve Gas Line To po Open To Atmosphere Drip Leg Cap With Fitting gt Manometer Manometer Measuring Inlet Gas Pressure Alt Method Gas ManiroLD PRESSURE MEASUREMENT caution TO PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE THE GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE GAS VALVE IS FACTORY SET AND DOES NOT REQUIRE ANY FIELD ADJUSTMENT DO NOT ATTEM PT TO ADJUST VALVE The manifold pressure must be measured with the burners operating To measure 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 Outlet pressure tap connections Remove the outlet pres sure boss plug Install an 1 8 NPT hose barb fitting into the outlet pressure tap 4 Attach a hose and manometer to the outlet pressure barb fitting 5 Turn ON the gas supply 6 Turn on power and close thermostat R and
55. HE OUTDOOR UNIT 15 A PART OF THE COMFORTNET FAMILY OF EQUIPMENT N ID O OQO F D VOCUVUVVOOA UA 24 V THERMOSTAT CONNECTIONS AUX Low Voltage Connections with Auxiliary Terminals The auxiliary contacts are shipped with a factory installed jumper As an option the auxiliary contacts may be wired to a normally closed float switch In the event of open con tacts the furnace will be disabled until the condition is cor rected These are 24 volt terminals fed internally do not apply another voltage source to these terminals Furnace Integrated Control Module l Dehumidistat Remote Optional Condensing Unit Single Stage Cooling Thermostat Single Stage Heating with Single Stage Cooling 26 IMPORTANT NOTE TO APPLY A SINGLE STAGE HEATING THERMOSTAT THE THERM OSTAT SELECTOR SWITCH ON THE INTEGRATED CONTROL M ODULE M UST BE SET ON SINGLE STAGE OO 9 69 69 Furnace Integrated Control Module Dehumidistat Optional Remote Condensing Unit Single Stage Cooling Thermostat Two Stage Heating with Single Stage Cooling Furnace Integrated Control Module ON Dehumidistat Optional Remote 4 Condensing Unit Two Stage Cooling Thermostat Two Stage Heating with Two Stage Cooling Thermostat Wiring Diagrams IMPORTANT NOTE SET DIP SWITCH 14 TO ON POSITION WHEN USING 2 STAGE COOLING THERMOSTAT THERMOSTAT APPLICATION The modulating fu
56. HE RISK OF INJURY ELECTRICAL SHOCK OR DEATH THE FURNACE MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH LOCAL CODES OR IN THEIR ABSENCE WITH THE LATEST EDITION OF THE NATIONAL ELECTRICAL CODE To ensure proper unit grounding the ground wire should run from the furnace ground screw located inside the furnace junc tion box all the way back to the electrical panel NOTE Do not use gas piping as an electrical ground To confirm proper unit grounding turn off the electrical power and perform the following check l Measureresistance between the neutral white con nection and one of the burners 2 Resistance should measure 10 ohms or less This furnace is equipped with a blower door interlock switch which interrupts unit voltage when the blower door is opened for servicing Do not defeat this switch 24 THERMOSTAT WIRING IMPORTANT NOTE WIRE ROUTING MUST NOT INTERFERE WITH CIRCULATOR BLOWER OPERATION FILTER REMOVAL OR ROUTINE MAINTENANCE REMOVABLE PLUG CONNECTOR IS PROVIDED WITH THE CONTROL TO MAKE THERMOSTAT WIRE CONNECTIONS THIS PLUG MAY REMOVED WIRE CONNECTIONS MADE TO THE PLUG AND REPLACED IT IS STRONGLY RECOMMENDED THAT MULTIPLE WIRES INTO A SINGLE TERMINAL BE CONNECTED WITH A WIRE NUT AND ONLY ONE WIRE BE INSERTED IN THE LOW VOLT CONNECTOR FAILURE TO DO SO MAY RESULT IN INTERMITTENT OPERATION IMPORTANT NOTE Dip swiTCH 13 MUST SET TO MATCH THERMOSTAT TYPE TO USE THE CTKO1 COMMUNICATIN
57. IATIONS AND DEFINITIONS e IFC Integrated furnace control e HSI Hot surface element e LPS Low pressure switch Induced draft blower e HPS High pressure switch Variable Frequency Drive VFD Control of the in duced draft blower is carried out by Variable Frequency Drive By varying the voltage and frequency to the draft inducer the RPM can be controlled A section of the IFC is dedicated to this task Trial for Ignition Period TFI The period of time between initiation of gasflow and the action to shut off the gas flow in the event of failure to establish proof of the supervised ignition source or the super vised main burner flame GasValve Sequence Period The total period of time of gas flow starting from the first initiation of gasto the final action to shut off the gas before going to lockout e ignition Activation Period IAP The period between energizing the main gas valve and deactivation of the ignition source prior to the end of TFI Flame Recognition Period FRP The period between deactivation of the ignition source and the expira tion of the TFI Flame Failure Response Time FFRT The period between loss of the supervised main burner flame and the action to shut off the gas supply e igniter Warm up Time The length of time allowed for the hot surface igniter to heat up prior to the initiation of gas flow e Pre purge Time The period of time intended to al low for the dissipation o
58. ISCONNECT ELECTRICAL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING 4 furnace integrated control module is equipped with line voltage accessory terminals for controlling power to an elec tronic air cleaner The accessory load specifications are as follows The furnace control board also has a set of dry contacts for humidifier connection 1 0 Amp maximum at 120 VAC Electronic Air Cleaner 1 0 Amp maximum at 120 VAC Turn OFF power to the furnace before installing any accesso ries Follow the humidifier or air cleaner manufacturers in structions for locating mounting grounding and controlling these accessories Accessory wiring connections are to be made through the 1 4 quick connect terminals provided on the fur nace integrated control module The Electronic air cleaner hot terminal is identified as EAC It is necessary to remove the protective tab on the board cover to access the EAC Terminal The EAC neutral terminal is identified as NEU TRAL Aline voltage humidifier may be connected between one of the HUM contacts and NEUTRAL The other HUM con tact must be fed from the L1 terminal 27 OPERATION All field wiring must conform to applicable codes Connections should be made as shown in the following figure ELECTRONIC AIR CLEANER HUMIDIFIER TRANSFORMER 0000000 NEUTRAL 11 no
59. O y 33 SOPIAOId Suruuni st 10onpur LTINFA j he juo1moJ9A0 d ejdsip oxjuoo pue 4 uiojs s 1952 1030 8 e 1 e 0 s rej 8 YOOYD 5110108 J2 SOULIOU pereurunjr UOOT Kressooou JI 998 day 10 gt JE SOULIOU JONIIOFWUIOD 528 jo A 528 BUISO D MOIS e 10119 p3 eurep Zungu 10 JIA eur 1oumq Suou e erdsip npour oyuoo redox 108095 INVITA 395244 oq ooeumj ON A snonuruoo suni 04 440 UML 10 105095 11045 1991100 ur PUNOI 3104 e FH YIdOYANI pasuas e ha pue JIMO Q YLIP uonoouuoo ZULM 3991109 JO 55 QOBUIN Y peeds Kressooou Suum 21594 8110295 JeISOULIOY Jonon 1odo1d pue Ji oov doi 10 payoouuos 10 500 e uoor ISI 10 yarog pue 10JOUI po rej 10 99IAI
60. OFF THE ELECTRICAL SUPPLY Tolocate an authorized servicer please consult your telephone book or the dealer from whom you purchased this product For further assistance please contact CONSUMER INFORMATION LINE CONSUMER INF ORMATION LINE GOODMAN BRAND PRODUCTS AMANA BRAND PRODUCTS TOLL FREE TOLL FREE 1 877 254 4729 U S only 1 877 254 4729 U S only email us at email us at hac consumer affairsgamanahvac com fax us at 731 856 1821 Not a technical assistance line for dealers customerservice goodmanmfg com fax us at 731 856 1821 Not a technical assistance line for dealers Outside the U S call 1 713 861 2500 Not a technical assistance line for dealers Your telephone company will bill you for the call IMPORTANT INFORMATION DANGER PELIGRO CARBON MONOXIDE POISONING HAZARD Special Warning for Installation of Furnace or Air Handling Units in Enclosed Areas such as Garages Utility Rooms or Parking Areas Carbon monoxide producing devices such as an automobile space heater gas water heater etc should not be operated in enclosed areas such as unventilated garages utility rooms or parking areas because of the danger of carbon monoxide CO poisoning resulting from the exhaust emissions If a furnace or air handler is installed in an enclosed area such as a garage utility room or parking area and a carbon monoxide producing device is operated therein there must be adequate direct outside ventila
61. ONOXIDO DE CARBONO Advertencia especial para la instalaci n de calentadores 6 manejadoras de aire en reas cerradas como estacionamientos 6 cuartos de servicio Los equipos aparatos que producen mon xido de carbono tal como autom vil calentador de gas calentador de agua por medio de gas etc no deben ser operados en reas cerradas debido al riesgo de envenenamiento por mon xido de carbono CO que resulta de las emisiones de gases de combusti n Si el equipo aparato se opera en dichas reas debe existir una adecuada ventilaci n directa al exterior Esta ventilaci n es necesaria para evitar el peligro de envenenamiento por CO que puede ocurrir si un dispositivo que produce mon xido de carbono sigue operando en el lugar cerrado Las emisiones de mon xido de carbono pueden circular a trav s del aparato cuando se opera en cualquier modo El mon xido de carbono puede causar enfermedades severas como da o cerebral permanente 6 muerte B10259 216 RISQUE D EMPOISONNEM ENT AU M ONOXYDE DE CARBONE Avertissement special au sujet de l installation d appareils de chauffage ou de traitement d air dans des endroits clos tets les garages les locaux d entretien et les stationnements Evitez de mettre en marche les appareils produisant du monoxyde de carbone tels que les automobile les appareils de chauffage autonome etc dans des endroits non ventil s tels que les d empoisonnement au monoxyde de carbone Si vous devez f
62. P p4 CONVENTIONAL 1 STAGE COMPRESSOR HEATING WHEN 2 STAGE COMPESSOR IS SET UP po CONVENTIONAL 2 STAGE COMPRESSOR HEATING WHEN 2 STAGE COMPESSOR IS SET UP BO OF HIGH HEAT 66 Wiring Diagram MVM97 A CVM97 A TO 115VACA Q eoHZ POWER SUPPLY WITH ID BLOWER MODULATING PRESSURE OVERCURRENT SWITCH ASSEMBLY PROTECTION DEVICE HOT SURFACE IGNITER WARNING DISCONNECT LOW FIRE PRESSURE POWER BEFORE SERVICING WIRING TO UNIT MUST BE SWITCH PRESSURE PROPERLY POLARIZED SWITCH DISCONNECT AND GROUNDED HIGH FIRE XO8 2 CIRCUIT CONNECTOR TO 115VAC 1 60 HZ POWER SUPPLY WITH OVERCURRENT PROTECTION DEVICE MODULATING E N WARNING GAS VALVE HONEY WELL FLAME DISCONNECT POWER 1 TO UNIT MUST BE SENSOR BEFORE SERVICING WIRING TO UNIT le FRONT COVER MUST BE PROPERLY PRESSURE SWITCH POLARIZED AND GROUNDED a L 0008 SWITCH i d M JUNCTION BOX ip DISCONNECT MANUAL RESET ROLLOUT LIMIT CONTROLS SINGLE CONTROL ON 40 kBTU t Mult PU PK LJ AUTO RESET PRIMARY OR LIMIT CONTROL IS unt SISSVHO th INDUCED DRAFT BLOWER ing tall CES 5 BURNER COMPARTMENT SND NEUTRAL BLOWER COMPARTMENT PU AUTO RESET AUXILIARY LIMIT CONTROL ELECTRONIC NEUTRAL AIR CLEANER OPTIONAL Icing or 115 NEUTRAL HUMIDIFIER OPTION
63. PLIER WARNING THE INFORMATION IN THESE INSTRUCTIONS 15 NOT FOLLOWED EXACTLY FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE PERSONAL INJURY OR LOSS OF LIFE DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE OF THIS OR ANY OTHER APPLIANCE WHAT TO DO IF YOU SM ELL GAS DO NOT TRY TO LIGHT ANY APPLIANCE DO NOT TOUCH ANY ELECTRICAL SWITCH DO NOT USE ANY PHONE IN YOUR BUILDING IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR S PHONE FOLLOW THE GAS SUPPLIER S INSTRUCTIONS IF YOU CANNOT REACH YOUR GAS SUPPLIER CALL THE ARE DEPARTMENT INSTALLATION AND SERMCE MUST BE PERFORMED BY A QUALIFIED INSTALLER SERVICE AGENCY OR THE GAS SUPPLIER WARNING THIS PRODUCT CONTAINS OR PRODUCES CHEMICAL OR CHEMICALS WHICH MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER BIRTH DEFECTS OR OTHER REPRODUCTIVE WARNING HEATING UNIT SHOULD NOT BE UTILIZED WITHOUT REASONABLE ROUTINE INSPECTION MAINTENANCE AND SUPERVISION IF THE BUILDING IN WHICH ANY SUCH DEVICE IS LOCATED WILL BE VACANT CARE SHOULD BE TAKEN THAT SUCH DEVICE IS ROUTINELY INSPECTED MAINTAINED AND MONITORED IN THE EVENT THAT THE BUILDING MAYBE EXPOSED TO FREEZING TEM PERATURES AND WILL BE VACANT ALL WATER BEARING PIPES SHOULD BE DRAINED THE BUILDING SHOULD BE PROPERLY WINTERIZED AND THE WATER SOURCE CLOSED IN THE EVENT THAT THE BUILDING
64. PPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING Inlet gas supply pressures must be maintained within the ranges specified in the following table The supply pressure must be constant and available with all other household gas fired appli ances operating The minimum gas supply pressure must be maintained to prevent unreliable ignition The maximum must not be exceeded to prevent unit overfiring Inlet Gas Supply Pressure Natural Gas Minimum 4 5 Maximum 10 0 w c Gas Minimum 11 0 w c Maximum 13 0 w c Propane Gas CONVERSION 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 Gas PiPING CONNECTIONS WARNING AVOID POSSIBLE UNSATISFACTORY OPERATION OF EQUIPMENT DAMAGE DUE TO UNDERFIRING OR EQUIPMENT USE THE PROPER SIZE OF NATURAL PROPANE GAS PIPING NEEDED WHEN RUNNING PIPE FROM THE METER TANK TO THE FURNACE When sizing a trunk line be sure to include all appliances which will operate simultaneously when sizing a trunk line 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 in
65. R BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH i 1 Turn off all power sources 2 Remove the two wires from the auxiliary limit switch 3 Using an ohmmeter check for a closed circuit across the two limit contacts this will be the same reading that you see by touching your two meter leads to gether 55 SERVICING AUXILIARY LIMIT AUXILIARY CONTROL Auxiliary Limit Control Location S 302 CHECKING FLAME ROLLOUT CONTROL Atemperature activated manual reset control is mounted to the manifold assembly on modulating furnace as shown in the following illustration FLAME ROLLOUT SWITCHES Flame Rollout Switch Location 90 Upflow Furnace Shown Counterflow Similar A HIGH VOLTAGE Disconnect ALL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH 1 Turn off all power sources 2 Remove the two wires from the roll out switch 3 Using an ohmmeter check a closed circuit across the two roll out switch contacts this will be the same reading that you see by touching your two meter leads together 56 S 303 INDUCED DRAFT BLOWER MOTOR Induced Draft Blower IDB All modulating furnace models use a three phase induced draft blower to draw flue ga
66. RIMING The drain trap must be primed prior to furnace startup To prime fill the drain trap with water This ensures proper fur nace drainage upon startup and prohibits the possibility of flue gases escaping through the drain system OPERATION Gas Supply PRESSURE MEASUREMENT caution TO PREVENT UNRELIABLE OPERATION OR EQUIPM ENT DAMAGE THE INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING The line pressure supplied to the gas valve must be within the range specified below The supply pressure can be measured at the gas valve inlet pressure boss or at a hose fitting installed in the gas piping drip leg The supply pressure must be measured with the burners operating To measure the gas supply pres sure use the following procedure PS ATMOSPHERE CONNECTION PORT gt FLOW gt DIRECTION Honeywell Model VR9205R 2 PIN POWER Monae Mose CONNECTOR N Inlet Pressure 1 8 Outlet Pressure Tap 1 8 NPT hb Honeywell Model VR9205R Connected to Manometer 1 Turn OFF gasto furnace at the manual gas shutoff valve external to the furnace 2 Connect a calibrated water manometer or appropri a
67. RS 5 555 55 e 555 9 555 IS QLL 525 KS 5 05 oS oS A RS MEASURE HERE Temperature Rise Measurement CIRCULATOR BLOWER SPEEDS WARNING TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL 5 TURN OFF POWER TO THE FURNACE BEFORE CHANGING SPEED TAPS This furnace is equipped with multi speed circulator blower This blower provides ease in adjusting blower speeds The heating blower speed is shipped set at B and the cooling blower speed is set at These blower speeds should be adj usted by the installer to match the installation requirements so asto provide the correct heating temperature rise and cor rect cooling CFM Use the dual 7 segment LED display adjacent to the DIP switches to obtain the approximate airflow quantity The airflow quan tity is displayed as a number on the display rounded to the nearest 100 CFM The display alternates airflow delivery indi cation and the operating mode indication 37 OPERATION Example The airflow being delivered is 1225 CFM The dis play indicates 12 If the airflow being delivered is 1275 the display indicates 13 1 Determine the tonnage of the cooling system installed with the furnace If the cooling capacity BTU hr divide it by 12 000 to convert capacity to TONS Example Cooling Capacity of 30 000 BTU hr 30 000 12 000 22 5 Tons 2 Determine the proper air flow for the cooling system Most co
68. SOULIDY JONLOFWIOD BULIIM 3994109 pue 3221 uoor Kressooou 18 pun 991195 10 E 1924109 Ayia A posioAo1 10119 y redox Kyurepod 3991109 SI 10 ooeuing ALTA SI _ Kejdsip Jord 440 Jomod 0 SULIIM MINIY 0 JV 3 0A ST JO DV HOA SIT e 0 o eum4 SULIIM 3291100 JO 81 uonoui joejuoo 10 jurod jas YIJIMS ainssaid 1291107 Suum ressooou po1oeuuoo 10 25007 S panog ooueurioj1od sjoejuoo ed juouroov do1 YeIp yooyo Joys 10 jurod 3291109 JOS YOJIMS ounssoid J921IOOU 8 5 gp S 1094646 xou uo s 4 e uoreururo pue 5 1809 10 6 poxoo q Sune1odo jueureoe doi 3994109 YM eSexoo q 107 Surdid adid 10 pue pexoo gq SI 19MO Q yep poonpu e opoo 10110 63 yams oinssoid jo ur 10 pue an yodsuy pos
69. 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 THE GAS UNDETECTABLE EXCEPT WITH A WARNING DEVICE Agas detecting warning system is the only reliable way to detect a propane gas leak Rust can reduce the level of odorant in propane gas Do not rely on your sense of smell Contact local propane gas supplier about installing a gas detecting warning system If the presence of gasis suspected follow the instruc tions listed in the Safety Precautions section of this manual All propane gas equipment must conform to the safety stan dards of the National Board of Fire Underwriters NBFU Manual 58 For satisfactory operation propane gas pressure must be 10 WC 5 WCatthe furnace manifold with all gasappliancesin operation Maintaining proper gas pressure depends on three main factors l Vaporization rate depending on temperature of the liquid and wetted surface area of the container or containers 2 Proper pressure regulation Two stage regulation is recommended for both cost and efficiency 3 Pressure drop in lines between regulators and be tween second stage regulator and the appliance Pipe size will depend on length of pipe run and total load of all appliances Complete information regardi
70. Service Instructions 97 Modulating Gas Furnaces 34 5 Chassis ACVM AMVM GCVM GMVM amp Accessories This manual is to be used by qualified professionally trained HVAC technicians only Goodman does RS6612009r1 not assume any responsibility for property damage or personal injury due to improper service November 2014 procedures or services performed by an unqualified person Amana isa registered trademark of Maytag Corporation or its related companies and is used under license to Goodman Company L P Houston TX All rights reserved Copyright 2014 Goodman Company L P TABLE OF CONTENTS IMPORTANT INFORMATION 2 4 OPERATIONAL 5 49 51 PRODUCT IDENTIFICATION 5 8 MAINTENANCE oreet rre tbt Rr ens 52 ACCESSORIES xad bladi ge I1 SERVICING TABLE OF 5 53 LIGHTING INSTRUCTIONS oi 12 SERVICING ccecce 54 60 PRODUCT DESIGN ss 13 24 TROUBLESHOOTING 61 65 OPERATION aristas 25 247 STATUS CODES Mide 66 SERVICE AND 1 48 WIRING 1 67 IMPORTANT INFORMATION Pride and
71. T YOYO 10205 JEISOULIDY 10 pereurumq uor quauuooedei 3921109 YUM 99IM9S 10 U 18 SOULHOU JONWOFWUOD Yous 21155944 Zum uoys YIJIMS 55 sJIOUS 1049 8 Jo peys epoo 10119 3 sopr o1d ardor UOJIMS Sup ons sjoejuoo dISOTO SI YOITAS Xe dstp o3juoo 0 440 1o od UML 21155914 8 5 55 28215 MOT IH ISd 91155914 2883 MOT 13 0 s rej ooeuin eou uriojiod Yeap 1edoudur yep 10 Suruado yams ounsso1d 19409 uoneuruno Surdid uonsnquos pue yy3ua Jo pue SNJ uonornso1 107 801414 1994 10 91155914 ses P9ZIPIXO 10 pue pojeoo JI JOSUDS Apddns pues 1994 528 oq osne S Te3op Surdid 107 uonoos IOUS 8 10 jueurgsi q so JO 5507 998 10SU9S oure j ogessoui DOVUIN SI ooeuinj ons JO 7 YOY 8110198 JON HOFUOT
72. TE To energize the furnace the Door Interlock Switch must be engaged at this point 4 Noreading indicates open wiring open line voltage fuse no power or faulty Door Interlock Switch from unit to fused disconnect service Repair as needed 5 With proper voltage at line voltage connectors ener gize the furnace blower motor by jumpering termi nals R to G on the integrated ignition control 6 Withthe blower motor in operation the voltage should be 115 volts 10 percent 7 If the reading falls below the minimum voltage check the line wire size Long runs of undersized wire can cause low voltage If wire size is adequate notify the local power company of the condition 8 After completing check and or repair replace J unc tion Box cover and reinstall the service panel doors 9 Turnon electrical power and verify proper unit opera tion S 2 CHECKING WIRING WARNING Disconnect ALL POWER BEFORE SERVICING 1 Check wiring visually for signs of overheating dam aged insulation and loose connections 2 Use an ohmmeter to check continuity of any suspected open wires 54 3 If any wires must be replaced replace with AWM 105 C 2 64 thick insulation of the same gauge or its equiva lent CHECKING THERMOSTAT WIRING AND ANTICIPATOR S 3A THERMOSTAT AND WIRING Disconnect ALL POWER BEFORE SERVICING 1 Remove the blower compartment door to gain access to the thermostat low voltage wires located at
73. These are dry contacts rated at 1 amp Atypical application of these contacts would be to supply one of the Hum contacts with power from the L1 terminal and connect the remaining Hum terminal to a humidifier transformer primary When used with the CTKO2 CTK03 and CTK04 thermostats these contacts will close with a call for humidity and the furnace indoor blower will be powered at continuousfan speed When used with a 24 volt control system the Hum contacts will close on a call for heat when the induced draft blower is powered EAC Terminal EAC terminal is provided Any time the indoor blower motor is powered the EAC terminal will be powered Contact is rated for 1 amp Flame Proving Flame signal is continuously monitored by the IFC The flame rod flame rod wire and proper ground ing are all critical to proving the presence of flame Be cause of the design of the Honeywell flame proving system reading flame signal with a microamp meter will not pro vide reliable and consistent results and is therefore not a recommended practice The IFC has a built in warning E6 if flame signal is approachingthe low threshold Field Test Mode This feature can be used by the service technician to quickly bring a furnace up to high fire Enter ing field test mode will by passthe staging routine and al low the furnace to run at 100 of rated input To use field test mode during a call for heat pressthe fault recall but ton twice within 5 secon
74. W1 con 7 36 tacts to provide a call for low stage heat Modulating furnaces light at 80 of max input For natu ral gas the expected manifold pressure at ignition will be in a range of 1 8 2 5 WC For LP gas the range will be 5 8 6 8 WC NOTE Measure the gas manifold pressure with the burn ers firing After every time the main power is turned off and back on the furnace will enter a calibration rou tine on the next call for heat The inducer will ramp up and down during the calibration routine After calibra tion the furnace will proceed to ignition cycle Furnace MANIFOLD PRESSURES 9 10 11 12 13 NATURAL GAS L P GAS 35 _ 5 WC 35 _ 1 2 50 9 WC 50 2 5 WC 60 1 25 WC 60 3 7 WC 70 1 70 WC 70 5 0 WC 80 2 20 WC 80 6 5 WC 90 2 80 WC 90 8 0 WC 100 3 50 WC 100 10 0 Test Mode is intended to help service person troubleshoot and check out an installed appliance by bringing the furnace up to High fire 100 input by passing the normal modulating routine To enter Field Test Mode the Fault Recall Push Button must be pressed twice within 5 second period at any time during a heating cycle at which time the display will show Ft While the display is showing Ft press ing and holding the Fault Recall Push Button for 3 sec onds will enable the field test mode and override the no
75. able limits listed on individual lengths for inlet and flue and NOT a combination Minimum requirement for each vent pipe is five 5 feet in length and one elbow tee Tee used in the vent flue termination must be included when de termining the number of elbows in the piping system 2 1 2 or 3 diameter pipe can be used in place of 2 diameter pipe Increased Clearance Configurations using 2 45 deg Elbows should be considered equivalent to one 90 deg elbow One 90 elbow should be secured to the combustion air intake connection PRODUCT DESIGN Clearance above grade veranda porch deck or balcony See 1 24 6 i 9 b B Clearance to window or door that may be opened C Clearance to permanently closed window D Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet 61 cm from the center line of the terminal E Clearance to unventilated soffit F Clearance to outside corner Clearance to inside corner H Clearance to each side of center line extended above meter regulator assembly Inside Corner Detail FIXED CLOSED FS OPERABLE Canadian Installations 12 in 30 cm 15 cm for appliances 10 000 Btuh 3 kW 12 in 30 cm for appliances 10 000 Btuh 3 KW and 100 000 Btuh 30 kW 36 in 91 cm for appliances 100 000 Btuh 30 kW 3 ft 91 cm within a hei
76. ace models The High Efficiency Electronic Air Cleaner is designed to remove air contaminants down to 01 microns Carbon filters optional remove odors Dual indicator lights show unit operation ata glance Electronic proving switch cycles the air cleaner On Off with the system fan Durable powder coat paint finish resists corrosion N A CTK01AA Counterflow Subbase Kit For use with Goodman amp Amana Brand modulating 34 5 furnace models These kits are available for the following furnace widths 17 5 wide CFSB17 21 wide CFSB21 and 24 wide CFSB24 The kits must be used to prevent excessive temperature from reaching combustible materials if the furnace is installed on a combustible floor This subbase effectively separated the furnace base and plenum from combustible materials To ensure safe installation do not install the counterflow floor base directly on carpeting tile or other combustible material other than wood flooring Communicating Thermostat Kit Digitally communicating touchscreen thermostat a necessary part of any communicating system Designed for use with compatible Brand or Goodman Brand Air Handlers or Furnaces and outdoor split AC or Heat Pump units This thermostat supports up to three stages of heat two stages of cooling dual fuel applications dehumidification filter maintenance reminders outdoor temperature display and advanced menus including diagnostics The 1 kit includes
77. air is available for the fur nace Improper or insufficient combustion air can ex pose building occupants to gas combustion products that could include carbon monoxide Refer to Combustion and Ventilation Air Requirements Set the furnace on a level floor to enable proper conden sate drainage If the floor becomes wet or damp at times place the furnace above the floor on a concrete base sized approximately 1 1 2 larger than the base of the fur nace Refer to the Horizontal Applications and Consid erations for leveling of horizontal furnaces Ensure upflow or horizontal furnaces are not installed di rectly on carpeting or any other combustible material The only combustible material allowed is wood A special accessory subbase must be used for upright counterflow unit installations over any combustible ma terial including wood Refer to subbase instructions for installation details NOTE A subbase will not be required if an air conditioning coil islocated beneath the furnace between the supply air opening and the combus tible floor Exposure to contaminated combustion air will result in safety and performance related problems Do not install the furnace where the combustion air is exposed to the following substances permanent wave solutions chlorinated waxes or cleaners chlorine based swimming pool chemicals water softening chemicals deicing salts or chemicals carbon tetrachloride halogen type refrigerants cleaning
78. aire fonctionner ces appareils dans un endroit clos assures vous qu il y ait une ventilation directe provenant de l exterier Cette ventilation est n cessaire pour viter le danger d intoxication au CO pouvant survenir si un appareil produisant du monoxyde de carbone continue de fonctionner au sein de la zone confin e Les missions de monoxyde de carbone peuvent etre recircules dans les endroits clos si l appareil de chauffage ou de traitement d air sont en marche Le monoxyde de carbone peut causer des maladies graves telles que des dommages permanents au cerveau et meme la mort B10259 216 13 PRODUCT DESIGN WARNING SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF TURN OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE FURNACE BEFORE TURNING OFF THE ELECTRICAL SUPPLY WARNING POSSIBLE PROPERTY DAMAGE PERSONAL INJURY OR DEATH DUE TO FIRE EXPLOSION SM OKE SOOT CONDENSATION ELECTRICAL SHOCK OR CARBON MONOXIDE MAY RESULT FROM IM PROPER INSTALLATION REPAIR OPERATION OR MAINTENANCE OF THIS PRODUCT Electrostatic Discharge ESD Precautions NOTE Discharge your body s static electricity before touch ing unit An electrostatic discharge can adversely affect electrical components Use the following precautions during furnace installation and servicing to protect the integrated control module from damage By puttingthe furnace the control and the per son at the same electrostatic potential
79. ally manual reset sensors These limits guard against burner flames not being properly drawn into the heat exchanger PRESSURE SWITCHES The pressure switches are normally open closed during opera tion negative air pressure activated switches They monitor the airflow combustion air and flue products through the heat exchanger via pressure tapslocated on the induced draft blower and the coil front cover These switches guard against insuffi cient airflow combustion air and flue products through the heat exchanger and or blocked condensate drain conditions FLAME SENSOR The flame sensor is a probe mounted to the burner manifold assembly which uses the principle of flame rectification to de termine the presence or absence of flame OPERATIONAL CHECKS Troubleshooting WARNING HIGH VOLTAGE TO AVOID PERSONAL INJURY OR DEATH DUE TO yi ELECTRICAL SHOCK DISCONNECT ELECTRICAL POWER BEFORE PERFORMING ANY SERVICE OR MAINTENANCE Refer to the Troubleshooting Codes for assistance in determin ing the source of unit operational problems The dual 7 seg ment LED display will display an error code that may contain a letter and number The error code may be used to assist in troubleshootingthe unit RESETTING From Lockout Furnace lockout results when a furnace is unable to achieve ignition after three attempts during a single call for heat It is characterized by a non functioning furnace and a EO code dis played
80. and thermal damage when installed Ensure alu minum alloy tubing and connectors are coated to pro tect against external corrosion when in contact with masonry plaster or insulation or subjected to re peated wetting by liquids such as water except rain water detergents or sewage WARNING EDGES OF SHEET METAL HOLES BE SHARP USE GLOVES AS PRECAUTION WHEN REMOVING HOLE PLUGS Gas Piping CHECKS Before placing unit in operation leak test the unit and gas con nections WARNING TO AVOID THE POSSIBILITY OF EXPLOSION OR FIRE NEVER USE A MATCH OR OPEN FLAME TO TEST FOR LEAKS Check for leaks using an approved chloride free soap and water solution an electronic combustible gas detector or other ap proved testing methods NOTE Never exceed specified pressures for testing Higher pressure may damage the gas valve and cause subsequent overfiring resulting in heat exchanger failure Disconnect this unit and shutoff valve from the gas supply pip ing system before pressure testing the supply piping system with pressures in excess of 1 2 psig 3 48 kPa Isolate this unit from the gas supply piping system by closing its external manual gas shutoff valve before pressure testing sup ply piping system with test pressures equal to or less than 1 2 psig 3 48 kPA 29 OPERATION Propane Gas TANKS AND PIPING WARNING IF THE GAS FURNACE IS INSTALLED IN A BASEMENT AN EXCAVATED AREA OR CONFINED
81. arances must also accommodate an installation 5 gas electrical and drain trap and drain line con nections If the alternate combustion air intake or vent flue connections are used additional clearance must be provided to accommodate these connections Refer to Vent Flue Pipe and Combustion Air Pipe for details NOTE In addition to the required clearances to combustible materials a minimum of 24 inches service clearance must be available in front of the unit TOP SIDE BOTTOM BOTTOM Upflow Counterflow Horizontal THERMOSTAT LOCATION The thermostat should be placed approximately five feet from the floor on a vibration free inside wall in an area having good air circulation Do not install the thermostat where it may be influenced by any of the following Drafts or dead spots behind doors in corners or under cabinets Hot or cold air from registers Radiant heat from the sun Light fixtures or other appliances e Radiant heat from a fireplace Concealed hot or cold water pipes or chimneys e Unconditioned areas behind the thermostat such as an outside wall Consult the instructions packaged with the thermostat for mounting instructions and further precautions Combustion amp Ventilation Air Requirements WARNING TO AVOID PROPERTY DAM AGE PERSONAL INJURY OR DEATH SUFFICIENT FRESH AIR FOR PROPER COM BUSTION AND VENTILATION OF FLUE GASES MUST BE SUPPLIED M OST HOM ES REQUIRE OUTSIDE
82. ate MANUAL GAS instructions intitul es Comment couper l admission follow the instructions To Turn LEVER SHOWN de gaz de l appareil et appeler un technicien Off Gas To Appliance and call your IN ON POS qualifi ou le fournisseur de gaz Service technician or gas company TO TURN OFF GAS APPLIANCE MN POUR COUPER L ADMISSION En DE GAZ DE L APPAREIL 1 Set the thermostat to lowest setting 1 R gler le thermostat la temp rature la plus bass 2 Turn off all electric power to the appliance 2 Couper l alimentation lectrique de l appareil s il service is to be performed faut proc der des operations d entretien 3 Push the gas control lever to Position 3 Pousse le levier du contr le du gaz OFF ARRET position Do not force Ne pas forcer 4 Replace control access panel 4 Remettre en place le panneau d acc s 0140F00996 REV A 12 PRODUCT DESIGN Adhere to the following warnings and cautions when in stalling adjusting altering servicing or operating the furnace To ensure proper installation and operation thoroughly read this manual for specifics pertaining to the installation and application of this product WARNING TO PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION ADJUSTMENT ALTERATION SERVICE OR MAINTENANCE REFER TO THIS MANUAL FOR ADDITIONAL ASSISTANCE OR INFORMATION CONSULT A QUALIFIED INSTALLER SERVICER AGENCY OR THE GAS SUP
83. ation with Conventional 2 Stage Thermostat DIP switch selects 2 stage heat Call for 2nd Stage Heat Thermostat contacts close R to W1 W2 After a successful Light Off Sequence and expiration of the Ignition Stabilization Period e The IFC adjusts to the low firing rate After 2 minutes the IFC increases to 80 e Thereafter the IFC will increase 10 at a rate of 1 per second every 10 minutes for the remainder of the call for heat e circulator is adjusted to the appropriate CFM corresponding to the current firing rate UNIT CALL FOR HEAT ENDS IGNITION 80 S 78 3 50 FOR I2ND STAGE HEAT MIN TIME Call for 2nd Stage Heat with 1st Stage call for heat call in progress with conventional 2 Stage Thermostat e The IFC increases the firing rate to 100 at a rate of 1 per second for the remainder of the W2 call e circulator is adjusted to the appropriate CFM corresponding to the current firing rate 34 Call for 2nd Stage Heat satisfied Call for 1st Stage Heat remains e IFC remains at the current firing rate until the 1st Stage call for heat is satisfied HEATING OPERATION wirH CTKO1 Thermostat Communi CATING e When the Thermostat Heat Setup DIP switch is set to 2 Stage heat the IFC operation will be compatible with a CTKO1communicating thermostat When acall for heat is sent the furnace will
84. be ignored e The circulator will operate according to one of the selectable ramping profiles When the cool request is satisfied the circulator is de energized per one of the selectable ramping pro files 2 STAGE COOLING CONVENTIONAL THERMOSTAT e 2 Stage Cooling DIP switch on the IFC must be ON to enable 2 stage cooling control with a conven tional thermostat for 2 stage cooling is signaled by the shorting of R to Y2 while a valid call for first stage cooling exists After the cool fan on delay the circulator is ener gized at the low cooling speed when the 1 stage cool request is detected and switches to high cooling speed immediately after the 274 stage cool request is de tected The circulator will be controlled according to the se lected ramping profile e When the cool requests are satisfied the circulator is de energized per the selected ramping profile 41 OPERATION COOLING OPERATION WITH A COMMUNICATING THERMOSTAT AND CoNVENTIONAL SINGLE Stace A C e The call for cooling will be communicated the ClimateTalk protocol e The Y1terminal of the IFC becomes output via the on board Y1 relay e The IFC does not provide short cycle protection e circulator operates as commanded by the com municating thermostat COOLING OPERATION WITH A COMMUNICATING THERMOSTAT AND Outpoor e The furnace receives the demand from the com municating outdoor u
85. cal connections ensure that the supply voltage frequency and phase correspond to that speci fied on the unit rating plate Power supply to the furnace must be NEC Class 1 and must comply with all applicable codes The furnace must be electrically grounded in accordance with local codes or in their absence with the latest edition of The National Electric Code ANSI NFPA 70 and or The Canadian Electric Code CSA C22 1 Use a separate fused branch electrical circuit containing prop erly sized wire and fuse or circuit breaker The fuse or circuit breaker 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 loca tion 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 Line polarity must be observed when making field connec tions Line voltage connections can be made through either the right or left side panel The furnace is shipped configured for a right side left side for counterflows electrical connec tion with the j unction box located inside the burner compart ment To make electrical connections through the opposite side of the furnace the junction box mus
86. ch having 6 switches Switches are numbered from 1 to 18 The ON position is UP The chart shows all 18 DIP switches their function and their factory position Switches 1 amp 2 Select cooling speed A B C or D Factory setting is D both switches up in the ON position These switches are ignored when using a CTK0 communicating thermostat Switches 3 amp 4 Select heating speed A B Cor D Factory setting is B 3 ON 4 OFF These switches are ignored when using a CTK0 communicating thermostat Switches 5 amp 6 Select continuous fan speed A B Cor D Factory setting is B 5 ON 6 OFF These selections are based off of percentages of the maximum CFM that each model furnace is rated for A 25 B 50 C 75 D 100 These switches are ignored when using a CTK0 communi cating thermostat Switches 7 amp 8 Select cooling ramping profiles A B C or D Factory setting is A both switches down in the OFF position Each ramping profile provides a different routine for the indoor blower motor to follow in a call for cooling Rather than bringing the motor up to cooling speed imme diately ramping profiles bringthe motor up to cooling speed in stages NOTE Reductions in CFM for ramping are not added to re ductions in CFM for DEHUM Example CFM is reduced for the fist several minutes of a cooling call by 15 if a call for DEHUM is present during this CFM reduction CFM will not be reduced by another 15 Rather after the ra
87. continuously monitored during the Igniter Warm up and Ignition Activa tion Periods ECM Motor An Emerson UltraTech four wire indoor fan motor pro vides supply air to the conditioned space Thisisthe same motor used on Goodman amp Amana previous generation com municating furnaces The ECM motor consists of two sections 1 A motor body containing 3 phase motor windings 2 Anelectronic control module end bell In the event of a non operating motor the following items should be checked There are two harnesses which connect the blower motor to the IFC The line voltage 5 Pin har ness provides 115 volts directly off of the IFC L1 and neu tral terminals on hp ECM motors On furnaces with 34 and 1 HP ECM motors L1 is fed to the motor through an induc tor coil The inductor coil conditions the power supply to the motor smoothing out spikes and electrical noise The low voltage harness is a 4 wire harness that supplies 12 volts DC to terminals 1 amp 4 of the motor and communicat ing signals on terminals 3 amp 4 WARNING THE CONTROL MODULE CONTAINS COMPONENTS WHICH CAN HOLD AN ELECTRICAL CHARGE FOR SEVERAL MINUTES BEFORE THE MOTOR IS TAKEN APART IT MUST BE ALLOWED TO DISSIPATE VOLTAGE BY WAITING FIVE MINUTES BEFORE IT IS INSPECTED INTERNALLY THE END BELL CAN BE SEPARATED FROM THE MOTOR BODY BY REMOVING THE THREE SCREWS WHICH JOIN THEM ONCE THE SCREWS ARE REMOVED THE INTERANL HARNESS CAN BE SEPARATED THE CONTROL
88. ditioned space The anticipator is a part of the thermostat and if it should fail for any reason the thermostat must be replaced Other thermostats have a cycle rate adjustment to adjust cycles per hour This should be set to match system type S 4 CHECKING TRANSFORMER AND CONTROL CIRCUIT A step down transformer 120 volt primary to 24 volt sec ondary 40 VA Heating and Cooling Models supplies ample capacity of power for either operation warninc HIGH VOLTAGE DISCONNECT ALL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH 1 Remove blower compartment door to gain access to the thermostat low voltage wires located at the fur nace integrated control module 2 Remove the thermostat low voltage wires at the fur nace integrated control module terminals With Power On and Door Interlock Switch closed LINE VOLTAGE NOW PRESENT 3 Use voltmeter check voltage across terminals R and C Must read 24 VAC 4 No voltage indicates faulty transformer open fuse bad wiring bad splice or open door interlock switch 5 Check transformer primary voltage at incoming line voltage connections fuse splices and blower door interlock switch 6 If line voltage is available to the primary side of transformer and not at secondary side the trans former is inoperative Replace 7 After completing c
89. ds the display will change to Ft then press and hold the fault recall button for a few seconds until the display flashes Ft The furnace will stay in field test mode for 5 minutes or until the call for heat is re moved Dual 7 Segment Displays The modulating furnace IFC has dual 7 segment displaysto provide service information This information includes present thermostat demand CFM and fault codes Fault Recall Thisfeature allowsthe service person to check for any fault history The board memory is capable of re cording and storing 10 fault codes To use thisfeature the furnace must not have an existing thermostat call Pres sure fault recall button from 2 5 seconds until the display goes blank then release all faults will be displayed one at a time beginning with the most recent max of 3 consecu tive faults will be stored When all errors have been dis played the display returns to ON To erase stored faults hold the fault recall button until the display starts flashing then release PRODUCT DESIGN WARNING TO PREVENT POSSIBLE EQUIPMENT DAMAGE PROPERTY DAMAGE PERSONAL INJURY OR DEATH THE FOLLOWING BULLET POINTS MUST BE OBSERVED WHEN INSTALLING THIS UNIT WARNING POSSIBLE PROPERTY DAMAGE PERSONAL INJURY OR DEATH DUE TO FIRE EXPLOSION SMOKE SOOT CONDENSATION ELECTRICAL SHOCK OR CARBON MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION REPAIR OPERATION OR MAINTENANCE OF THIS PRODUCT CLEARANCES AND
90. ducted from the outside or Direct vent dual pipe central forced air furnace in which all combustion air supplied directly to the furnace burn ersthrough a field installed combustion air pipe This furnace may be used as a construction site heater ONLY if all of the following conditions are met e The vent system is permanently installed per these in stallation instructions e Aroom thermostat is used to control the furnace Fixed jumpers that provide continuous heating CANNOT be used and can cause long term equipment damage e Returnair ducts are provided and sealed to the furnace Areturn air temperature range between 60 F 16 C and 809F 279C is maintained Air filters are installed in the system and maintained during construction replaced as appropriate during con struction and upon completion of construction Theinput rate and temperature rise are set per the fur nace rating plate e 100 outside air is provided for combustion air require ments during construction Temporary ducting can be used NOTE Do not connect the temporary duct directly to the furnace The duct must be sized for adequate combus tion and ventilation in accordance with the latest edi tion of the National Fuel Gas Code NFPA 54 ANSI Z223 1 or CAN CSA B149 1 Installation Codes e Thefurnace heat exchanger components duct system air filters and evaporator coils are thoroughly cleaned followingfinal construction clean up e Al
91. e A MVM970603BN D A MVM970803BN E D A MVM970804CN D A B MVM971005CN MVM971205DN CVM970603BN c D A B CVM970803BN C D A CVM970804CN CVM971005CN D 100 shown will vary proportionally with the gas valve BTU H input Airflow Table Brower Heat Orr DeLay 5 The integrated control module provides a selectable heat off delay function The heat off delay period may be set to 90 120 150 180 seconds using the DIP switches or jumper provided on the control module The delay isfactory shipped at 150 seconds but may be changed to suit the installation requirements and or homeowner preference ComfortNet System OVERVIEW NOTE DIP switch 13 MUST be set to match thermostat type To use the communicating thermostat DIP switch 13 must be set to ON position This is also the correct setting for a non communicating 2 stage thermo stat To use the CTK02 amp CTK04 modulating ther mostat check to make sure DIP switch 13 is in the OFF position factory position Thisis also the correct position when using a non communicating single stage thermostat The ComfortNet system is a system that includes a ComfortNet compatible furnace and air conditioner or heat pump with a CTKO thermostat A valid ComfortNet system could also be a compatible furnace CTKO communicating single stage air conditioner Any other system c
92. e Calibration routine immediately If during the 5 minute interval LPS is sensed closed or call for heat is removed the IFC clearsthe error code and resumes normal operation OPERATION High Pressure Switch Operation e High Pressure Switch action is used to determine the inducer speed required to achieve the 100 firing rate of the appliance The determination is made by the IFC during the calibration process HPS must remain closed during 100 fire tion If it opens during 100 fire operation the IFC will increase the inducer speed at a rate of 1 sec in an attempt to re close the pressure switch up to the maximum allowed RPM If the HPS is re closed successfully the IFC will complete the Heat mode and perform the Calibration routine on the next call for heat If the HPS remains open the IFC will end the Heat mode through the Post purge and perform the Calibration routine immediately error code E9 is flashed until calibration routine is successful High Pressure Switch check takes place during the Calibration routine If the switch is stuck open or closed calibration will not be completed and the ap propriate error code will be logged and displayed Hot Surface Igniter Operation The IFC energizes a relay to control the line voltage Hot Surface Igniter The HSI warm up time will be fixed for all ignition trials Both the continuity of the igniter and the ability of the relay to energize the igniter are
93. e gas ket between the inducer and the collector box cover any air leak here will have a negative effect on combus tion Checkthe orifice hole inthe collector box it must be free of burrs on both sides Make sure burners are clean not out of position and line up correctly with exchanger tubes includingthe heat Venti exchanger orifice plate between the burners and the heat exchanger tubes make sure it is not loose missing The venting system should be planned and installed with screw or hanging down between the burners and heat the following in mind ai exchangers causing flame impingement 4 Make sure the field installed gas line is not binding and causing distortion of burner assembly Burner Flame Combustion Quality Combustion quality can be affected by several factors Major factors are venting and draining 49 Ma CHECKS If the furnace is installed as one pipe system make sure the surrounding area and structure are adequate to provide combustion air 6 Make sure there are no cabinet air leaks allowing sup ply air to affect combustion 7 If heat exchanger integrity is uncertain follow proce dures in Service Bulletin SF 041 Memory 5 Memory chips are a service only item and are not sent out with new equipment They are used only in the rare occur rence where communicating equipment shared data needs to be restored Memory chips should not be routinely installed at the
94. ed and grounded Line and Neutral polarity must be correct OPERATION Upon power up all segments in the dual seven segment display will illuminate briefly and then display ON indicat ing the furnace is standing by ready to receive commands from the thermostat Once a call for heat is received by the furnace control board the furnace will enter a calibration routine The calibration routine allows the furnace to adapt to the installed venting and combustion air piping The in ducer will ramp up and down momentarily to determine what the closing points and opening points of the pressure switches are compared to inducer RPM The calibration routine is described in detail on page 43 The illustrations following show firing rates with 24 volt legacy thermostats as well as with communicating thermostats Modulating furnaces light off at 80 firing rate The dual seven segment display will alternate showing 1 Current Operating Mode legacy or communicat ing call for heat C communicating call for cooling C1 C2 legacy call for cooling Y G 0 P1 P2 legacy call for heat heat pump Y call for constant fan 2 Gas heat firing rate 35 HI 100 3 A demand for supply air 4 Air Quantity Single or double digit displayed CFM X 100 UNIT CALL FOR HEAT ENDS 100 IGNITION 80 10 MINS D 78 ul 5 57 iL MIN TIME Operation with Conventional 1 Stage The
95. er mainte nance 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 01900 CAN ULCS111 standards If the furnace is installed without filters the war ranty will be voided On upflow units guide dimples locate the side return cutout locations Use a straight edge to scribe lines connecting the dimples Cut out the opening on these lines NOTE An under sized opening will cause reduced airflow 32 AIR FLOW CENTRAL RETURN 2 GRILLE SIDE RETURN EXTERNAL FILTER RACK KIT EITHER SIDE Possible Upright Upflow FILTER ACCESS DOOR RETURN DUCT CENTRAL FILTER __ i SUPPORT n BRACKET Field Supplied im AIR FLOW Possible Upright Counterflow Filter Locations Startup Procedure Before placing any furnace into service for the first time or after performing service on an existing furnace the build ing gas piping system building piping connection to the furnace and gas train inside the furnace cabinet must be proven safe and leak free Verifying a leak free status is most thoroughly accomplished when a combination of ap proved methods is used meter dial test electronic gas leak detector liquid leak detector solution The furnace must have a 115 volt power supply properly connect
96. er than to have the system compo nents installed completely and correctly On the initial power up or any time that power to the furnace is switched off then back on again and a call for heat is applied the fur nace will go through a calibration routine During the cali bration routine the IFC runs the induced draft blower at different speedsto determine the opening and closing points of the pressure switches It records this information and uses it as reference points for determining the draft in ducer speeds for all gas input rates from 3596 10096 Before beginning a calibration routine the IFC will check that both pressure switches are in the open position The IFC powers the draft inducer at a predetermined speed and checks to see if the LPS has closed If the LPS is not closed the IFC will increase the draft inducer RPM in small steps until it detects a closed LPS The IFC then begins to reduce RPM until it detects that the HPS is open e records the RPM point where the HPS went open e The IFC then adds predetermined amount of draft inducer RPM to both the recorded points e These new RPM points are the draft inducer speed for 35 lowest input rate and 100 highest input rate The IFC then is able to control draft inducer speed through the IFC VFD throughout the entire range of modulating operation 44 100 Max Closed RPM HPS Closed LPS Time Inducer Calibration Routine ABBREV
97. f any unburned gas or re sidual products of combustion at the beginning of a furnace operating cycle prior to initiating ignition OPERATION Beginning from the moment the pressure switch is sensed closed and lasting until the ignition source is energized e nter purge Time The period of time intended to allow for the dissipation of any unburned gas or re sidual products of combustion just prior to initiating ignition retries during the Ignition Retries sequence Post purge Time The period of time to allow for the dissipation of any unburned gas or residual products of combustion at the end of a furnace burner operat ing cycle Post purge begins at the loss of flame sense e Ignition Stabilization Period The period between sensing of the main burner flame and the transition from the Ignition Firing Rate to the Target Firing Rate e Ignition Recycles The additional attempts within the same thermostat cycle for ignition after loss of the supervised ignition source or the supervised main burner flame e Ignition Retries The additional attempts within the same thermostat cycle for ignition when the super vised main burner flame is not proven within the Trial for Ignition Period Low Fire Rate The lowest firing rate the IFC trols to during a heating cycle High Firing Rate The maximum firing rate that an installed appliance can attain based on manifold ori fices and the high pressure switch setting e I
98. f the heat exchanger firing tubes INpucED DRAFT AND CIRCULATOR BLOWERS The bearings in the induced draft blower and circulator blower motors are permanently lubricated by the manufacturer No fur ther lubrication is required Check openings on motor hous ing for accumulation of dust which may cause overheating Clean as necessary CONDENSATE TRAP AND Drain System QUALIFIED SERVICER Onty Annually inspect the drain tubes drain trap and field supplied drain line for proper condensate drainage Check drain system for hose connection tightness blockage and leaks Clean or repair as necessary FLAME SENSOR QUALIFIED SERVICER ONLY Under some conditions the fuel or air supply can create a nearly invisible coating on the flame sensor This coating acts as an insulator causing a drop in the flame sense signal If the flame sense signal dropstoo low the furnace will not sense flame and will lock out The flame sensor should be carefully cleaned by a qualified servicer using steel wool SERVICING S 1 5 2 S 3A S 3B 5 4 5 300 5 301 5 302 5 303 5 304 5 304 SERVICING CHECKING VOLTAGE iii ctt trs 54 305 CHECKING WIRING ei inciter 54 306 THERMOSTAT AND WIRING 54 307 HEATING ANTICIPATOR CYLCE RATE 55 308 CHECKING TRANSFORMER 5 309 AND CONTROL CIRCUIT nero 55 5 30 CHECKING PRIMARY LIMIT CONTROL 55 531 CHECKING AUXILIARY LIMIT CONTROL
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100. gas control lever appelez le service des incendies Never use tools If the lever will not push in or turn by C Ne pousser ou tourner la manette d admission du gaz hand don t try to repair it call a qualified service qu la main Ne jamais emploer d outil cette fin technician Force or attempted repair may result in a fire Si la manette reste coinc e ne tenter pas de la or explosion r parer appelez un technicien qualifi Quiconque tente de forcer la manette ou de la r parer peut D Do not use this appliance if any part has been underwater E provoquer une explosion ou un incendie Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been underwater D Ne pas se servir de cet appareil s il a t plong dans l eau m me partiellement Faire inspecter l appareil par un technicien qualifi et remplacer toutr partie du syst me de contr le et toute commande qui ont t plong es dans l eau OPERATING INSTRUCTIONS MO MISE EN MARCHE 1 STOP Read the safety information above on 1 ARRETEZ Lisez les instructions de s curit dans la this label section sup rieure de cette tiquette 2 Set the thermostat to lowest setting 2 R gler le thermostat la temp rature la plus basse 3 Turn off all electric power to the appliance 3 Couper l alimentation lectrique de l appareil 4 This appliance
101. ght 15 ft 4 5 m above the meter regulator assembly OPERABLE CLOSED V VENT TERMINAL AIR SUPPLY INLET AREA WHERE TERMINAL 15 NOT PERMITTED FIXED DIRECT VENT TERMINAL CLEARANCES US Installations 12 in 30 cm 15 cm for appliances 10 000 Btuh 3 kW 9 in 23 cm for appliances gt 10 000 Btuh 3 KW and 50 000 Btuh 15 kW 12 in 30 cm for appliances 500 000 Btuh 15 kW 1 Canadian Installations U S Installations Clearance to service 3 ft 91 cm regulator vent outlet J Clearance to nonmechanical air supply inlet to building or the combustion air inlet to any other appliance 6 in 15 cm for appliances 10 000 Btuh 3 kW 12 in 30 cm for appliances gt 10 000 Btuh and 100 000 Btuh 30 KW 36 in 91 cm for appliances gt 100 000 Btuh 30 kW 6 in 15 for appliances 10 000 Btuh 3 kW 9 in 23 cm for appliances gt 10 000 Btuh 3kW and 50 000 Btuh 15 kW 12 in 30 for appliances gt 50 000 Btuh 15 kW K Clearance to a mechanical ft 1 83 m 3 ft 91 cm above if within air supply inlet 10 ft 3 m horizontally L Clearance above paved sidewalk or 7 ft 2 13m t paved driveway located public property M Clearance under veranda porch 12 in 30 deck or balcony In accordance with the current CSA B149 1 Natural Gas and Propane
102. gnition Firing Rate The target firing rate at which the appliance always lights off The appliance stays at this firing rate until the Ignition Stabilization Pe riod expires It then moves to the target firing rate called for by the operating sequence Target Firing Rate The firing rate that the IFC con trolsthe inducer to attain at a given time in the op erating sequence Heat Fan On Delay The period between proof of the supervised main burner flame and the activation of the blower motor at the low heat speed Heat Fan Off Delay The period between the loss of supervised main burner flame after the call for heat has ended and the deactivation of the blower motor 2 Stage On Delay This applies to systems config ured for 1 stage thermostats The length of time operating in normal low fire mode before switching to mid fire mode e Auto Restart Delay The time delay waited before the control is able to perform a new trial for ignition in the case of Soft Lockout Soft Lockout A state caused a system fault such as loss of flame or pressure switch failure Hard Lockout A state caused by a failure internal to the control or by a system fault such as a flame rollout Fault Debouncing Time The period between sys tem fault occurring and the IFC recognizing the fault has occurred Thistime varies depending on the spe cific fault e Factory Shared Data Data used by a ClimateTalk device for spec
103. go through the Light Off Sequence After the successful Light Off Sequence and expiration of the Ignition Stabili zation Period e The IFC adjusts to the low firing rate After 2 minutes the IFC accepts the specific Heat Requested Demand e the differential is equal to or less than 2 degrees the IFC will follow the conventional 2 Stage algorithm equivalent to a W1 request e Ifthe heat differential is greater than 2 degrees the IFC will follow the conventional 2 Stage algorithm equivalent to a W2 request e The circulator will operate per the heat airflow pro file HEATING OPERATION witH CTKO2 CTKO3 amp 4 THERMOSTAT MODULATING COMMUNICATING When the Thermostat Heat Setup DIP switch is set to 1 Stage heat the IFC operation will be compatible with a modulating communicating thermostat 02 e Whena call for heat is sent the furnace will go through the Light Off Sequence After the successful Light Off Sequence and expiration of the Ignition Stabili zation Period e The IFC adjusts to the low firing rate After 2 minutes the IFC accepts the specific Heat Requested Demand e Ifthe differential is 2 degrees or less the Heat Cur rent Demand Status will show 50 e If the specific Heat Requested Demand is above 2 degrees the Heat Current Demand Status will track the specific Heat Requested Demand e The circulator will operate per the heat airflow pro file Drain P
104. he furnace features a Honeywell gas valve capable of variable gas input rates as low as 35 and up to 100 of rated input Indoor air is delivered by a variable speed ECM mo tor which bases the CFM need off of the burner input The modulating furnace operation is based off of negative pres sure created by the draft inducer The Integrated Furnace Control IFC receives commands from the room thermo stat The IFC then controls the RPM of the 3 phase in ducer by varying the frequency and voltage to the inducer This is known as variable frequency drive VFD PRODUCT DESIGN Acceptable Equipment Combinations With CT KO Communicating Thermostat 1 Modulating furnace alone 2 Modulating furnace with Goodman brand Amana brand communicating split A C or H P unit no sepa rate dual fuel control is required 3 Modulating furnace with non communicating 1 stage A C split unit can not support 2 stage non communicating heat pump With Conventional Non Communicating Thermostat Single or Multi Stage 1 Modulating furnace alone 2 Modulating furnace with Goodman brand Amana brand communicating split A C or H P unit a dual fuel thermostat or separate dual fuel control is re quired for H P 3 Modulating furnace with non communicating split A C or H P a dual fuel thermostat or separate dual fuel control is required for H P Product Application This furnace is primarily designed for re
105. heck and or replacement of trans former and check and or repair of control circuit re install blower compartment door 8 electrical power and verify proper unit opera tion S 300 CHECKING PRIMARY LIMIT CONTROL All modulating furnaces use a nonadjustable automatic reset bi metal type limit control The primary limit con trol islocated onthe front panel of the furnace between heat exchanger tubes This is a normally closed control warnine HIGH VOLTAGE Disconnect ALL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH 1 Turn off all voltage sources 2 Remove the two wires from the limit switch 3 Using an ohmmeter check for a closed circuit across the two limit contacts this will be the same reading that you see by touching your two meter leads to gether S 301 CHECKING AUXILIARY LIMIT CONTROL Automatic Reset Auxiliary Limit Located in Blower Hous ing Modulating furnaces use an auxiliary limit s automatic reset control connected in series with the main limit switch If its temperature should be exceeded it will open inter rupting the voltage in the limit circuit The auxiliary limit is located on the side of the blower housing This is a nor mally closed switch To check auxiliary limits perform the following steps HIGH VOLTAGE Disconnect ALL POWE
106. iels des lesions A This appliance does not have a pilot It is equipped corporelles ou la perte de vies humaines with an ignition device which automatically lights the burner Do not try to light the burner by hand A Cet appareil ne comporte pas de veilleuse Il est muni d un dispositif d allumage qui allume B BEFORE OPERATING smell all around the appliance automatiquement le br leur Ne pas tenter area for gas Be sure to smell next to the floor d allumer le br leur manuellement because some gas is heavier than air and will B AVANT DE LE FAIRE FONCTIONNER settle on the floor renifler tout autour de l appariel pour dec ler une odeur de gaz Renifler pr s du plancher car TO DO IF YOU SMELL GAS certains gaz sont plus lourds que l air et Do not try to light any appliance peuvent s accumuler au niveau du sol QUE FAIRE S IL UNE ODEUR DE GAZ do 11 phone in your building o Ne pas tenter d allumer d appareils a mmediatelyscall your gas supplier fromaneighbors o Ne toucher aucun interrupteur ne as vous servir phone Follow the gas supplier s instructions des telephones dahs le a o If you cannot reach your gas supplier a Il the fire d o Appelez imm diatement votre fournisseur de gaz depuis call the fire department n un voisin Suivez les instructions du fournisseur de gaz o Sivous ne pouvez rejoindre le fournisseur de gaz C Use only your hand to push in or turn the
107. iewed by looking through the sight glass in the blower compartment door The failure codes are retrieved via an on board momen tary push button switch Pressing the button for 2 5 sec onds will force the failure codes to be displayed on the diagnostic indicator 59 SERVICING S 314 CHECKING FLAME SENSOR A flame sensing device is used in conjunction with the ig nition control module to prove combustion If proof of flame is not present the control will de energize the gas valve and retry for ignition or lockout warninc 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 60 Flame signal is continuously monitored by the IFC flame rod flame rod wire and proper grounding are all critical to proving the presence of flame Because of the design of the Honeywell flame proving system reading flame signal with a microamp meter will not provide reli able and consistent results and is therefore not recom mended practice The IFC has a built in warning E6 if flame signal is approaching the low threshold NOTE Contaminated fuel or combustion air can create a nearly invisible coating on the flame sensor This coating works as an insulator causing a loss in the flame sense signal If this situation occurs the flame sensor must be cleaned with steel wool Troubleshootin
108. ific configuration parameters This data will be programmed in at the Goodman factory HSI Warm Up Same for all trials 15 sec 17 sec 3 sec 1 sec D 2 2 5 E Exchanger Prepurge nition Activation Period Gas Valve Sequence Period lame Debounce Period nition Recycles lame Failure Response Time 4 sec 2 S 3 5 TFI IAP Time it takes to debounce flame presence or failure 3 trials total 3 flame losses total of target high fire rate of target high fire rate Ignition Activation Chart Ignition Retries When flame is not sensed during the Trial for Ignition Pe riod e valve is de energized e Theinducer remains energized at ignition speed dur ingthe Inter purge Period circulator if already running remains energized at the current CFM for the circulator fan off delay period When the Inter purge Period expires the control pro ceeds to the HSI Warm up and then a new Trial for Ignition is started again for up to a maximum of two additional trials 3 attempts total After the third Trial for Ignition has failed to light the burner the IFC proceeds to Soft Lockout through the Post purge where the inducer remains energized at the ignition speed Error code EO is flashed during the Soft Lock out period The retry count is cleared if flame is sensed for longer than 10 seconds after ex
109. ing the modulating furnace with a heat pump the preferred installation would include a communicating thermostat A communicating thermostat provides control of gas heat and heat pump operation and eliminates the need for a separate dual fuel control A legacy dual fuel thermostat could also be used with 24 volt wiring to con trol the gas furnace and heat pump If a communicating thermostat or legacy dual fuel thermostat are not used the AFE18 60A kit must be added to provide control of the equipment This control is mounted indoors near the fur nace and provides terminals for thermostat furnace and heat pump wiring The AFE18 60A may be used with or without a separate outdoor thermostat OT18 60A OUTDOOR THERMOSTAT For use in a legacy dual fuel installation to lock out the heat pump at a selected temperature CFSB17 21 24 COUNTER FLOW BASE The CFSB base must be used when installing a CVC97 fur nace in the vertical position on a combustible floor without a coil under the furnace 11 LIGHTING INSTRUCTIONS md FOR YOUR SAFETY LIRE AVANT DE METTRE READ BEFORE OPERATING EN MARCHELIRE MARNI NG If you do not follow these instructions AVERTISSEMENT Quiconque ne respecte pas Exactly a fire or explosion may result causing property la lettre les instructions dans le pres nt manuel damage personal injury or loss of life risque de d clencher un incendie ou une explosion entra nant des dommages mat r
110. is logged and displayed indicating the rollout switch circuit has opened e future thermostat heat requests are ignored The IFC will remain in this state until the rollout switch closes Once the manual rollout switch has been re set the IFC will clear the error code and return to normal operation If the rollout switch circuit opens in any mode other than Heat it will be ignored Limit Switch Operation If the limit switch circuit is open during a heating cycle e The valve isimmediately de energized e inducer will run for the Post purge period at its current speed e The circulator is immediately energized at high heat speed The IFC will remain in this state until the limit switch circuit closes e The IFC logs and displays an error code indicating the limit circuit is open e Oncethe limit switch circuit closes and a call for heat is present a new ignition sequence is started and the circulator will remain energized for the selected fan off delay If the burner islit before expiration of the selected fan off delay the fan off timing is 46 stopped and the circulator will adjust to the speed requested by the heating sequence If the limit switch circuit opens in any mode other than Heat it will be ignored Pressure Switch Configuration e The IFC monitors the contacts of a SPST single pole single throw low pressure switch with a set point that ensures the switch will be closed at approximately 35
111. iting Trial for Ignition or upon exit of Soft Lockout 12 sec 10 sec 5 o EN c N 5 71 g g Post purge 29 sec Other Parameters Low Fire Rate Ignition Fire Rate High Fire Rate 30 sec 35 80 100 45 OPERATION Ignition Recycles When flame is established during Trial for Ignition and then lost e gas valve is de energized inducer moves to the ignition speed and holds forthe Inter purge Period e The circulator if already running remains energized at the current CFM for the circulator fan off delay period e When the Inter purge Period expires the control pro ceeds to the HSI Warm up and then a new Trial for Ignition is started maximum of two recycles 3 flame losses are al lowed on a single call for heat before the control pro ceeds to Soft Lockout through the Post purge where the inducer remains energized at the current speed Error code EO is flashed during the Soft Lockout period e Therecycle count is not cleared until the current de mand for heat is satisfied or upon exit of Soft Lock out Rollout Circuit Operation If the manual reset rollout switch circuit opens during a heating cycle e The valve isimmediately de energized e inducer will run for the Post purge period at its current speed e Ifthe circulator fan ison it will run for the normal fan off delay at the current heat speed e Anerror code
112. ke and exhaust pipes located side by side or with one pipe above the other See the section in this manual under Vent Flue and Com bustion Air Pipe Terminations for more information or consult the Installation Instructions 10 805 Horizontal Installation Vertical Installation LPLPO3 LOW LP GAS PRESSURE SHUT OFF KIT Installation of the LPLPO3 kit is recommended on every LP converted furnace to protect the furnace against low LP gas supply pressure Low LP supply pressure can cause poor combustion and carbon in the heat exchanger The LPLP03 kit will open the electrical circuit to the gas valve in the event of low supply pressure The kit contains a pressure switch gas fittings and electrical harness to connect the switch in series with the gas valve LPM 09 LP CONVERSION KIT This furnace is factory equipped to operate on Natural Gas but may be field converted to operate on LP gas To con vert a MVM97 or CVM97 furnace to operate on LP gas the LPM 09 conversion kit must be used The LPM 09 kit contains a modulating gas valve ready for use with LP gas as well asa set of 1 25 mm orifices to replace the factory installed natural gas orifices Do not attempt to convert or adjust a modulating furnace gas valve Factory burners are suitable for both gases L P and Natural Burner re placement is not required when the furnace is converted for use with L P gas AFE18 60A DUAL FUEL ACCESSORY When install
113. l panel Proper grounding can be con firmed by disconnectingthe electrical power and measur ing resistance between the neutral white connection and the burner closest to the flame sensor Resistance should be less than 10 ohms The ignition control is a combination electronic and elec tromechanical device and is not field repairable Complete unit must be replaced A WARNING These tests must be completed within a given time frame due to the operation of the ignition control The ignition control is capable of diagnosing many furnace failures to help in troubleshooting The PCBKF201 and PCBKF 202 controls utilize a dual 7 segment LED display to indicate diagnostic codes When the control is powered up normally the light will be on continuously The PCBKF201 and PCBKF202 displays will indicate ON when powered and in standby mode This can be used to test for 120 volts and 24 volts to the control since both must be present for the light to be on If this step fails check for 120 volts to the control and check the transformer and its associated wiring If this step is successful give the control a call for heat and wait five 5 seconds or until the furnace goes into lockout If the con trol detects a failure it will now be shown on the diagnostic indicator light display Refer to the Abnormal Operation section in the Sequence of Operation section of this manual for more detail on failure codes The indicator light display may be v
114. le from the motor control unit end bell Connect the 4 wire connector of the diagnostic tool to the end bell communicating connector Attach one of the alligator clips of the diagnostic tool to the 24 volt hot terminal of the furnace transformer and the other alligator clip to the 24 volt common ground terminal The alligator clips are not polarity sensitive Turn ON furnace power The orange button of the diagnostic tool sends a sig nal to the UltraTech motor to rotate when pressed There may be a five second delay between the time the button is pressed and the motor begins to rotate If the orange button does not illuminate when pressed the tool is not connected to a 24 volt supply or it is defective The GREEN LED isan indicating signal that communication is taking place If the green LED does not blink the end bell should be replaced OPERATIONAL CHECKS BL C ML Normal condition condition y None e None Flashes ee of box reset pe o LED Learn button depressed Rapid Flashing Normal network traffic Control is talking on None network as expected On Solid Data 1 Data 2 miss wire Data 1 and data 2 wires reversed Check communications at furnace thermostat or wiring data 1 data 2 communicating compatible wires outdoor AC HP Green Receive Short between data 1 and Check wire connections at LED data 2 wires terminal block Short be
115. lead to the ground screw on the furnace junction box NOTE Ground wire may not be present on all dehumidistats 5 Turn ON power to furnace To enable the dehumidify function on the integrated control mod ule set the dehumidification ENABLE DIP switch from OFF to ON Once the switch is set the dehumidify function is enabled dur ing a combination call for cooling T Stat and dehumidification DEHUM Stat Referto the DIP switch chart in the back sec tion of this manual FUEL APPLICATIONS This furnace can be used in conjunction with a heat pump in a fossil fuel application Afossil fuel application refersto a com bined gas furnace and heat pump installation which uses an outdoor temperature sensor to determine the most cost effi cient means of heating heat pump or gas furnace heat pump thermostat with three stages of heat is required to properly use a two stage furnace in conjunction with a heat pump Refer to the fossil fuel kit installation instructions for additional thermostat requirements Strictly follow the wiring guidelines in the fossil fuel kit installa tion instructions All furnace connections must be made to the furnace two stage integrated control module and the FURNACE terminal strip on the fossil fuel control board 115 Line Connection or ACCESSORIES HUMIDIFIER AND ELECTRONIC AIR CLEANER WARNING HIGH VOLTAGE TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK D
116. left or right side down CVM97 models may be installed down flow or horizontally with left or right side down Do not install any furnace on its back Horizontal Installations 1 Horizontal installations require 5 5 under the furnace to accommodate the drain trap 2 Horizontal furnaces must be installed with 34 slope from back to front to permit condensate flow towards the front of the furnace When installing a MVM97 horizontally with the left side down there two options for connecting the vent pipe to the furnace 1 Venting may be connected to the furnace vent pipe fit ting on the original top now the end of the furnace 2 Theinternal vent pipe and elbow may be removed from the furnace to permit the vent to exit the top original side of the furnace If this option is used an RF000142 Vent Drain coupling must be used to keep condensate from collecting in the inducer assembly Refer tothe following instructions and illustration 20 Insert flange Cut 2 Y long RF000142 y E E AAA fe A LJ gt Es e ojo D 4 gt H Figure 10 FLANGE N AA les 3 5 VF 0 gt Vent Flue Pipe Cuts Figure 11 Remove screws from vent flange Remove internal elbow and vent pi
117. lfurnace operating conditions including ignition in put rate temperature rise and venting are verified accordingto these installation instructions NOTE The Commonwealth of Massachusetts requires that the following additional requirements must also be met Gasfurnaces must be installed by a licensed plumber gas fitter e AT handle gas cock must be used e Ifthe unit isto be installed in an attic the passageway to and the service area around the unit must have floor ing To ensure proper furnace operation install operate and maintain the furnace in accordance with the installation manual shipped with the furnace as well asall local build ingcodes and ordinances Intheir absence follow the latest edition of the National Fuel Gas Code 54 ANSI 7223 1 and or CAN CSA B149 Installation Codes local plumbing or waste water codes and other applicable codes 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 1430 Broadway New York NY 10018 15 PRODUCT DESIGN National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 CSA International 8501 East Pleasant Valley Cleveland 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 The total heat loss should be calculated by an approved method or in accordance with ASHRAE G
118. ment special au sujet de l installation d appareils de chauffage ou de traitement d air dans des endroits clos tets les garages les locaux d entretien et les stationnements Evitez de mettre en marche les appareils produisant du monoxyde de carbone tels que les automobile les appareils de chauffage autonome etc dans des endroits non ventil s tels que les d empoisonnement au monoxyde de carbone Si vous devez faire fonctionner ces appareils dans un endroit clos assures vous qu il y ait une ventilation directe provenant de l exterier Cette ventilation est n cessaire pour viter le danger d intoxication au CO pouvant survenir si un appareil produisant du monoxyde de carbone continue de fonctionner au sein de la zone confin e Les missions de monoxyde de carbone peuvent etre recircules dans les endroits clos si l appareil de chauffage ou de traitement d air sont en marche Le monoxyde de carbone peut causer des maladies graves telles que des dommages permanents au cerveau et meme la mort 810259 216 isa registered trademark of Maytag Corporation or its related companies and is used under license to Goodman Company L P Houston TX All rights reserved PRODUCT IDENTIFICATION M v Lm 97 ooo 3 Le PRODUCT TYPE FURNACE TYPE MAJ OR G Goodman V Variable Speed REVISION Brand CABINET A Initial Release WIDTH Brand B 17 1 2 C 21
119. mping time period has expired the CFM would continue at the 15 re duction to satisfy the DEHUM request These switches are ignored when using a CTK0 communicating thermostat Switches 9 amp 10 Select CFM Trim Adjustment Choices are 0 10 10 Factory setting is A Trim adjustments add or subtract from the CFM selections made by heat and cool CFM selections Trim adjustments affect cooling and heating fan speeds These switches are ignored when using a CTK0 communicating thermostat Switches 11 amp 12 Select fan off delay in heat Choices are 90 120 150 or 180 seconds Factory setting is C 150 seconds These switches are ignored when using CTKO communicating thermostat Switch 13 Selects thermostat type for heating Factory setting for this switch is OFF this is the correct setting for a conventional single stage stat or a CTK02 CTK03 and CTK04 communicating modulating stats To use a conven tional two stage heating thermostat or a CTK01 thermo stat move this switch to the ON position Switch 14 Selects compressor setup for cooling Factory position is OFF This is the correct position for a single stage condensing unit In this position Y from the room thermostat would connect to Y1 on the IFC Full CFM se lected by switches 1 amp 2 will be delivered during a Y1 call If using a two stage outdoor unit move this switch to the ON position and wire Y1 from the room stat to Y1 on the IFC wire Y2 on the r
120. n manual that was shipped with the furnace 14 Our 34 5 modulating furnace is one of the products in our newly redesigned line of shorter chassis furnaces It comes in two models an up flow horizontal model and a down flow horizontal model The up flow horizontal 34 5 modulating furnace is avail able in the following nominal capacities 60 000 BTUH 3 ton drive 80 000 BTUH ton drive 80 000 BTUH 4 ton drive 100 000 BTUH 5 ton drive 120 000 BTUH 5 ton drive MVM970603BN MVM970803BN MVM970804CN MVM971005CN MVM971205DN The down flow horizontal 34 5 modulating furnace is available in the following nominal capacities capacities 60 000 BTUH 3 ton drive 80 000 BTUH 3 ton drive 80 000 BTUH 4 ton drive 100 000 BTUH 5 ton drive CVM970603BN CVM970803BN CVM970804CN CVM971005CN Product Description Features General Information The modulating furnace is part of the Goodman brand Amana brand family of communicating ready products The furnace may be used with conventional single or multi stage thermostats as well as Goodman CTK01 communi cating thermostats amp CTK02 CTK03 and CTK04 commu nicating modulating thermostats using the ClimateTalk communicating protocol Burner manifold pressure is con trolled by negative air pressure created by the draft in ducer Gas valve pressure switch assembly and induced draft blower are linked together by pneumatic tubing T
121. natural gas orifices At 100 of gas input each burner will provide approximately 20 000 BTUH The A GMVM951155DX models uses 743 gas orifices at 22 500 per hour If converting to LP gas the factory installed mani fold assembly must be replaced by the manifold assembly provided in the LP kit ECM Motor A variable speed ECM four wire indoor fan motor provides supply air to the conditioned space Thisisthe same motor used on Goodman amp Amana previous generation communi cating furnaces Induced Draft Blower IDB All modulating furnace models use a three phase induced draft blower to draw flue gases through the heat exchanger The inducer uses ball bearings and is permanently lubri cated This motor is driven at varying speeds by the VFD variable frequency drive section of the IFC The IFC takes typical single phase power supplied to the furnace and con verts it to a three phase supply to operate the draft inducer at the desired speed The windings of the induced draft motor will have equal resistance 5 Normal resistance readings at room temperature will range from 14 17 ohms The voltage supplied by the IFC to drive the induced draft blower will vary from 15 110 volts A C between any two windings This would be read between any two of the three power wires between the IFC and the induced draft blower 17 PRODUCT DESIGN This voltage to the IBD will vary between furnace models and is dependant on what percentage of maximum
122. ng tank sizing for vaporization recommended regulator settings and pipe sizing is available from most regulator manufacturers and propane gas suppliers Use only pipe dope approved for both L P and natural gases Refer to the following illustration for typical propane gas instal lations and piping 5 to 15 PSIG First Stage 20 PSIG Max Regulator Continuous Ti W C 200 PSIG Maximum Second Stage Regulator Propane Gas Installation Typ 30 Sizing Between First and Second Stage Regulator Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting Capacities in 1 000 BTU hour Pipe or Tubing Length Feet Nominal Pipe Size Schedule 40 Tubing Size O D Type L 60 700 1300 2200 3 300 1 300 3 100 so 20 60 1200 1 900 2 900 1200 2 600 125 200 490 900 1 400 2300 900 2100 To convert to capacities at 15 psig settings multiply by 1 130 To convert to capacities at 5 psig settings multiply by 0 879 Propane Gas Piping Chart I Sizing Between Second or Second Stage Regulator amp Appliance Maximum Propane Capacities listed are based on 1 2 W C pressure drop at 11 W C setting Capacities in 1 000 BTU hour Nominal Pipe Size Schedule 40 ae 1 2 sa 12 1 faia 1 02 590 1 so 4t 90 145 233 129 267 504 1 059 1 559 60 16 35 72 1211 1
123. ngle of Gas Stream B A dent or burr will cause a severe deflection of the gas stream S 307 CHECKING GAS PRESSURE Gas Supply Pressure Measurement 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 Gas inlet and manifold pressures should be checked in ac cordance to the type of fuel being consumed The line pressure supplied to the gas valve must be within the range specified below The supply pressure can be mea sured at the gas valve inlet pressure tap or at a hose fit ting installed in the gas piping drip leg The supply pres sure must be measured with the burners operating To mea sure the gas supply pressure use the following procedure WARNING DISCONNECT ELECTRICAL POWER AND SHUT OFF GAS SUPPLY 1 After turning off gas to furnace at the manual gas shut off valve external to the furnace remove burner com partment door to gain access to the gas valve 2 Connect a calibrated water manometer or appropriate gas pressure gauge at either the gas valve inlet pres sure tap or the gas piping drip leg as shown in the fol lowing figures 97 SERVICING GAS LINE GAS SHUTOFF VALVE GAS LINE TO OPEN TO ATMOSPHERE DRIP LEG CAP WITH FITTING MANOMETER HOSE MANOMETER Measuring Inlet Gas Pressure Alternate Method 3 Turn ON the
124. nit Catt FoR Coot witH CALL FOR Hear PRESENT DuaL FUEL DEFROST OPERATION e While in defrost the standard light off sequence will be followed The IFC will then fire at 100 for the remainder of the defrost call e While in defrost the circulator will use the selected heat speed Fan CONVENTIONAL THERMOSTAT Two seconds after G request becomes active without Y1 request IFC will run the circulator at the appropriate speed as selected by the DIP switches unless circulator is run ning asa result of Heat or Cool mode The circulator speed required by the heat or cool demand always has priority over G speed COMMUNICATING THERMOSTAT If conventional request is present without a heat or cool request from the communicating thermostat the circulator will run at the selected fan speed Humipiry CONTROL HUMIDIFIER OUTPUT CONVENTIONAL T HERMOSTAT One set of isolated relay contacts are wired to a pair of terminalsfor connection to a humidifier When the inducer is on the IFC closes the humidifier relay contacts except fromthe calibration routine where the humidifier relay con tacts are always open HUMIDIFIER OUTPUT COMMUNICATING T HERMOSTAT One set of isolated relay contacts are wired to a pair of terminals for connection to a humidifier Upon receipt of a Humidification Requested Demand the IFC will 42 e Close the humidifier relay contacts e Energize the circulator at the circulation speed
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126. o o Kejdsip 18 Kressooou pojoouuoo 10 JOU SI YMS E 28215 MO uo jeuuou ooeuing 03 440 19MOd UML asoy Y9JIMS ornssoid yoodsuy poxoo q ISOY YIJIMS oJnsso1q 64 N3dO ZST 911559214 28835 8 e 53 ogejs 8 uo 0 s rej ooeumnq K uo 80 5 uo 5311481240 si e red Sune1odo jueurooe do1 3991109 YL BULIM SI e 10119 g3 SaplAO d Yyoums ainssoid soe doy Suri poys YOJIMS 531049 21949 Jo 3186 orjuoo paje1397u medal qoas Sup ons sjoejuoo Q3SO 12 je PASO SI YAMS _ eges uo A eurrou saerado 440 Mod un 98915 8 ooe doy yoyms 28215 uar 94 254 ainssoid 28215 e 8035 y3ry uo 0 510 ooeumq 2 5910 Suonoy 9AD293 H07 IAISSOS 8 55 AO Wow 1 PNHOJUO D uondinsoq sepo snjejs onsougeiq 38350 EINER IO O 10345 63 Troubleshooting 10 SUOYDAIPISUO 2 sjuauasnbay 2 10npo4q 29
127. of the firing rate of the furnace e IFC monitors the contacts of a SPST high pres sure switch with a set point that ensures the switch will be closed at approximately 100 of the firing rate of the furnace HFitting The H fitting conditions the negative pressure signal which is applied to the gas valve Restricting Orifice Restricting Orifice H Fitting The low pressure switch assembly includes an H fitting as sembly and tubing that provides pressure signals to the Honeywell amplified gas air gas valve The H fitting con tains an orifice which conditions the negative air pressure controlling the gas valve This has the effect of allowing only smooth changes in air pressure to reach the gas valve Low Pressure Switch Operation e for heat exists and the low pressure switch is closed already before the ignition sequence has be gun the IFC will wait 5 minutes Afterthe 5 minute delay and if the LPS is still closed the IFC will log and display an error code indicatingthe low pressure switch is stuck closed When the LPS is sensed open the IFC clearsthe error code and resumes normal op eration If the ignition sequence has begun and the low pressure switch fails to close within 30 seconds the IFC logs and displays an error code indicatingthe low pressure switch is stuck open The inducer continues to run for a total of 5 minutes at which time the IFC de energizes the inducer and then attempts th
128. oling systems are designed to work with air flows between 350 and 450 CFM per ton Most manu facturers recommend an air flow of about 400 CFM per ton Example 2 5 tons X 400 per ton 1000 The cooling system manufacturer s instructions must be checked for required air flow Any electronic air cleaners or other de vices may require specific air flows consult installation instruc tions of those devices for requirements 3 Knowingthe furnace model locate the high stage cooling air flow charts in the Specification Sheet ap plicable to your model Look upthe cooling air flow determined in step 2 and find the required cooling speed and adjustment setting Example A MVM960603BX furnace installed with a 2 5ton air conditioning system The air flow needed is 1000 CFM Looking at the cooling speed chart for MVM960603BX find the air flow closest to 1000 CFM A cooling airflow of 1000 CFM can be attained by se lectingthe cooling speed C and the adjustment to normal 4 Continuous fan speed is selectable at 25 50 7596 or 100 of the furnace s maximum airflow capability Example Ifthefurnace s maximum airflow capa bility is 2000 CFM the continuous fan speed will be 0 25 x 2000 or 500 CFM 5 Locatethe blower speed selection DIP switches on the integrated control module Select the desired cool ing speed tap by positioning switches 1 and 2 appro priately Select the desired adjust tap by positioning switches
129. on the dual 7 segment display If the furnace lock out it will or can be reset in any of the following ways 1 Automatic reset The integrated control module will auto matically reset itself and attempt to resume normal opera tions following a one hour lockout period 2 Manual power interruption Interrupt 115 volt power to the furnace 3 Manual thermostat cycle Lower the thermostat so that there is no longer a call for heat for 1 20 seconds then reset to previous setting NOTE If the condition which originally caused the lockout still exists the control will return to lockout Refer to the Troubleshooting Codes for aid in determining the cause 51 MAINTENANCE Maintenance WARNING TO AVOID ELECTRICAL SHOCK INJURY OR DEATH DISCONNECT ELECTRICAL POWER BEFORE PERFORMING ANY MAINTENANCE YOU MUST HANDLE THE IGNITER HANDLE WITH CARE TOUCHING THE IGNITER ELEMENT WITH BARE FINGERS ROUGH HANDLING OR VIBRATION COULD DAMAGE THE IGNITER RESULTING IN PREM ATURE FAILURE ONLY A QUALIFIED SERVICER SHOULD EVER HANDLE THE IGNITER ANNUAL INSPECTION The furnace should be inspected by a qualified installer or ser vice agency at least once per year This check should be per formed at the beginning of the heating season This will ensure that all furnace components are in proper working order and that the heating system functions appropriately Pay particular attention to the following items
130. onfigurations are considered invalid ComfortNet systems and must be connected as a tradi tional or non communicating system see Electrical Connec tions for wiring connections A ComfortNet heating air conditioning system differs from a non communicating traditional system in the manner in which the indoor unit outdoor unit and thermostat interact with one another In a traditional system the thermostat sends com mands to the indoor and outdoor units via analog 24 VAC sig nals It isa one way communication path in that the indoor and outdoor unitstypically do not return information to the thermo stat The indoor unit outdoor unit and thermostat comprising a ComfortNet system communicate digitally with one another creating a two way communications path The thermostat still sends commands to the indoor and outdoor units However the thermostat may also request and receive information from both the indoor and outdoor units This information may be displayed on the ComfortNet thermostat The indoor and out door unitsalso interact with one another The outdoor unit may send commandsto or request information from the indoor unit Thistwo way digital communications between the thermostat and subsystems indoor outdoor unit and between subsystems is the key to unlocking the benefits and features of the ComfortNet system CTKO 1 2 Thermostat Furnace Integrated HOBO Control Module 40VA Transformer OOO Sys
131. oom stat to Y2 on the IFC This switch is ignored when using a CTK0 communicating thermostat Switch 15 Selects DEHUM Enabling this feature will re duce CFM in a call for cooling by 1596 Factory position is OFF in this position DEHUM is disabled To use this fea ture the DIP switch must be turned to the ON position and a normally closed dehumidistat be used This switch is ig nored when using a CTK0 communicating thermostat Switches 16 17 18 These are system switches critical to the ClimateTalk communicating network and must be left in the factory enabled ON position System Operating Airflow Demand Source Mode Air Conditioner Heatin Fum Furnace 9 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 slow stage cool ing airflow demand The air conditioner will then send a fan request along with the low stage cooling airflow de mand to the furnace Once received the furnace will send the low stage cooling airflow demand to the ECM motor The ECM motor then delivers the low stage cooling airflow See the applicable ComfortNet air conditioner or heat pump installation manual for the airflow delivered during cooling or heat pump heating Cooling Heat Pump Heating Heat Pump Only Furnace Auxiliary Heating Continuous Fan Furnace Non Comm 1stg Air Conditioner 39 DIP Switches
132. pe Cut pipe 2 1 2 from flange Remove cabinet plug adjacent to inducer outlet and in stall an original cabinet vent hole Install RF000142 coupling on inducer outlet Install flanged vent section removed in step 2 amp secure with clamps 7 Secure flange to cabinet using screws removed in step 1 gt aH UI PRODUCT DESIGN Duct CONNECTIONS Return duct must not be connected to the back of any fur nace Up flow furnacesinstalled vertically may have return air duct connections on either side or the furnace bottom When airflow requirements are greater than 1 800 CFM for heating or cooling both sides or a bottom return must be used Down flow furnaces installed vertically must have the re turn duct connection on top the furnace For any furnace installed horizontally return duct must be attachedtothe end of the furnace AIR DISCHARGE EEE Return Duct Return Return Duct Duct Connection Connection Bottom Return A Duct E 8 Connection 2 AIR DISCHARGE UPFLOW UPRIGHT COUNTERFLOW Bottom lt 1 Return AIR Duct DISCHARGE UPFLOW HORIZONTAL LEFT AIR DISCHARGE Bottom Return Duct AIR DISCHARGE UPFLOW HORIZONTAL RIGHT AIR DISCHARGE Recommended Installation Positions Propane Gas High Altitude Installations WARNING POSSIBLE PROPERTY DAMAGE PERSONAL INJURY OR DEATH MAY OCCUR IF THE CORRECT CONVERSION KITS NOT INSTALLED
133. per ignition combustion and extinction are primarily due to burner design orifice sizing gas pressure pri mary and secondary air vent and proper seating of burn ers Depending on the size of the furnace each furnace will havefrom three to five inshot burners Burners are pre cisely constructed of aluminized steel and designed to pro vide proper ignition and flame stability When converting a modulating furnace to L P gas the factory installed burn ers must be replaced by burners that come in the L P kit Disconnect ALL Gas AND ELECTRICAL POWER SUPPLY In checking main burners look for signs of rust oversized and undersized carry over ports restricted with foreign material etc refer to Beckett Burner drawing 025 002 Beckett Burner S 306 CHECKING ORIFICES A fixed gas orifice is used in all Goodman brand Amana brand furnaces That is an orifice which has a fixed bore and position as shown in the following drawing No resizing should be attempted until all factors are taken into consideration such as inlet and manifold gas pres sure alignment and positioning specific gravity and BTU content of the gas being consumed Orifices should be treated with care in order to prevent damage They should be removed and installed with a box end wrench in order to prevent distortion In no instance should an orifice be peened over and redrilled GAS STREAM The length of Dimension A determines the a
134. rature Rise Temperature rise must be within the range specified on the unit rating plate An incorrect temperature rise may result in condensing in or overheating of the heat exchanger An air flow and temperature rise table is provided in the Specifica tion Sheet applicable to your model Determine and adjust temperature rise asfollows l Operate furnace with burners firing for approxi mately ten minutes Ensure all registers are open and all duct dampers are in their final fully or par tially open position 2 Placethermometers in the return and supply ducts as close to the furnace as possible Thermometers must not be influenced by radiant heat by being able to see the heat exchanger 3 Subtract the return air temperature from the supply air temperature to determine the air temperature rise Allow adequate time for thermometer readings to stabilize 4 Adjusttemperature rise by adjustingthe circulator blower speed Increase blower speed to reduce tem perature rise Decrease blower speed to increase temperature rise Referto Startup Procedure and Adjustment Circulator Blower Speeds for speed changing details CROSS HATCHED AREA SUBJECTED TO RADIANT HEAT DO NOT MEASURE SUPPLY AIR TEMPERATURE IN THIS AREA eee a eR cup D gt AIR T SUPPLY RISE T SUPPLY T RETURN i T RETURN 525254 x 0 5 2 A 2 lt gt 5 0000 5555555 A
135. rd recom mended or removed once equipment is powered down again Safety Circuit Description A number of safety circuits are employed to ensure safe and proper furnace operation These circuits serve to control any potential safety hazards and serve as inputs in the monitoring and diagnosis of abnormal function These circuits are continu ously monitored during furnace operation by the integrated con trol module INTEGRATED Furnace ConTROL IFC The integrated control module isan electronic device which if a potential safety concern is detected will take the necessary precautions and provide diagnostic information through an LED display Primary Limit The primary limit control is located on the partition panel and monitors heat exchanger compartment temperatures It isa normally closed electrically automatic reset temperature ac tivated sensor The limit guards against overheating as a re sult of insufficient conditioned air passing over the heat ex changer AUXILIARY Limit The auxiliary limit controls are located on or near the circulator blower and monitors blower compartment temperatures They are anormally closed electrically auto reset sensors These limits guard against overheating as a result of insufficient con ditioned air passing over the heat exchanger RoLLour Limit The rollout limit controls are mounted on the burner manifold assembly and monitor the burner flame They are normally closed electric
136. rmal firing rate sequence at a rate of 100 for 5 min utes or until the end of the call for heat The display will show the normal Hi while the control is firing at 100 If the Fault Recall Push Button has not been pressed within 5 seconds of displaying Ft the display will re vert back to normal NOTE Gas valve is factory set and does NOT require any field adjustment Do NOT attempt to adjust valve Turn off all electrical power and gas supply to the sys tem Remove the manometer hose from the hose barb fit ting Remove the 1 8 NPT hose barb fitting from the outlet pressure tap Replace the outlet pressure boss plug and seal with a high quality thread sealer Turn on electrical power and gas supply to the system Close thermostat contacts and W1 W2 to ener gize the valve Usinga leak detection solution or soap suds check for leaks at outlet pressure boss plug Bubbles forming indicate a leak SH UT OFF GAS AND REPAIR ALL LEAKS IMMEDIATELY NOTE For natural gasto LP conversion consult the furnace Specification Sheet Manifold Gas Pressure cs Nominal High Stage 9 5 10 5 wc 10 0 w c OPERATION Gas INPUT RATE MEASUREMENT Natural Gas ONLY The gas input rate to the furnace must never be greater than that specified on the unit rating plate To measure natural gas input using the gas meter use the following procedure 1 Turn OFF the gas supply to all other gas b
137. rmostat DIP switch selections 1 Stage heat Call for heat thermostat energizes W1 on IFC W2 input is ignored After a successful Light Off Sequence and expiration of the Ignition Stabilization Period e After 2 minutes the IFC increases to 57 at a rate of 1 per second e After 10 total minutes the IFC increases to 78 at a rate of 1 per second e After 20 total minutes the IFC increases to 100 at a rate of 1 per second for the remainder of the call for heat circulator is adjusted to the appropriate CFM corresponding to the current firing rate IGNITION 80 70 10 MINS 60 50 FIRE RATE MIN TIME Operation with Conventional 2 Stage Thermostat DIP switch selects 2 stage heat Call for 1st Stage Heat Thermostat contacts close R to W1 After a successful Light Off Sequence and expiration of the Ignition Stabilization Period e The IFC adjusts to the low firing rate e After 2 minutes the IFC increases to 50 fort he next 8 minutes Thereafter the IFC will increase 10 at a rate of 1 per second every 10 minutes for the remainder of the call for heat See above figure circulator is adjusted to the appropriate corresponding to the current firing rate 33 OPERATION 10 MINS 90 IGNITION 80 70 60 50 FIRE RATE MIN TIME Oper
138. rnace can be operated with a com municating thermostat or 2 CTK03 CTK04 com municating modulating thermostat It also facilitates op eration with a non communicating single or two stage heat cool thermostat NOTE DIP switch 13 Heating thermostat selection must be checked and set regardless of the thermostat chosen Factory setting is OFF single stage this is also the cor rect position if using CTK02 CTK03 and CTK04 thermo stats To use a CTK01 or a non communicating two stage thermostat set the switch to the ON position Operation with CTK03 amp CTK04 OPERATION 1 Humidification Options are ON OFF with the CTKO3 When 15 selected the humidification relay on the furnace control board will function during a heat call if a humidity demand exists Selecting Off meansthe hu midification relay will not function 2 If the CTK03 and 4 are set up so the compressor off delay is 0 min it will display a cool heat call immedi ately regardless of the delay built into the outdoor unit control board This means the CTKO3AA could show COOL ON when the outdoor unit is still in a delay period The recommendation is to set up the compressor delay to at least 3 minutes 3 Dual Fuel When the and 4 call for gas heat the heat pump will shut off after a delay of approxi mately 3 minutes it will then turn on gas heat 4 Dehumidification lowering of CFM to
139. rnaces converted to LP gas The kit monitors gas line pressure with a pressure switch and will open the circuit to the gas valve if the LP tank pressure gets low LP Conversion Kit Converts a 34 5 modulating furnace to operate L P gas The kit contains an L P gas valve and a set of six L P orifices N A Drain Coupling Kit For use when the drain vent elbow has been removed in a horizontal left installation This kit prevents condensate from getting in the inducer and routes the condensate to a drain 1st Revision to Modulating Control Software revision to allow ECM motor to store shared data Board 2nd Revision to Modulating Control Software revision for operation with Daikin Inverter Board x 0HL9 jeg 50315 97 Mod Furnace Accessories ACCESSORIES 20910 60 INd 1 47 4J 12150 10910 gt 28 JUEL d 26 lt X 27100044 Dyo uen 20848 19314 ul x lt X 128540 eseqqns sIpIuNnyeq SL 218649 eseqqns 0 HA
140. s e Install a drip leg to trap dirt and moisture before it can enter the gas valve The drip leg must be a mini mum of three inches long e Install a 1 8 NPT pipe plug fitting accessible for test gage connection immediately upstream of the gas supply connection to the furnace e Always use a back up wrench when making the con nection 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 ex cessive over tightening may damage the gas valve e Install a manual shutoff valve between the gas meter and unit within six feet of the unit If a union is installed the union must be downstream of the manual shutoff valve between the shutoff valve and the fur nace e Tighten all joints securely e Connect the furnace to the building piping by one of the following methods 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 pen etration rigid pipe must be used to reach the outside of the cabinet A semi rigid connector to the gas pip ing may be used from there Uselisted gas appliance connectors in accordance with their instructions Connectors must be fully in the same room as the furnace e Protect connectors and semirigid tubing against physi cal
141. ses through the heat exchanger The inducer uses ball bearings and is permanently lubricated This motor is driven at varying speeds by the VFD variable frequency drive section of the IFC The IFC takes typical single phase power supplied to the furnace and converts it to a three phase supply to operate the draft inducer at the desired speed The windings of the induced draft motor will have equal resistance 5 Normal resistance readings at room temperature will range from 14 17 ohms The voltage supplied by the IFC to drive the induced draft blower will vary from 15 110 volts A C between any two windings This would be read between any two of the three power wires between the IFC and the induced draft blower This voltage to the IBD will vary between furnace models and is dependant on what percentage of maximum fire is being called for The power wires are colored red white and black A green colored ground wire is also present S 304 CHECKING MODULATING GAS VALVE Gas ValveModulating furnaces use a 24 VAC pneumatically operatedgas valve by Honeywell The valve is energized by the inte grated furnace control on a call for heat wired in series through the front cover pressure switch The fir ing rate percentage is determined by the negative pres sure created by the operation of the draft inducer The gas valve is factory set and non adj ustable in the field Do not remove the seal covering the regulator screws or at tempt to adj ust ei
142. shback should occur check for the following 1 Improper gas pressure adjust to proper pressure See S 307 CHECKING GAS PRESSURE 2 Check burner for proper alignment and or replace burner 3 Improper orifice size check orifice for obstruction S 310 CHECKING PRESSURE CONTROL The pressure control is a safety device to prevent the com bustion cycle from occurring with inadequate venting caused by a restricted or blocked vent pipe on the modulating fur nace Also on the modulating furnaces there is a pressure control that will prevent the combustion cycle from occur ring with inadequate condensate drainage due to a partial or blocked recuperator coil or drain w RNiNG 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 1 Remove burner compartment door to gain access to pressure switch es 2 Remove wires from the pressure switch es electrical terminals SERVICING 3 Using check from common terminal to NO Nor mally Open should read open If switch reads as above proceed to Step 4 otherwise replace control 4 Remove the pressure control hose from the control and interconnect with an inclined manometer as shown in the following figure Low amp High Pressure Switch Modulating E Gas Valve Assembly Front Cover Pressure Switch
143. sidential home heating applications It is NOT designed or certified for use in mobile homes trailers or recreational vehicles Neither isit designed or certified for outdoor applications The furnace MUST be installed indoors i e attic space crawl space or garage area provided the garage area is enclosed with an operating door This furnace can be used in the following non industrial commercial applications Schools Office buildings Churches Retail stores Nursing homes Hotels motels Common or office areas In such applications the furnace must be installed with the following stipulations e It must be installed per the installation instructions pro vided and per local and national codes tmust be installed indoorsin a building constructed on site e tmust be part of a ducted system and not used in a free air delivery application e t must not be used as a make up air unit e It must be installed with two pipe systems for combus tion air e All other warranty exclusions and restrictions apply This furnace is an ETL dual certified appliance and is appro priate for use with natural or propane gas NOTE using propane a propane conversion kit is required Dual certification means that the combustion air inlet pipe is optional and the furnace can be vented asa Non direct vent single pipe central forced air furnace in which combustion air is taken from the installation area or from air
144. solutions such as perchloroethylene printing inks paint removers varnishes hydrochloric acid cements and glues antistatic fabric softeners for clothes dryers and masonry acid washing materials Isolate a non direct furnace from an area contami nated 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 If the furnace is used in connection with a cooling unit install the furnace upstream or in parallel with the cooling coil Premature heat exchanger failure will result if the cooling coil is placed upstream of the furnace For vertical upflow or downflow applications the minimum cooling coil width shall not be less than fur nace width minus 1 Additionally a coil installed above an upflow furnace or under a counterflow fur nace may be the same width as the furnace or may be one size larger than the furnace Example width coil may be installed with a B width fur nace For upflow applications the front of the coil and fur nace must face the same direction If the furnace is installed in a residential garage posi tion the furnace so that the burners and ignition source are located not less than 18 inches 457 mm above the floor Protect the
145. speed unless the circulator is commanded to a dif ferent speed by a heat demand DEHUMIDIFICATION CONVENTIONAL THERMOSTAT e DEHUM functionality is enabled by a DIP switch set ting e IFC varies circulator speed operation based on the DEHUM signal from the thermostat e 24 is not connected to DEHUM through a Humidistat and both Y1 and O terminals are ener gized then the IFC control reduces the cooling CFM by 15 e If both Y1 and O terminals are not energized the DEHUM signal is ignored DEHUMis ignored during any heating request LEARN Pusu BurroN Pressing the learn button re sets the communicating net work and allows the IFC to search for communicating equip ment The press and release of the button startsthe same learning process as during power up of the system CLiMATETALK Communication LEDs The IFC has two LEDs Redcommunications LED Indicates the status of the network OFFisnormal condition 2slow flashes on power up ON for second OFF for 34 second for second OFF e Continuous slow flash indicates communication fail ure ON for second OFF for Y second e Green receive LED Indicates network traffic Fast sporadic flashes indicates normal bus commu nication ON solid indicates Data 1 Data 2 miswire OPERATION Low 100 Low heat High Stage Model Tap Stage Cool Heat CFM for Cool CFM 2 stag
146. stallation must comply with local codes or in their absence with the latest edition of the National Fuel Gas Code 54 ANSI 7223 1 OPERATION Natural Gas Capacity of Pipe In Cubic Feet of Gas Per Hour CFH Nominal Black Pipe Size Length of Pipe in Feet Pressure 0 5 psig or less and pressure drop of 0 3 W C Based on 0 60 Specific Gravity Gas BTUH Furnace Input Heating Value of Gas BTU Cubic Foot CFH To connect the furnace to the building s gas piping the in staller must supply a ground joint union drip leg manual shutoff valve and line and fittings to connect to gas valve In some cases the installer may also need to supply a transition piece from 1 2 pipe to a larger pipe size The following stipulations apply when connecting gas piping e Gas piping must be supported external to the furnace cabinet so that the weight of the gas line does not distort the burner rack manifold or gas valve Use black iron or steel pipe and fittings for building piping Where possible use new pipe that is prop erly chamfered reamed and free of burrs and chips If old pipe is used be sure it is clean and free of rust scale burrs chips and old pipe joint compound Use pipe joint compound on male threads ONLY ways use pipe joint compound pipe dope that is AP PROVED FOR ALL GASSES DO NOT apply compound to the first two threads e ground joint union
147. t Compatible AC HP Integrated Control Module System Wiring using Four Wires Two Wire Ourpoon Four Wire InDoor WIRING Two wirescan be utilized between the indoor and outdoor units For this wiring scheme only the data lines 1 and 2 are needed between the indoor and outdoor units 40VA 208 230 to 24VAC transformer must be installed in the outdoor unit to pro vide 24VAC power to the outdoor unit s electronic control The transformer isincluded with the CTKO1AA CTK03 and CTK04 kits See kit instructions for mounting and wiring instructions If using a CTK02 or CTKO1BA an accessory transformer is available Four wires are required between the in door unit and thermostat NOTE Use of the CTKO transformer is recommended if installing a dual fuel fossil fuel system Failure to use the transformer in the outdoor unit could result in over loading of the furnace transformer 15 STAGE CONVENTIONAL THERMOSTAT e Acallfor cooling is signaled by Rpowering Y1 and simultaneously e Rpowering Y1 O and G simultaneously compressor and condenser fan energized di from the Y1 terminal from the thermostat e The circulator is energized after cool fan on delay e Ifthe 2 Stage Cooling DIP switch is set to e then circulator will run at low cooling speed with 1 request e OFF then circulator will run at high cooling speed with Y1 request a Y2 request will
148. t be in stalled in the drain line nearthe cooling coil to relieve positive air pressure from the coil s plenum Thisisnec essary to prohibit any interference with the function of the furnace s drain trap e Ifa cooling coil is installed on top of an upflow fur nace and a common drain line is used for the cooling coil and the furnace the cooling coil drain must be vented to avaoid inference with furnace draining 24 Electrical Connections WARNING HIGH VOLTAGE TO AVOID THE RISK OF ELECTRICAL SHOCK WIRING TO THE UNIT MUST BE POLARIZED AND GROUNDED WARNING HIGH VOLTAGE TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK DISCONNECT ELECTRICAL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING caution LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS WARING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION VERIFY PROPER OPERATION AFTER SERVICING Wiring Harness The wiring harness is an integral part of this furnace Field alteration to comply with electrical codes should not be re quired Wires are color coded for identification purposes Refer to the wiring diagram for wire routings If any of the original wire as supplied with the furnace must be replaced it must be replaced with wiring material having a temperature rating of at least 105 C Any replacement wiring must be a copper conductor OPERATION 115 Line Connections Before proceeding with electri
149. t be relocated to the other side of the burner compartment prior to making electri cal connections To relocate the junction box follow the steps shown below NOTE Wire routing must not to interfere with circulator blower operation filter removal or routine maintenance JUNCTION Box RELOCATION WARNING EDGES OF SHEET METAL HOLES MAY BE SHARP USE GLOVES AS PRECAUTION WHEN REMOVING HOLE PLUGS WARNING TO PREVENT PERSONAL INJURY OR DEATH DUE TO ELECTRIC SHOCK DISCONNECT ELECTRICAL POWER BEFORE INSTALLING OR SERVICING THIS UNIT WARNING HIGH VOLTAGE TO AVOID THE RISK OF INJURY ELECTRICAL SHOCK OR DEATH THE FURNACE MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH LOCAL CODES OR IN THEIR ABSENCE WITH THE LATEST EDITION OF THE NATIONAL ELECTRIC CODE 4 Line voltage connections be made through either the right or left side panel The furnace is shipped configured for right side electrical connection To make electrical connec tions through the opposite side of the furnace the junction box must be relocated to the left side prior to making electri cal connections To relocate the junction box perform the following steps 1 Removethe burner compartment door 2 Remove and save the two screws securing the junc tion box to the side panel 3 Relocate junction box and associated plugs and grom mets to opposite side panel Secure with screws re moved in step 2 A WARNING TO AVOID T
150. te gas pressure gauge at either the gas valve inlet pressure boss or the gas piping drip leg See Honeywell VR9205R gas valve figure for location of in let pressure boss NOTE If measuring gas pressure at the drip leg or Honeywell VR9205R gas valve a field supplied hose barb fitting must be installed prior to making the hose connection 3 Turn ON the gas supply and operate the furnace and all other gas consuming appliances on the same gas supply line Field Test Mode is intended to help a service person troubleshoot and check out an installed appliance To enter Field Test Mode the Fault Recall Push Button must be pressed twice within a 5 second period at any time during a heating cycle at which time the display will show Ft While the display is showing Ft press ing and holding the Fault Recall Push Button for 3 sec onds will enable the field test mode and override the normal firing rate sequence at a rate of 100 for 5 min utes or until the end of the call for heat The display will show the normal Hi while the control is firing at 100 If the Fault Recall Push Button has not been pressed within 5 seconds of displaying Ft the display will revert back to normal 4 Measure furnace gas supply pressure with burners firing Supply pressure must be within the range specified in the Inlet Gas Supply Pressure table Inlet Gas Supply Pressure Natural Gas Minimum 4 5 w c Maximum 10 0 w c Propane
151. tem Wiring using Two Wires between Furnace and AC HP and Four Wires between Furnace and Thermostat ComfortNet Compatible ComfortNet Compatible AC HP Integrated Control Module CoMPATIBLE Furnace wrrH Non ComrortNet SINGLE STAGE AIR CONDITIONER Four wires are required between the furnace and thermostat Two wires required between the furnace control and single stage air conditioner For this system configuration the Y1 terminal the integrated furnace control becomes an output ratherthan an input The Y1 connection to the outdoor unit is made using both 4 position thermostat connectors in the CTKO kit Remove the red keying tabs from the on board connector block and position both 4 position connector such that 1 2 R C and Y1 positions are filled 43 OPERATION CTKO Thermostat 4 Position Connectors from CTKO Thermostat Kit ComfortNet Compatible GGG C wi wa v ea Furnace Integrated Control Module System Wiring between Furnace and Non Communicating Compatible Single Stage Air Conditioner Non ComfortNet Compatible Single Stage AC Pressure Switch Calibration Routine The modulating fur nace must go through a pressure switch calibration routine before it can begin its first heat cycle This is performed automatically by the furnace and requires no action on the part of the installer oth
152. ther of the regulator screws Even though the modulating gas valve is non adj ustable in the field gas industry procedure dictates that the installing ser vicing technician should know that the appliance is oper ating as designed before leaving newly installed or ser viced equipment The gas valve is equipped with 1 8 NPT fittings to access both the inlet and manifold gas pres sures To do a manifold gas pressure check the furnace can be operated in field test mode This mode will quickly bringthe furnace up to high fire To enter field test mode during a call for heat press the fault recall button twice within a five second period when the dual seven segment displays show Ft press the fault recall button again to enter field test mode The furnace will stay in field test for five minutes or until the call for heat is satisfied Gas valve orientation must be such that the switch is facing out towards the front of the furnace S 304A CHECKING INDUCTOR COIL Wired in series with 34 and 1 HP ECM motors the inductor coil conditionsthe power supply to the motor smoothing out spikes and electrical noise With voltage applied to one side of the inductor coil the output voltage to the motor should be the same as incoming voltage SERVICING S 305 CHECKING MAIN BURNERS The main burners are used to provide complete combus tion of various fuels in a limited space and transfer this heat of the burning process to the heat exchanger Pro
153. these steps will help avoid exposing the integrated control module to elec trostatic discharge This procedure is applicable to both installed and non installed ungrounded furnaces l 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 elec trostatic charge to ground 2 Firmly touch a clean unpainted metal surface of the furnaces near the control Any toolsheld ina person s hand during grounding will be discharged 3 Service integrated control module or connecting wir ing following the discharge process in step 2 Use caution not to recharge your body with static elec tricity i e do not move or shuffle your feet do not touch ungrounded objects etc If you come in contact with an ungrounded obj ect repeat step 2 be fore touching control or wires 4 Discharge your body to ground before removing a new control from its container Follow steps 1 through 3 if installing the control on a furnace Re turn any old or new controlstotheir containers be fore touching any ungrounded obj ect WARNING TO PREVENT PROPERTY DAMAGE PERSONAL INJURY OR DEATH DUE TO FIRE DO NOT INSTALL THIS FURNACE IN MOBILE HOME TRAILER OR RECREATIONAL VEHICLE Introduction This is a Category IV furnace This furnace uses a pressur ized venting system and must be installed per National and local codes requirements and the installatio
154. tion This ventilation is necessary to avoid the danger of CO poisoning which can occur if a carbon monoxide producing device continues to operate in the enclosed area Carbon monoxide emissions can be re circulated throughout the structure if the furnace or air handler is operating in any mode CO can cause serious illness including permanent brain damage or death B10259 216 RIESGO DE INTOXICACION POR MONOXIDO DE CARBONO Advertencia especial para la instalaci n de calentadores 6 manejadoras de aire en reas cerradas como estacionamientos 6 cuartos de servicio Los equipos aparatos que producen mon xido de carbono tal como autom vil calentador de gas calentador de agua por medio de gas etc no ser operados en reas cerradas debido al riesgo de envenenamiento por mon xido de carbono CO que resulta de las emisiones de gases de combusti n Si el equipo aparato se opera en dichas reas debe existir una adecuada ventilaci n directa al exterior Esta ventilaci n es necesaria para evitar el peligro de envenenamiento por CO que puede ocurrir si un dispositivo que produce mon xido de carbono sigue operando en el lugar cerrado Las emisiones de mon xido de carbono pueden circular a trav s del aparato cuando se opera en cualquier modo El mon xido de carbono puede causar enfermedades severas como da o cerebral permanente 6 muerte B10259 216 RISQUE D EM POISONNEM ENT AU MONOXYDE DE CARBONE Avertisse
155. tion e Receiving commands for dehumidification and humidi fication e Communicating with the ECM motor for proper air delivery to the conditioned space Assuring safe ignition by checking the state of pres sure switches and limit switches before and after ig nition Assuring safe operation by continuously monitoring the presence of flame the state of the pressure switches and limit and roll out switches Displays information on the dual seven segment dis plays regarding thermostat call air flow delivery and fault status e Controlling the speed of the induced draft blower by variable voltage amp frequency Features of the IFC Aux Terminals Located next to the low voltage connector there are two terminals labeled aux in aux out A factory jumper is installed between these two terminals As an op tion the jumper may be removed and the terminals wired up to a normally closed float switch The switch must be closed for normal operation If the switch is sensed open the IFC will 18 Terminate a call for gas heat e When the modulating furnace is installed with a com municating thermostat and a non communicating a c unit the IFC will open the Y1 relay to turn off the condensing unit Logand display an auxiliary open error code e Once the auxiliary switch re closes the IFC reverts back to normal operation Hum Terminals A pair of HUM terminals are located on the board to power a humidifier
156. turn duct at the inlet of the furnace Negative Pressure 2 Measure the static pressure of the supply duct Posi tive Pressure 3 The difference between the two numbers is 4 w c Example static reading from return duct 2 0 1 w c static reading from supply duct 0 3 w c total external static pressure on this system 0 4 W C NOTE Both readings may be taken simultaneously and read directly on the manometer if so desired If an air condi tioner coil or Electronic Air Cleaner is used in conjunction with the furnace the readings must also include theses components as shown in the following drawing 4 Consult proper tablesfor the quantity of air If the total external static pressure exceeds the maximum listed on the furnace rating plate check for closed damp ers registers undersized and or oversized poorly laid out duct work SUPPLY AIR CUTAWAY OF DUCTWORK TO EXPOSE COIL INCLINED MANOMETER RETURN AIR Checking Static Pressure Bottom RETURN Air OPENING UrrLow MobeLs 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 sec tions 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
157. tween data 1 or Check data 1 data 2 data 2 wires and R voltages 24 or C 24VAC common Should not be longer than necessary e Use45 elbowsrather than 90 elbows when possible e Must not sag or otherwise trap condensate Operational Checks BunNER FLAME The burner flames should be inspected with the burner com partment door installed Flames should be stable quiet soft Use longest radius fittings possible and blue dust may cause orange tips but they must not be If using 3 venting make the transition from 2 to 3 yellow Flames should extend directly outward from the burn as close as practically possible ers without curling floating or lifting off Flames must not e Make sure there is no flue gas recirculation into the impinge on the sides of the heat exchanger firing tubes combustion air pipe Condensate Drainage Furnace combustion can be affected if a furnace is holding condensate Check for proper connections of drain hoses make sure furnace condensate trap is clean Make sure Check tho furnace is not improperly sloped Make sure air condition Burner Flames for ing coil drain is not interfering with furnace drain 1 Stable soft and blue 2 Not curling floating or lifting off Other Causes 1 Manifold Gas Pressure must be set for the gas being used Natural or L P high and low firing rates If con verted to L P gas check size of all orifices 2 Remove Draft Inducer Check the integrity of th
158. uide or Manual J Load Cal culations published by the Air Conditioning Contractors of America A copy of the CAN CSA B149 Installation Codes can also be obtained from CSA International 178 Rexdale Boulevard Etobicoke Ontario Canada M9W 1R3 FURNACE INSTALLATION REQUIREMENTS Thoroughly read the Installation Manual shipped with the furnace before conducting installation or repairs 16 Centrally locate the furnace with respect to the proposed or existing air distribution system Ensure the temperature of the return air entering the furnace is between 55 F and 100 F when the furnace is heating Provide provisions for venting combustion products out doors through a proper venting system Special consid eration should be given to vent flue pipe routing and combustion air intake pipe when applicable Refer to Vent Flue Pipe and Combustion Air Pipe Termination Locations for appropriate termination locations and to determine if the piping system from furnace to termina tion can be 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 Refer to Condensate Drain Lines and Trap for further details Ensure adequate combustion
159. urning ap pliances except the furnace 2 Whilethe furnace is operating time and record one complete revolution of the smallest gas meter dial 3 Calculate the number of seconds per cubic foot sec ft3 of gas being delivered to the furnace If the dial is a one cubic foot dial divide the number of sec onds recorded in step 2 by one If the dial isatwo cubic foot dial divide the number of seconds re corded in step 2 by two 4 Calculatethe furnace input in BTUs per hour BTU hr Input equals the sum of the installation s gas heating value and a conversion factor hours to sec onds divided by the number of seconds per cubic foot The measured input must not be greater than the input indicated on the unit rating plate EXAMPLE Installation s gas heating HTG value 1 000 BTU ft Obtained from gas supplier Installation s seconds per cubic foot 34 sec ft Conversion Factor hours to seconds 3600 sec hr Input Htg value x 3600 seconds per cubic foot Input 1 000 BTU ft x 3600 sec hr 34 sec ft Input 106 000 BTU hr NOTE The final manifold pressure cannot vary by more than x 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 5 Turn ON gasto and relight all other appliances turned off instep 1 Be certain that all appliances are func tioning properly and that all pilot burners are operat ing Tempe
160. workmanship go into every product to provide our customers with quality products It is possible however that during its lifetime a product may require service Products should be serviced only by a qualified service technician who isfamiliar with the safety procedures required in the repair and who is equipped with the proper tools parts testinginstruments and the appropriate service manual REVIEW ALL SERVICE INFORMATION IN THE APPROPRIATE SERVICE MANUAL BEFORE BEGINNING REPAIRS IMPORTANT NOTICES FOR CONSUMERS AND SERVICERS RECocNIzE SAFETY SYMBOLS WORDS AND LABELS THIS UNIT SHOULD NOT BE CONNECTED TO OR USED IN CONJUNCTION WITH ANY DEVICES THAT ARE NOT DESIGN CERTIFIED FOR USE WITH THIS UNIT OR HAVE NOT BEEN TESTED AND APPROVED BY GOODMAN SERIOUS PROPERTY DAMAGE OR PERSONAL INJURY REDUCED UNIT PERFORMANCE AND OR HAZARDOUS CONDITIONS MAY RESULT FROM THE USE OF DEVICES THAT HAVE NOT BEEN APPROVED OR CERTIFED BY GOODMAN WARNING A WARNING INSTALLATION AND REPAIR OF THIS UNIT SHOULD BE PERFORMED ONLY BY INDIVIDUALS MEETING THE REQUIREMENTS OF AN ENTRY LEVEL TECHNICIAN AT A MINIMUM AS SPECIFIED BY THE AIR To PREVENT THE RISK OF PROPERTY DAMAGE PERSONAL INJURY OR DEATH CONDITIONING HEATING AND REFRIGERATION INSTITUTE AHRI DO NOT STORE COMBUSTIBLE MATERIALS OR USE GASOLINE OR OTHER ATTEMPTING TO INSTALL OR REPAIR THIS UNIT WITHOUT SUCH FLAMMABLE LIQUIDS OR VAPORS IN THE VICINITY OF THIS APPLIANCE BACKGROUND MAY RESULT IN PRO

Service Manual - Alpine Home Air Products

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