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Goodman ACVM Service Instructions Manual

Manual is about: 96% Modulating Gas Furnaces & Accessories

Summary of ACVM

  • Page 1

    1 96% modulating gas furnaces acvm, amvm, gcvm, gmvm & accessories rs6612001r9 november 2013 this manual is to be used by qualified, professionally trained hvac technicians only. Goodman does not assume any responsibility for property damage or personal injury due to improper service procedures or s...

  • Page 2: Important Information

    2 important information pride and 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 is familiar with the safety proc...

  • Page 3: Important Information

    3 important information 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...

  • Page 4: Product Identification

    Product identification 4 the model and manufacturing number are used for positive identification of component parts used in manufacturing. Please use these numbers when requesting service or parts information. G m v m 96 060 3 b x a a supply type m: upflow/horizontal c: downflow/horizontal furnace t...

  • Page 5: Product Identification

    Product identification 5 model # mfg. # description acvm96****** acvm96******aa amana® brand 96% modulating gas furnace, downflow/horizontal left and right, 40" tall, induced draft, climatetalk™ communicating furnace. Modulating gas input from 35% -100% of rated input. 4 wire serial ecm motor. Indep...

  • Page 6: Product Identification

    Product identification 6 model # mfg # description afe18-60a n/a fossil fuel kit. The afe18-60a control is designed for use where the indoor coil is located above/downstream of a gas or fossil fuel furnace when used with a heat pum p. It will operate with single and two stage heat pumps and single a...

  • Page 7: Product Identification

    Product identification 7 model # mfg # description lplp03 n/a lp gas low pre ssure kit. Designe d for application on goodman® and amana® brand's 80% and 9 0% single-stag e, two-stage and modulating fu rnaces converted to lp gas. The kit monitors gas line pressure with a pressure switch and will open...

  • Page 8: Accessories

    Accessories 8 m odel num ber af e180-60a am u / gm u asas / gsas cfb17 cf b21 cfb24 ct k01* ctk02** ct k03aa descriptio n f ossil f uel kit m edia air cleaners electronic air cleaner downflo w subbase 17.5" do wnflow subbase 21" do wnflow subbase 24.5" co m. T hermo stat kit com t hermo stat kit -m ...

  • Page 9: Accessories

    Accessories 9 m odel num ber afe180-60a am u / gm u asas / gsas cfb17 cfb21 cfb24 ctk01* ctk02** ctk03aa description fossil fuel kit m edia air cleaners electronic air cleaner downflow subbase 17.5" downflow subbase 21" downflow subbase 24.5" com. Thermostat kit com thermostat kit -m odulating, high...

  • Page 10: Accessories

    Accessories 10 side wall vent kit (0170k00000s) v e rtical in sta lla tio n h o riz o n ta l insta lla tio n this side wall only vent kit #0170k00000s is to be used with 2” - 3” vent systems. This kit is not intended for use with single pipe (indirect vent) installations. The vent kit must terminate...

  • Page 11: Lighting Instructions

    11 lighting instructions risque de déclencher un incendie ou une explosion du gaz arrivee inlet gas position. Gaz. Renifler tout autour de l'appareil, y compris prés du "off/ arret" "on/marche" arrÊtez . In "on" pos lever shown manual gas "on/marche" manuel, en pos robinet a gaz plancher, pour décel...

  • Page 12: Product Design

    Product design 12 adhere to the following warnings and cautions when installing, adjusting, altering, servicing, or operating the furnace. To ensure proper installation and operation, thoroughly read this manual for specifics pertaining to the installation and appli- cation of this product. T o prev...

  • Page 13: Product Design

    Product design 13 electrostatic discharge (esd) precautions note: discharge body’s static electricity before touching unit. An electrostatic discharge can adversely affect electri- cal components. Use the following precautions during furnace installation and servicing to protect the integrated contr...

  • Page 14: Product Design

    Product design 14 • all other warranty exclusions and restrictions apply this furnace is an etl dual-certified appliance and is appropri- ate for use with natural or propane gas (note: if using propane, a propane conversion kit is required). Dual certification means that the combustion air inlet pip...

  • Page 15: Product Design

    15 furnace components heat exchanger assembly the primary heat exchanger is a tubular type constructed of high quality steel (stainless steel for amana brand, alumi- nized for goodman) the heat exchanger assembly consists of primary and secondary sections crimped together on a back transition plate....

  • Page 16: Product Design

    16 • 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 con- densing unit • log and display an auxiliary open error code • once the auxiliary switch re-closes the ifc reverts back to normal opera...

  • Page 17: Product Design

    17 • 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 softeni...

  • Page 18: Product Design

    18 t o p b o t t o m s id e s id e s id e t o p b o t t o m u p flo w c o u n te rflo w h o riz on ta l a furnace installed in a confined space (i.E., a closet or utility room) must have two ventilation openings with a total minimum free area of 0.25 square inches per 1,000 btu/hr of furnace input r...

  • Page 19: Product Design

    19 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 inst...

  • Page 20: Product Design

    20 a lternate v ent /f lue and c ombustion a ir c onnections in horizontal installations with the furnace laying on the left hand side, the alternate vent connection may be used. In this configuration, the internal elbow is removed the stan- dard piping connections may also be used in these posi- ti...

  • Page 21: Product Design

    21 vent/flue pipe & combustion air pipe f ailure to follow these instructions can result in bodily injury or death . C arefully read and follow all instructions given in this section . Warning u pon completion of the furnace installation , carefully inspect the entire flue system both inside and out...

  • Page 22: Product Design

    22 transition no less than 45 degrees to horizontal plane to avoid creating a water trap in vent piping. Acceptable no transition on horizontal plane, this creates a water trap and restricts flue gases precautions should be taken to prevent condensate from freezing inside the vent/flue pipe and/or a...

  • Page 23: Product Design

    Product design 23 v v x direct vent terminal clearances 1 in accordance with the current csa b149.1, natural gas and propane installation code. 2 in accordance with the current ansi z223.1/nfpa 54, national fuel gas code. † a vent shall not terminate directly above a sidewalk or paved driveway that ...

  • Page 24: Product Design

    24 s pecial v enting r equirements f or i nstallations i n c anada all installations in canada must conform to the requirements of csab149 code. All vent system components, including primer and cement, must be listed to ulc s636. The certi- fied pipe and fittings should be clearly marked with the ul...

  • Page 25: Product Design

    25 2. Upflow and counterflow units. Loosen the worm gear hose clamps on the rubber el- bow and detach it from both the induced draft blower and the vent/flue pipe. 3. Upflow and counterflow units. Remove the vent/flue pipe from the furnace. 4. Cut the vent/flue pipe 3.75 inches from the flanged end ...

  • Page 26: Product Design

    Product design 26 3 remove pipe 2 detach rubber elbow from id blower and vent/flue pipe 4 remove and relocate cabinet plug 5 externally mount rubber elbow and secure flange with 4 screws removed in step 1 7 externally mount rubber elbow and secure flange with 4 screws removed in step 1 5 install cab...

  • Page 27: Product Design

    27 7. Upflow and counterflow units. For upright installations, externally mount the rubber elbow to the vent/flue coupling using a worm gear hose clamp. Secure field supplied vent/flue piping to the rubber elbow using a worm gear hose clamp. Note: use of the alternate vent/flue location for upright ...

  • Page 28: Product Design

    28 v ent /f lue p ipe t erminations note: if either a 90 degree or 45 degree elbow is used for termination, it must be pointed downward. The vent/flue pipe may terminate vertically, as through a roof, or horizontally, as through an outside wall. Vertical vent/flue pipe terminations should be as show...

  • Page 29: Product Design

    29 if the combustion air intake pipe is to be installed above a finished ceiling or other area where dripping of condensate will be objec- tionable, insulation of the combustion air pipe may be required. Use 1/2” thick closed cell foam insulation such as armaflex™ or insultube™ where required. V ent...

  • Page 30: Product Design

    30 screen (optional) air intake 90° elbows 12" min. Above highest anticipated snow level 3”-24” between pipes combustion air intake may also be snorkeled to obtain 12” min ground clearance. Alternate vent termination above anticipated snow level (dual pipe) in a basement installation, the pipes may ...

  • Page 31: Product Design

    31 condensate drain lines & drain trap a condensing gas furnace achieves its high level of efficiency by extracting almost all of the heat from the products of combustion and cooling them to the point where condensation takes place. The condensate which is generated must be piped to an appro- priate...

  • Page 32: Operation

    32 u pright i nstallations -t rap on r ight s ide in a upright installation drain hoses are connected to drain ports on the rubber elbow and the recuperator coil front cover. The drain lines are then routed through the right side panel and into the drain trap secured to the outside of the cabinet. N...

  • Page 33: Operation

    33 a lternate v ent /f lue d rain h ose c onnections upright installations using the alternate vent/flue outlet will require “right-side only” drain hoses to be connected as follows. Refer to vent/flue pipe and combustion air pipe for details on alternate vent/flue pipe connection. 1. Remove the rub...

  • Page 34: Operation

    34 u pright i nstallations -t rap on l eft s ide note: for left side trap installation, grommets must be moved to the left side of the furnace and the plugs installed on the right side of the furnace. 1. Remove the rubber plug/cap from the left side drain port on the front cover. 2. Secure hose a to...

  • Page 35: Operation

    35 h orizontal i nstallations r ight s ide d own horizontal installations with the right side down require that the drain hoses be connected to the right side front cover drain port and the rubber elbow drain port. Note: on counterflow models, relocation of the front cover pressure switch hose is re...

  • Page 36: Operation

    36 horizontal installations with the left side panel down will require drain hoses to be connected to the left side front cover drain port and the side drain port on the rubber elbow. 1. Remove the rubber plug/cap from the front cover left (down) side drain port. 2. Relocate the front cover pressure...

  • Page 37: Operation

    37 electrical connections high voltage ! T o avoid the risk of electrical shock , wiring to the unit must be polarized and grounded . Warning high voltage ! T o avoid personal injury or death due to electrical shock , disconnect electrical power before servicing or changing any electrical wiring . W...

  • Page 38: Operation

    38 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 pe...

  • Page 39: Operation

    39 w1 w2 y2 furnace integrated control module remote condensing unit (two-stage cooling) dehumidistat [optional] y2 neu w1 w2 y2 thermostat - two-stage heating with two-stage cooling s et dip switch #14 to on position when using a 2- stage cooling thermostat . Important note thermostat wiring diagra...

  • Page 40: Operation

    40 115 v olt l ine c onnection of a ccessories (h umidifier and e lectronic a ir c leaner ) high voltage ! T o avoid personal injury or death due to electrical shock , disconnect electrical power before servicing or changing any electrical wiring . Warning the furnace integrated control module is eq...

  • Page 41: Operation

    41 p ropane g as c onversion warning p ossible property damage , personal injury or death may occur if the correct conversion kits are not installed . T he appropriate kits must be applied to ensure safe and proper furnace operation . A ll conversions must be performed by a qualified installer or se...

  • Page 42: Operation

    42 manual shut off valve (upstream from pipe union) grommet in standard gas line hole gas line plug in gas line hole height required by local code pipe union drip leg manifold burners gas valve horizontal [upflow model] manual shut-off valve (upstream from ground joint pipe union) drip leg grommet i...

  • Page 43: Operation

    43 • tighten all joints securely. • 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 lo- cations. In order to seal the grommet cabinet...

  • Page 44: Operation

    44 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 informati...

  • Page 45: Operation

    45 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 gau...

  • Page 46: Operation

    46 f ilters - r ead t his s ection b efore i nstalling t he r eturn a ir d uct work filters must be used with this furnace. Discuss filter maintenance with the building owner. Filters do not ship with this furnace, but must be provided, sized and installed externally by the installer. Filters must c...

  • Page 47: Operation

    47 h orizontal i nstallations filters must be installed in either the central return register or in the return air duct work. Startup procedure & adjustment furnace must have a 115 vac power supply properly connected and grounded. Proper polarity must be maintained for correct operation. In addition...

  • Page 48: Operation

    48 • the ifc remains at the current firing rate until the 1st- stage call for heat is satisfied. H eating o peration with ctk01 t hermostat (c ommuni - cating ) • when the thermostat heat setup dip switch is set to 2-stage heat, the ifc operation will be compatible with a ctk01communicating thermost...

  • Page 49: Operation

    49 f urnace o peration purge gas lines of air prior to startup. Be sure not to purge lines into an enclosed burner compartment. Check for leaks using an approved chloride-free soap and water solution, an electronic combustible gas detector, or other ap- proved method. Verify that all required kits (...

  • Page 50: Operation

    50 1. Turn off gas to furnace at the manual gas shutoff valve external to the furnace. 2. Connect a calibrated water manometer (or appropriate gas pressure gauge) at either the gas valve inlet pres- sure boss or the gas piping drip leg. See honeywell vr9205r gas valve figure for location of inlet pr...

  • Page 51: Operation

    51 8. Field test mode is intended to help a service person troubleshoot and check out an installed appliance by bringing the furnace up to high fire (100% input), by-pass- ing the normal modulating routine. To enter field test mode the fault recall push-button must be pressed twice within a 5 second...

  • Page 52: Operation

    52 supply air return air temperature rise measurement c irculator b lower s peeds t o avoid personal injury or death due to electrical shock , turn off power to the furnace before changing speed taps . Warning this furnace is equipped with a multi-speed circulator blower. This blower provides ease i...

  • Page 53

    53 dip switches 123456 789 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 a o ff o f f -- - -- - -- - -- - -- - -- - --- -- - --- -- - -- - -- - -- - -- - --- -- - b o n o f f -- - --- -- - -- - -- - -- - -- - -- - -- - -- - -- - -- - -- - --- -- - -- - c o f f o n -- - --- -- - -- - -- - -- - -- - -- - -- - -...

  • Page 54: Operation

    54 • profile a provides only an off delay of one (1) minute at 100% of the cooling demand airflow. Off 100% cfm 100% cfm 1 min off • profile b ramps up to full cooling demand airflow by first stepping up to 50% of the full demand for 30 seconds. The motor then ramps to 100% of the required airflow. ...

  • Page 55: Operation

    55 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 selected by switches 1 & 2 will be delivered during a y1 call. If using a...

  • Page 56: Operation

    56 ctk0* w iring note: refer to electrical connections for 115 volt line connections to the furnace. Note: a removable 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 t...

  • Page 57: Operation

    57 f an m ode c onventional t hermostat two seconds after g request becomes active without y1 re- quest, ifc will run the circulator at the appropriate speed (as selected by the dip switches), unless circulator is running as a result of heat or cool mode. The circulator speed re- quired by the heat ...

  • Page 58: Abbreviations & Definitions

    58 7. Select the heating speed for your model from the heat- ing speed chart in the specification sheet. The “ad- just” setting (already established by the cooling speed selection) determines which set of speeds are avail- able. The selected speed must provide a temperature rise within the rise rang...

  • Page 59: Abbreviations & Definitions

    59 pressure switch calibration routine the modulating furnace must go through a pressure switch calibration rou- tine 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 other than to have the system compo- nent...

  • Page 60: Abbreviations & Operation

    60 • low fire rate: the lowest firing rate the ifc controls 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. • ignition firing rate: the target firing rate at which the app...

  • Page 61: Service & Operation

    61 • the 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. • a maximum of two recycles (3 flame losses) are al- low...

  • Page 62: Service & Operation

    62 high pressure switch operation • 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. • the hps must remain closed during 100% fire opera- tion. If it open...

  • Page 63: Operational Checks

    63 led led status indication possible causes corrective action(s) off • normal condition • none • none • control power up • learn button depressed rapid flashing • normal network traffic • control is “talking” on network as expected • none • data 1 and data 2 wires reversed at furnace, thermostat or...

  • Page 64: Operational Checks

    64 to use a memory chip; 1. Power down all hvac equipment in the system. 2. As when handling any electronic components, discharge any static electricity you may be carrying by touching grounded metal. 3. Insert the memory card in the slot on the control board. 4. Power the system back up and allow a...

  • Page 65: Maintenance

    65 maintenance maintenance t o avoid electrical shock , injury or death , disconnect electrical power before performing any maintenance . I f you must handle the igniter , handle with care . T ouching the igniter element with bare fingers , rough handling or vibration could damage the igniter result...

  • Page 66: Servicing

    66 servicing s-1 checking voltage ................................. 67 s-2 checking wiring ..................................... 67 s-3a thermostat and wiring ....................... 67 s-3b heating anticipator/ cylce rate ....... 68 s-4 checking transformer and controlcircuit .........................

  • Page 67: Servicing

    Servicing 67 s-1 checking voltage warning high voltage d isconnect all power before servicing or changing any electrical wiring. M ultiple power sources may be present. F ailure to do so may cause property damage, personal injury or death. 1. Remove the blower door to gain entry to the junction box....

  • Page 68: Servicing

    68 servicing s-3b heating anticipator/ cylce rate older heating thermostats may have an adjustable anticipa- tor. This is a wire wound adjustable heater which is ener- gized during the "on" cycle to help prevent overheating of the conditioned space. The anticipator is a part of the thermostat and if...

  • Page 69: Servicing

    Servicing 69 auxiliary limit control auxiliary limit control blower housing auxiliary limit control location s-302 checking flame rollout con- trol a temperature activated manual reset control is mounted to the manifold assembly on modulating furnace, as shown in the following illustration. * * * * ...

  • Page 70: Servicing

    70 servicing upflow model shown for representation only. Actual unit may vary in appearance. Modulating furnace pneumatic tubing diagram black tee must be left open low & high pressure switch assembly with “h” fitting + port is open to the atmosphere front cover pressure switch negative (-) port on ...

  • Page 71: Servicing

    Servicing 71 s-305 checking main burners the main burners are used to provide complete combustion of various fuels in a limited space, and transfer this heat of the burning process to the heat exchanger. Proper ignition, combustion, and extinction are primarily due to burner design, orifice sizing, ...

  • Page 72: Servicing

    72 servicing gas line gas shutoff valve gas line to furnace drip leg cap with fitting manometer hose manometer open to atmosphere measuring inlet gas pressure (alternate method) 3. Turn on the gas and electrical power supply and oper- ate the furnace and all other gas consuming appliances on the sam...

  • Page 73: Servicing

    Servicing 73 if switch reads as above proceed to step 4, otherwise re- place control. 4. Remove the pressure control hose from the control and interconnect with an inclined manometer as shown in the following figures. Upflow model shown for representation only. Actual unit may vary in appearance. Mo...

  • Page 74: Servicing

    74 servicing s-314 checking flame sensor a flame sensing device is used in conjunction with the igni- tion 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. Warning high voltage d isconnect all power b...

  • Page 75

    75 troubleshooting co m fo r tnet therm ost a t on ly sym ptom s of a bnor m a l opera ti on (n on-c o m m unicat in g & c o m fortn e t™ therm ost a t) d ia g no st ic /st a tus led codes fault de scr ipt ion messa g e code p o ss ib le c a u se s correct ive action s no tes & ca utio ns x fur nace...

  • Page 76

    76 troubleshooting co m fo r tnet therm ost at on ly sym ptom s of a bnor m al opera ti on (n on-c om m unicat in g & c o m fortn et™ therm ost at) d ia g no st ic /st atus led codes fault de scr ipt ion messa ge code p o ss ib le c a u se s correct ive action s no tes & ca utio ns x ci rcu lato r b...

  • Page 77

    77 co m fo r tnet therm o st at on ly sym ptom s of a bnor m a l opera ti on (n on-c o m m unicat in g & c o m fortn et™ therm ost a t) d ia g no st ic /st a tus led codes fault de scr ipt ion messa ge code p o ss ib le c a u se s correct ive action s no tes & ca utio ns x fur nace fa ils to opera t...

  • Page 78

    78 troubleshooting com fortnettherm ostat only sym ptom s of a bnor m al opera ti on (n on-c om m unicat in g & c o m fortn et™ therm ost at) d ia g no st ic /st atus led codes fault de scr ipt ion messa ge code p o ss ib le c a u se s correct ive action s no tes & ca utio ns x op erat ion di fferen...

  • Page 79

    79 co m fo r tnet therm ost a t on ly sym ptom s of a bnor m a l opera ti on (n on-c o m m unicat in g & c o m fortn et™ therm o st at) d ia g no st ic /st a tus led codes fault de scr ipt ion messa ge code p o ss ib le c a u se s correct ive action s no tes & ca utio ns x fur nace fa ils to opera t...

  • Page 80

    80 status codes no power o n normal operation a indicates airflow, followed by cfm b 0 blower motor not running b 1 blower communication error b 2 blower hp mis-match b 3 blower motor operating in power, temperature, or speed limit b 4 blower motor current trip or lost rotor b 5 blower motor locked ...

  • Page 81

    81 hi g h vol t age! Di sconnect all pow er be fo re s e rv ic ing or i n st al li ng t h is uni t. M u lt ip le pow er sour ces m ay b e pr esent . Fai lur e t o do so m ay cause pr oper ty dam a ge, p e rs ona l in ju ry or de ath. Wiring is subject to change. Always refer to the wiring diagram on...