background image

23

S

S

S

S

S

T

T

T

T

TA R

A R

A R

A R

A RT

T

T

T

T

-----

U P

U P

U P

U P

U P

  P

  P

  P

  P

  P

R

R

R

R

R O C E D U R E

O C E D U R E

O C E D U R E

O C E D U R E

O C E D U R E

     

A N D

A N D

A N D

A N D

A N D

  A

  A

  A

  A

  A

D J U

D J U

D J U

D J U

D J US T M E N T

S T M E N T

S T M E N T

S T M E N T

S T M E N T

Gas Valve On/Off
Selector Switch

Regulator
Vent

High Fire
Regulator
Adjust

Low Fire
Regulator
Adjust

Honeywell Model VR9205 (Two-Stage)

i

Manometer

Manometer

Hose

Common
Terminal(C)

High Fire Coil
Terminal (HI)

Low Fire Coil 
Terminal (LO)

Inlet Pressure Tap
1/8 NPT

Open to

Atmosphere

Outlet Pressure Tap
1/8 NPT

Honeywell Model VR9205 Connected to Manometer

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 pressure boss or
the gas piping drip leg. See Honeywell VR9205 gas valve
figure or White-Rodgers 36G54 gas valve figure for location
of inlet pressure boss.

NOTE:

NOTE:

NOTE:

NOTE:

NOTE: If measuring gas pressure at the drip leg or Honeywell VR9205
gas valve, a field-supplied hose barb fitting must be installed prior
to making the hose connection. If using the inlet pressure boss on
the White-Rodgers 36G54 gas valve, then use the 36G Valve Pressure
Check Kit, Goodman Part No. 0151K00000S.

3. Turn ON the gas supply and operate the furnace and all other

gas consuming appliances on the same gas supply line.

4. Measure furnace gas supply pressure with burners firing.

Supply pressure must be within the range specified in the

Inlet Gas Supply Pressure

 table.

Natural Gas

Minimum: 5.0" w.c.

Maximum:10.0" w.c.

Propane Gas

Minimum: 11.0" w.c.

Maximum:13.0" w.c.

Inlet Gas Supply Pressure

If supply pressure differs from table, make the necessary adjust-
ments to pressure regulator, gas piping size, etc., and/or consult
with local gas utility.

5. Turn OFF gas to furnace at the manual shutoff valve and

disconnect manometer.  Reinstall plug before turning on
gas to furnace.

6. Turn OFF any unnecessary gas appliances stated in step 3.

Gas Line

Gas
Shutoff
Valve

Gas Line 
To Furnace

Drip Leg Cap 
With Fitting

Manometer Hose

Manometer

Open To
Atmosphere

Measuring Inlet Gas Pressure (Alt. Method)

G

G

G

G

G

AS

AS

AS

AS

AS

 M

 M

 M

 M

 M

ANIFOLD

ANIFOLD

ANIFOLD

ANIFOLD

ANIFOLD

 P

 P

 P

 P

 P

RESSURE

RESSURE

RESSURE

RESSURE

RESSURE

 M

 M

 M

 M

 M

EASUREMENT

EASUREMENT

EASUREMENT

EASUREMENT

EASUREMENT

     

AND

AND

AND

AND

AND

 A

 A

 A

 A

 A

DJUSTMENT

DJUSTMENT

DJUSTMENT

DJUSTMENT

DJUSTMENT

T

O

 

PREVENT

 

UNRELIABLE

 

OPERATION

 

OR

 

EQUIPMENT

 

DAMAGE

,

 

THE

 

GAS

 

MANIFOLD

 

PRESSURE

 

MUST

 

BE

 

AS

 

SPECIFIED

 

ON

 

THE

 

UNIT

 

RATING

 

PLATE

.

 

O

NLY

 

MINOR

 

ADJUSTMENTS

 

SHOULD

 

BE

 

MADE

 

BY

 

ADJUSTING

 

THE

 

GAS

 

VALVE

 

PRESSURE

 

REGULATOR

.

CAUTION

Only small variations in gas pressure should be made by adjusting
the gas valve pressure regulator.  The manifold pressure must be
measured with the burners operating.  To measure and adjust the
manifold pressure, use the following procedure.

1. Turn OFF gas to furnace at the manual gas shutoff valve

external to the furnace.

2. Turn off all electrical power to the system.
3. Outlet pressure tap connections:

a. Honeywell VR9205 valve: Remove the outlet pressure boss

plug.  Install an 1/8" NPT hose barb fitting into the outlet
pressure tap.

b. White-Rodgers 36G54 valve: Back outlet pressure test

screw (inlet/outlet pressure boss) out one turn
(counterclockwise, not more than one turn).

4. Attach a hose and manometer to the outlet pressure barb

fitting (Honeywell valve) or outlet pressure boss (White-
Rodgers valve).

5. Turn ON the gas supply.
6. Turn on power and close thermostat “R” and “W1” contacts

to provide a call for low stage heat.

Summary of Contents for GDVC80703B

Page 1: ...afety practices follow them The precautions listed in this Installation Manual are intended as supplemental to existing practices However if there is a direct conflict between existing practices and t...

Page 2: ...L 12 CHECK 3 CHIMNEY CROWN CONDITION 12 CHECK 4 DEBRIS IN CLEANOUT 12 CHECK 5 LINER CONDITION 12 CHECK 6 DILUTION AIR 13 CHECK 7 COMPLETE THE INSTALLATION 13 FIX 1 LINER TERMINATION 13 FIX 2 CHANGE VE...

Page 3: ...33 POWER UP 33 HEATING MODE 33 COOLING MODE 33 FAN ONLY MODE 34 OPERATIONAL CHECKS 34 SAFETY CIRCUIT DESCRIPTION 34 INTEGRATED CONTROL MODULE 34 PRIMARY LIMIT 34 AUXILIARY LIMIT 34 ROLLOUT LIMIT 34 P...

Page 4: ...ANY HYDRONIC COIL UNITS SHOULD BE DRAINED AS WELL AND IN SUCH CASE ALTERNATIVE HEAT SOURCES SHOULD BE UTILIZED WARNING TO PREVENT POSSIBLE PROPERTY DAMAGE PERSONAL INJURY OR DEATH DUE TO ELECTRICAL S...

Page 5: ...ntial these steps will help avoid exposing the inte gratedcontrolmoduletoelectrostaticdischarge Thisprocedureis applicable to both installed and non installed ungrounded fur naces 1 Disconnect all pow...

Page 6: ...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...

Page 7: ...RE NOT APPROVED FOR HORIZON ARE NOT APPROVED FOR HORIZON ARE NOT APPROVED FOR HORIZON ARE NOT APPROVED FOR HORIZON T T T T TAL OR UPFL AL OR UPFL AL OR UPFL AL OR UPFL AL OR UPFLOW INST OW INST OW INS...

Page 8: ...23 1 tion 1 23 1 tion 1 23 1 The following steps shall be fol lowedwitheachapplianceconnectedtotheventingsystemplaced inoperation whileanyotherappliancesconnectedtotheventing systemarenotinoperation a...

Page 9: ...TION TION A A A A AIR IR IR IR IR R R R R REQUIREMENT EQUIREMENT EQUIREMENT EQUIREMENT EQUIREMENTS S S S S TO AVOID PROPERTY DAMAGE PERSONAL INJURY OR DEATH SUFFICIENT FRESH AIR FOR PROPER COMBUSTION...

Page 10: ...Disconnecttheinduceddraftblowerpowerleads fluepipe andpressureswitchtubing 3 Removetheroundcutoutfromtherightsideofthewrapper 4 Remove and save the four screws that fasten the induced draft blower to...

Page 11: ...C C CHECKLIST HECKLIST HECKLIST HECKLIST HECKLIST S S S S SUMMARY UMMARY UMMARY UMMARY UMMARY This checklist serves as a summary of the items to be checked beforeventingan80 furnaceintoamasonrychimne...

Page 12: ...ey Fix 4 C C C C CHECK HECK HECK HECK HECK 5 L 5 L 5 L 5 L 5 LINER INER INER INER INER C C C C CONDITION ONDITION ONDITION ONDITION ONDITION Ifametallinerispresent itmustbechecked Itcannotbeassumed th...

Page 13: ...t in accordance with nationally recognized building codes or stan dards OnesuchstandardwhichmaybereferencedistheStandard forChimneys Fireplaces Vents andSolidFuelBurningAppliances ANSI NFPA 211 Next u...

Page 14: ...orts such as fire stops or thimbles must be used to prevent the B vent fromcomingintodirectcontactwiththetilelinerorchimneywalls Direct contact would result in higher heat loss with an increased possi...

Page 15: ...ES MAY BE SHARP USE GLOVES AS A PRECAUTION WHEN REMOVING HOLE PLUGS WARNING Line voltage connections can be made through either the right or left side panel The furnace is shipped configured for a rig...

Page 16: ...and dehumidification features require a jumper betweenY1 and O andY1 and DEHUM respectively NOTE NOTE NOTE NOTE NOTE Thermostat R requiredifoutdoorunitisequippedwitha Comfort Alert module or if the o...

Page 17: ...binationcallforcooling T Stat anddehumidification DEHUM Stat 9 10 DEHUM Unused Move to the ON position to enable dehumidification ON OFF S5 F F F F FOSSIL OSSIL OSSIL OSSIL OSSIL F F F F FUEL UEL UEL...

Page 18: ...e furnace can result in premature heat exchanger failure Gas pressures in excess of 13 inches water column can also cause permanent damage to the gas valve At all altitudes the manifold pressure must...

Page 19: ...three inches long Installa1 8 NPTpipeplugfitting accessiblefortestgage connection immediately upstream of the gas supply connection to the furnace Use two pipe wrenches when making connection to the...

Page 20: ...PANE G G G G GAS AS AS AS AS T T T T TANKS ANKS ANKS ANKS ANKS AND AND AND AND AND P P P P PIPING IPING IPING IPING IPING IF THE GAS FURNACE IS INSTALLED IN A BASEMENT AN EXCAVATED AREA OR CONFINED SP...

Page 21: ...stalledbetweentheunitandtheutility roomwall Aroom closet oralcovemustnotbeusedasareturnair chamber When the furnace is used in connection with a cooling unit the furnaceshouldbeinstalledinparallelwith...

Page 22: ...perly connected andgrounded Properpolaritymustbemaintainedforcorrectop eration Inadditiontothefollowingstart upandadjustmentitems refertofurtherinformationinOperationalCheckssection H H H H HEAT EAT E...

Page 23: ...cessary adjust ments to pressure regulator gas piping size etc and or consult withlocalgasutility 5 Turn OFF gas to furnace at the manual shutoff valve and disconnect manometer Reinstall plug before t...

Page 24: ...tion 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 seconds rec...

Page 25: ...The cooling system manufacturer s instructions must be checked for required air flow Any electronic air cleaners or other devices may require specific air flows consult installation instructions of t...

Page 26: ...Mode B ON OFF ON OFF ON OFF ON OFF C OFF ON OFF ON OFF ON OFF ON B 30 sec 50 60 sec 100 D ON ON ON ON ON ON ON ON D 30 sec 50 7 5 min 82 30 sec 50 Select desired Comfort Mode profile see profiles abo...

Page 27: ...ctory setting 8 Select the desired heating speed tap by positioning switches7and8appropriately Refertofigureabove Verify CFMbynotingthenumberdisplayedonthedual7 segment LEDdisplay In general lower hea...

Page 28: ...ystem controls are power with 24 VAC Thus a maximum of 4 wires between the equipment and thermostat is all that is required to operate the system CTK01AA W CTK01AA W CTK01AA W CTK01AA W CTK01AA WIRING...

Page 29: ...fig onfig onfig key again for approximately3secondstoentertheAdvancedInstaller Configurationmenu Clean Display Installer Config Set Time Set Schedule Run Schedule Upon entering the advanced menus the...

Page 30: ...YES Selecting YES clears the fault history NOTE Consecutively repeated faults are shown a maximum of 3 times DIAGNOSTICS Submenu Item Indication for Display Only not User Modifiable Model Number MOD N...

Page 31: ...oveinAccessingandNavigat ingtheAdvancedFeaturesMenus NOTE NOTE NOTE NOTE NOTE It is highly recommended that the fault history be cleared when performing maintenance or servicing the furnace N N N N NE...

Page 32: ...a power up reset x Depress and hold for 2 seconds for an out of box reset Red Communications LED 2 Flashes x Out of box reset x Control power up x Learn button depressed x None x None Off x No power x...

Page 33: ...t changes the call from low heat tohighheat theintegratedcontrolmodulewillimmediately switch the induced draft blower gas valve and circulator blowertotheirhighstagesettings Ifthetwo stagethermostatch...

Page 34: ...or near the circulator blowerandmonitorsblowercompartmenttemperatures Theyare a normally closed electrically auto reset sensors These limits guardagainstoverheatingasaresultofinsufficientconditionedai...

Page 35: ...henreset toprevioussetting NOTE NOTE NOTE NOTE NOTE If the condition which originally caused the lockout still exists the control will return to lockout Refer to the Diagnostic Chart for aid in determ...

Page 36: ...eel wool Following cleaning the flamesensesignalshouldbeasindicatedintheSpecificationsSheet F F F F FLUE LUE LUE LUE LUE P P P P PASSAGES ASSAGES ASSAGES ASSAGES ASSAGES Q Q Q Q QUALIFIED UALIFIED UAL...

Page 37: ...per gas pressure or restriction in flue and or combustion air piping front cover pressure switch opening or improper induced draft blower performance x Locate and correct gas interruption x Check fron...

Page 38: ...ck Furnace message E4 x Flame sensed with no call for heat IMPROPER FLAME E4 x Short to ground in flame sense circuit x Lingering burner flame x Slow closing gas valve x Correct short at flame sensor...

Page 39: ...y connected wiring x Inspect pressure switch hose Repair replace if necessary x Inspect flue and or inlet air piping for blockage proper length elbows and termination Check drain system Correct as nec...

Page 40: ...ck Furnace message b1 x Integrated control module has lost communications with circulator blower motor MOTOR COMM b1 x Loose wiring connection at circulator motor control leads x Failed circulator blo...

Page 41: ...le LED display provides b6 error code x ComfortNet thermostat Call for Service icon illuminated x ComfortNet thermostat scrolls Check Furnace message b6 x Circulator blower motor shuts down for over o...

Page 42: ...SURE SWITCH STUCK CLOSED AT START OF HEATING CYCLE HIGH STAGE PRESSURE SWITCH STUCK OPEN REVERSED 115 VAC POLARITY DATA NOT YET ON NETWORK INVALID MEMORY CARD DATA BLOWER MOTOR NOT RUNNING BLOWER COMM...

Page 43: ...Tap B is 10 Tap C 10 Set dip switches 3 and 4 to the appropriate ON OFF positions Speed Selection Dip Switches 390 520 650 780 A B C D 600 800 1000 1200 735 805 875 935 1050 1150 1250 1350 520 715 91...

Page 44: ...LACEMENT PARTS MUST BE USED WHEN SERVICING ONLY C AIR CLEANER HIGH FIRE PRESS SWTICH INDOOR HUMIDIFIER PK PINK WH 9 IND LO 14 Y2 40 VA 3 HUM YL JUNCTION BLWR PU PURPLE 1 CIRCULATOR BLOW ER R 1 JUNCTIO...

Page 45: ...INAL 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 USE COPPER CONDUCTORS ONLY INTEGRATED CONTROL MODULE RD I...

Page 46: ...46 THIS PAGE LEFT BLANK INTENTIONALLY...

Page 47: ...47 THIS PAGE LEFT BLANK INTENTIONALLY...

Page 48: ...48 Goodman Manufacturing Company L P 5151 San Felipe Suite 500 Houston TX 77056 www goodmanmfg com 2009 2010 Goodman Manufacturing Company L P...

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