Goodman *MH81405D Series, Installation Instructions Manual

Page 1: ... to install the product safely and to know it well enough to be able to instruct a customer in its safe use Safety is a matter of common sense a matter of thinking before acting Most dealers have a list of specific good safety 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 exi...

Page 2: ... APPLIANCES VENTED INTO THIS CHIMNEY CHANNEL 13 CHECK 3 CHIMNEY CROWN CONDITION 14 CHECK 4 DEBRIS IN CLEANOUT 14 CHECK 5 LINER CONDITION 14 CHECK 6 DILUTION AIR 14 CHECK 7 COMPLETE THE INSTALLATION 15 FIX 1 LINER TERMINATION 15 FIX 2 CHANGE VENTING ARRANGEMENTS 15 FIX 3 REBUILD THE CROWN 15 FIX 4 RELINING 15 ELECTRICAL CONNECTIONS 16 WIRING HARNESS 16 115 VOLT LINE CONNECTIONS 16 FOSSIL FUEL APPLI...

Page 3: ...ERATION 25 FURNACE START UP 25 FURNACE SHUTDOWN 25 GAS SUPPLY PRESSURE MEASUREMENT 25 GAS MANIFOLD PRESSURE MEASUREMENT ANDADJUSTMENT 28 GAS INPUT RATE MEASUREMENT NATURAL GAS ONLY 29 TEMPERATURE RISE 29 CIRCULATOR BLOWER SPEED ADJUSTMENT 30 CIRCULATOR BLOWER FAN TIMING ADJUSTMENT 30 SETTING FURNACE OPERATING MODE DH8 ME8 AND MH8 MODELS ONLY 30 OPERATIONAL CHECKS 31 BURNER FLAME 31 AUXILIARY LIMIT...

Page 4: ...ALIFIED SERVICER ONLY 33 IGNITER QUALIFIED SERVICER ONLY 33 BURNERS 33 CLEANING QUALIFIED SERVICER ONLY 34 BEFORE LEAVING AN INSTALLATION 34 REPAIR AND REPLACEMENT PARTS 34 COMPONENT IDENTIFICATION 35 36 APPENDIX 37 TROUBLESHOOTING CHART 37 BLOWER PERFORMANCE DATA 40 M H S 8 40 D H S8 41 GME8 42 M D H S8 WIRING DIAGRAM 43 GME8 WIRING DIAGRAM 44 M D H WIRING DIAGRAM 45 ...

Page 5: ...RCE CLOSED IN THE EVENT THAT THE BUILDING MAY BE EXPOSED TO FREEZING TEMPERATURES AND WILL BE VACANT 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 SHOCK THE FURNACE MUST BE LOCATED TO PROTECT THE ELECTRICAL COMPONENTS FROM WATER WARNING CARBON MONO...

Page 6: ... potential these steps will help avoid expos ing the integrated control module to electrostatic discharge This procedure is applicable to both installed and non installed ungrounded furnaces 1 Disconnect all power to the furnace Do not touch the integrated control module or any wire connected to the control prior to discharging your body s electrostatic charge to ground 2 Firmly touch a clean unpa...

Page 7: ...Registration Complete the registration as prompted To register yourAmana brand unit go to www amana hac com and click Warranty Registration Complete the registration as prompted Product limited warranty certificates for models currently in pro ductioncanbeviewedatwww goodmanmfg comor www amana hac com If your model is not currently in production or does not appear on the website please contact you...

Page 8: ...d Ventilation Air Requirements 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 If the furnace is installed in an application where the typical operating sound level of a furnace is deemed objectionable an optional sound reduction kit is a...

Page 9: ... neces sary Suspended Furnace Do not connect this furnace to a chimney flue that serves a separate appliance designed to burn solid fuel For counterflow installations the air conditioning coil must be downstream from the heat exchanger of the furnace Counterflow installation over a noncombustible floor Before setting the furnace over the plenum opening ensure the surface around the opening is smoo...

Page 10: ...observed during any of the above tests the common venting system must be corrected Corrections must be in accordance with the latest edition of the National Fuel Gas Code NFPA54 ANSI Z223 1 and or CAN CSA B149 Installation Codes If resizing is required on any portion of the venting system use the appropriate table in Appendix G in the latest edition of the National Fuel Gas Code ANSI Z223 1 and or...

Page 11: ...ose shown above may be required or allowed When an existing furnace is re moved from a venting system serving other appliances the venting system may be too large to properly vent the remaining attached appliances Upflow or Horizontal units are shipped with the induced draft blower discharging from the top of the furnace Top is as viewed for an upflow installation The induced draft blower can be r...

Page 12: ...chers have discovered that the winter design temperatures have a direct impact on the suitability of this type of venting In most situations the existing masonry chimneys will require a properly sized metallic liner POSSIBILITY OF PROPERTY DAMAGE PERSONAL INJURY OR DEATH DAMAGING CONDENSATION CAN OCCUR INSIDE MASONRY CHIMNEYS WHEN A SINGLE FAN ASSISTED CATEGORY I APPLIANCE 80 AFUE FURNACE IS VENTE...

Page 13: ...L Solid fuel appliances include fireplaces wood stoves coal fur naces and incinerators Proper Chimney Termination Check 1 Chimney channel free of solid and liquid fuel appliances Check 2 Change venting arrangements Fix 2 Crown in good condition Check 3 Rebuild crown Fix 3 and or Reline Fix 4 Reline Fix 4 Reline Fix 4 Cleanout free of debris Check 4 Liner in good condition Check 5 Reline Fix 4 Dilu...

Page 14: ...through the draft hood of a natural draft appliance only if the appliance s vent connector does not include a vent damper If dilution air will not be available the chimney must be relined Fix 4 Liquid fuel appliances include oil furnaces oil fired boilers and oil fired water heaters Appliances which burn propane sometimes referred to as LP liquefied petroleum gas are considered gas fired appliance...

Page 15: ...s Flexible liners specifically intended and tested for gas applications are listed in the UL Gas and Oil Equipment Directory UL Standard 1777 CHECK 7 COMPLETE THE INSTALLATION If Checks 1 through 6 have been satisfactory and the liner is an acceptable size as determined by the tables in National Fuel Gas Code NFPA 54 ANSI Z223 1 latest edition and in the National Standard of Canada CAN CSAB149 1 a...

Page 16: ...ELECTRICAL WIRING WARNING LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION VERIFY PROPER OPERATION AFTER SERVICING CAUTION 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 ELECTR...

Page 17: ...supplied wire tabs when rotating junction box to the left side Low voltage wires may be connected to the terminal strip IMPORTANT NOTE To avoid possible equipment malfunction route the low voltage wires to avoid interference with filter re moval or other maintenance HIGH VOLTAGE TO AVOID THE RISK OF INJURY ELECTRICAL SHOCK OR DEATH THE FURNACE MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH LOCAL...

Page 18: ...g by 10 Set the heat anticipator on the thermostat to match this reading Example If the reading on the ammeter is 4 divide this by 10 The anticipator setting will be 4 amps 115VOLT LINE CONNECTION OF ACCESSORIES ELECTRONIC AIR CLEANER HIGH VOLTAGE TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK DISCONNECT ELECTRICAL POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING WARNING The fur...

Page 19: ...hes w c of that listed in the Specification Sheet applicable to your model for the fuel used At all altitudes and with either fuel the air temperature rise must be within the range listed on the fur nace nameplate Should this appliance be converted to LP refer to the instructions included in the factory authorized LP conversion kit HIGH ALTITUDE DERATE IMPORTANT NOTE The furnace will naturally der...

Page 20: ...ng piping Use pipe joint compound on male threads only Pipe joint compound must be resistant to the action of the fuel used Use ground joint unions Install a drip leg to trap dirt and moisture before it can enter the gas valve The drip leg must be a minimum of three inches long Install a 1 8 NPT pipe plug fitting accessible for test gage connection immediately upstream of the gas supply connection...

Page 21: ...ng its manual shutoff valve before pressure testing of gas sup ply piping system with test pressures equal to or less than 1 2 psig 3 48 kPa PROPANE GAS TANKS AND PIPING IF THE GAS FURNACE IS INSTALLED IN A BASEMENT AN EXCAVATED AREA OR CONFINED SPACE IT IS STRONGLY RECOMMENDED TO CONTACT A PROPANE SUPPLIER TO INSTALL A GAS DETECTING WARNING DEVICE IN CASE OF A GAS LEAK SINCE PROPANE GAS IS HEAVIE...

Page 22: ...90A and 90B A closed return duct system must be used with the return duct connected to the furnace NOTE Ductwork must never be attached to the back of the furnace For installations requiring more than 1800 CFM use a bottom return or two sided return Supply and return connections to the furnace may be made with flexible joints to reduce noise transmission To prevent the blower from interfering with...

Page 23: ...TWORK Filters must be used with this furnace Discuss filter mainte nance with the building owner Filters do not ship with this furnace but must be provided by the installer Filters must com ply with UL900 or CAN ULCS111 standards If the furnace is installed without filters the warranty will be voided NOTE An undersized opening will cause reduced airflow The bottom return is set up as a knock out U...

Page 24: ...monitors flame presence Gas valve will remain open only if flame is detected Circulator blower is energized on low heat speed following a fixed thirty second blower on delay Electronic air cleaner terminals are energized with circulator blower Furnace is now operating in low stage heating mode Furnace operates integrated control module monitors safety circuits continuously If low stage delay perio...

Page 25: ...s R and G thermostat contacts close initiating a call for fan Integrated control module performs safety circuit checks Circulator blower is energized on low heat speed Electronic air cleaner terminals are energized Circulator blower runs integrated control module monitors safety circuits continuously R and G thermostat contacts open completing the call for fan Circulator blower is de energized Ele...

Page 26: ... THE GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE ONLY MINOR ADJUSTMENTS SHOULD BE MADE BY ADJUSTING THE GAS VALVE PRESSURE REGULATOR CAUTION 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...

Page 27: ...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 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 Pre...

Page 28: ...s at outlet pressure boss plug Honeywell valve or screw White Rodgers valve Bubbles forming indicate a leak SHUT OFF GAS AND REPAIR ALL LEAKS IMMEDIATELY 8 Measure the gas manifold pressure with burners firing Adjust manifold pressure using the Manifold Gas Pressure table shown below Manifold Gas Pressure Natural Gas 3 5 w c Propane Gas 10 0 w c 9 Remove regulator cover screw from the outlet press...

Page 29: ... c 3 5 w c Propane Low Stage 5 7 6 3 w c 6 0 w c High Stage 9 7 10 3 w c 10 0 w c Manifold Gas Pressure Gas 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 burning appliances except t...

Page 30: ...ite for the applicable Specification Sheet referred to in this manual 3 Relocate desired motor leads to the circulator blower heat and cool speed terminals on the integrated control module Terminals are identified as LO HEAT HI HEAT and COOL hot for M D H8 models and HEAT and COOL for M H D S8 models If a heating speed and the cooling speed are the same a jumper wire must be used between the heat ...

Page 31: ...wer door The auxiliary limit control is designed to pre vent furnace operation in case of main blower failure on hori zontal installations It may also open if the power supply is interrupted while the furnace is firing The auxiliary limit control is suitable for both horizontal right and horizontal left installa tions Regardless of airflow direction it does not need to be relocated TO AVOID PERSON...

Page 32: ...your body to ground before removing a new control from its container Follow steps 1 through 3 if installing the control on a furnace Return any old or new controls to their containers before touching any ungrounded object DIAGNOSTIC CHART Refer to the troubleshooting chart in the Appendix for assis tance in determining the source of unit operational problems The red diagnostic LED blinks to assist...

Page 33: ...in either the central return register or a side panel external filter rack upflow only A media air filter or electronic air cleaner can be used as an alter nate filter Follow the filter sizes given in the Recommended Minimum Filter size table or instruction provided by the media or electronic air cleaner manufacturer to ensure proper unit performance To remove filters from an external filter rack ...

Page 34: ...ion Refer to Operational Checks section to verify burner flame characteristics BEFORE LEAVING AN INSTALLATION Cycle the furnace with the thermostat at least three times Verify cooling and fan only operation Review the Owner s Manual with the homeowner and discuss proper furnace operation and maintenance Leave literature packet near furnace REPAIR AND REPLACEMENT PARTS When ordering any of the list...

Page 35: ...grated Control Module 14 Blower Door Interlock Switch 15 Circulator Blower 16 Gas Line Entrance Alternate 躀 Pressure Switch Tubular Heat Exchanger Flue Pipe Connection Gas Line Entrance Alternate Induced Draft Blower Chimney Transition Top Shipped Loose Gas Line Entrance Gas Valve Rollout Limit Junction Box Wiring Harness Grommet Gas Manifold Inshot Burner Blower Door Interlock Switch Integrated C...

Page 36: ...egrated Control Module 14 Blower Door Interlock Switch 15 Circulator Blower 16 Gas Line Entrance Alternate Tubular Heat Exchanger Flue Pipe Connection Chimney Transition Top Shipped Loose Gas Line Entrance Alternate Induced Draft Blower Gas Line Entrance Gas Valve Rollout Limit Junction Box Wiring Harness Grommet Gas Manifold Inshot Burner Blower Door Interlock Switch Integrated Control Module Tra...

Page 37: ... switch contacts sticking Shorts in pressure switch circuit Inspect pressure switch hose Repair if neces sary Inspect flue for blockage proper length elbows and termination Correct pressure switch setpoint or contact motion Tighten or correct wiring connection Inspect masonry chimney and flue remove blockage Pressure switch hose blocked pinched or connected improperly Blocked flue or weak induced ...

Page 38: ...Check flue and air inlet piping for blockage proper length elbows and termination Correct as necessary Check rollout limit Replace if necessary Check induced draft blower for proper performance Replace if necessary Tighten or correct wiring connection Repair short in 24 volt AC control safety circuit s Replace integrated control module fuse 3A Flame rollout Misaligned burners blocked flue and or a...

Page 39: ...d and blue wires connected to transformer Turn power OFF prior to repair Normal operation LED is steady on STEADY Furnace not operating Integrated control module diagnostic LED is flashing EIGHT 8 flashes 8 FLASHES Problem with igniter circuit Improperly connected igniter Bad igniter Poor unit ground Poor burner ground Faulty integrated control module Check and correct wiring from integrated contr...

Page 40: ...80804B MED 3 5 1736 1708 35 1652 36 1611 37 1540 38 1475 1394 1307 MEDIUM MED LO 3 0 1693 35 1668 36 1459 41 1429 41 1389 43 1339 1274 1204 LOW 2 5 1200 49 1185 50 1180 50 1173 51 1158 51 1125 1125 1080 HIGH 5 0 2290 2229 2155 2047 1960 1837 1712 1584 M H S 80805C MED 4 0 1852 1820 1777 1719 1641 36 1567 1469 1382 MEDIUM MED LO 3 5 1615 37 1592 37 1556 38 1516 39 1470 40 1405 1346 1235 LOW 3 0 129...

Page 41: ...e vs External Static Pressure 0 1 0 2 0 3 0 4 0 5 Model Heating Speed As Shipped Motor Speed EXTERNAL STATIC PRESSURE Inches Water Column Tons AC at 0 5 ESP CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE HIGH 3 0 1739 1656 1601 1551 1513 20 1460 22 8 1413 23 6 1353 24 6 GHS80403A MED 2 5 1422 21 1399 21 1378 22 1350 22 1305 23 1275 26 1 1220 27 3 1178 28 3 MEDIUM MED LO 2 ...

Page 42: ... 2106 35 2014 37 1896 1813 1669 Notes CFM Temperature Rise vs External Static Pressure 0 1 0 2 0 3 0 4 0 5 Model Heating Speed As Shipped Motor Speed EXTERNAL STATIC PRESSURE Inches Water Column GME81005C CFM in chart is without filter s Filters do not ship with this furnace but must be provided by the installer If the furnace requires two return filters this chart assumes both filters are install...

Page 43: ...iagram on the unit for the most up to date wiring M D H S8 WIRING DIAGRAM HIGH VOLTAGE D ISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT M ULTIPLE POWER SOURCES MAY BE PRESENT F AILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH BOX ...

Page 44: ... ORANGE YL YELLOW 6 7 8 BKBLACK GRGREEN BRBROWN PKPINK RD RED GYGRAY BLBLUE WH WHITE PU OVERCURRENTPROTECTIONDEVICE JUNCTIONBOX MUSTBE WARNING SWITCH WIRINGTOUNIT BEFORESERVICING DISCONNECTPOWER LINE H DOOR ANDGROUNDED POLARIZED PROPERLY L GND LINE N DISCONNECT N SWITCH TEMP FIELDSPLICE SWITCH PRESS PROT DEVICE OVERCURRENT EQUIPMENTGND TERMINAL JUNCTION HIVOLTAGEFIELD HIVOLTAGE 115V LOWVOLTAGEFIEL...

Page 45: ...S LOW FLAME SIGNAL 5 FLASHES FLAME SENSE WITHOUT GAS VALVE 4 FLASHES OPEN HIGH LIMIT 3 FLASHES PRESSURE SWITCH STUCK OPEN 2 FLASHES PRESSURE SWITCH STUCK CLOSED STEADY ON NORMAL OPERATION OFF CONTROL FAILURE 5 1 FLASH 0 1 2 3 4 PU 6 FLASHES OPEN ROLLOUT OR OPEN FUSE COLOR CODES PU PURPLE OR ORANGE YL YELLOW 6 7 8 BK BLACK GR GREEN BR BROWN PK PINK RD RED GY GRAY BL BLUE WH WHITE PU RATING OF AT LE...

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

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

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 ...