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Goodman GCS9 User Manual

Goodman GCS9
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Goodman Manufacturing Company, L.P.
2550 North Loop West, Suite 400, Houston, TX 77092
www.goodmanmfg.com
© 2004-2005 Goodman Manufacturing Company, L.P.
INSTALLATION INSTRUCTIONS
GMS9/GCS9
G
AS
-F
IRED
W
ARM
A
IR
F
URNACE
IO-244E
11/05
*NOTE: Please contact your distributor or our
website for the applicable product data book
referred to in this manual.
ATTENTION INSTALLING PERSONNEL
As a professional installer you have an obligation to know the product better than the customer. This includes all safety
precautions and related items.
Prior to actual installation, thoroughly familiarize yourself with this Instruction Manual. Pay special attention to all safety
warnings. Often during installation or repair it is possible to place yourself in a position which is more hazardous than
when the unit is in operation.
Remember, it is your responsibility 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 existing practices and the content of this manual, the precautions listed here take precedence.
(Type FSP CATEGORY IV Direct or Non Direct Vent Air Furnace)
RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION.
Installer: Affix all manuals adjacent to the unit.
C
US
®
These furnaces comply with requirements
embodied in the American National Standard
/ National Standard of Canada ANSI
Z21.47·CSA-2.3 Gas Fired Central Furnaces.

Table of Contents

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Goodman GCS9 Specifications

General IconGeneral
ModelGCS9
TypeGas Furnace
Efficiency RatingUp to 96% AFUE
Warranty10-Year Parts Limited Warranty with online registration
AFUEUp to 96%
Cabinet TypeMulti-Position
AFUE RatingUp to 96%
Heating Capacity40, 000 to 120, 000 BTU/h
Blower MotorVariable Speed
Fuel TypeNatural Gas or Propane
StagesSingle-Stage, Two-Stage
Blower Motor TypeVariable Speed

Summary

Attention Installing Personnel

For The Owner

For The Installer

Transportation Damage Inspection

Component Identification

Safety Precautions

Electrostatic Discharge (ESD) Precautions

Steps to prevent damage to electronic components from static discharge.

Product Application

Location Requirements & Considerations

General Location Guidelines

Factors to consider for furnace placement and clearances.

Clearances and Accessibility

Minimum clearances required for safe operation and service.

Furnace Suspension Methods

Instructions for suspending the furnace securely.

Existing Furnace Removal

Guidance on safely removing an old furnace.

Thermostat Location

Recommended placement for optimal temperature sensing.

Combustion & Ventilation Air Requirements

Equipment in Unconfined Spaces

Air supply requirements for equipment in unconfined spaces.

Equipment in Confined Spaces

Air supply requirements for equipment in confined spaces.

Installation Positions

Horizontal Applications & Considerations

Specific requirements and considerations for horizontal installations.

Horizontal Applications & Considerations

General Horizontal Installation Notes

Key factors for horizontal furnace installation.

Horizontal Drain Trap and Lines

Installing the condensate drain trap and lines for horizontal units.

Horizontal Leveling Requirements

Ensuring the furnace is level for proper drainage.

Alternate Vent/Flue & Combustion Air Connections

Using alternate connection points for vent and air piping.

Propane Gas / High Altitude Installations

Vent/Flue Pipe & Combustion Air Pipe

General Vent/Flue Pipe Guidelines

Essential instructions and warnings for vent/flue pipe installation.

Dual Certification: Non-Direct/Direct Vent

Understanding the furnace's dual certification for venting types.

Materials and Joining Methods

Specifications for PVC/ABS pipe, primer, cement, and fittings.

Proper Vent/Flue & Combustion Air Piping Practices

Best practices for secure, airtight, and properly sloped piping.

Vent/Flue Termination Locations

Restrictions and requirements for vent and air intake termination points.

Canadian Venting Requirements

Specific venting requirements for installations in Canada.

Standard Furnace Connections

Using factory-provided couplings for vent and air intake connections.

Alternate Furnace Connections

Using alternative side panel locations for piping connections.

Alternate Vent/Flue Location Setup

Procedure for using the alternate vent/flue pipe location.

Alternate Combustion Air Intake Location Setup

Procedure for using the alternate combustion air intake location.

Non-Direct Vent (Single Pipe) Piping

Requirements for single-pipe venting systems.

Vent/Flue Pipe Lengths and Diameters

Table of maximum allowable pipe lengths and elbow counts.

Vent/Flue & Combustion Air Pipe Terminations

Diagrams and requirements for vertical and horizontal pipe terminations.

Direct Vent (Dual Pipe) Piping

Requirements for dual-pipe venting and air intake systems.

Multiple Direct Vent Furnace Terminations

Clearance requirements for terminating multiple direct vent units.

Concentric Vent Termination

Instructions for using the Concentric Vent Kit.

Condensate Drain Lines & Drain Trap

General Condensate Drainage

Requirements for piping condensate to a drain location.

Upright Installation Drain Hose Connections

Connecting drain hoses for upright furnace installations.

Standard Side Drain Hose Connections

Attaching drain hoses using standard side connections.

Horizontal Installation Drain Hose Connections

Connecting drain hoses for horizontal furnace installations.

Alternate Vent/Flue Drain Hose Connections

Connecting drain hoses for alternate vent/flue outlet installations.

Upright Drain Trap Mounting

Mounting the drain trap to the side panel in upright installations.

Horizontal Drain Trap Mounting

Mounting the drain trap in horizontal installations.

Electrical Connections

Wiring Harness Information

Details on wire color coding and replacement.

115 Volt Line Connections

Connecting 115V power to accessories like humidifiers and air cleaners.

24 Volt Thermostat Wiring

Connecting low voltage thermostat wiring to the control module.

24 Volt Humidifier Connection

Connecting a 24VAC humidifier to the pressure switch.

Gas Supply and Piping

Inlet Gas Supply Pressure

Required inlet gas pressure ranges for natural and propane gas.

High Altitude Derate Requirements

Procedures for adjusting for high altitude conditions.

Propane Gas Conversion

Instructions and warnings for propane conversion.

Gas Valve Operation

Information on the gas valve and its manual control.

Gas Piping Connections

Guidelines for connecting the gas piping to the furnace.

Propane Gas Tanks and Piping

Circulating Air & Filters

Ductwork and Air Flow Design

Proper duct system design for optimal air flow and static pressure.

Filter Requirements and Installation

Essential information on filter selection, maintenance, and installation.

Horizontal Filter Installation

Filter placement for horizontal furnace installations.

Startup Procedure & Adjustment

Heat Anticipator Setting

Adjusting the thermostat heat anticipator for proper cycling.

Drain Trap Priming

Procedure to fill the drain trap with water before startup.

Furnace Operation Checks

Pre-startup checks including gas lines and leak detection.

Furnace Startup Steps

Step-by-step instructions for initial furnace startup.

Gas Supply Pressure Measurement

How to measure and verify inlet gas supply pressure.

Gas Manifold Pressure Measurement & Adjustment

Measuring and adjusting the gas manifold pressure.

Gas Input Rate Measurement (Natural Gas)

Procedure to measure and verify the natural gas input rate.

Temperature Rise Measurement

How to measure and adjust temperature rise for proper operation.

Circulator Blower Speed Adjustment

Steps to adjust blower speeds for optimal heating/cooling performance.

Normal Sequence of Operation

Power Up Sequence

Initial power application and system checks.

Heating Mode Operation

Step-by-step sequence of operations during heating.

Cooling Mode Operation

Step-by-step sequence of operations during cooling.

Fan Only Mode Operation

Sequence of operations when only the fan is active.

Operational Checks

Burner Flame Inspection

Visual inspection of burner flames for proper appearance.

Primary Limit Control Check

Verifying the function of the primary limit control.

Safety Circuit Description

General Safety Circuit Principles

Overview of safety circuits and their role.

Integrated Control Module Function

Description of the electronic control module's safety functions.

Primary Limit Safety Control

Function and purpose of the primary limit safety control.

Auxiliary Limit Safety Control

Function and purpose of the auxiliary limit safety control.

Rollout Limit Safety Control

Function and purpose of the rollout limit safety control.

Pressure Switches Function

Role of pressure switches in monitoring airflow.

Flame Sensor Function

How the flame sensor detects the presence of flame.

Troubleshooting Procedures

Diagnostic Chart

Reference for interpreting diagnostic LED codes and fault descriptions.

Resetting From Lockout

Procedures for resetting the furnace after a lockout condition.

Maintenance Requirements

Annual Inspection Checklist

Key items to inspect annually for proper furnace function.

Filter Maintenance and Replacement

Guidance on filter maintenance, removal, and types.

Flue Passage Cleaning (Servicer)

Procedure for cleaning heat exchanger flue passageways.

Internal Filter Removal

Bottom Return Filter Removal

Steps to remove filters from the bottom return.

Blower Compartment Filter Removal

Steps to remove filters from the blower compartment.

Before Leaving Installation

Repair & Replacement Parts

Troubleshooting Chart

Wiring Diagram

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