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York GM9S*DH User's Manual

1. a _ hc dal 40 6 1 Bh RS EM eC OC M E b mE 17 E m LL gt AED b Il d E 1 4A w A4 0 St lL A9 kan ERA Mi 2 7 1 4 Pai NHN EZ uw LAO ADM o OW AD LL LM lt Ey BM M eel E 10 CD CRC _ ___ I 2 E Oe AE A A Uu UM A UM 3 hl E E A E L OU Ap WW AJ aM Uu UU I D Jg 3 M M I 8 m e LEM 5 LB D L M 1 0n nh hAA5 ____ WM LL WM DULL m L E OE A HIGH EFFICIENCY TUBULAR HEAT EXCHANGER SERIES ama MODELS GY9S DH GM9S DH GF9S DH Single Stage Downflow Horizontal 40 120 MBH INPUT 11 72 35 17 KW INPUT d YT 9000 REX ISR ISO 9001 Certified Quality Management System LIST OF SECTIONS SAFETY dora 1 TWINNING AND STAGING
2. WALL THERMOSTAT FIGURE 14 Single Stage Twinning Wiring Diagram STAGING In applications where more heating capacity or more airflow capacity is needed than what one furnace can deliver twinning can be used to make two furnaces operate in tandem using one duct system and one room thermostat This control can also be used along with a two stage wall thermostat to stage two twinned furnaces making them operate like a single two stage furnace This allows only one furnace to supply heat during times when the heat output from one furnace is sufficient to satisfy the demand When one duct system is used for two furnaces it is necessary that the two blowers operate in unison The twinning func tion of this board ensures that both blowers turn on and off simulta neously and operate on the same blower speed Even when only one furnace is supplying heat both furnace blowers must run Single Wire Staging The single wire twinning feature of this board can also be used for stag ing of two furnaces With this feature a single wire is connected between the TWIN terminal on one furnace board to the TWIN terminal on the second furnace board The board then communicates the blower status from one furnace to the other along this wire This communica tion makes the second furnace blower come on at the same time and on the same speed as the first furnace blower 14 Single Wire Staging Instruct
3. 99 LM M 10H 10H E H 1009 45114 CA A A UOWLUOD M 4 ve LOOH LONG veoLOVH odd vc LOOH ION LVLSOWYSAHL 104409 seues 6 610 150 N O64AX 1 08 08 56 8 1 0 Apeay 5 eoeuiny 1 ejBuirS M LXdH SHH3 09 3 d H eels ve LOONeeNA IVISONWH3HL 104 1 15 LVAH TOULNOD ADVLS ATONIS 25 01195 eq ISNW 1 JequinN aej eisu 5 0 01195 eq jsnui ed JOQUINN 9119 Jej eisu 1e1souu9u jou 1 uo U9IIMS 23 13 SV9 10 95 ye SIPIWNH Unitary Products Group 268890 UIM B 0607 Ave 1009 ONINOILIGNOD 39V S ATONIS 1009 puooeg ejBuis 1 1514 M 1000 10H HOA 7Z Od HINAX 38H 1514 02911 LVLSOWYAHL 06 1 N O84AX
4. VENT TERMINAL AIR SUPPLY AREA WHERE TERMINAL IS NOT PERMITTED OPERABLE FIGURE 17 Home Layout Direct Vent Terminal Clearances Canadian Installations US Installation A 22 above grade veranda porch deck 45 inches 30 cm 12 inches 30 cm 12 inches 30 cm for models lt 100 000 BTUH 30 kW Two pipe direct vent applications 9 inches 23 cm 36 inches 91 cm for models gt 100 000 BTUH 30 kW 07 modes lt 50 000 i E Clearance to permanently closed window 12 inches 30 cm 12 inches 30 cm D Vertical clearance to ventilated soffit located 12 inches 30 cm or in accordance with local 12 inches 30 cm or in accordance with local above the terminal within a horizontal distance installation codes and the requirements of the gas installation codes and the requirements of the gas sup of 2 feet 61 cm from the center line of the terminal supplier plier 12 inches 30 cm or in accordance with local 12 inches 30 cm or in accordance with local E Clearance to unventilated soffit installation codes and the requirements of the gas installation codes and the requirements of the gas supplier supplier 12 inches 30 cm or in accordance with local 12 inches 30 cm or in accordance with local F Clearance to outside corner installation codes and the requirements of the gas installation codes and the requirements of the gas supplier supplier B Clearance to win
5. Flue em In cm Closet Alcove Line Contact 1 Combustible floor base or air conditioning coil required for use on combusti ble floor 2 Line contact only permitted between lines formed by the intersection of the rear panel top in horizontal position of the furnace jacket and building joists studs or framing SECTION Il DUCTWORK DUCTWORK GENERAL INFORMATION The duct system s design and installation must 1 Handle air volume appropriate for the served space and within the operating parameters of the furnace specifications 2 installed in accordance with standards of NFPA National Fire Protection Association as outlined in NFPA pamphlets 90A and 90B latest editions or applicable national provincial or state and local fire and safety codes 3 Create a closed duct system For residential and Non HUD Modu lar Home installations when a furnace is installed so that the sup ply ducts carry air circulated by the furnace to areas outside the space containing the furnace the return air shall also be handled by a duct s sealed to the furnace casing and terminating outside the space containing the furnace 4 Complete a path for heated or cooled air to circulate through the air conditioning and heating equipment and to and from the condi tioned space A CAUTION The cooling coil must be installed in the supply air duct down stream of the furnace C
6. S6 8 1 9 1514 M 1002 10H Ou 10H HH 002 eDeis 154 A UOWLUOD 9 100911 VZLOVOL Lda 11001139 109911 9 jeoH 1514 M 1002 10H OH HNX 10H 002 1514 9 IVISONWH3HL Apeay ajbuls 19 Thermostat Chart FIGURE 11 12 ACCESSORY CONNECTIONS The furnace control will allow power switching control of various acces sories Refer to Figure 12 for connection details HUM HOT 115 VOLT BLK HUMIDIFER SWITCHED CIRCUITS EAC HOT 115 VOLT ELECTRONIC AIR CLEANER NEUTRALS FIGURE 12 Accessory Connections ELECTRONIC AIR CLEANER CONNECTION Two 1 4 0 64 cm spade terminals EAC and NEUTRAL for electronic air cleaner connections are located on the control board The terminals provide 115 VAC 1 0 amp maximum during circulating blower opera tion HUMIDIFIER CONNECTION Two 1 4 0 64 cm spade terminals HUM and NEUTRAL for humidi fier connections are located on the control board The terminals provide 115 VAC 1 0 amp maximum during heating system operation SECTION VI TWINNING AND STAGING NOTE You can twin two furnaces that have the same integrated co
7. gt gt 5 5 Es pw 5 ew eps ssp pm ps pm pum Med Low 20 TEA DEA ER SIRE ER LIEN d ER NOTES 1 Airflow expressed in standard cubic feet per minute CFM and in cubic meters per minute m3 min 2 Motor voltage at 115 V NR Operation at this static pressure is not recommended FILTER PERFORMANCE NOTE The filter pressure drop values in Table 19 are typical values for the type of filter listed and should only be used as a guideline Actual pressure drop ratings for each filter type vary between filter manufactur ers The airflow capacity data published in Table 18 represents blower per formance WITHOUT filters To determine the approximate blower per formance of the system apply the filter drop value for the filter being used or select an appropriate value from the Table 19 TABLE 19 Filter Performance Pressure Drop Inches W C and kPa Minimum Filter Type Opening Size Disposable Washable Fiber Pleated TE In NE NES SNL 148 ooa o0 ooz 015 008738 0 901246 005 00145 020 004982 Airflow Range Wm _ 0 750 0 21 4 751 1000 21 25 28 32 1251 1500 1501 1750 1751 2000 2001 amp Above oo 00291 025 00627
8. 16 Filter Performance Pressure Drop Inches W C and kPa 37 SECTION I SAFETY This is a safety alert symbol When you see this symbol on A WARNING A labels or in manuals be alert to the potential for personal injury Improper installation may create a condition where the operation of the product could cause personal injury or property damage Improper installation adjustment alteration service or mainte nance can cause injury or property damage Refer to this manual Understand and pay particular attention to the signal words DANGER WARNING or CAUTION DANGER indicates an imminently hazardous situation which if not for assistance or for additional information consult a qualified con avoided will result in death or serious injury tractor installer or service agency WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury A CAUTION CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It is also used to hd lert against unsafe practices and hazards involving only property dam any ane 2 including but not limited to building electrical and mechanical codes This product must be installed in strict compliance with the installa 268890 UIM B 0607 268890 UIM B 0607 SPECIFIC SAFETY RULES AND PRECAUTI
9. ar oe ore m m mmm a ve oso soe we zo pm oo oo oe ir ie ie i Ser os oor fos ela sear sea seo s s ps spmspespes a w w opo roar rear 45 35 meses ar ar zz pepepepsepu 9 s e Fer m m mw 57 w s s me ee ww mepwepepepeeesssspu ror 7 57 oer 5 47 2 1687 165 pepe a Med High 80 1200 B TENET Med High 80 1600 C 1256 127 ma Med High 100 1600 C 1167 115 ___ ass 100 2000 C TEES 1626 158 120 2000 D r 2 r oj T IID I r I r 5 8 2 gt gt 5 E
10. 1 Maximum return air velocity in rigid duct 700 feet per minute 213 m min 2 Example return main trunk duct minimum dimensions 3 Maximum supply air velocity in rigid duct O 900 feet per minute 274m min TABLE 3 Round Duct Size Round Duct Size Calculated Area For Each Round Duct Size IE 28 2 182 38 4 248 50 2 324 63 6 410 1 Air Temperature Rise is determined by subtracting the Return Air Temperature Reading from the Supply Air Temperature Read ing 2 External Static Pressure is determined by adding the Supply Duct Static Pressure reading to the Return Duct Static Pressure reading TABLES 2 AND are to be used as a guide only to help the installer determine if the duct sizes are large enough to obtain the proper air flow CFM through the furnace TABLES 2 and 3 ARE NOT to be used to design ductwork for the building where the furnace is being installed There are several variables associated with proper duct sizing that are not included in the tables To properly design the ductwork for the build ing Refer to the ASHRAE Fundamentals Handbook Chapter on DUCT DESIGN or a company that specializes in Residential and ular Home duct designs IMPORTANT If the supply air duct is being connected to the furnace without the use of an accessory duct connector then a transition duct must be installed with flanges or tabs that are securely attach and sealed to the supply air d
11. 22 oms 030 007473 uos onde 030 007473 ooms 030 007678 m6 390 mess ooer cose 399 39 3 Unitary Products Group 37 268890 UIM B 0607 APPLYING FILTER PRESSURE DROP TO DETERMINE SYSTEM AIRFLOW To determine the approximate airflow of the unit with a filter in place fol low the steps below 1 2 3 38 Select the filter type Determine the External System Static Pressure ESP without the filter Select a filter pressure drop from the table based upon the number of return air openings or return air opening size and add to the ESP from Step 2 to determine the total system static If total system static matches a ESP value in the airflow table i e 0 20 0 60 etc the system airflow corresponds to the intersection of the ESP column and Model Blower Speed row If the total system static falls between ESP values in the table i e 0 58 0 75 etc the static pressure may be rounded to the nearest value in the table determining the airflow using Step 4 or calculate the airflow by using the following example Example For a 120 000 Btuh furnace operating on high speed blower it is found that total system static is 0 58 w c To determine the system airflow complete the following steps 1 Obtain the airflow value
12. 31 5 30 02 HOLIMS 34055344 412 413911049 30 31108 1200 1 NOISS3Hd 30 YNALVLNWNOD HUOIN3A XOG YINUNG HOLIMS 38055384 47 SJION 3181511 3511 _ 3102 1 YNFLVLAWWOD 2508 3015 1H918 HOLIMS 100 1108 ZSO AUSNTOSENT SUY 9 3102 1N3W31n0N 30 YNALVLNWWOD 1508 3015 1337 HOLIMS LNO 7708 1504 5311998 83408 TIN SLIINNOJS LA Ad AQUA 5 NOILONGNI G un31 W NY 311WI 30 YNALVLNWWOD ZSI HOLIMS LINIT N320Q0NI 251 A1H3dONd 38 LSAW SIN3NOdWOO 1 3432 1438 11V 1217836 31 23AV 820320844 30 JIVdIONIYd 3LIWIT 30 YNALVLINWWOD 151 HOLIMS LIWIT AYVWIYd 151 KINO 54012004802 834402 318 11 5 SYOLDANNOD Sur SI NOILONGNI G YNILOW 514 Z 312 143238 13 35184 75 74 YOLOW YFONGNI LY 137205 9114 Nid S d 2 501 4 122 15937 LV 40 ONILVY 3HnlVH3dN3l 32 4805 30 NOILINOI Q 514 Z V 310v1d303H 13 35184 ES Ed YOLINS 32 43815 LOH LV 134205 Nid 2 S E d 11 i NOJLAVOGIYd NOILINDI 0 31031402 30 FLLINOVId VI 8015 19 v V 312 143238 13 35194 25 24 10H1NOO NOILINOI NO 139205 Ond Nid 25 24 A 5 1 49 7 4 NOILINOI Q 31081 02 30 311300 14 UNS 514 21 312 143238 13 35194 15 14 10H1NOO NOILINOI NO 137205 15 14 LOSS 3009 3913 NYIOVNYO 97 LINN SIHL 9NIDIAYIS 32 4805 30 NOILIND NOI YJLIN9I JOV4YNS LO
13. Drilling out a gas orifice will cause misalignment of the burner flames causing premature heat exchanger burnout high levels of carbon monoxide excessive sooting a fire hazard personal injury property damage and or death BTU cu ft Gas Heating Value Gas Heating Value 5 5 5 2 9 E 2 EE EE 5 2500 LP 8 SECTION V ELECTRICAL POWER ELECTRICAL POWER CONNECTIONS A CAUTION Field wiring to the unit must be grounded Electric wires that are field installed shall conform to the temperature limitation for 63 F 35 C rise Coney wire when installed in accordance with instructions Refer to Table 7 in these instructions for specific furnace electrical data TABLE 7 Electrical and Performance Data Input Cabinet Output Nominal Airflow Cabinet Width Total Unit 1 5 AFUE Air Temp Rise 108 x8 9 9 35 65 9 36 9 92 35 65 19 36 9 o 35 65 19 36 35 65 19 96 Max Outlet Min Wire Size Operation Protect Way 7x10 Annual Fuel Utilization Efficiency AFUE numbers are determined in accordance with DOE Test procedures Wire size and over current protection must comply with the National Electrical Code NFPA 70 latest edition and all local codes The furnace shall be installed so that the electrical components are protected from water NOTES 1 For altitudes above 2000 ft 609 m reduce capacity 4 for ea
14. Unitary Products Group 268890 UIM B 0607 Horizontal Right Air Flow Inducer High Refer to Figures 33 36 Installation with condensate trap bracket Front of casing Refer to Figure 33 amp 34 1 2 Remove the 2 knockout on the casing side away from the inducer motor Remove all the condensate hoses inside the furnace including the 3 8 barbed nipple factory installed in the rain gutter Remove the drain cap from the bottom rain gutter drain and insert the 3 8 barbed nipple removed above in the bottom rain gutter drain Place the cap just removed to the other side of the rain gut ter on the inducer Remove the condensate trap and its bracket from inside the fur nace saving the screws for later use Remove the large condensate cap from the side of the condensate pan and install it on the middle drain of the condensate pan from where 1 hose was removed Install longer dogleg end of hose 10 through the casing hole on to the side drain of the condensate pan where cap was removed in step 3 Some lubricant may have to be used to facilitate this installation as the hose is designed to be a tight fit over the con densate drain The other smaller dogleg end of hose 10 should be installed into the large recessed drain in the condensate trap Install the condensate trap bracket with the condensate trap on to the front side of the furnace using the screws removed in step 1 Install the dogleg end of hose 9
15. 1 Long radius sweep elbows are recommended Standard elbows may be used but since they have a longer equivalent length they will reduce the total length of pipe that will be allowed Short radius plumbing vent elbows are not allowed The standard dimensions of the acceptable elbows are shown below 2 The maximum equivalent length listed in Table 8 is for the vent pip ing and the air intake piping separately For example if the table allows 65 equivalent feet for a particular model then the vent can have 65 equivalent feet of pipe AND the combustion air intake can have another 65 equivalent feet of pipe 3 Three vent terminal elbows two for the vent and one for the com bustion air intake are already accounted for and need not be included in the equivalent length calculation 4 All combustion air and vent pipe must conform to American National Standards Institute ANSI and American Society for Test ing and Materials ASTM standards D1785 Schedule 40 PVC D2665 PVC DWV F891 PVC DWV Cellular Core D2261 ABS DWV or F628 Schedule 40 ABS Pipe cement and primer must conform to ASTM Standard D2546 PVC or D2235 ABS If ABS pipe is to be used any joint where ABS pipe is joined to PVC pipe must be glued with cement that is approved for use with BOTH materials Metallic materials must not be used for venting or air intake 5 flexible connector is used in the vent system it must be made of a material that is resis
16. 13 DUCTWORK 4 COMBUSTION AIR AND VENT SYSTEM 14 PILIERS 7 CONDENSATE PIPING 22 GAS PIPING sods adie causes onder dhs oo eq 9 SAFETY CONTROLS 826 3 3 hud e m OR ca 31 ELECTRICAL POWER Focal eta send 10 START UP AND ADJUSTMENTS 31 WIRING DIAGRAM 39 LIST OF FIGURES Transition Kit Assembly 6 Sealed Combustion Air Intake Connection and Vent Connection 19 DIMENSIONS 7 Combustion Airflow Path Through The Furnace Casing to the Burner Return Filter Grill and Return Duct Installation 8 J 20 Typical Attic Installation 8 Outside and Ambient Combustion 21 Typical Suspended Furnace Crawl Space Installation 9 Attic Combustion Air Termination 22 Cr STEEL TET TOT E T ETT 9 Condensate Drain Internal Hose Routing 22 Downflow Gas Piping 9 Downflow Condensate Drain Hose Configuration 23 Horizontal Gas Piping 22222 22 4 4 424 9 Horizontal Left Condensate Drain Hose Config
17. A CAUTION Perform the following procedures only after the condensate trap has been properly piped to a drain connection using the procedure in this instruction Be sure proper ventilation is available to dilute and carry away any vented gas TOOLS AND INFORMATION THAT WILL BE REQUIRED IN ORDER TO PROPERLY PERFORM THE FURNACE STARTUP PROCEDURE 1 the local gas supplier to obtain heating value of the natural gas If you cannot obtain the heating valve of the gas from the gas supplier you may use a default value of 1030 BTU SCF 38 4 MJ m 2 You will need a thermometer or portable digital thermometer to read the supply and return air temperatures 3 You will need a U tube manometer or digital equipment that has the ability to read pressures between 0 15 in w c 0 3 73 kPa in order to measure the gas line and the manifold pressures 4 You will need a 3 32 Allen wrench for the pressure port plugs in the gas valve 5 You will need 2 pieces of 1 8 0 3 cm ID flexible tubing that is 12 30 cm in length 2 pieces of 1 8 0 3 cm tubing that are 4 10 1 cm in length a 1 8 0 3 cm tee and a 1 8 0 3 cm adapter to connect the U tube manometer or the digital pressure measur ing equipment to the gas valve pressure ports 31 268890 UIM B 0607 There is an accessory kit 1PK0601 available from Source 1 which has the following items e 1 12 30 cm length x 1 8 0 3 cm diameter tubing e 2 pi
18. FIGURE 36 Horizontal Right Condensate Drain Hose Configuration Option 2 Back of Casing 30 Unitary Products Group CONDENSATE DRAIN TERMINATION DO NOT terminate condensate drain in a chimney or where the drain line may freeze The line must terminate at an inside drain to prevent freezing of the condensate and possible property damage DO NOT trap the drain line at any other location than at the condensate drain trap supplied with the furnace A condensate sump pump MUST be used if required by local codes or if no indoor floor drain is available The condensate sump pump must be approved for use with acidic con densate CONDENSATE DRAIN PRE START UP PROCEDURE The condensate trap must be filled with water before putting the furnace into operation Perform the following procedures only after the conden sate trap has been properly piped to a drain connection using the pro cedure in this instruction The recommended procedure is as follows 1 Disconnect the condensate drain hose from the induced draft blower discharge 2 Elevate this hose and fill with water using a funnel 3 Replace the condensate drain hose and clamps If this procedure is not followed the unit may not properly drain on initial start up SECTION IX SAFETY CONTROLS CONTROL CIRCUIT FUSE A 3 amp fuse is provided on the control circuit board to protect the 24 volt transformer from overload caused by control circuit wiring errors This is an ATO 3 automot
19. Installation with condensate trap bracket Back of casing Refer to Figure 35 amp 36 Remove the 2 knockout on the casing side away from the inducer motor Remove all the condensate hoses inside the furnace including the 3 8 barbed nipple factory installed in the rain gutter Remove the drain cap from the bottom rain gutter drain and insert the 3 8 barbed nipple removed above in the bottom rain gutter drain Place the cap just removed to the other side of the rain gut ter on the inducer Remove the condensate trap and it s bracket from inside the fur nace saving the screws for later use Remove the large condensate cap from the side of the condensate pan and install it on the middle drain of the condensate pan from where 1 hose was removed Do not remove condensate trap from the condensate trap bracket Cut 2 1 2 straight piece from hose 1 and install it through the knockout opening in the casing on the side of the condensate pan from where the cap was previously removed Insert the other end of the hose into the large recessed drain on the condensate trap Install the condensate trap bracket to the 2 inch hole on the side of casing using existing holes lining up the condensate pan open ing with the larger opening on the condensate trap Install the dogleg end of hose 9 on the Wye drain and route the hose through the opening on top of the furnace Install the other end of the 9 hose to the barbed tee
20. air intake pipe should be located either through the wall horizontal or side vent or through the roof vertical vent Care should be taken to locate side vented systems where trees or shrubs will not block or restrict supply air from entering the terminal Also the terminal assembly should be located as far as possible from a swimming pool or a location where swimming pool chemicals might be stored Be sure the terminal assembly follows the outdoor clearances listed in Section 1 COMBUSTION AIR QUALITY LIST OF CONTAM INANTS Fresh air pipe can either be routed through the furnace or routed out side the furnace Ambient Combustion Air Supply This type installation will draw the air required for combustion from within the space surrounding the appliance and from areas or rooms adjacent to the space surrounding the appliance This may be from within the space in a non confined location or it may be brought into the furnace area from outdoors through permanent openings or ducts It is not piped directly into the burner box A single properly sized pipe from the furnace vent connector to the outdoors must be provided For down flow models combustion air is brought into the furnace through the unit top panel opening Do not install a pipe into the combustion air pipe at the top of the furnace Refer to Figures 19 amp 26 This type of installation requires that the supply air to the appli 5 be of a sufficient
21. amount to support all of the appliance s in the area Operation of a mechanical exhaust such as an exhaust fan kitchen ventilation system clothes dryer or fireplace may cre ate conditions requiring special attention to avoid unsatisfactory operation of gas appliances A venting problem or a lack of supply air will result in a hazardous condition which can cause the ance to soot and generate dangerous levels of CARBON MONOX IDE which can lead to serious injury property damage and or death An unconfined space is not less than 50 cu ft 1 42 m per 1 000 Btu hr 0 2928 kW input rating for all of the appliances installed in that area Rooms communicating directly with the space containing the appli ances are considered part of the unconfined space if openings are not furnished with doors A confined space is an area with less than 50 cu ft 1 42 m per 1 000 Btu hr 0 2928 kW input rating for all of the appliances installed in that area The following must be considered to obtain proper air for combus tion and ventilation in confined spaces VENT PIPE PASSES COMBUSTION THROUGH TOP PANEL AIRFLOW eS U 1 TT NERA N 7 4 COMBUSTION AIRFLOW 3 WAY TRANSITION FIGURE 26 Combustion Airflow Path Through The Furnace Casing to the Burner Box 20 Combustion Air Source From Outdoors The blocking effects of louvers grilles and screens m
22. be supported to prevent sagging The vent system may be supported by the use of clamps or hangers secured to a permanent part of the structure every 4 ft 1 22 m VENTING MULTIPLE UNITS Only the sealed combustion system can be used for installations requir ing more than one furnace in a structure A separate sealed combustion air pipe and a separate vent pipe must be installed for each furnace Do not connect more than one furnace to a combustion air pipe or a vent pipe The combustion air and vent termination must be located as shown in Figures 23 or 24 COMBUSTIONAIR o pra MIN FIGURE 23 Double Horizontal Sealed Combustion Air and Vent Termination Unitary Products Group 268890 UIM B 0607 FIGURE 24 Double Vertical Sealed Combustion Air and Vent Termination COMBUSTION AIR SUPPLY All installations must comply with Section 5 3 Air for Combustion and Ventilation of the National Fuel Gas Code ANSI Z223 1 or Sections 7 2 7 3 or 7 4 of CAN CGA B149 1 or 2 Installation Code latest edi tions This furnace is certified to be installed with one of three possible com bustion air intake configurations 1 OUTDOOR COMBUSTION AIR This is a sealed combustion air configuration where the combustion air is supplied through a PVC or ABS pipe that is connected to the PVC coupling attached to the burner box and is terminated in the same atmospheric zone as the vent This type of installation is approved on all mode
23. inside the furnace Install the dogleg end of hose 4 on 3 8 barbed nipple in the rain gutter The other end of hose 4 should be installed on the 3 8 barbed tee Install one end of hose 7 on the 3 8 barbed tee inside the fur nace Guide the other end of hose 7 towards the condensate trap and install it on the tap on the condensate trap Install the dogleg end of hose 2 on the bottom drain of the inducer Guide the other end of hose 2 towards the condensate trap and install it on the small recessed drain in the condensate trap Ensure that all hoses are properly installed have no kinks and are draining properly All hoses on the condensate trap should be pushed all the way down to ensure against leakage All hoses on the condensate pan should be pulled all the way up to ensure proper operation Unitary Products Group 268890 UIM B 0607 NOILISOd SIH L HO Q3TIVISNI ANOLOVS SVH HOLIMS J1VSN3QNOO ASOH JHL 3801 SIHL ASOH 11 8 6 ISOH 6 ISOH FIGURE 33 Horizontal Right Condensate Drain Hose Configuration Option 1 Front of Casing 27 Unitary Products Group 268890 UIM B 0607 PEGE L ASOH Ht ISOH 119 Le px L dNV19 ONIYdS iL 954 m e 06 7 I Mm CZF zl
24. that the normally open pressure switch contacts are stuck in the closed position The control confirms these contacts are open at the beginning of each heat cycle This would indicate a faulty pressure switch or miswiring 3 RED FLASHES This indicates the normally open pressure switch contact did not close after the inducer was energized This could be caused by a number of problems faulty inducer blocked vent pipe bro ken pressure switch hose or faulty pressure switch 4 RED FLASHES This indicates that a primary or auxiliary limit switch has opened its normally closed contacts With this fault code the control will operate the supply air blower and inducer This condition may be caused by dirty filter improperly sized duct system incorrect blower speed setting incorrect firing rate or faulty blower motor 5 RED FLASHES This fault is indicated if the normally closed contacts in the rollout switch opens The rollout control is manually reset If it has opened check for proper combustion air proper inducer operation and primary heat exchanger failure or burner problem Be sure to reset the switch after correcting the failure condition 6 RED FLASHES This indicates that after the unit was operating the pressure switch opened 4 times during the call for heat If the main blower is in a Delay on mode it will complete it and any subsequent delay off period The furnace will lock out for one hour and then restart 7 RED FLASHES Th
25. using a cubic foot gas meter For Natural Gas multiply the Heat content of the gas MJ m or Default 38 4 times 2 cubic ft of gas x 0 028 to convert from cubic feet to cubic meters measured at the gas meter times a barometric pressure and temperature correction factor of 0 960 times 3600 then divided by the time it took to measure 2 cubic ft 0 056 m of gas from the gas meter For Propane LP Gas multiply the Heat content of the gas MJ m or Default 93 15 times 1 cu ft of gas x 0 028 to convert from cubic feet to cubic meters measured at the gas meter times a barometric pressure and temperature correction factor of 0 960 times 3600 then divided by the time it took to measure 1 cubic ft 0 028 m of gas from the gas meter The formula for metric input calculation using a cubic foot gas meter MJ m x 2 cu ft x 0 028 x 0 960 x 3600 _ x 3412 14 Seconds it took to measure the 2 cu ft of gas NATURAL GAS INPUT CALCULATION EXAMPLE 38 4 x 2x s 0 960 x 3600 341214 77 796 80 Natural Gas 1030 BTU SCF 38 4 MJ m PROPANE LP GAS INPUT CALCULATION EXAMPLE 93 15x 1x a 0 960 x 3600 _ 23 18 3412 14 79 093 4 Propane Gas 2500 BTU SCF 93 15 MJ m In Canada use the following formula to calculate the furnace input if you are using a gas meter that measures cubic meters For Natural Gas multiply the Heat content of the gas MJ m or Default 38 4 times 0 10 m of gas measured at the gas meter times a barometric p
26. 1 2 Place the 2 5 08 cm 45 PVC street elbow on the vent connec tion shown in Figure 18 Place the 2 5 08 cm PVC WYE Y assembly on the 2 5 08 cm 45 PVC street elbow as shown in Figure 18 Refer to the DOWNFLOW HORIZONTAL CONDENSATE INTER NAL DRAIN CONFIGURATIONS for futher details MAINTAIN 12 MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL MAXIMUM 24 ABOVE ROOF FIGURE 19 Termination Configuration 1 Pipe 12 VERTICAL SEPARATION BETWEEN COMBUSTION AIR 12 MINIMUM AND VENT BELOW OVERHANG 12 MINIMUM SEPARATION BETWEEN BOTTOM OF COMBUSTION AIR PIPE AND BOTTOM OF VENT 1 Place the 2 5 08 cm 45 PVC street elbow on the vent connec tion shown in Figure 18 2 Place the 2 5 08 cm PVC WYE Y assembly on the 2 5 08 cm 45 PVC street elbow as shown in Figure 18 Locate the rubber condensate hose in front of the blower access panel MAINTAIN 12 MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL MAINTAIN 12 Slide the hose through the hole in the top cover and insert the hose on to the barbed fitting on the bottom of the 2 5 08 cm PVC WYE Y assembly as shown in Figure 18 MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS HIGHER RETURN 2 5 08 cm VENT PIPE RETURN 2 PVC AIR WYE FURNACE HORIZONTAL LEFT VENT PIPE FIGURE 20 Termination Configurati
27. 2 cubic ft 0 0566 m of gas 3 Calculate the furnace input by using one of the following equa tions Unitary Products Group 268890 UIM B 0607 In the USA use the following formula to calculate the furnace input For natural gas multiply the heat content of the gas BTU SCF or Default 1030 BTU SCF 38 4 MJ m times 2 cubic ft 0 056 m of gas measured at the gas meter times a barometric pressure and temperature correction factor of 0 960 times 3600 then divided by the time In seconds it took to measure 2 cubic ft 0 056 m of gas from the gas meter For propane LP gas multiply the heat content of the gas BTU SCF or Default 2500 BTU SCF 93 15 MJ m times 1 cubic ft 0 028 m of gas mea sured at the gas meter times a barometric pressure and temperature correction factor of 0 960 times 3600 then divided by the time In seconds it took to measure 1 cubic ft 0 028 m of gas from the gas meter The formula for US input calculation using a cubic foot gas meter BTU ft x 2 cu ft x 0 960 x 3600 _ BTU H BTU ft x 1 cu ft x 0 960 x 3600 oeconds it took to measure the 2 cu ft of gas oeconds it took to measure the 1 cu ft of gas NATURAL GAS INPUT CALCULATION PROPANE LP GAS INPUT CALCULATION EXAMPLE EXAMPLE 1030 x 2 0 380 3600 78 666 90 2500 x 1 0 360 3600 80 000 00 Natural Gas Propane Gas 1030 BTU SCF 2500 BTU SCF In Canada you will use the following formula to calculate the furnace input if you are
28. 3 360 2322 Rectangular in x in cm x cm 40 000 11 7 1 200 34 0 280 1806 14 x 20 35 6 x 90 8 18 45 7 268890 UIM B 0607 2 The square inch area for 7 inch round ducts 38 4 square inch x 2 76 8 square inches 3 Thentake the 192 square inch from the rectangular duct and add it to the 76 8 square inch of round duct The total square inch of duct attached to the furnace supply plenum is 268 8 square inches This exceeds the recommended 216 square inch of duct In this example the duct system attached to the plenum has a sufficient area so that the furnace operates at the specified external static pres sure and within the air temperature rise specified on the nameplate Providing the return duct is properly sized as well Supply Rectangular in cm dia 216 1394 12 x 18 30 5 x 45 7 in x in cm x cm 16 40 6 18 x 20 45 7 x 50 8 22 55 8 280 1806 14 x 20 35 6 x 50 8 18 45 7 100 000 29 3 1 600 45 3 360 2322 18 x 20 45 7 x 50 8 22 55 8 280 1806 14 x 20 35 6 x 50 8 18 45 7 100 000 29 3 2 000 56 6 440 2839 20 x 22 50 8 x 55 8 24 60 9 390 2516 16 x 22 40 6 x 55 8 22 55 8 120 000 35 2 2 000 56 6 440 2839 20x22 50 8x55 8 24 60 9 390 2516 16x22 40 6 55 8 22 55 8 NOTE This chart does not replace proper duct sizing calculations or take into account static pressure drop for run length and fittings Maintain proper temperature rise and static pressures
29. 5 Typical Attic Installation This appliance is design certified for line contact when the furnace is installed in the horizontal left or right position The line contact is only permissible between lines are formed by the intersection of the top and two sides of the furnace and the building joists studs or framing This line may be in contact with combustible material IMPORTANT In either a horizontal left or right installation a minimum of 8 20 3 cm clearance is required beneath the furnace to allow for the installation of the condensate trap and drain pipe Refer to CON DENSATE PIPING section of this manual for more information When a furnace 15 installed in an attic or other insulated space keep all insulating materials at least 12 inches 30 5 cm away from furnace and burner combustion air openings If this furnace is installed over a finished space a condensate safety pan must be installed SUSPENDED FURNACE CRAWL SPACE INSTALLATION The furnace can be hung from floor hoists or installed on suitable blocks or pad Blocks or pad installations shall provide adequate height to ensure the unit will not be subject to water damage Units may also be suspended from rafters or floor joists using rods pipe angle supports or straps Angle supports should be placed at the supply air end and near the blower deck Do not support at return air end of unit All four sus pension points must be level to ensure qu
30. 6 3SOH ISOH dVal JIVSN3QNOO ISOH 8 18 ASOH vIe gt OLZ 3SOH 93T 90d A m ONINdS aivsmadwoo TRA aasn x _ dI AV IO 9NISdS IO NIHdS _ gt EU 3SOH ISOH ISOH ISOH 6 ISOH 47 FIGURE 34 Horizontal Right Condensate Drain Hose Configuration Option 1 Front of Casing Unitary Products Group 28 268890 UIM B 0607 HOSE 2 l 3 WAY TRANSITION Shown Provided with some furnaces CUT FROM 2 1 2 long HOSE 1 3 8 BARBED TEE HOSE 4 BLOCKED CONDENSATE SWITCH HAS BEEN FACTORY INSTALLED FOR THIS POSITION THIS TUBE FOR THE HOSE 7 FIGURE 35 Horizontal Right Condensate Drain Hose Configuration Option 2 Back of Casing Unitary Products Group 29 268890 UIM B 0607 o io S 1 ioi li LLI o gt le I lt e 4 LL 02 o lt 2 I LLI I uz a o lt o O D 9 2 a HOSE 9 EL SPRING CLAMP DOGLEG DOG LEG HOSE 8 SPRING CLAMP HOSE 2 3 8 BARBED NIPPLE HOSE 1 HOSE 7 HOSE 9 RECOMMENDED CONDENSATE TRAP ORIENTATION
31. BINET 3 WAY TRANSITION KIT All MODELS Unitary Products Group 268890 UIM B 0607 WIRING DIAGRAM SECTION XI 1070 8 228892 QuvVOg TOYLNOD NOILd3ONOO 8031 30 539731084 LNOS SYNILOW S31 9 NOILIN9I Q 31081NO2 39 3113 XAS 51 13 4 34 SALOVINOD NOILIN9I NO SIOVINOO AV 13H NOLIVIN3AITV 1 YNOd lt 80312 07510 S31 Z3SSINNfOJ S S1I3HVddV 13 N3l1NVHO 30 399714 321A30 ONIUIM 07313 18831 3 3SIW 319 3813 1100 IN3N32OV1dW3H 30 31NVSOdWOO 31001 7 S1I3uVddV 13 3 150 1 30 39 113 5321 30 ONY AYOLOVI FYAIND 30 114 YNOd S31138VN 530 L1N3W3703S 7 43I LNVHO 30 1N3A3QuODDVU NOILOANNOD 91314 2 501 3 122 SNIOW 32314 30 LYLSOWYJHL 1N343QNODOVM J LYLSOWYJHL WOOY NOIIO3NNOO AVZ 3unlvs3dWil 30 v 83151524 LNVANOd Xnviu3lvW 23AV 2813 1 3 411 301 1N3A3NNOILI2NOJ 30 YNALIOVdVD YOLIOVdVD NAY 0314114340 1104 11 3 3lUlVd 3 Jo 146384 3813 1109 39113 31 IS e VAOv YNINWYOISNYYL 11 VAO u3WHOJSNVHl LI 2 313114301 LN3WANNOILONOS 30 UnillOVdVO OUI cat 00 13 32 1VNOIIVN 72313 3002 V NO13S H3II1NYHO NJ 39 114 LNOL NOIIVSN3QNOO NOISS3Hd 30 YNFLVINWWOD
32. H NOL WO QNV 3002 2313 IYNOILYN Y 2834 ONIMIM 071313 11V 180438 SLOANNODSIG 340 749 34 34 4006 AD JAVA SVO AOD NOLLNVD NOLONOPSIG 30 YNFLVLNWNOD 0 HOLIMS 123NNOOS Q 50 6 0 N ASTI IO 1 5 1 1VISOWH3Hl 1002 1V3H 39NVUO NYO 1 39 40 2v9 34 3444104 d 534 4005 30 1 139 314404 ae 183A 38431 83389 39 2508 ISON m 38831 3 549 134 T 235 2 01134 L j 038 n 1510700 woo 4 11191 mg SIV13H 8108 918 4S 1YNYNO4 Yov18 CLONGNI O AV 144 V1 30 31081109 1734 397115 YNJINOD 30 3002 JOYLNOD JOvNUNS m8 30nvH2 3293315 di 18 AX 310100 TAIM 30 NOILINOI Hf 31ON 4031V214101NDnH Q ETT C 3WRY 13 LIMANA 51 138 3ov4uns 10 S 30 YNILdYD 7 9 1 VOASI1 30 34 4 05 mmm OVASII SVO YOSNAS 3WV1j 118 19 0021 790 z 18 Na nia 0002 oz 31804 30 un31V1nWW02 ias icu 3183143005 10 0 MS O N 3000 1 3 2 1V3H nia 918 0002 001 NI ANO HOLIMS W31S4AS 2313 341114 1002 1 3 2 y18 nig 00911 001 38831 NI oy 4112 1002 AW 138 1n3N LHM 438018 1143144005 WI19 4NWHD 19733
33. NOT REMOVE THE SET SCREW FROM THE PRESSURE PORT Read the inlet gas pressure using either of the two meth ods below Reading the gas pressure with the burner box cover in place A Disconnect the pressure reference hose from the right side of the burner box Using a tee fitting and a short piece of hose connect the negative side of the manometer to the burner box as described in below B Remove one end the 5 16 0 8 cm ID flexible tubing over the pressure port on the burner box C Insert the end of the 5 16 0 8 cm tubing that has the 1 8 0 3 cm adapter at the end of the tube in to the 1 8 0 3 cm tee D Connect the 1 8 0 3 cm tee to the burner box adapter and to the negative side of a U tube manometer or digital pres sure measuring equipment with 2 1 8 0 3 cm tubes E Use the 5 16 0 8 cm x 1 8 0 3 cm reducing coupling and a 4 10 2 cm piece of 1 8 0 3 cm tubing to connect the posi tive side of the manometer to the gas valve pressure refer ence port Refer to Figure 39 for connection details 34 Reading the gas pressure with the burner box cover removed Remove the screws securing the burner box front cover plate Remove the cover The gasket and may stick in place Connect the positive side of the manometer to the gas valve as described in E above There will be no second connection to the manometer as it will reference atmo spheric pressure Refer to Figure 39 for connection de
34. NSPECTION As soon as a unit is received it should be inspected for possible dam age during transit If damage is evident the extent of the damage should be noted on the carrier s freight bill A separate request for inspection by the carrier s agent should be made in writing Also before installation the unit should be checked for screws or bolts which may have loosened in transit There are no shipping or spacer brackets which need to be removed FURNACE LOCATION AND CLEARANCES The furnace shall be located using the following guidelines 1 Where a minimum amount of air intake vent piping and elbows will be required 2 As centralized with the air distribution as possible 3 Where adequate combustion air will be available particularly when the appliance is not using outdoor combustion air 4 Where it will not interfere with proper air circulation in the confined space 5 Where the outdoor combustion air vent terminal will not be blocked or restricted Refer to COMBUSTION AIR VENT CLEAR ANCES located in SECTION VII of these instructions These min imum clearances must be maintained in the installation 6 Where the unit will be installed in a level position with no more than 1 4 0 6 cm slope side to side and front to back to provide proper condensate drainage Installation in freezing temperatures 1 Furnace shall be installed in an area where ventilation facilities provide for safe limits of ambient te
35. ONS 1 Only Natural gas or Propane LP gas approved for use with this furnace Refer to the furnace rating plate or Section IV of these instructions Install this furnace only in a location and position as specified in SECTION of these instructions A gas fired furnace for installation in a residential garage must be installed as specified in SECTION of these instructions Provide adequate combustion and ventilation air to the furnace space as specified in SECTION VI of these instructions Combustion products must be discharged outdoors Connect this furnace to an approved vent system only as specified in SEC TION VII of these instructions FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in serious injury death or property damage Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for detection of leaks to check all connections A fire or explosion may result causing prop erty damage personal injury or loss of life Tests for gas leaks as specified in SECTION X of these instruc tions Always install the furnace to operate within the furnace s intended temperature rise range Only connect the furnace to a duct system which has an external static pressure within the allowable range as specified on the furnace rating plate When a furnace is installed so that supply ducts carry air circulated by the furnace to
36. OTE Sidewall vent terminal may be used for sidewall vent termina tions Refer to part list in the back of the USERS INFORMATION AND SERVICE AND MAINTENANCE MANUAL for the terminal part number TABLE 11 Combustion Air Intake and Vent Connection Size at Furnace All Models FURNACE VENT CONNECTION SIZES 40 100 MBH 120 MBH 17 5 29 3 kW 35 2 kW 2 5 1 cm 3 7 6 cm 2 5 1 cm 2 5 1 cm Furnace Input Intake Pipe Size Vent Pipe Size Vent pipe size must be increased to 3 diameter after connection to furnace on this model IMPORTANT Accessory concentric vent intake termination kits 1C T0302 and 1CT0303 are available and approved for use with these furnaces Horizontal sidewall vent terminations kits 1 0901 8 1 0902 are also approved for use with these furnaces IMPORTANT Furnace vent pipe connections are sized for 2 5 1 cm pipe Any pipe size change must be made outside the furnace casing in a vertical pipe section to allow proper drainage of condensate An offset using two 45 degree elbows will be required for plenum clearance when the vent is increased to 3 7 6 cm 16 COMBUSTION AIR AND VENT PIPING ASSEMBLY The final assembly procedure for the combustion air and vent piping is as follows 1 Cut piping to the proper length beginning at the furnace 2 Deburr the piping inside and outside 3 Chamfer bevel the outer edges of the piping 4 Dry fitthe vent piping a
37. RN END Cabinet Dimension es a rena 32 308 444 93 3 19 3 4 50 2 540 2000866 D 622 2334 ser 22 58 232 6 RESIDENTIAL AND NON HUD MODULAR HOME DOWNFLOW AND HORIZONTAL RETURN PLENUM CONNECTION The return duct system must be connected to the furnace inlet and the return duct system must terminate outside the space containing the fur nace When replacing an existing furnace if the existing plenum is not the same size as the new furnace then the existing plenum must be removed and a new plenum installed that is the proper size for the new furnace Attach the return plenum to the furnace inlet duct flanges This is typi cally through the use of S cleat material when a metal plenum is used The use of an approved flexible duct connector is recommended on all installations The connection of the plenum to the furnace and all the ducts connecting to the plenum must be sealed to prevent air leakage The sheet metal should be crosshatched to eliminate any popping of the sheet metal when the indoor fan is energized The duct system is a very important part of the installation If the duct system is improperly sized the furnace will not operate properly The ducts attached to the furnace must be of sufficient size so that the fur nace operates at the specified external static pressure and within the air temperature rise specified on the nameplate At
38. able 7 ELECTRICAL AND PERFORMANCE DATA The supply air temperature cannot exceed the Maximum Supply Air Temperature specified in these instructions and on the fur nace rating plate Under NO circumstances can the furnace be allowed to operate above the Maximum Supply Air Temperature Operating the furnace above the Maximum Supply Air Temperature will cause premature heat exchanger failure high levels of Carbon Monoxide fire hazard personal injury property damage and or death The temperature rise or temperature difference between the return air and the heated supply air from the furnace must be within the range shown on the furnace rating plate and within the application limitations as shown in Table 7 After about 20 minutes of operation determine the furnace temperature rise Take readings of both the return air and the heated air in the ducts about six feet 1 83 m from the furnace where they will not be affected by radiant heat Increase the blower speed to decrease the temperature rise decrease the blower speed to increase the rise FAN OFF ADJUSTMENT JUMPER FIGURE 40 Furnace Control Board Unitary Products Group 268890 UIM B 0607 WITH BURNER BOX COVER REMOVED GAS VALVE BURNER BOX PRESSURE REFERENCE HOSE WATER COLUMN GAS PRESSURE SHOWN MANOMETER gt gt gt All direct drive blowers have multi speed motors The blower motor speed taps ar
39. above the furnace CLOSET COMBUSTION 527 EN RETURN AIR AIR bs 4 1 2 2 2 1 2 1 1 1 1 amp 1 1 FILTERS EITHER SIDE FIGURE 4 Return Filter Grill and Return Duct Installation IMPORTANT Air velocity through throwaway type filters must not exceed 300 feet per minute 91 m min All velocities over this require the use of high velocity filters Refer to Table 19 A CAUTION All installations must have a filter installed HORIZONTAL APPLICATION Horizontal Filters All filters and mounting provision must be field supplied Filters s may be located in the duct system external to the furnace or in a return filter grille s Filters s may be located in the duct system using an external duct filter box attached to the furnace plenum Any branch duct rectan gular or round duct attached to the plenum must attach to the vertical plenum above the filter height The use of straps and or supports is required to support the weight of the external filter box An accessory filter rack is available ATTIC INSTALLATION LINE CONTACT ONLY PERMISSIBLE BETWEEN LINES FORMED BY THE INTERSECTION OF FURNACE TOP AND TWO SIDES AND BUILDING COMBUSTION FILTER RACK JOISTS STUDS OR FRAMING AIR 5K A 4 mat SUPPLY am _ T LI 4 RETURN m 2 7 30 MIN WORK AREA VENT PIPE maintain required clearances to 12 CLEARANCE combustible FOR SERVICE FIGURE
40. and Non HUD Modular Homes The sealed combustion air vent system is the only configuration that can be installed in a Non HUD Modular Home Unitary Products Group This furnace may not be common vented with any other appliance since it requires separate properly sized air intake and vent lines The furnace shall not be connected to any type of B BW or vent or vent connector and not connected to any portion of a factory built or masonry chimney The furnace shall not be connected to a chimney flue serving a sep arate appliance designed to burn solid fuel A CAUTION When combustion air pipe is installed above a suspended ceiling or when it passes through a warm and humid space the pipe must be insulated with 1 2 Armaflex or other heat resistant type insulation Vent piping must be insulated with 1 2 insulation if it will be sub Jected to freezing temperatures such as routing through unheated areas or through an unused chimney COMBUSTION AIR VVENT PIPE SIZING The size of pipe required will be determined by the furnace model the total length of pipe required and the number of elbows required Table 8 lists the maximum equivalent length of pipe allowed for each model of furnace The equivalent length of elbows is shown in Table 9 The equivalent length of the vent system is the total length of straight pipe PLUS the equivalent length of all of the elbows The following rules must also be followed
41. areas outside the space containing the furnace the return air shall also be handled by duct s sealed to the fur nace casing and terminating outside the space containing the fur nace It is permitted to use the furnace for heating of buildings or struc tures under construction Installation must comply with all manu facturer s installation instructions including Proper vent installation e Furnace operating under thermostatic control Return air duct sealed to the furnace e Air filters in place Set furnace input rate and temperature rise per rating plate marking e Means for providing outdoor air required for combustion Return air temperature maintained between 55 F 13 C and 80 F 27 C The air filter must be replaced upon substantial completion of the construction process Clean furnace duct work and components upon substantial completion of the construction process and verify furnace operating conditions including ignition input rate temperature rise and venting according to the manufacturer s instructions When installed in a Non HUD Approved Modular Home or building constructed on site combustion air shall not be supplied from occupied spaces The size of the unit should be based on an acceptable heat loss calculation for the structure ACCA Manual J or other approved methods may be used SAFETY REQUIREMENTS This furnace should be installed in accordance with all national and local b
42. argest input VENTILATED CRAWL SPACE Asquare or rectangular shaped duct shall only be used when the required free area of the supply opening is ATTIC 9 58 06 or larger When a square or rectangular TOP ABOVE duct is used its small dimensionshall not be less than INSULATION 3 in 7 6 cm 4 VENTILATED An air inlet supply from outdoors shall be equipped with SOFFIT a means to prevent the direct entry of rain and wind Such means shall not reduce the required free area of the air supply opening 7 An air supply inlet opening from the outdoors shall be located not less than 12 30 5 cm above the outside grade level FIGURE 27 Outside and Ambient Combustion Air Vent and Supply Outside Air Safety Check Procedure Follow the procedure in ANSI 2223 1 National Fuel Gas Code Refer to the section on the Recommended Procedure for Safety Inspection of an Existing Appliance or in Canada B149 1 00 Natural Gas and Pro pane Installation Code section on Venting Systems and Air Supply for Appliances and all local codes In addition to the procedure specified in ANSI Z223 1 it is recommended that you follow the venting safety pro cedure below This procedure is designed to detect an inadequate ven tilation system that can cause the appliances in the area to operate improperly causing unsafe levels of Carbon Monoxide or an unsafe condition to occur 1 Inspect the venting system for proper size a
43. binet outlet duct flanges through the use of S cleat material when a metal plenum is used The use of an approved flexible duct connector is recommended on all installations The connection to the furnace air conditioning coil cabinet and the supply plenum should be sealed to prevent air leakage The sheet metal plenum should be crosshatched to eliminate any pop ping of the sheet metal when the indoor fan is energized The minimum plenum height is 12 30 5 cm If the plenum is shorter than 12 30 5 cm the turbulent air flow may cause the limit controls not to operate as designed or the limit controls may not operate at all Also the plastic drain pan in the under the air conditioning coil can overheat and melt Refer to the installation instructions supplied with the air conditioning coil for additional information Horizontal Installations Without a Cooling Coil Cabinet When installing this appliance the furnace must be installed so as to create a closed duct system the supply duct system must be con nected to the furnace outlet and the supply duct system must terminate outside the space containing the furnace When replacing an existing furnace if the existing plenum is not the same size as the new furnace then the existing plenum must be removed and a new plenum installed that is the proper size for the new furnace Attach the supply plenum to the furnace outlet duct flanges through the use of S cleat material when a metal plenum is
44. body of the gas valve when installing piping A wrench must be placed on the octagonal hub located on the gas inlet side of the valve Placing a wrench to the body of the gas valve will damage the valve causing improper oper ation and or the valve to leak Gas piping may be connected from either side of the furnace using any of the gas pipe entry knockouts on both sides of the furnace Refer to Figure 3 dimensions GAS ORIFICE CONVERSION FOR PROPANE LP This furnace is constructed at the factory for natural gas fired operation but may be converted to operate on propane LP gas by using a fac tory supplied LP conversion kit Follow the instructions supplied with the LP kit Refer to Table 6 or the instructions in the propane LP con version kit for the proper gas orifice size HIGH ALTITUDE GAS ORIFICE CONVERSION This furnace is constructed at the factory for natural gas fired operation at 0 8 000 feet 0 m 2 438 m above sea level The manifold pressure must be changed in order to manitain proper and safe operation when the furnace is installed in a location where the altitude is greater than 8 000 feet 2 438 m above sea level Refer to to Table 6 for proper manifold pressure settings HIGH ALTITUDE PRESSURE SWITCH CONVERSION For installation where the altitude is less than 8 000 feet 2 438 m it is not required that the pressure switch be changed For altitudes above 8 000 feet 2 438 m see Field I
45. ch 1000 ft above sea level 2 Wire size based on copper conductors 140 F 60 C 3 voltage drop 3 Continuous return air temperature must not be below 55 F 12 8 C SUPPLY VOLTAGE CONNECTIONS IMPORTANT The power connection leads and wiring box may be relo cated to the left side of the furnace Remove the screws and cut wire tie holding excess wiring Reposition on the left side of the furnace and fas ten using holes provided 1 Provide a power supply separate from all other circuits Install overcurrent protection and disconnect switch per local national electrical codes The switch should be close to the unit for conve nience in servicing With the disconnect or fused switch in the OFF position check all wiring against the unit wiring label Refer to the wiring diagram shown in Figure 41 2 Remove the screws retaining the junction box cover Route the power wiring through the opening in the unit into the junction box with a conduit connector or other proper connection In the junc tion box there will be three wires a Black Wire a White Wire and a Green Wire Connect the power supply as shown on the unit wir ing label on the inside of the blower compartment door or Figure 10 The black furnace lead must be connected to the L1 hot wire from the power supply The white furnace lead must be connected to neutral Connect the green furnace lead equipment ground to the power supply ground An alternate wiring meth
46. d in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level In the event that the requirements of this subdivision can not be met at the time of completion of installation the owner shall have a period of thirty 30 days to comply with the above requirements provided however that during said thirty 30 day period a battery operated carbon mon oxide detector with an alarm shall be installed APPROVED CARBON MONOXIDE DETECTORS Each car bon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI UL 2034 listed and IAS certified SIGNAGE A metal or plastic identification plate shall be perma nently mounted to the exterior of the building at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUC TIONS INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspector observes car bon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5 08 2 a 1 through 4 Unitary Products Group 268890 UIM B 0607 I
47. dow or door that may be opened G Clearance to inside corner 3 feet 91 cm 3 feet 91 cm Above meter regulator assembly within 3 feet 91 cm Above a meter regulator assembly within 3 feet 91 H Clearance to each side of center line horizontally of the vertical center line of the regulator horizontally of the vertical center line of the regula extended above meter regulator assembly vent outlet to a maximum vertical distance of 15 feet tor vent outlet to a maximum vertical distance of 15 4 5 cm above the meter regulator assembly feet 4 5 cm above the meter regulator assembly 3 feet 91 cm or in accordance with local installation Clearance to service regulator vent outlet 3 feet 91 cm codes and the requirements of the gas supplier J Clearance to nonmechanical air supply inlet to Two pipe direct vent applications 9 inches 23 cm building or the combustion air inlet to any other 12 Inches ioo cin 10r ede QU RN for models lt 50 000 BTUH 15 kW 12 inches 30 cm 36 inches 91 cm for models gt 100 000 BTUH 30 kW appliance for models gt 50 000 BTUH 15 kW K Clearance to a mechanical supply inlet 6 feet 1 83 m 3 feet 91 above IT within 10 Teet S horizontally L Clearance above paved sidewalk or paved 7 feet 2 13 m or in accordance with local installation 7 feet 2 13 m T driveway located on public property codes the requirements of the gas supplier 12 inches 30 cm or in acco
48. e Area Appliance 1 Appliance 2 Total Input 100 000 30 000 130 000 4 000 32 5 Sq In Vertical Appliance 1 Appliance 2 Total Input 100 000 30 000 130 000 2 000 65 In Horizontal BTUH Input Rating Horizontal Duct 2 000 TABLE 14 Unconfined Space Minimum Area in Square Inches BTUH Input Rating Minimum Free Area Required for Each Opening 40 000 40 258 cm 60 000 60 387 cm 80 516 cm 100 645 cm 120 774 cm 80 000 100 000 120 000 Unitary Products Group 268890 UIM B 0607 AIR SUPPLY OPENINGS AND DUCTS VENTILATED ATTIC TOP ABOVE 1 An opening may be used in lieu of a duct to provide to provide the outside air supply to an appliance unless otherwise permitted by the authority having jurisdiction The opening shall be located within 12 30 5 cm horizontally from the burner level of the appliance Refer to AIR SOURCE FROM OUTDOORS AND VENT AND SUPPLY AIR SAFETY in these instructions for additional information and safety check procedure _ The duct shall be either metal or a material meeting the class 1 requirements of CAN4 S110 Standard for Air Ducts OUTLE AIR b The duct shall be least the same cross sectional area as the free area of the air supply inlet opening to which it connects The duct shall terminate within 12 in 30 5 cm above and within 24 in 61 cm horizontally from the burner level of the appliance having the l
49. e located in the control box in the blower compartment Refer to Figure 40 and the unit wiring label to change the blower speed To use the same speed tap for heating and cooling the heat ter minal and cool terminal must be connected using a jumper wire and connected to the desired motor lead Place all unused motor leads on Park terminals Two are provided A CAUTION Do not energize more than one motor speed at a time or damage to the motor will result USTMENT FAN CONTROL SETTINGS This furnace is equipped with a time on time off heating fan control The fan on delay is fixed at 30 seconds The fan off delay has 4 settings 60 90 120 and 180 seconds The fan off delay is factory set to 120 sec onds The fan off setting must be long enough to adequately cool the furnace but not so long that cold air is blown into the heated space The fan off timing may be adjusted by positioning the jumper on two of the four pins as shown in Figure 40 The blower speed connections shown in Figure 40 are typical How ever these connections may vary from model to model and may be changed as needed to give proper heating and cooling airflow YELLOW MED LOW RED LOW BLACK HI PARK PARK BLUE MED 35 268890 UIM B 0607 FURNACE CONTROL DIAGNOSTICS The furnace has built in self diagnostic capability If a system problem occurs a blinking LED shows a fault code The LED can flash red green or amber to i
50. e time When the thermostat is satisfied both blowers will stay on for 60 seconds then will shut off at the same time Continuous Fan On a thermostat call for continuous fan G signal both furnace blowers will come on at the same time in cooling speed and will stay on until the G signal is removed FURNACE 1 CONTROL BOARD FURNACE 2 CONTROL BOARD CBB ISOLATION RELAY WALL THERMOSTAT FIGURE 15 Two Stage Twinning Wiring Diagram SECTION VII COMBUSTION AIR AND VENT SYSTEM COMBUSTION AIR AND VENT SAFETY This Category IV dual certified direct vent furnace is designed for resi dential application It may be installed without modification to the con densate system in a basement garage equipment room alcove attic or any other indoor location provided the space temperature is 32 F 090 or higher and where all required clearance to combustibles and other restrictions are met The combustion air and the venting system must be installed in accordance with Section 5 3 Air for Combustion and Ventilation of the National Fuel Gas Code Z223 1 NFPA 54 latest edition or Sections 7 2 7 3 or 7 4 of CSA B149 1 National Gas and Propane Codes latest edition or applicable provisions of the local building code and these instructions IMPORTANT The VENT SYSTEM must be installed as specified in these instructions for Residential
51. eces of 4 10 cm length x 1 8 0 3 cm diameter tubing e 1 5 16 0 8 cm tee e 1 5 16 0 8 cm x 1 8 3 175 mm reducing coupling 1 1 8 0 3 cm adapter There is a accessory kit 1 0602 available from Source 1 which has the following items 12 30 cm length x 1 8 0 3 cm diameter tubing 2 pieces of 4 10 length x 1 8 0 3 cm diameter tubing e 1 5 16 0 8 cm tee e 1 5 16 0 8 cm x 1 8 0 3 cm reducing coupling e 1 1 8 0 3 cm adapter 1 Dwyer Manometer These items are required in order to properly perform the required star tup procedure IGNITION SYSTEM SEQUENCE 1 Turn the gas supply ON at external valve and main gas valve 2 thermostat above room temperature to call for heat 3 System start up will occur as follows a The induced draft blower motor will start and come up to speed Shortly after inducer start up the hot surface igniter will glow for about 17 seconds b After this warm up the ignition module will energize open the main gas valve After flame is established the supply air blower will start in about 30 seconds FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in serious injury death or property damage Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of leaks to check all connections A fire or explo
52. ecting the location for a horizontal combustion air vent termi nation the following should be considered 2 Observe all clearances listed in vent clearances in these instruc tions Termination should be positioned where vent vapors will not dam age plants or shrubs or air conditioning equipment Termination should be located where it will not be affected by wind gusts light snow airborne leaves or allow recirculation of flue gases Termination should be located where it will not be damaged or exposed to flying stones balls etc Termination should be positioned where vent vapors are not objec tionable Horizontal portions of the vent system must slope upwards and be supported to prevent sagging The vent system may be supported by the use of clamps or hangers secured to a permanent part of the structure every 4 ft 1 22 m Sealed combustion air systems must be installed so the vent and the combustion air pipes terminate in the same atmospheric zone Refer to Figures 19 20 amp 21 DOWNFLOW VENT ASSEMBLY HORIZONTAL VENT ASSEMBLY Horizontal Left Vent Assembly 1 2 3 Place the 2 5 08 cm 45 PVC street elbow on the vent connec tion shown in Figure 18 Place the 2 5 08 cm PVC WYE Y assembly on the 2 5 08 cm 45 PVC street elbow as shown in Figure 18 Refer to the DOWNFLOW HORIZONTAL CONDENSATE INTER NAL DRAIN CONFIGURATIONS for futher details Horizontal Right Vent Assembly
53. eet of 3 pipe 3 90 sweep elbow 3 45 sweep elbow 3 90 standard elbow 3 45 standard elbow 2 corrugated connector 3 corrugated connector Example An 80 000 BTUH furnace requires 32 feet of pipe and four 90 elbows Using 2 pipe and standard elbows the total equivalent length will be 32 feet of 2 pipe 4 90 standard 2 elbows 4x10 Total 32 equivalent feet 40 equivalent feet 72 equivalent feet of 2 pipe This exceeds the 65 foot maximum equivalent length of 2 pipe allowed for that model and is thus not acceptable By using sweep elbows the total equivalent length will be 32 feet of 2 pipe 4 90 standard 2 elbows 4x5 Total 32 equivalent feet 20 equivalent feet 52 equivalent feet of 2 pipe This is less than the 65 foot maximum equivalent length of 2 pipe allowed for that model and is thus acceptable Alternatively using 3 pipe and standard elbows the total equivalent length will be 32 feet of 3 pipe 4 90 standard 2 elbows 4x5 Total 32 equivalent feet 40 equivalent feet 72 equivalent feet of 3 pipe This is less than the 90 foot maximum equivalent length of 3 pipe allowed for that model and is thus acceptable 15 268890 UIM B 0607 STANDARD ELBOW LONG SWEEP ELBOW FIGURE 16 Dimensions TABLE 10 Elbow Dimensions 2 Standard 3 Standard 2 3 Sweep 4 1 16 Dimensions are those required in Standard ASTM D 3311 N
54. he cooling coil cabinet MUST BE SEALED as needed to prevent leaks AND SECURED Refer to the assembly drawing in Figure 2 IMPORTANT On all installations without a coil a removable access panel is recommended in the outlet duct such that smoke or reflected light would be observable inside the casing to indicate the presence of leaks in the heat exchanger This access cover shall be attached in such a manner as to prevent leaks TRANSITION DOWNFLOW FURNACE REFRIGERANT COOLING COIL CABINET CONNECTIONS AIRFLOW Y TRANSITION N KIT AIRFLOW FIGURE 2 Transition Kit Assembly Horizontal Models IMPORTANT This furnace may be installed in a horizontal position on either side as shown above It must not be installed on its back Horizontal Installations With a Cooling Coil Cabinet The furnace should be installed with the cooling coil cabinet specifically intended for horizontal applications If a matching cooling coil is used it may be placed directly on the supply air side of the furnace and sealed to prevent leakage A warm air duct plenum with 1 2 54 cm is installed through the opening provided The supply air duct system is connected to the warm air plenum and sealed to prevent leaks IMPORTANT The furnace the cooling coil cabinet and all duct work MUST BE SEALED as needed to prevent leaks AND SECURED Refer to the assembly drawing in Figure 2 Attach the supply plenum to the air conditioning coil ca
55. he opening pro vided The supply air duct is then secured to the duct system with screws and sealed to prevent leaks If a matching cooling coil is used it may be placed directly on the furnace outlet using the accessory transi tion kit and sealed to prevent leakage The transition kit must be used to secure the cooling coil cabinet to the furnace casing when installed ina downflow configuration These kits are required in downflow application when using G F series coils These kits are not required with MC FC series coils but please ensurethat the coil and furnace are sucured and that there are noair leaks This transition kit may be installed in one of two ways The transition kit may be installed and secured to either the furnace or the cooling coil cabinet by the use of screws and then it must be sealed to prevent leaks e lf the transition kit has been installed on the cooling coil cabinet it must be secured to the cooling coil cabinet with screws The sup ply air side of the furnace is then placed on the cooling coil cabi net and then sealed for leaks e lf the transition kit has been installed on the supply air side of the furnace it must be secured to the furnace with screws The fur nace and the transition kit are then placed on the cooling coil cab inet and then sealed for leaks NOTE Refer to instructions packed out with coil cabinet for securing and sealing to the furnace IMPORTANT The furnace transition kit and t
56. ing to retrieve error codes To retrieve the error codes push the LAST ERROR button The LED on the control will then flash the error codes that are in memory starting with the most recent There will be a two second pause between each flash code After the error codes have all been displayed the LED will resume the normal slow green flash after a five second pause To repeat the series of error codes push the button again If there are no error codes in memory the LED will flash two green flashes To clear the memory push the LAST ERROR button and hold it for more than five seconds The LED will flash three green flashes when the memory has been cleared then will resume the normal slow green flash after a five second pause Unitary Products Group 268890 UIM B 0607 TABLE 18 Blower Performance CFM MODELS Airflow with Top Return without Filters CFM Airflow with Top Return without Filters m min Input Speed External Static Pressure Inches W C External Static Pressure Inches kPa Airflow caminet oa oa os os o7 oa i i 40 1200 A mss mes wr wr ss we we s et or ss we wo mew pez ar ar ar om mpm ww es oe er om zr oo ve pp pw es oor vr D 9 wm we wea www oo
57. ion use two 90 elbows with the open end in a downward position Be sure to maintain 12 30 5 cm clearance above any insulation flooring or other material A crawl space combustion air installation consists of a straight pipe from the PVC coupling on the burner box that extends into the crawl space and terminates with a 1 4 0 63 cm mesh screen and no elbows 21 268890 UIM B 0607 IMPORTANT Condensate must be disposed of properly Follow local plumbing or wastewater codes The drain line must maintain a 1 4 per foot 0 635 cm per meter slope to the drain CONDENSATE DRAIN TRAP AND DRAIN FREEZE PROTECTION Special precautions MUST be made if installing furnace in an area which may drop below freezing This can cause improper operation or damage to the equipment If the furnace is installed in an area that has the potential of freezing the drain line and the drain trap must be pro tected Use a 3 to 6 watt per foot at 115 vac 40 F 4 4 self regulat ing shielded and waterproof heat tape Wrap the drain trap and the drain line with the heat tape and secure with ties Follow the heat tape manufacturer s recommendations CONDENSATE DRAIN HOSE PART NUMBERS TABLE 15 Condensate Drain Hose 12 MINIMUM BETWEEN BOTTOM OF BELOW AND ANY MATERIAL FIGURE 28 Attic Combustion Air Termination Specially Engineered Installations The above requirements shall be permitted to be waived where special engineering approved by
58. ions Connect the control wiring as shown in the Figure 15 1 Connect the low voltage wiring from the wall thermostat to the ter minal strip on the control board of Furnace 1 For staging applica tions the wire from thermostat W1 is connected to the W connection on the board on Furnace 1 The wire from thermostat W2 is connected to Furnace 2 through a separate relay as described below 2 Connect a wire from the TWIN terminal of Furnace 1 to the TWIN terminal of Furnace 2 3 Install a separate 24V relay as shown in the diagram below Use of this relay is required as it ensures that the transformers of the two furnaces are isolated thus preventing the possibility of any safety devices being bypassed Single Wire Staging Operation Heating On a call for first stage heat W1 signal from the wall thermo stat Furnace 1 will start the ignition sequence and the burners will light About thirty seconds after the burners light the blowers on both furnaces will come on in heating speed When the thermostat is satis fied the burners will shut off and after the selected blower off delay time both blowers will shut off at the same time On a call for second stage of heat the burners of Furnace 2 will also light and both blowers will run The twinning control ensures that both blowers come on and shut off at the same time Cooling On a call for cooling Y signal from the wall thermostat both furnace blowers will come on at the sam
59. is fault code indicates that the flame could not be established This no light condition occurred 3 times 2 retries during the call for heat before locking out Low gas pressure faulty gas valve faulty hot surface ignitor or burner problem may cause this The furnace will lock out for one hour and then restart 8 RED FLASHES This fault is indicated if the flame is lost 5 times 4 recycles during the heating cycle This could be caused by low gas pressure or faulty gas valve The furnace will lock out for one hour and then restart 36 9 RED FLASHES Indicates reversed line voltage polarity or grounding problem Both heating and cooling operations will be affected Check polarity at furnace and branch Check furnace grounding Check that flame probe is not shorted to chassis 10 RED FLASHES Gas valve energized with no call for heat Check gas valve and gas valve wiring 11 RED FLASHES This indicates that a primary or auxiliary limit switch has opened its normally closed contacts and has remained open for more than five minutes This condition is usually caused by a failed blower motor or blower wheel 12 RED FLASHES This code indicates an open igniter circuit which could be caused by a disconnected or loose wire or by a cracked or bro ken igniter STEADY ON RED Control failure Replace control board 60 MINUTE AUTOMATIC RESET FROM LOCKOUT This control includes a watchdog type circuit that will reset from a lockout cond
60. ite furnace operation When suspending the furnace use a secure a platform constructed of plywood or other building material secured to the floor joists Refer to Figure 6 for typical crawl space installation Unitary Products Group ANGLE IRON BRACKET SUPPORT BRACKET 1 MAX BETWEEN Pte Cor renege 6 MIN BETWEEN ROD amp FURNACE 1 MAX BETWEEN ROD amp FURNACE FIGURE 6 Typical Suspended Furnace Crawl Space Installation A CAUTION In any application where temperatures below freezing are possible see BELOW FREEZING LOCATIONS SECTION IV GAS PIPING GAS SAFETY ADANGER An overpressure protection device such as a pressure regulator must be installed in the gas piping system upstream of the furnace and must act to limit the downstream pressure to the gas valve so it does not exceed 0 5 PSI 14 w c 3 48 kPa Pressures exceed ing 0 5 PSI 14 w c 3 48 kPa at the gas valve will cause damage to the gas valve resulting in a fire or explosion or cause damage to the furnace or some of its components that will result in property damage and loss of life OUTLET PRESSURE PORT VENT PORT OUTLET INLET PRESSURE PORT MAIN REGULATOR ADJUSTMENT ON OFF SWITCH Shown in ON position FIGURE 7 Gas Valve IMPORTANT Plan your gas supply before determining the correct gas pipe entry Use 90 degree service elbow s or short nipples and co
61. ition after 60 minutes Operational faults 6 7 8 will be reset This provides protection to an unoccupied structure if a temporary condition exists causing a furnace malfunction An example would be a low incoming gas supply pressure preventing unit operation When the gas pressure is restored at some point the watchdog would restart the unit and pro vide heat for the house NOTE If a flame is detected the control flashes the LED for 1 8 of a second and then enters a flame stabilization period IGNITION CONTROL Normal flame sense current is approximately 3 7 microamps DC Low flame signal warning starts at 1 5 microamps Low flame signal control lockout point is 0 1 microamps DC DIAGNOSTIC FAULT CODE STORAGE AND RETRIEVAL The control in this furnace is equipped with memory that will store up to five error codes to allow a service technician to diagnose problems more easily This memory will be retained even if power to the furnace is lost This feature should only be used by a qualified service tech nician The control stores up to five separate error codes If more than five error codes have occurred since the last reset only the five most recent will be retained The furnace control board has a button labeled LAST ERROR that is used to retrieve error codes This function will only work if there are no active thermostat signals So any call for heating cooling or continuous fan must be terminated before attempt
62. ive type fuse and is located on the control board BLOWER DOOR SAFETY SWITCH This unit is equipped with an electrical interlock switch mounted in the blower compartment This switch interrupts all power at the unit when the panel covering the blower compartment is removed Electrical supply to this unit is dependent upon the panel that covers the blower compartment being in place and properly positioned A CAUTION Main power to the unit must still be interrupted at the main power disconnect switch before any service or repair work is to be done to the unit Do not rely upon the interlock switch as a main power dis connect Blower and burner must never be operated without the blower panel in place ROLLOUT SWITCH CONTROLS These controls are mounted on the burner box assembly If the temper ature in the burner box exceeds its set point the ignition control and the gas valve are de energized The operation of this control indicates a malfunction in the combustion air blower heat exchanger or a blocked vent pipe connection Corrective action is required These are manual reset controls that must be reset before operation can continue PRESSURE SWITCHES This furnace is supplied with a pressure switch which monitors the flow through the combustion air vent piping system This switch de ener gizes the ignition control module and the gas valve if any of the follow ing conditions are present Refer to Figure 37 for tubi
63. l board of Furnace 1 2 Connect a wire from the TWIN terminal of Furnace 1 to the TWIN terminal of Furnace 2 3 Install a separate 24V relay as shown in the diagram below Use of this relay is required as it ensures that the transformers of the two furnaces are isolated thus preventing the possibility of any safety devices being bypassed Single Wire Twinning Operation Heating On a call for heat W signal from the wall thermostat both furnaces will start the ignition sequence and the burners on both fur naces will light About thirty seconds after the burners light the blowers on both furnaces will come on in heating speed When the thermostat is satisfied the burners will all shut off and after the selected blower off delay time both blowers will shut off at the same time The twinning control ensures that both blowers come on and shut off at the same time Cooling On a call for cooling Y signal from the wall thermostat both furnace blowers will come on at the same time in cooling speed When the thermostat is satisfied both blowers will stay on for 60 seconds then will shut off at the same time Continuous Fan On a thermostat call for continuous fan G signal both furnace blowers will come on at the same time in cooling speed and will stay on until the G signal is removed FURNACE 1 CONTROL BOARD FURNACE 2 CONTROL BOARD W G ISOLATION e
64. ls Refer to Figures 25 amp 27 2 AMBIENT COMBUSTION AIR Combustion air is supplied from the area surrounding the furnace through the combustion air pipe in the furnace casing The combustion air and the vent pipes are not terminated in the same atmospheric zone Refer to Figures 19 amp 26 for vent terminations Refer to AMBIENT COMBUSTION AIR SUPPLY and VENT AND SUPPLY OUTSIDE AIR SAFETY CHECK PROCEDURE for proper installation 3 VENTILATED COMBUSTION AIR Combustion air is supplied through a PVC or ABS pipe that is connected to the PVC coupling attached to the burner box and is terminated in a ventilated attic or crawl space The combustion air and the vent pipes are not termi nated in the same atmospheric zone Refer to Figure 28 for crawl space and attic termination Only the combustion air intake may terminate in the attic The vent must terminate outside Outdoor Combustion Air Combustion Air Intake Vent Connections This installation requires combustion air to be brought in from outdoors This requires a properly sized pipe shown in Figures 31 33 or 35 that will bring air in from the outdoors to the furnace combustion air intake collar on the burner box The second pipe shown in Figures 31 33 or 35 is the furnace vent pipe 2 5 08 cm VENT CONNECTION r7 gt lm AIR INTAKE FIGURE 25 Sealed Combustion Air Intake Connection and Vent Connection 19 268890 UIM B 0607 The combustion
65. mperature under normal oper ating conditions Ambient temperatures must not fall below 32 F 0 C unless the condensate system is protected from freezing 2 Do not allow return air temperature to be below 55 F 13 C for extended periods To do so may cause condensation to occur in the main heat exchanger leading to premature heat exchanger failure A WARNING Improper installation in an ambient below 32 F 0 0 C could create a hazard resulting in damage injury or death dfthis furnace is installed in any area where the ambient tempera ture may drop below 32 F 0 C a UL listed self regulated heat tape must be installed on any condensate drain lines It is required that self regulating heat tape rated at 3 watts per foot be used This must be installed around the condensate drain lines in the unconditioned space Always install the heat tape per the manu facturer s instructions Cover the self regulating heat tape with fiberglass Armaflex or other heat resistant insulating material 4 If this unit is installed in an unconditioned space and an extended power failure occurs there will be potential damage to the conden sate trap drain lines and internal unit components Following a power failure situation do not operate the unit until inspection and repairs are performed Clearances for access Ample clearances should be provided to permit easy access to the unit The following minimum clearances are rec
66. n ventional 90 degree elbow s to enter through the cabinet access holes GAS PIPING INSTALLATION Properly sized wrought iron approved flexible or steel pipe must be used when making gas connections to the unit If local codes allow the use of a flexible gas appliance connection always use a new listed con nector Do not use a connector that has previously serviced another gas appliance Some utility companies or local codes require pipe sizes larger than the minimum sizes listed in these instructions and in the codes The furnace rating plate and the instructions in this section specify the type of gas approved for this furnace only use those approved gases The instal lation of a drip leg and ground union is required Refer to Figure 8 Unitary Products Group 268890 UIM B 0607 EXTERNAL MANUAL SHUTOFF VALVE N Pa GROUNDED JOINT UNION MAY BE INSTALLED LEG INSIDE OR OUTSIDE UNIT MANUAL SHUT OFF a LEG GAS BURNERS GAS VALVE MANUAL SHUT OFF VALVE FIGURE 9 Horizontal Gas Piping IMPORTANT An accessible manual shutoff valve must be installed upstream of the furnace gas controls and within 6 feet 1 8 m of the fur nace The furnace must be isolated from the gas supply piping system by closing its individual external manual shutoff valve during any pressure testing of the gas supply piping system at pressures equal to or less than 1 2 psig 3 5 kPa A CAUTION Never apply a pipe wrench to the
67. nd horizontal pitch Determine that there is no blockage restriction leakage corrosion or other deficiencies which could cause an unsafe condition 2 Close all building doors and windows and all doors clothes dryers and TURN ON any exhaust fans such as range hoods and bathroom exhausts so they shall operate at maximum speed Open the fireplace dampers Do not operate a summer exhaust fan 4 Follow the lighting instructions Place the appliance being inspected in operation Adjust thermostat so the appliance shall operate continuously 5 Test each appliance such as a water heater equipped with a draft hood for spillage down draft or no draft at the draft hood relief opening after 5 minutes of main burner operation Appliances that do not have draft hoods need to be checked at the vent pipe as close to the appliance as possible Use a combustion analyzer to check the CO2 and CO levels of each appliance Use a draft gauge to check for a downdraft or inadequate draft condition 6 After it has been determined that each appliance properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their normal condition 7 f improper venting is observed during any of the above tests a problem exists with either the venting system or the appliance does not have enough combustion air Supply Air from outside to complete combustion This conditi
68. ndicate various conditions It is located behind a clear view port in the blower compartment door The control continuously monitors its own operation and the operation of the system If a failure occurs the LED will indicate the failure code If the failure is internal to the control the light will stay on continuously In this case the entire control should be replaced as the control is not field repairable Flash sequence codes 1 through 10 are as follows LED will turn on for 1 4 second and off for 1 4 second This pattern will be repeated the number of times equal to the code For example six on flashes equals a number 6 fault code All flash code sequences are broken by a 2 sec ond off period SLOW GREEN FLASH Normal operation SLOW AMBER FLASH Normal operation with call for heat RAPID RED FLASH Twinning error incorrect 24V phasing Check twinning wiring RAPID AMBER FLASH Flame sense current is below 1 5 microamps Check and clean flame sensor Check for proper gas flow 4 AMBER FLASHES The control board is recieving a Y signal from the thermostat without a signal indicating improper thermostat wir ing 1 RED FLASH This indicates that flame was sensed when there was not a call for heat With this fault code the control will turn on both the inducer motor and supply air blower A gas valve that leaks through or is slow closing would typically cause this fault 2 RED FLASHES This indicates
69. ng connections Blockage of combustion air piping or terminal Blockage of vent piping or terminal Failure of combustion air blower motor Blockage of condensate drain piping pommes Unitary Products Group 268890 UIM B 0607 DOWNFLOW HORIZONTAL FIGURE 37 Pressure Switch Tubing Routing LIMIT CONTROLS There is high temperature limit control located on the furnace vestibule panel near the gas valve This is an automatic reset control that pro vides over temperature protection due to reduced airflow This may be caused by 1 Dirty filter 2 Ifthe indoor fan motor should fail or 3 Too many supply or return registers closed or blocked off The control module will lockout if the limit trips 5 consecutive times within a single call for heat Control will reset and try ignition again after 1 hour SECTION X START UP AND ADJ USTMENTS The initial start up of the furnace requires the following additional procedures IMPORTANT All electrical connections made in the field and in the fac tory should be checked for proper tightness When the gas supply is initially connected to the furnace the gas piping may be full of air In order to purge this air it is recommended that the ground union be loosened until the odor of gas is detected When gas is detected immediately retighten the union and check for leaks Allow five minutes for any gas to dissipate before continuing with the start up procedure
70. ng system and or to the supply out side air system must be in accordance with the National Fuel Gas Code 2223 1 B149 1 00 Natural Gas and Propane Installation Code latest editions If the vent system must be resized follow the appropriate tables in Appendix G of the above codes or for this appliance refer to Table 8 of these instructions Ventilated Combustion Air The ventilated attic a crawl space from which the combustion air is taken must comply with the requirements specified in COMBUS TION AIR SOURCE FROM OUTDOORS in this instruction or in Sec tion 5 3 Air for Combustion and Ventilation of the National Fuel Gas Code ANSI Z223 1 latest edition This type installation requires two properly sized pipes One brings combustion air from a properly venti lated attic space or crawl space and a second pipe that extends from the furnace vent connection top right of unit to the exterior of the build ing Refer to Table 8 for intake pipe sizing allowable length and elbow usage Follow all notes procedures and required materials in the SEALED COMBUSTION AIR SUPPLY section in these instructions when installing the combustion air pipe from the unit and into a venti lated attic space or crawl space DO NOT terminate vent pipe in an Attic or Crawl Space Ventilated Combustion Air Termination Refer to Figure 28 for required attic termination for the combustion air intake pipe For attic terminat
71. nig 0091 80 Nag 30 un310W Q Nag MOT 1349 PU TS uu HIOA 09 1 S11 NOILVIN3NITVO y18 nia 0021 80 NUD 01102 o 8 esou 31ON 335 09 1 511 414405 83004 Qo ime ana agen ia Q34 03A n18 S1300W NI AINO 5 9 31831434005 un3lOW 04 LUVHD 335 31545 YOLOW H3MO18 IN3A3IVNHON O N 3184 30 YNALVIAWWOD 19 0021 0 18 211 5 3004 MS O N CYWI T9 138183 31 4 33111 3 31 1 071 506 351 004 1009 IH W39 1fdNI K 1N3N3Q8S002VH 349 3AWVHOVIQ 3 3AWNVHOVIQ 318314400S 30 355311 30 3LYVHO NOLLOANNOD TV LINOZIIOH MOTANMOd 06 INVNDVIG LNVHO 45 iagram D iring W FIGURE 41 39 Unitary Products Group NOTES Subject to change without notice Printed in U S A 268890 UIM B 0607 Copyright by York International Corp 2007 All rights reserved Supersedes 268890 UIM A 0407 Unitary 5005 Norman Product York OK Group Drive 73069
72. nstalled Accessories High Altitude pressure Switch 268890 UIM B 0607 TABLE 6 Nominal Manifold Pressure Manifold Pressures in wc Manifold Pressures kpa Altitude feet Altitude m 8000 8999 410 08 06 08 ADANGER PROPANE AND HIGH ALTITUDE CONVERSION KITS It is very important to choose the correct kit and or gas orifices for the altitude and the type of gas for which the furnace is being installed Only use natural gas in furnaces designed for natural gas Only use propane LP gas for furnaces that have been properly converted to use pro pane LP gas Do not use this furnace with butane gas Incorrect gas orifices or a furnace that has been improperly converted will create an extremely dangerous condition resulting in premature heat exchanger failure excessive sooting high levels of carbon monoxide personal injury property damage a fire hazard and or death High altitude and propane LP conversions are required in order for the appliance to satisfactory meet the application An authorized distributor or dealer must make all gas conversions In Canada a certified conversion station or other qualified agency using factory specified and or approved parts must perform the conversion The installer must take every precaution to insure that the furnace has been converted to the proper gas orifice size when the furnace is installed Do not attempt to drill out any orifices to obtain the proper orifice size
73. nstalled into the large recessed drain in the condensate trap 6 Install the condensate trap bracket with the condensate trap on to the front side of the furnace using the screws removed in step 1 Unitary Products Group HOSE 4 with 3 8 HOSE 5 3 42 3 4 Y gt poc lt DOGLEG e ge HOSE 2 if drain aligned HOSE 4 268890 UIM B 0607 SPRING CLAMP CUT PIECE 2 3 4 HOSE 1 HOSE 3 SPRING CLAMP 1 1 8 HOSE 2 17 1 2 4318 3 4 SPRING CLAMP NS Ss LEG USED AFTER CONDENSATE TRAP HOSE 8 22 1 8 SPRING CLAMP HOSE 9 Switch the blocked condensate hose to the condensate tap on the bottom of the condensate pan close to the inducer Install hose 9 between the external drain on the Wye and the condensate trap with the dogleg end installed on the protruded stub drain of the condensate trap The length of hose 9 may have to be trimmed to ensure proper condensate drainage Remove all condensate hoses off the 3 8 barbed tee Cut 1 1 2 length of straight 3 8 hose off of hose 5 and install it on the 3 8 barbed tee The other end of the 1 1 2 hose should be installed on the welled opening on the condensate trap Install one end of the 3 8 barbed tee on hose 4 as shown Ensure that hose 4 follows a gradual downward slope all the way to the barbed tee Install hose 6 between the top drain of the rain gutter
74. ntrol module Check the part number on the integrated control module You cannot twin two furnaces that have different integrated control module part numbers If the part numbers of the two integrated control modules are different they may not communicate with each other so they will not work in a twinning application In applications where more heating capacity or more airflow capacity is needed than what one furnace can deliver twinning can be used to make two furnaces operate in tandem When two furnaces are installed using the same duct system it is very important that the two furnace cir culating air blowers operate in unison If one blower starts before the second blower the duct system will become pressurized and the blower on the second furnace will turn backwards causing the second furnace to overheat resulting in damage to the furnace Twinning is used to make two furnaces operate in tandem using one duct system one room thermostat and causing both furnaces to turn on and off simulta Before installing the relay and wiring disconnect electrical power to both furnaces Failure to cut power could result in electrical shock or equipment damage A CAUTION The relay must not be installed in any location where it could be exposed to water If the relay has been exposed to water in any way it must not be used Unitary Products Group 268890 UIM B 0607 TWINNING DUCT SYSTEM Twinned furnaces mu
75. o do so could result in serious personal injury and or equipment damage FOR FURNACES INSTALLED IN THE COMMON WEALTH OF MASSACHUSETTS ONLY For all side wall horizontally vented gas fueled equipment installed in every dwelling building or structure used in whole or in part for resi dential purposes including those owned or operated by the Com monwealth and where the side wall exhaust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following require ments shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back up is installed on the floor level where the gas equipment is to be installed In addition the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling building or structure served by the side wall horizontal vented gas fueled equipment It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors a n the event that the side wall horizontally vented gas fueled equipment is installe
76. o that the furnace plenum should be if sufficient size so that the fur nace operates at the specified external static pressure and within the air temperature rise specified on the nameplate Table 2 is a guide for determining whether the rectangular duct system that the furnace is being connected to be of sufficient size for proper fur nace operation Unitary Products Group Use the Example below to help you in calculating the duct area to deter mine whether the ducts have sufficient area so that the furnace oper ates at the specified external static pressure and within the air temperature rise specified on the nameplate The following are general duct sizing guidelines that may not serve to requirements of every application Example The furnace input is 80 000 1 200 CFM blower requirement The recommended duct area is 216 sq in there are two 8 12 rectangular ducts attached to the plenum and there are two 7 inch round ducts attached to the furnace 1 Take 8 x 12 which equals 96 square inch x 2 192 square inches then go to round duct size located in Table 3 TABLE 2 Minimum Duct Sizing For Proper Airflow Nominal Airflow BTU H kW CFM m min In cm 60 000 17 6 1 200 34 0 280 1806 14x20 35 6 x 50 8 18 45 7 216 1394 12x18 30 5 x 45 7 16 40 6 80 000 23 4 1 200 34 0 280 1806 14x20 35 6 x 50 8 18 45 7 216 1394 12x18 30 5 x 45 7 16 40 6 80 000 23 4 1 600 45
77. od is to use a field provided 2 5 08 cm x 4 10 2 cm box and cover on the outside of the furnace Route the furnace leads into the box using a protective bushing where the wires pass through the furnace panel After making the wiring connections replace the wiring box cover and screws furnace s control system requires correct polarity of the power supply and a proper ground connection If the power supply polar ity is reversed the control board will flash 9 times The furnace will not operate until the polarity is corrected Refer to Furnace Diag nostics section of the User s Information Maintenance amp Ser vice Manual provided with this furnace Unitary Products Group 268890 UIM B 0607 BLOWER COMBUSTION COMPARTMENT AIR VENT PIPE CLASS 2 SYSTEM CONTROL WIRING TO THERMOSTAT IGNITION MODULE HI TRANSFORMER JUNCTION BOX BLK LI HOT WHT N GRN GND FIGURE 10 Electrical Wiring LOW VOLTAGE CONTROL WIRING CONNECTIONS Install the field supplied thermostat by following the instructions that come with the thermostat With the thermostat set in the OFF position and the main electrical source disconnected connect the thermostat wiring from the wiring connections on the thermostat to the terminal board on the ignition module as shown in Figure 11 Electronic thermo stats may require the common wire to be connected as shown with the dashed line in Figure 11 Apply s
78. of the inducer and the remaining open end of 3 8 barbed tee Ensure that all hoses are properly installed have no kinks and are draining properly All hoses on the condensate trap should be pushed all the way down to ensure against leakage 23 268890 UIM B 0607 HOSE 9 lt 25 1 Is lt 2 gt 2 2 Famgosau2dr it lt 21 n g LLI Oo i lt 2 SSsoger2Z5e aaura 5 ve Oa lt lt MOF 5 N E 0 Ow 5 amp 52 59 2 OL 0 c Z 0 lt Ya o I wa COMBUSTION 1 FIGURE 31 Horizontal Left Condensate Drain Hose Configuration 24 Unitary Products Group 268890 UIM B 0607 5 JSOH 8 6 v ASOH 8 6 S3 lddIN 8 6 9 ISOH LED seli dI AV IO 9NISdS git T 8 22 m JIVSN3JQIQNO2 S dWV10 SNIMdS 0351 Es 3S0H 9 ISOH dVal ALVSNAGNOO Q3GaN3alWNWO23H ZEN qagasva 8 6 8 6 8 ISOH FIGURE 32 Horizontal Left Condensate Drain Hose Configuration 25
79. ommended 1 Twenty four 24 inches 61 cm between the front of the furnace and an adjacent wall or another appliance when access is required for servicing and cleaning 2 Eighteen 18 inches 46 cm at the side where access is required for passage to the front when servicing or for inspection or replacement of flue vent connections In all cases accessibility clearances shall take precedence over clear ances for combustible materials where accessibility clearances are greater 268890 UIM B 0607 AWARNING Downflow Horizontal furnaces for installation on combustible floor ing only when installed on the accessory combustible floor base on wood flooring only and shall not be installed directly on carpeting tile or other combustible material Check the rating plate and power supply to be sure that the electri cal characteristics match All models use nominal 115 VAC 1 Phase 60Hz power supply Furnace shall be installed so the electrical components are pro tected from water Installation in a residential garage 1 A gas fired furnace for installation in a residential garage must be installed so the burner s and the ignition source are located not less than 18 inches 46 cm above the floor and the furnace must be located or protected to avoid physical damage by vehicles TABLE 1 Unit Clearances to Combustibles Application Rea nem 09 Lat Soften 09 125 bu T 3m 0 0 Les
80. on 2 Pipe 12 MINIMUM SEPARATION BETWEEN BOTTOMOF COMBUSTION AIR PIPE AND TOP OF VENT MAINTAIN 12 MIN CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL DOWNFLOW RETURN AIR gt BARBED FITTING HORIZONTAL RIGHT FIGURE 18 Downflow Horizontal Vent Assembly FIGURE 21 Termination Configuration 2 Pipe Horizontal ie itary Products Group 12 MINIMUM BELOW OVERHANG 12 MINIMUM SEPARATION BETWEEN BOTTOM OF COMBUSTION AIR PIPE AND BOTTOM OF VENT MAINTAIN 12 MINIMUM CLEARANCE 97 ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS HIGHER VENT DRAIN FIGURE 22 Crawl Space Termination Configuration 2Pipe VERTICAL VENT APPLICATIONS AND TERMINATION Roof mounted vertical terminals may be field fabricated Standard PVC SRD fittings may be used If installing a vertical venting system through any unconditioned space such as an attic or crawl space it must be insulated 1 Observe all clearances listed in vent clearances in these instruc tions 2 Termination should be positioned where vent vapors are not objec tionable 3 Termination should be located where it will not be affected by wind gusts light snow or allow recirculation of flue gases 4 Termination should be located where it cannot be damaged plugged or restricted by tree limbs leaves and branches 5 Horizontal portions of the vent system must slope upwards and
81. on Configuration 2 19 Furnace Control Board 35 Double Horizontal Sealed Combustion Air and Vent Termination 19 Wirmo Diara Een deae tbe 39 Double Vertical Sealed Combustion Air and Vent Termination 19 LIST OF TABLES Unit Clearances to Combustibles 4 Combustion Air Intake and Vent Connection Size at Furnace Minimum Duct Sizing For Proper Airflow 5 GAN 16 a SEHEN ses 5 Estimated Free Area 20 Cabinet and Duct Dimensions 7 Free Area Outdoor Air 20 Recommended Filter Sizes 7 Unconfined Space Minimum Area in Square Inches 20 Nominal Manifold Pressure 10 Condensate Drain Hose 22 Electrical and Performance Data 10 Inlet Gas Pressure Range 34 Maximum Equivalent Pipe Length 15 Nominal Manifold 34 Equivalent Length of Fittings 15 Blower Performance 37 Elbow Dimensions
82. on must be corrected before the appliance can function safely Unitary Products Group COMBUSTION AIR SOURCE FROM OUTDOORS 1 Two permanent openings one within 12 in 30 5 mm of the top and one within 12 in 30 5 mm of bottom of the confined space Two permanent openings shall communicate directly or by means of ducts with the outdoors crawl spaces or attic spaces One permanent openings commencing within 12 in 30 5 mm of the top of the enclosure shall be permitted where the equipment has clearances of at least 1 in 2 54 cm from the sides and back and 6 in 15 24 cm from the front of the appliance The opening shall communicate directly with the outdoors and shall have a minimum free area of 1 square in per 3000 Btu per hour 6 45 cm 0 879 kW of the total input rating of all equipment located in the enclosure b Notless than the sum of all vent connectors in the confined space 3 The duct shall be least the same cross sectional area as the free area of the air supply inlet opening to which it connects INLET 4 The blocking effects of louvers grilles and screens must be given AIR a consideration in calculating free area If the free area of a specific louver aor grille is not known FURNACE NOTE An unsafe condition exists when the CO reading exceeds 40 ppm and the draft reading is not in excess of 0 1 in W C 25 kPa with all of the appliance s operating at the same time 8 corrections to the venti
83. on the Wye drain and route the hose through the opening on top of the furnace as shown Install the other end of the 9 hose to the barbed tee inside the furnace Install the dogleg end of hose 4 to the rain gutter on the inducer The other end of hose 4 should be installed on the 3 8 barbed tee Install one end of hose 7 on the 3 8 barbed tee inside the fur nace Guide the other end of hose 7 towards the condensate trap and install it on the tap on the condensate trap Install the dogleg end of hose 2 on the bottom drain of the inducer Guide the other end of hose 2 towards the condensate trap and install it on the small recessed drain in the condensate trap Ensure that all hoses are properly installed have no kinks and are draining properly All hoses on the condensate trap and conden sate pan should be pushed all the way down to ensure against leakage and performance Some hoses may have to be trimmed for proper fit NOTE The condensate trap can also be installed on the 2 knockout opening in this configuration using the provided condensate trap bracket Some modifications may however have to be made to the condensate hoses 26 A CAUTION Ensure all condensate hoses are pushed all the way down on the condensate trap barbed fittings and condensate pan drains 1 2 11 12 Plug all unused condensate trap condensate pan and inducer drain connection points using plugs provided
84. ooled air may not be passed over the heat exchanger When the furnace is used in conjunction with a cooling coil the coil must be installed parallel with or in the supply air side of the furnace to avoid condensation in the primary heat exchanger When a parallel flow arrangement is used dampers or other means used to control airflow must be adequate to prevent chilled air from entering the furnace If manually operated the damper must be equipped with means to pre vent the furnace or the air conditioner from operating unless the damper is in full heat or cool position The duct system must be properly sized to obtain the correct airflow for the furnace size that is being installed Refer to Table 7 and the furnace rating plate for the correct rise range and static pressures If the ducts are undersized the result will be high duct static pres sures and or high temperature rises which can result in a heat exchanger OVERHEATING CONDITION This condition can result in premature heat exchanger failure which can result in personal injury property damage or death FLOOR BASE AND DUCTWORK INSTALLATION Downflow Combustible Floor Base Installations on combustible materials require the use a com bustible floor base shown in Figure 1 The floor base must be secured to the floor A supply air duct plenum with 1 2 54 cm flange is installed through the opening provided The supply air duct is then secured to the duct sy
85. ovided Wye s drain is aligned with the opening in the top of the furnace hose 2 can be used If it is desired that the Wye and street eloow assembly point away from the opening in the casing top then the 2 hose will have to be replaced with provided 9 hose The dogleg end of hose 9 hose should be installed on the drain of the Wye Unitary Products Group above the hole in furnace top barbed nipple 3 8 Barbed Tee HOSE 5 HOSE 1 HOSE 3 FIGURE 30 Downflow Condensate Drain Hose Configuration Horizontal Left Air Flow Inducer Low Refer to Figures 31 amp 32 1 Remove all the condensate hoses inside the furnace leaving the 3 8 barbed nipple and hose 4 both factory installed in the rain gutter 2 Remove the condensate trap and its bracket from inside the fur nace saving the screws for use later 3 Remove the yellow cap from the top drain of the rain gutter and install loosely packed 3 8 barbed nipple in it 4 Remove the large condensate cap from the side of the condensate pan and install it on the middle drain of the condensate pan from where 1 hose was removed 5 Install longer dogleg end of hose 10 through the casing hole on to the side drain of the condensate pan where cap was removed in step 4 Some lubricant may have to be used to facilitate this installation as the hose is designed as a tight fit over the conden sate drain The other shorter dogleg end of hose 10 should be i
86. ps and or sup ports is required to support the weight of the external filter box If the accessory electronic air cleaner is installed be sure the air cleaner is designed to accommodate the furnace CFM cm m and the air cleaner 15 installed so it does not obstruct the return airflow Consid eration should be given when locating the air cleaner for maintenance and temperatures should the indoor fan motor fail to operate The use of straps and or supports is required to support the weight of the elec tronic air cleaner It is recommended that the air cleaner not be located within 12 inches 30 5 cm from the top of the return air opening on the furnace Refer to the instructions supplied with the electronic air cleaner A CAUTION All loose accessories shipped with the furnace must be removed from the blower compartment prior to installation If pleated media air filters or any filter that has a large pressure drop is installed in the return air duct system be sure that the pressure drop caused by the air filter will not prevent the furnace from operating within the rise range specified on the rating plate If the furnace does not oper ate within the specified rise range then a larger air filter or an air filter that has a lower pressure drop must be installed IMPORTANT For easier filter access in a downflow configuration a removable access panel is recommended in the vertical run of the return air plenum immediately
87. rdance with local installa Clearance under veranda porch deck or balcony 12 inches 30 tion codes and the requirements of the gas supplier 1 In accordance with the current CSA B149 1 00 Natural Gas and Propane Installation Code 2 In accordance with the current ANSI Z223 1 54 National Gas Code 3 n accordance with the current ANSI Z21 47 CSA 2 3 American National Standard T A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings 12 inches 30 cm up from the bottom edge of the structure for Two pipe direct vent applications per ANSI Z223 1 54 National Gas Code Permitted only if veranda porch deck or balcony is fully open on a minimum of two sides beneath the floor and the distance between the top of the vent termina tion and the underside of the veranda porch or deck is greater than 1 foot 30 cm as specified in CSA B149 1 00 A vent shall not terminate less than 1 foot 30 cm above a grade level Any fresh air or make up inlet for dryer or furnace area is considered to be forced air inlet Avoid areas where condensate drippage may cause problems such as above planters patios or adjacent to windows where steam may cause fogging A terminus of a vent shall be fitted with a cap in accordance with the vent manufacturer s installation instructions or in accordance with the installation instruc
88. ressure and temperature correction factor of 0 960 times 3600 then divided by the time it took to measure 0 10 m of gas from the gas meter For Propane LP Gas multiply the Heat content of the gas MJ m or Default 93 15 times 0 10 m of gas measured at the gas meter times a baro metric pressure and temperature correction factor of 0 960 times 3600 then divided by the time it took to measure 0 10 m of gas from the gas meter The formula for metric input calculation using a cubic meter gas meter MJ m x m x 0 960 x 3600 Seconds it took to measure the 0 10 m of gas NATURAL GAS INPUT CALCULATION EXAMPLE 38 4 x 0 1 x 0 960 x 3600 160 MJ H x 0 2777 kW X 3412 14 82 94 X 0 2777 23 03 X 3412 14 Natural Gas 1030 BTU SCF 38 4 MJ m PROPANE LP GAS INPUT CALCULATION EXAMPLE 93 15 x 0 1 x 0 960 x 3600 387 83 19 X 0 2777 23 10 X 3412 14 78 826 3 Propane Gas 2500 BTU SCF 93 15 MJ m DO NOT ADJUST the manifold pressure regulator if the actual input is equal to or within 8 less than the furnace input specified on the rating plate or if the furnace rise is above the specified rise range on the rating plate If the actual input is significantly higher than the furnace input specified on the rating plate then replace the gas orifices with the gas orifices of the proper size for the type of gas you are using Unitary Products Group 33 268890 UIM B 0607 A CAUTION Be sure to relight any gas appliance
89. s at 0 50 amp 0 60 ESP Airflow 0 50 2152 CFM Airflow 0 60 2042 CFM Subtract the airflow 0 50 from the airflow 0 60 to obtain air flow difference 2042 2152 110 CFM Subtract the total system static from 0 50 and divide this differ ence by the difference in ESP values in the table 0 60 0 50 to obtain a percentage 0 58 0 50 0 60 0 50 0 8 Multiply percentage by airflow difference to obtain airflow reduc tion 0 8 x 110 88 Subract airflow reduction value to airflow 0 50 to obtain actual airflow 0 58 ESP 2152 88 2064 FIELD INSTALLED ACCESSORIES NON ELECTRICAL MODEL NO 1NP0347 1CT0302 1CT0303 1PS0904 1PS0901 1PS0902 1PS0903 1 0301 1 0901 1HT0902 1CB0314 1CB0317 1 0321 1 0324 1TK0914 1TK0917 1TK0921 1TK0924 1VK0901 COIL TRANSITION KIT HIGH ALTITUDE PRESSURE SWITCH KIT Does Not Include Orifices DESCRIPTION USED WITH PROPANE LP CONVERSION KIT CONCENTRIC INTAKE VENT 2 ALL MODELS EXCEPT 120 MBH CONCENTRIC INTAKE VENT 3 ALL MODELS ALL MODELS CONDENSATE NEUTRALIZER KIT ALL MODELS SIDEWALL VENT TERMINATION KIT 3 ALL MODELS SIDEWALL VENT TERMINATION KIT 2 ALL MODELS COMBUSTIBLE FLOOR BASE These kits are required in downflow application when using G F series coils These kits are not required with MC FC series coils but please ensure that the coil and furnace are secured and that there are noair leaks 24 1 2 CA
90. s that were turned off at the start of this input check TABLE 16 Inlet Gas Pressure Range INLET GAS PRESSURE RANGE Propane CP 8 0 W C 1 99 kPa 13 0 3 24 kPa W C 4 5 W C 1 12 kPa Tem Maximum 10 5 W C 2 61 kPa IMPORTANT The inlet gas pressure operating range table specifies what the minimum and maximum gas line presures must be for the fur nace to operate safely The gas line pressure MUST BE 7 1 74 for Natural Gas 11 W C 2 74 for Propane LP Gas in order to obtain the BTU input specified on the rating plate and or the nominal manifold pressure specified in these instructions and on the rating plate ADJ USTMENT OF MANIFOLD GAS PRESSURE Manifold gas pressure may be measured by two different procedures It may be measured with the burner box cover in place or it may be mea sured with the burner box cover removed Follow the appropriate sec tion in the instructions below Refer to Figure 38 for a drawing of the locations of the pressure ports on the gas valve Turn gas off at the ball valve or gas cock on gas supply line before the gas valve Find the pressure ports on the gas valve marked OUT P and IN P 1 manifold pressure must be taken at the port marked OUT P 2 The gas line pressure must be taken at the port marked IN P 3 Using a 3 32 2 4 mm Allen wrench loosen the setscrew by turn ing it 1 turn counter clockwise DO
91. se nominal 115 VAC 1 Phase 60 Hertz power supply DO NOT CONNECT THIS APPLI ANCE TO A 50 HZ POWER SUPPLY OR A VOLTAGE ABOVE 130 VOLTS Furnace shall be installed so the electrical components are pro tected from water Installing and servicing heating equipment can be hazardous due to the electrical components and the gas fired components Only trained and qualified personnel should install repair or service gas heating equipment Untrained service personnel can perform basic maintenance functions such as cleaning and replacing the air filters When working on heating equipment observe precau tions in the manuals and on the labels attached to the unit and other safety precautions that may apply These instructions cover minimum requirements and conform to existing national standards and safety codes In some instances these instructions exceed certain local codes and ordinances especially those who have not kept up with changing residential and non HUD modular home construction practices These instructions are required as a minimum for a safe installation COMBUSTION AIR QUALITY LIST OF CONTAMINANTS The furnace will require OUTDOOR AIR for combustion when the fur nace is located in any of the following environments Restricted Environments Commercial buildings Buildings with indoor pools Furnaces installed in laundry rooms Furnaces installed in hobby or craft rooms Furnaces installed near chemical storage areas Chemical e
92. sion may result causing property damage personal injury or loss of life 32 IMPORTANT Burner ignition may not be satisfactory on first startup due to residual air in the gas line or until gas manifold pressure is adjusted The ignition control will make 3 attempts to light before lock ing out With furnace in operation check all of the pipe joints gas valve connec tions and manual valve connections for leakage using an approved gas detector a non corrosive leak detection fluid or other leak detection methods Take appropriate steps to stop any leak If a leak persists replace the component The furnace and its equipment shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1 2 PSI 3 45 kPa The furnace must be isolated from the gas supply piping system by closing the equipment shutoff valve during any pressure testing of the gas supply piping system CALCULATING THE FURNACE INPUT NATURAL GAS NOTE Burner orifices are sized to provide proper input rate using natu ral gas with a heating value of 1030 BTU Ft 38 4 MJ m If the heat ing value of your gas is significantly different it may be necessary to replace the orifices NOTE Front door of burner box must be secured when checking gas input 1 Turn off all other gas appliances connected to the gas meter At the gas meter measure the time with a stop watch it takes to use
93. ssembly from the furnace to the outside ter mination checking for proper fit support and slope 5 Dry fit the combustion air piping assembly checking for proper fit support and slope on the following systems A Sealed combustion air systems from the furnace to the out side termination B Ventilated combustion air systems from the furnace to the attic or crawl space termination A CAUTION Solvent cements are flammable and must be used in well ventilated areas only Keep them away from heat sparks and open flames Do not breathe vapors and avoid contact with skin and eyes 6 Disassemble the combustion air and vent piping apply cement primer and the cement per the manufactures instructions Primer and cement must conform to ASTM D2564 for PVC or ASTM D2235 for ABS piping 7 Alljoints must provide a permanent airtight and watertight seal 8 Support the combustion air and vent piping such that it is angled a minimum of 1 4 per foot 0 635 cm m so that condensate will flow back towards the furnace Piping should be supported with pipe hangers to prevent sagging 9 Seal around the openings where the combustion air and or vent piping pass through the roof or sidewalls COMBUSTION AIR VENT CLEARANCES IMPORTANT The vent must be installed with the minimum clearances as shown in Figure 17 and must comply with local codes and require ments Unitary Products Group 268890 UIM B 0607 VENT CLEARANCES
94. st be provided as specified with these instruc tions Since the furnaces are side by side with no space between gas supplies must enter on the right and left respectively All gas piping must be in accordance with the national fuel gas code ANSI Z223 1 latest edition and or all local code or utility requirements TWINNING In applications where more heating capacity or more airflow capacity is needed than what one furnace can deliver twinning can be used to make two furnaces operate in tandem using one duct system and one room thermostat When one duct system is used for two furnaces it is necessary that the two blowers operate in unison The twinning function of the board in this furnace ensures that both blowers turn on and off simultaneously and operate on the same blower speed Single Wire Twinning The control in the furnace has the single wire twinning feature With this feature a single wire is connected between the TWIN terminal on one furnace board to the TWIN terminal on the second furnace board The board then communicates the blower status from one furnace to the other along this wire This communication makes the second furnace blower come on at the same time and on the same speed as the first furnace blower 13 268890 UIM B 0607 Single Wire Twinning Instructions Connect the control wiring as shown in the Figure 14 1 Connect the low voltage wiring from the wall thermostat to the ter minal strip on the contro
95. st only be applied on a common duct system A single air supply plenum must be used for both furnaces and coil s Separate plenums and supply ducts systems cannot be utilized A sin gle return air plenum common to both furnaces must be used Both furnaces must be identical models in both heating capacity and CFM capacity Both furnaces must be operated on the same motor speed tap See typical application Figure 13 If furnace staging is desired with two single stage furnaces on a com mon duct where the gas burner on the first furnace operates on W1 and the gas burner on the second furnace operates on W2 then the use of an air mixing device in the plenum to mix the air from both fur naces is strongly recommended The mixing device must be installed before any ducts that supply air to occupied spaces Twinning causes both indoor fans to operate simultaneously If a mixing device is not used any ducts that are connected down stream from the furnace that operates on W2 will be supplying cold air in the Heating mode to the occupied spaces unless W2 is energized VENT PIPE GAS SUPPLY BOTH SIDES ELECTRICAL SUPPLY 1 COIL FOR EACH FURNACE FIGURE 13 Typical Twinned Furnace Application IMPORTANT When two furnaces are twinned typical system total air flow will be approximately 85 of additive individual furnaces i e two 2000 CFM 56 6 m m units will yield a total 3400 CFM 96 3 m m GAS PIPING Furnace gas supplies mu
96. stem with screws and sealed to prevent leaks Do not shoot screws through the flanges of the supply air duct into the top of the combustible floor base Install the furnace on the combustible floor base so that the corners of the furnace are parallel with the corner brackets of the floor base Follow the instructions supplied with the combustible floor base accessory This combustible floor base can be replaced with a matching cooling coil properly sealed to prevent leaks Follow the instructions supplied with the cooling coil cabinet for installing the cabinet to the duct connec tor Refer to the installation instructions for additional information When replacing an existing furnace if the existing plenum is not the same size as the new furnace then the existing plenum must be removed and a new plenum installed that is the proper size for the new furnace Ductwork Installation NOTE When attaching duct flange do not shoot the screw down into the casing Use the formed flange intended for duct flange attachment A proper Heat Loss Gain Calculation should be done on all installations for proper application of equipment From this the ductwork sizing can be calculated ACCA Manual J and D and industry standards are help ful The duct system is a very important part of the installation If the duct system is improperly sized the furnace will not operate properly The ducts attached to the furnace plenum should be of sufficient size s
97. tails IMPORTANT The cap for the pressure regulator must be removed entirely to gain access to the adjustment screw Loosening or tightening the cap does not adjust the flow of gas 1 Refer to Figure 38 for location of pressure regulator adjustment cap and adjustment screw on main gas valve 2 Turn gas and electrical supplies on and follow the operating instructions to place the unit back in operation 3 Adjust manifold pressure by adjusting gas valve regulator screw for the appropriate gas per the following TABLE 17 Nominal Manifold Pressure NOMINAL MANIFOLD PRESSURE 3 5 w c 0 87 kPa 10 0 w c 2 488 kPa Natural Gas Propane LP Gas OUTLET PRESSURE PORT VENT PORT INLET PRESSURE PORT MAIN REGULATOR ADJUSTMENT ON OFF SWITCH Shown in ON position FIGURE 38 Gas Valve IMPORTANT If gas valve regulator is turned in clockwise manifold pressure is increased If screw is turned out counterclockwise mani fold pressure will decrease 4 After the manifold pressure has been adjusted re calculate the furnace input to make sure you have not exceeded the specified input on the rating plate Refer to CALCULATING THE FURNACE INPUT NATURAL GAS 5 Once the correct BTU kW input has been established turn the gas valve to OFF and turn the electrical supply switch to OFF then remove the flexible tubing and fittings from the gas valve pressure tap and the pressure reference hose from
98. tant to acidic exposure and to at least 225 F temperature Flexible connectors are also allowed in the combustion air pipe 6 All models are supplied with 2 vent connections When the pipe must be increased to 3 diameter the transition from 2 to 3 must be done as close to the furnace as possible For upflow models the transition from 2 to 3 should be done immediately above the furnace For downflow or horizontal models the transition from 2 to 3 pipe should be done immediately after the drain tee or drain elbow 7 n Canada vents shall be certified to ULC S636 Standard for Type BH Gas Venting Systems IPEX System 636 PVC is certified to this standard 8 n Canada the first three feet 900 mm of the vent must be readily accessible for inspection Unitary Products Group 268890 UIM B 0607 TABLE 8 Maximum Equivalent Pipe Length Maximum Equivalent length feet m 60 18 3 18 Model Input BTUH kW Pipe Size Inches cm 40 000 11 7 40 000 11 7 60 000 17 6 60 000 80 000 80 000 23 4 100 000 29 3 100 000 29 3 120 000 29 3 17 6 23 4 N NI Ni c1 Ni oi Ny Ni Oi TABLE 9 Equivalent Length of Fittings 2457 sweep 2 90 standard elbow 10 feet of 2 pipe 2 45 standard elbow 2 1 2 f
99. the authority having jurisdiction provides an adequate supply of air for combustion ventilation and dilution of flue Be sure to instruct the owner not to block this intake pipe SECTION VIII CONDENSATE PIPING Description Vent system Down flow CONDENSATE DRAIN TUBE 5 8 1 59 cm FIGURE 29 Condensate Drain Internal Hose Routing CONDENSATE DRAIN The condensate drain connection is provided in the furnace for field installation It consists of the hoses shown below a NPT male connec tion and a 1 2 1 27 cm female x 3 4 1 9 cm PVC slip coupling Some of the drain hoses will be needed to convert the condensate drain system when the furnace is installed in a horizontal left or right configu ration Refer to Figures 30 36 for the condensate hose sizes for con densate drain connections IMPORTANT The condensate drain from the furnace may be con nected in common with the drain from an air conditioning coil if allowed by local code 22 Before Tee Horizontal RT Drain tube Condensate pan Horizontal drain closer to the front of the furnace both LT amp RT Hoses 2 4 5 along with a barbed nipple and a barbed tee are part of condensate hose assembly 028 151 76 000 028 15197 000 10 DOWNFLOW HORIZONTAL CONDENSATE INTERNAL DRAIN CONFIGURATIONS Downflow Refer to Figure 30 Furnace is shipped with one end of condensate hose 2 left open in the furnace If the pr
100. the right side of the burner box and tighten the pressure tap plug using the 3 32 Allen wrench Replace the burner box front cover if it was removed and place the pressure reference hose back on the gas valve 6 Turn the electrical and gas supplies back on and with the burners in operation check for gas leakage around the gas valve pressure port for leakage using an approved gas detector a non corrosive leak detection fluid or other leak detection methods The manifold pressure must be checked with the screw off cap for the gas valve pressure regulator in place If not the manifold pres sure setting could result in an over fire condition A high manifold pressure will cause an over fire condition which could cause pre mature heat exchanger failure If the manifold pressure is too low sooting and eventual clogging of the heat exchanger could occur Be sure that gas valve regulator 15 in place and burner box to gas valve pressure reference hose is connected Unitary Products Group WITH BURNER BOX COVER IN PLACE BURNER BOX PRESSURE REFERENCE 3 5 IN WATER COLUMN GAS PRESSURE HEB U TUBE MANOMETER FIGURE 39 Reading Gas Pressure USTMENT OF TEMPERATURE RISE The temperature rise or temperature difference between the return air and the supply heated air from the furnace must be within the range shown on the furnace rating plate and within the application limitations shown in T
101. tic installations must meet all minimum clearances to combustibles and have floor support with required service accessibility Unitary Products Group IMPORTANT If an external mounted filter rack is being used see the instructions provided with that accessory for proper hole cut size SECTION 111 FILTERS FILTER INSTALLATION All applications require the use of a filter Replacement filter size is shown in Table 5 TABLE 5 Recommended Filter Sizes Input Output CFM Cabinet BTU H kW m3 min Size 40 11 7 1200 34 0 17 8 0 23 4 0 Top Return Filter in cm 2 14 x 20 36 x 51 14 x 20 36 x 51 14 20 36 51 100 ee 14 x 20 6 51 ran as 29197 i sexes Goss NOTES 1 Air velocity through throwaway type filters may not exceed 300 feet per minute All velocities over this require the use of high velocity fil ters 29 3 14 x 20 86 x 51 254 268890 UIM B 0607 Downflow Filters Downflow furnaces typically are installed with the filters located above the furnace extending into the return air plenum or duct Any branch duct rectangular or round duct attached to the plenum must attach to the vertical plenum above the filter height Filters s may be located in the duct system external to the furnace using an external duct filter box attached to the furnace plenum or at the end of the duct in a return filter grille s The use of stra
102. tions for a special venting system IMPORTANT Consideration must be given for degradation of building materials by flue gases Sidewall termination may require sealing or shielding of building surfaces with a corrosion resistant material to protect against combustion product corrosion Consideration must be given to wind direction in order to prevent flue products and or condensate from being blown against the building surfaces If a metal shield is used it must be a stainless steel material at a minimum dimension of 20 inches It is rec ommended that a retaining type collar be used that is attached to the building surface to prevent movement of the vent pipe Responsibility for the provision of proper adequate venting and air supply for application shall rest with the installer Vent shall extend high enough above building or a neighboring obstruction so that wind from any direction will not create a positive pressure in the vicinity of the vent Unitary Products Group 17 268890 UIM B 0607 VENT SYSTEM This furnace is certified to be installed with one of two possible vent configurations 1 Horizontal vent system This vent system can be installed com pletely horizontal or combinations of horizontal vertical or offset using elbows Vertical vent system This vent system can be installed completely vertical or a combination of horizontal vertical or offset using elbows HORIZONTAL VENT APPLICATIONS AND TERMINATION When sel
103. train relief to thermostat wires passing through cabinet If air conditioning equipment is installed use thermo stat wiring to connect the Y and C terminals on the furnace control board to the yellow and brown wires on the condensing unit unit out side Refer to Figure 11 IMPORTANT Set the heat anticipator in the room thermostat to 0 45 amps Setting it lower will cause short cycles Setting it higher will cause the room temperature to exceed the set points Some electronic thermo stats do not have adjustable heat anticipators They may have other type cycle rate adjustments Follow the thermostat manufacturer s instructions The 24 volt 40 VA transformer is sized for the furnace components only and should not be connected to power auxiliary devices such as humidifiers air cleaners etc The transformer may provide power for an air conditioning unit contactor For additional connection diagrams for all UPG equipment refer to Low Voltage System Wiring document available online at www upgnet com in the Product Catalog Section 11 dung 01195 eq snu sN sowy Jo 6 deis 168H 01195 15 sN 5 10 deis 1967 14677 1009 ul 1009 ul 5 1eoH 1514 M INC 1eeH eDeis 1514 1eoH
104. uct and to the base of the furnace The transi tion duct must have insulation between the transition duct and any com bustible material Unitary Products Group The transition duct must be the same dimensional size as the rectangu lar opening in the base of the furnace DOWNFLOW 4 FURNACE WARM AIR PLENUM WITH 4 FLANGES FIBERGLASS INSULATION FIBERGLASS TAPE UNDER FLANGE _ COMBUSTIBLE FLOOR BASE ACCESSORY FIGURE 1 Combustible Floor Base Accessory AWARNING The supply air temperature MUST NEVER exceed the Maximum Supply Air Temperature specified on the nameplate Operating the furnace above the maximum supply air temperature will cause the heat exchanger to overheat causing premature heat exchanger failure Improper duct sizing dirty air filters incorrect manifold pressure incorrect gas orifice and or a faulty limit switch can cause the furnace to operate above the maximum supply air temperature Refer to sections ll IX amp X for additional informa tion on correcting the problem 268890 UIM B 0607 Downflow Air Conditioning Coil Cabinet The Cooling Coil Cabinet can be used in place of the combustible floor base for downflow installations on combustible materials The furnace should be installed with the cooling coil cabinet specifically intended for downflow applications The cooling coil cabinet must be secured to the floor A supply air duct plenum is installed through t
105. uilding safety codes and requirements local plumbing or wastewater codes and other applicable codes In the absence of local codes install in accordance with the National Fuel Gas Code ANSI Z223 1 NFPA 54 National Fuel Gas Code and or CAN CGA B149 1 Natural Gas and Propane Installation Code latest editions Furnaces have been certified to the latest edition of standard ANSI Z21 47 CSA 2 3 Refer to the unit rating plate for the furnace model number and then see the dimensions page of this instruction for return air ple num dimensions in Figure 3 The plenum must be installed according to the instructions Provide clearances from combustible materials as listed under Clearances to Combustibles in Table 1 Provide clearances for servicing ensuring that service access is allowed for both the burners and blower These models ARE NOT CSA listed or approved for installation into a HUD Approved Modular Home or a Manufactured Mobile Home This furnace is not approved for installation in trailers or recre ational vehicles Failure to carefully read and follow all instructions in this manual can result in furnace malfunction death personal injury and or property damage Furnaces for installation on combustible flooring shall not be installed directly on carpeting tile or other combustible material other than wood flooring Check the rating plate and power supply to be sure that the elec trical characteristics match All models u
106. uration 24 Electrical dca eoo 14 Horizontal Left Condensate Drain Hose Configuration 25 Thermostat Chart 12 Horizontal Right Condensate Drain Hose Configuration Accessory Connections 13 Option 1 Front of Casing 27 Typical Twinned Furnace Application 13 Horizontal Right Condensate Drain Hose Configuration Single Stage Twinning Wiring Diagram 14 Option 1 Front of Casing 28 Two Stage Twinning Wiring Diagram 14 Horizontal Right Condensate Drain Hose Configuration DIMENSIONS 16 Option 2 Back of Casing 29 Home E3yOllE 4 add Gs eens 17 Horizontal Right Condensate Drain Hose Configuration Downflow Horizontal Vent Assembly 18 Option 2 Back of Casing 30 Termination Configuration 1 Pipe 18 Pressure Switch Tubing Routing 31 Termination Configuration 2 Pipe 18 AS VON See ns Sey ee 34 Termination Configuration 2 Pipe Horizontal 18 Reading Gas Pressure 35 Crawl Space Terminati
107. used The use of an approved flexible duct connector is recommended on all installations This connection should be sealed to prevent air leakage The sheet metal should be crosshatched to eliminate any popping of the sheet metal when the indoor fan is energized On all installations without a coil a removable access panel is recommended in the outlet duct such that smoke or reflected light would be observable inside the casing to indicate the presence of leaks in the heat exchanger This access cover shall be attached in such a manner as to prevent leaks Unitary Products Group T STAT WIRING 7 8 K O HORIZONTAL m DRAIN OPENING 1 3 4 HORIZONTAL ale DRAIN OPENING 2 JUNCTION EON HOLE 7 8 GAS PIPE ENTRY 1 CONDENSATE DRAI HOLE 7 8 SIDE PIPING HOLE 3 3 8 lt 28 1 2 LEFT SIDE NS d 19 1 4 SUPPLY END FIGURE 3 Dimensions TABLE 4 Cabinet and Duct Dimensions BTUH kW Input Output 40 37 11 7 10 8 1200 34 0 60 56 17 6 16 4 1200 34 0 amer 1600 45 3 n 7795 sms 1600 a 3 21 28278 299868 Cabinet 14 1 2 17 1 2 268890 UIM B 0607 T STAT WIRING 7 8 K O HORIZONTAL CONDENSATE DRAIN OPENING 1 3 4 HORIZONTAL CONDENSATE DRAIN OPENING 1 3 4 JUNCTION BOX HOLE 7 8 GAS PIPE ENTRY 1 1 2 CONDENSATE DRAIN HOLE 7 8 RIGHT SIDE 23 1 4 TOP IMAGE RETU
108. ust be given con sideration in calculating free area If the free area of a specific louver or grille is not known refer to Table 12 to estimate free area TABLE 12 Estimated Free Area Wood or Metal Louvers or Grilles Wood 20 25 Metal 60 70 1 4 0 635 cm mesh or larger 100 Screens Do not use less than 1 4 0 635 cm mesh Free area or louvers and grilles varies widely the installer should follow lou ver or grilles manufacturer s instructions Dampers Louvers and Grilles Canada Only 1 The free area of a supply air opening shall be calculated by sub tracting the blockage area of all fixed louvers grilles or screens from the gross area of the opening 2 Apertures in a fixed louver a grilles or screen shall have no dimension smaller than 0 25 0 64 cm 3 A manually operated damper or manually adjustable louvers are not permitted for use 4 A automatically operated damper or automatically adjustable lou vers shall be interlocked so that the main burner cannot operate unless either the damper or the louver is in the fully open position TABLE 13 Free Area Outdoor Air Minimum Free Area Required for Each Opening Vertical Duct or Round Duct Opening to Outside 4 000 4 000 BTUH BTUH 20 sq in 129 cm 30 sq in 194 cm 15 sq in 97 cm 5 13 cm 40 sq in 258 cm 13 50 sq in 323 cm 15 60 sq in 387 cm 7 18 cm EXAMPLE Determining Fre
109. xposure The furnace will require OUTDOOR AIR for combustion when the fur nace is located in an area where the furnace is being exposed to the fol lowing substances and or chemicals Permanent wave solutions Chlorinated waxes and cleaners Chlorine based swimming pool chemicals Water softening chemicals De icing salts or chemicals Carbon tetrachloride Halogen type refrigerants Cleaning solvents such as perchloroethylene Printing inks paint removers varnishes etc Hydrochloric acid Cements and glues Antistatic fabric softeners for clothes dryers Masonry acid washing materials When outdoor air is used for combustion the combustion air intake pipe termination must be located external to the building and in an area where there will be no exposure to the substances listed above Unitary Products Group The furnace area must not be used as a broom closet or for any other storage purposes as a fire hazard may be created Never store items such as the following on near or in contact with the fur nace 1 Spray or aerosol cans rags brooms dust mops vacuum cleaners or other cleaning tools Soap powders bleaches waxes or other cleaning com pounds plastic items or containers gasoline kerosene ciga rette lighter fluid dry cleaning fluids or other volatile fluid Paint thinners and other painting compounds Paper bags boxes or other paper products Never operate the furnace with the blower door removed T

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