York D3HH 180 Installation manual

INSTALLATION MANUAL
HIGH EFFICIENCY
TUBULAR HEAT EXCHANGER SERIES
EFFICIENCY
RATING
CERTIFIED
MODELS: 91% GF9 / GM9 / GY9 (Downflow/Horizontal)
60 - 120 MBH INPUT
(17.58 - 35.17 KW) INPUT
This product was manufactured
in a plant whose quality system
is certified/registered as being
in conformity with ISO 9001.
TABLE OF CONTENTS
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TWINNING AND STAGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
COMBUSTION AIR AND VENT SYSTEM . . . . . . . . . . . . . . . . . . . . .12
CONDENSATE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
CONDENSATE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . .22
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
LIST OF FIGURES
Transition Kit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Accessory Downflow Filter Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Return Filter Grill and Return Duct Installation . . . . . . . . . . . . . . . . . . . 7
Typical Attic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Typical Suspended Furnace / Crawl Space Installation . . . . . . . . . . . . 8
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Polarity Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Heating and Cooling Thermostat Connections . . . . . . . . . . . . . . . . . 10
Accessory Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Typical Twinned Furnace Application . . . . . . . . . . . . . . . . . . . . . . . . 11
Single Stage Twinning Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . 12
Two-Stage Twinning Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 12
Home Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Downflow/Horizontal Vent Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 15
External Horizontal Vent Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Termination Configuration - 1 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Termination Configuration - 2 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Termination Configuration - 2 Pipe Horizontal . . . . . . . . . . . . . . . . . .16
Crawl Space Termination Configuration - 2Pipe . . . . . . . . . . . . . . . . .16
Double Horizontal Sealed Combustion Air and Vent Termination . . .16
Double Vertical Sealed Combustion Air and Vent Termination . . . . .16
Sealed Combustion Air Intake Connection and Vent Connection . . .17
Combustion Airflow Path Through The Furnace Casing
to the Burner Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Outside and Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . .18
Attic Combustion Air Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Condensate Drain Internal Hose Routing . . . . . . . . . . . . . . . . . . . . . .19
Downflow Condensate Drain Hose Configuration . . . . . . . . . . . . . . .19
Horizontal Left Condensate Drain Hose Configuration . . . . . . . . . . . .20
Horizontal Right Condensate Drain Hose Configuration . . . . . . . . . .21
Pressure Switch Tubing Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Typical Heat/Cool Speed Tap Connections . . . . . . . . . . . . . . . . . . . .25
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
LIST OF TABLES
Unit Clearances to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Minimum Duct Sizing For Proper Airflow . . . . . . . . . . . . . . . . . . . . . . . 4
Round Duct Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Filter Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
HIigh Alititude Pressure Switch Application . . . . . . . . . . . . . . . . . . . . . 9
High Altitude Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical and Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Combustion Air Intake and Vent Connection Size at Furnace
(All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Combustion Air Supply and Vent Piping . . . . . . . . . . . . . . . . . . . . . . .13
Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Unconfined Space Minimum Area in Square Inch . . . . . . . . . . . . . . .17
Condensate Drain Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Blower Performance CFM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Filter Performance - Pressure Drop Inches W.C. and (kPa) . . . . . . . .26
SECTION I: SAFETY
This is a safety alert symbol. When you see this symbol on
labels or in manuals, be alert to the potential for personal
injury.
Understand and pay particular attention to the signal words DANGER,
WARNING, or CAUTION.
DANGER indicates an imminently hazardous situation, which, if not
avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation, which, if not
avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation, which, if not
avoided may result in minor or moderate injury. It is also used to
alert against unsafe practices and hazards involving only property damage.
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 maintenance can cause injury or property damage. Refer to this manual
for assistance or for additional information, consult a qualified contractor, installer or service agency.
This product must be installed in strict compliance with the installation instructions and any applicable local, state, and national codes
including, but not limited to building, electrical, and mechanical
codes.
035-19939-002 Rev. B (0904)
035-19939-002 Rev. B (0904)
SPECIFIC SAFETY RULES AND PRECAUTIONS
1.
Only Natural gas or Propane (LP) gas are approved for use with
this furnace. Refer to the furnace rating plate or Section IV of
these instructions.
2.
Install this furnace only in a location and position as specified in
SECTION I of these instructions.
3.
A gas-fired furnace for installation in a residential garage must be
installed as specified in SECTION I of these instructions.
4.
Provide adequate combustion and ventilation air to the furnace
space as specified in SECTION VII of these instructions.
5.
Combustion products must be discharged outdoors. Connect this
furnace to an approved vent system only, as specified in SECTION 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 property damage, personal injury or loss of life.
6.
Tests for gas leaks as specified in SECTION XI of these instructions.
7.
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.
8.
When a furnace is installed so that supply ducts carry air circulated
by the furnace to areas outside the space containing the furnace,
the return air shall also be handled by duct(s) sealed to the furnace casing and terminating outside the space containing the furnace.
9.
The furnace is not to be used for temporary heating of buildings or
structures under construction.
10. When installed in a Non-HUD-Approved Modular Home or building
constructed on-site, combustion air shall not be supplied from
occupied spaces.
11. 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
•
•
•
•
2
This furnace should be installed in accordance with all national
and local building/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 plenum dimensions in Figure 1. The plenum must be installed
according to the instructions.
Provide clearances from combustible materials as listed under
Clearances to Combustibles.
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 recreational 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 electrical characteristics match. All models use nominal 115 VAC, 1
Phase, 60-Hertz power supply. DO NOT CONNECT THIS APPLIANCE TO A 50 HZ POWER SUPPLY OR A VOLTAGE ABOVE
130 VOLTS.
Furnace shall be installed so the electrical components are protected 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 precautions 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 furnace 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 Exposure
The furnace will require OUTDOOR AIR for combustion when the furnace is located in an area where the furnace is being exposed to the following 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
035-19939-002 Rev. B (0904)
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 furnace.
1. Spray or aerosol cans, rags, brooms, dust mops, vacuum
cleaners or other cleaning tools.
2. Soap powders, bleaches, waxes or other cleaning compounds; plastic items or containers; gasoline, kerosene, cigarette lighter fluid, dry cleaning fluids or other volatile fluid.
3. Paint thinners and other painting compounds.
4. Paper bags, boxes or other paper products
Never operate the furnace with the blower door removed. To
do so could result in serious personal injury and/or equipment
damage.
INSPECTION
As soon as a unit is received, it should be inspected for possible damage 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.
2.
3.
4.
5.
6.
Where a minimum amount of air intake/vent piping and elbows will
be required.
As centralized with the air distribution as possible.
Where adequate combustion air will be available (particularly
when the appliance is not using outdoor combustion air).
Where it will not interfere with proper air circulation in the confined
space.
Where the outdoor combustion air/vent terminal will not be blocked
or restricted. Refer to “COMBUSTION AIR / VENT CLEARANCES” located in SECTION VII of these instructions. These minimum clearances must be maintained in the installation.
Where the unit will be installed in a level position with no more
than 1/4” (6.4 mm) slope side-to-side and front-to-back to provide
proper condensate drainage.
Improper installation in an ambient below 32ºF (0.0° C) could create
a hazard, resulting in damage, injury or death.
3.
If this furnace is installed in any area where the ambient temperature 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 manufacturer'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 condensate 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 recommended:
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 clearances for combustible materials where accessibility clearances are
greater.
Downflow/Horizontal furnaces for installation on combustible flooring 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 electrical characteristics match. All models use nominal 115 VAC, 1
Phase 60Hz power supply.
Furnace shall be installed so the electrical components are protected from water.
Installation in freezing temperatures:
Installation in a residential garage:
1.
Furnace shall be installed in an area where ventilation facilities
provide for safe limits of ambient temperature under normal operating conditions. Ambient temperatures must not fall below 32°F
(0°C) unless the condensate system is protected from freezing.
1.
2.
Do not allow return air temperature to be below 55º 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, leading to premature heat exchanger failure.
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
TOP
FRONT
REAR
LEFT SIDE RIGHT SIDE
FLUE
APPLICATION
In. (mm) In. (mm) In. (mm)
DOWNFLOW
HORIZONTAL
1 (25.4)
1 (25.4)
FLOOR/
BOTTOM
In. (mm)
In. (mm)
In. (mm)
In. (mm)
CLOSET ALCOVE ATTIC
LINE
CONTACT
3 (76.2
0 (0)
0 (0)
0 (0)
0 (0)
1 (25.4)1
YES
YES
YES
NO
3 (76.2
(0)2
2
0 (0)
0 (0)
1 (25.4)
NO
YES
YES
YES3
0
0 (0)
1. Combustible floor base or air conditioning coil required for use on combustible floor.
2. Minimum of 8” clearance required to install condensate removal system.
3. Line contact only premitted between lines formed by the intersection of the rear panel (top in horizontal position) of the furnace jacket and building joists, studs or framing.
Unitary Products Group
3
035-19939-002 Rev. B (0904)
SECTION II: DUCTWORK
DUCTWORK GENERAL INFORMATION
The duct system’s design and installation must:
1.
Handle an air volume appropriate for the served space and within
the operating parameters of the furnace specifications.
2.
Be 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.
4.
Create a closed duct system. For residential and Non-HUD Modular Home installations, when a furnace is installed so that the supply 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.
Complete a path for heated or cooled air to circulate through the
air conditioning and heating equipment and to and from the conditioned space.
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
so that the furnace 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 furnace operation.
Use the Example below to help you in calculating the duct area to determine whether the ducts have sufficient area so that the furnace operates at the specified external static pressure and within the air
temperature rise specified on the nameplate.
Example: The furnace input is 80,000 BTUH, 1,200 CFM. The recommended duct area is 280 sq.in, there are two 8 x 14 rectangular ducts
attached to the plenum and there are two 7 inch round ducts attached to
the furnace.
1.
Take 8 x 14, which equals 112 sq.in. X 2, which equals 224 square
inch then go to round duct size located in Table 3.
2.
The square inch area for 7 inch round pipe is 38.5, multiply by 2 for
two round ducts which equals 76.9 square inch,
3.
Then take the 224 square inch from the rectangular duct and add it
to the 76.8 sq.in. of round duct. The total square inch of duct
attached to the furnace plenum is 300.9 square inch. This exceeds
the recommended 280 square inch of duct.
The cooling coil must be installed in the supply air duct, downstream of the furnace. Cooled 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 prevent 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 pressures 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.
In this example, the duct system attached to the plenum has a sufficient
area so that the furnace operates at the specified external static pressure and within the air temperature rise specified on the nameplate.
TABLE 2: Minimum Duct Sizing For Proper Airflow
Input Airflow Return1 Rectangular2 Round2 Supply3 Rectangular2 Round2
BTU/H
(kW)
In²
(cm²)
in. x in.
(cm x cm)
in. (cm)
dia.
In²
(cm²)
in. x in.
(cm x cm)
in. (cm)
dia.
60000 1,200
(17.58) (33.98)
280
(711)
14 x 20
(35.6 x 50.8)
18
(45.7)
216
(549)
12 x 18
(30.5 x 45.7)
16
(40.6)
80000 1,200
(23.44) (33.98)
280
(711)
14 x 20
(35.6 x 50.8)
18
(45.7)
216
(549)
12 x 18
(30.5 x 45.7)
16
(40.6)
80000 1,600
(23.44) (45.31)
360
(914)
18 x 20
(45.7 x 50.8)
22
(55.8)
280
(711)
14 x 20
(35.6 x 50.8)
18
(45.7)
100000 2,000
440
20 x 22
(29.31) (56.63) (1,118) (50.8 x 55.8)
24
(60.9)
390
(991)
16 x 22
(40.6 x 55.8)
22 (
55.8)
120000 2,000
440
20 x 22
(35.17) (56.63) (1,118) (50.8 x 55.8)
24
(60.9)
390
(991)
16 x 22
(40.6 x 55.8)
22
(55.8)
NOTE: This chart does not replace proper duct sizing calcualtions or take into account static pressure drop for run length and fittings. Watch out for the temperature rise and static pressures.
1. Maximum return air velocity in rigid duct @ 700 feet per minute (19.82 m3 / minute).
2. Example return main trunk duct minimum dimensions.
3. Maximum supply air velocity in rigid duct @ 900 feet per minute (25.49 m3 / minute).
FLOOR BASE AND DUCTWORK INSTALLATION
Downflow Combustible Floor Base
Installations on combustible materials require the use a
combustible 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 system 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 connector. 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.
4
CFM
(m³)
TABLE 3: Round Duct Size
Round Duct Size
Calculated Area For Each Round Duct Size
inches (cm)
Sq.in (cm2)
19.6 (126)
28.2 (182)
38.4 (248)
50.2 (324)
63.6 (410)
78.5 (506)
95 (613)
113.1 (730)
132.7 (856)
153.9 (993)
5 (13)
6 (15)
7 (18)
8 (20)
9 (23)
10 (25)
11 (28)
12 (30)
13 (33)
14 (36)
1.
2.
The Air Temperature Rise is determined by subtracting the Return
Air Temperature Reading from the Supply Air Temperature Reading.
The External Static Pressure is determined by adding the Supply
Duct Static Pressure reading to the Return Duct Static Pressure
reading.
Unitary Products Group
035-19939-002 Rev. B (0904)
TABLES 2 AND 3 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 building, Refer to the ASHRAE Fundamentals Handbook, Chapter on
“DUCT DESIGN” or a company that specializes in Residential and Modular 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 duct and to the base of the furnace. The transition duct must have insulation between the transition duct and any combustible material.
The transition duct must be the same dimensional size as the rectangular opening in the base of the furnace.
•
If the transition kit has been installed on the cooling coil cabinet it
must be secured to the cooling coil cabinet with screws. The supply air side of the furnace is then placed on the cooling coil cabinet and then sealed for leaks.
• If the transition kit has been installed on the supply air side of the
furnace it must be secured to the furnace with screws. The furnace and the transition kit are then placed on the cooling coil cabinet 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 the cooling coil cabinet
MUST BE SEALED as needed to prevent leaks, AND SECURED. Refer
to the assembly drawing in Figures 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.
AIRFLOW
DOWNFLOW
FURNACE
WARM AIR PLENUM
WITH 1” FLANGES
DOWNFLOW
FURNACE
FIBERGLASS
INSULATION
FIBERGLASS TAPE
UNDER FLANGE
COMBUSTIBLE FLOOR
BASE ACCESSORY
TRANSITION
KIT
AIRFLOW
AIRFLOW
COOLIMG
COIL
CABINET
TRANSITION
KIT
REFRIGERANT
LINES
DRAIN
CONNECTIONS
AIRFLOW
FIGURE 2: Transition Kit Assembly
FIGURE 1 : Combustible Floor Base Accessory
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 II, III and XI for additional information on correcting the problem.
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 the opening provided. 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 transition kit and sealed to prevent leakage. The transition kit must be used to
secure the cooling coil cabinet to the furnace casing when installed in a
downflow configuration.
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.
Unitary Products Group
Horizontal Models
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 cabinet 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 popping 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.
5
035-19939-002 Rev. B (0904)
Horizontal Installations Without a Cooling Coil Cabinet
Attach the supply plenum to the furnace 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.
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.
When installing this appliance, the furnace must be installed so as to
create a closed duct system, the supply duct system must be connected 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.
28-1/2
26-1/2
21-5/8
26-1/2
21-15/16
A
T’STAT WIRING
7/8” K.O.
T’STAT WIRING
7/8” K.O.
HORIZONTAL
CONDENSATE
DRAIN 2” K.O.
40
29
7/8” JUNCTION
BOX HOLE
7/8” JUNCTION
BOX HOLE
21-9/16
18-1/2
1-1/2” GAS
PIPE ENTRY
HORIZONTAL
CONDENSATE
DRAIN 2” K.O.
29
18-1/2
1-1/2” GAS
PIPE ENTRY
21-7/8
CONDENSATE
DRAIN 7/8” K.O.
11-11/16
7-1/2
CONDENSATE
DRAIN 7/8” K.O.
9-1/8
8-1/2
24-5/8
25-3/8
23-5/8
5/8
19-1/4
1-1/4
1-1/4
5/8
D
B
C
20
2-1/4
23-1/4
BOTTOM IMAGE
RETURN END
TOP IMAGE
SUPPLY END
FIGURE 3: Dimensions
BTUH (kW)
Input/Output
CFM
Cabinet
Size
60/55 (17.57/16.10)
80/75 (23.42/21.96)
80/75 (23.42/21.96)
100/95 (29.28/27.82)
100/95 (29.28/27.82)
120/112 (35.14/32.80)
1200 (33.98)
1200 (33.98)
1600 (45.31)
1600 (45.31)
2000 (56.63)
2000 (56.63)
B
B
C
C
C
D
Cabinet Dimension
A (in.)
17-1/2
17-1/2
21
21
21
24-1/2
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 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 return plenum to the furnace inlet duct flanges. This is typically 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
6
A (cm)
44.4
44.4
53.3
53.3
53.3
62.2
B (in.)
16-1/4
16-1/4
19-3/4
19-3/4
19-3/4
23-1/4
B (cm)
41.3
41.3
50.2
50.2
50.2
59.1
C (in.)
15-1/8
15-1/8
18-1/2
18-1/2
18-1/2
21-7/8
C (cm)
38.4
38.4
47.0
47.0
47.0
55.6
D (in.)
1-3/4
1-3/4
2-1/8
2-1/8
2-1/8
2-1/2
D (cm)
4.44
4.44
5.40
5.40
5.40
6.35
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 furnace operates at the specified external static pressure and within the air
temperature rise specified on the nameplate.
Attic installations must meet all minimum clearances to combustibles
and have floor support with required service accessibility.
IMPORTANT: If an external mounted filter rack is being used see the
instructions provided with that accessory for proper hole cut size.
Unitary Products Group
035-19939-002 Rev. B (0904)
SECTION III: FILTERS
FILTER INSTALLATION
All applications require the use of a filter. A high velocity filter and a side
return filter rack are provided for field installation on GM9 and GY9
models. GF9 models must have a field-supplied filter and mounting
hardware. A field supplied side return filter rack and filter are available
through Source 1 using 1 SF0101. Replacement filter size is shown in
Table 4.
TABLE 4: Filter Sizes
CFM
Input / Output
BTU/H (kW)
60/55 (17.57/16.10)
80/75 (23.42/21.96)
80/75 (23.42/21.96)
100/95 (29.28/27.82)
100/95 (29.28/27.82)
120/112 (35.14/32.80)
(m3/min)
1200 (34)
1200 (34)
1600 (45)
1600 (45)
2000 (57)
2000 (57)
Cabinet
Size
Top Return
Filter in(cm)
B
B
C
C
C
D
(2) 14 x 20 (36 x 51)
(2) 14 x 20 (36 x 51)
(2) 14 x 20 (36 x 51)
(2) 14 x 20 (36 x 51)
(2) 20 x 20 (51 x 51)
(2) 20 x 20 (51 x 51)
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 operate within the specified rise range then a larger air filter or an air filter
that has a lower pressure drop must be installed. Refer to Figures 4, 5
and furnace accessories for accessory external filter kit options.
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 above the furnace.
CLOSET
COMBUSTION
AIR
FILTER RACK
(factory supplied with some furnaces)
VENT
PIPE
RACK AND FILTERS SECURED
INSIDE BLOWER SECTION
FOR SHIPMENT
FIGURE 5: Return Filter Grill and Return Duct Installation
FILTER
RACK
DUCTWORK
GAS SUPPLY
(EITHER SIDE)
BRANCH
DUCTS
FILTERS
Accessory External Filter Installation
FH
1.
Install the return filter rack on the top of the furnace return air
opening. Secure the filter rack to the front and back flanges with
screws. The return air plenum can be placed over the filter rack
and the branch ducts (rectangular ducts and / or round ducts) can
be attached to the plenum. Route the combustion air and the vent
PVC pipes around the access panels for the filters.
2.
Install the filter(s) provided or you may install Permanent washable
filters. Filter should extend through the entire length of the filter
rack to prevent air from bypassing the filter. Make sure that any air
filter that is installed in the furnace does not cause an excessive
amount of pressure drop. Refer to Table 16 for air filter performance and pressure drops.
CROSS SECTION A-A
(with Plenum and filters)
FIGURE 4: Accessory Downflow Filter Rack
Downflow Filters
A top return filter rack is supplied with the furnace. Two standard filters
are supplied with some units. 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.
Refer to Figure 4 for proper installation.
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 straps and / or supports is required to support the weight of the external filter box. Refer to
Figure 5.
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 is installed so it does not obstruct the return airflow. Consideration 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 electronic 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.
Unitary Products Group
AIR
FILTERS
ELECTRICAL
SUPPLY
CASING SIZE DIMENSION FH
16-1/4”
12-3/4”
22-1/4”
11”
26-1/4”
8-1/4”
NOTE: FILTER ACCESS THROUGH
DUCTWORK MUST BE PROVIDED
FOR REMOVAL AND CLEANING
RETURN
AIR
IMPORTANT: Air velocity through throwaway type filters must not
exceed 300 feet per minute (1.52 m/m). All velocities over this require
the use of high velocity filters. Refer to Table 16.
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. Filters must be a minimum distance of 18” (45.8 cm) from the furnace. Any branch duct (rectangular 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. Refer to Figure 4 and the instructions supplied with the furnace accessory external filter kit options.
7
035-19939-002 Rev. B (0904)
ATTIC INSTALLATION
LINE CONTACT ONLY PERMISSIBLE
BETWEEN LINES FORMED BY THE
INTERSECTION OF FURNACE TOP
AND TWO SIDES AND BUILDING
COMBUSTION
JOISTS, STUDS OR FRAMING
AIR
FILTER RACK MUST BE A
MINIMUM DISTANCE
OF 18” (45.7 cm)
FROM THE FURANCE
GAS
PIPING
SECTION IV: GAS PIPING
GAS SAFETY
RETURN
AIR
SUPPLY
AIR
12” CLEARANCE
FOR SERVICE
In any application where temperatures below freezing are possible,
see “BELOW FREEZING LOCATIONS”.
VENT PIPE
(maintain required
clearances to
combustible)
30” MIN.
WORK AREA
FIGURE 6: Typical Attic Installation
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 exceeding
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.
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.
OUTLET
PRESSURE
PORT
INLET
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 "CONDENSATE PIPING" section of this manual for more information.
When a furnace is 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.
VENT PORT
OUTLET
WRENCH
BOSS
INLET
PRESSURE
PORT
FF
O
N
O
ON/OFF SWITCH
(Shown in ON position)
MAIN REGULATOR
ADJUSTMENT
FIGURE 8: Gas Valve
IMPORTANT: Plan your gas supply before determining the correct gas
pipe entry. Use 90-degree service elbow(s), or short nipples and conventional 90-degree elbow(s) to enter through the cabinet access holes.
CHECKING THE GAS PRESSURES
1.
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 suspension points must be level to ensure quite furnace operation. When
suspending the furnace use a secure a platform constructed of plywood
or other building material secured to the floor joists. Refer top Figure 7
for typical crawl space installation.
SUPPORT
BRACKET
ANGLE IRON
BRACKET
1” MAX. BETWEEN
ROD & FURNACE
6” MIN. BETWEEN
ROD & FURNACE
1” MAX. BETWEEN
ROD & FURNACE
2.
3.
4.
5.
6.
The pressure ports on the gas valve are marked OUT P and IN
P.
The manifold pressure must be taken at the port marked OUT P.
The inlet gas supply pressure must be taken at the port marked
IN P.
Using a 3/32” (0.2 cm) Allen wrench, loosen the set screw by
turning it 1 turn counter clockwise. DO NOT REMOVE THE
SET SCREW FROM THE PRESSURE PORT.
Push one end the 3/8” (0.9 cm) ID flexible tubing over the pressure port so that the body of the port is inside the tubing.
Use a reducer connector to connect the 3/8” (0.9 cm) ID flexible
tube to a 1/4” (0.6 cm) ID flexible tube that is connected to a "U”
tube manometer or digital pressure measuring equipment.
TABLE 5: Inlet Gas Pressure Range
INLET GAS PRESSURE RANGE
Natural Gas
Propane (LP)
Minimum
4.5” W.C. (1.12 kPa)
8.0” W.C. (1.99 kPa)
Maximum
10.5” W.C. (2.61 kPa)
13.0” (3.24 kPa) W.C.
IMPORTANT: The inlet gas pressure operating range table specifies
what the minimum and maximum gas line presures must be for the
furnace to operate safely. The gas line pressure MUST BE
• 7” W.C. (1.74 kPA) for Natural Gas
• 11” W.C. (2.74 kPA) 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.
FIGURE 7: Typical Suspended Furnace / Crawl Space Installation
8
Unitary Products Group
035-19939-002 Rev. B (0904)
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 connector. 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 installation of a drip leg and ground union is required. Refer to Figure 9.
TO GAS
SUPPLY
TO GAS
SUPPLY
MANUAL
SHUT-OFF
VALVE
DRIP
LEG
DRIP
LEG
GAS BURNERS
GAS VALVE
MANUAL
SHUT-OFF VALVE
FIGURE 10: 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 furnace.
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).
The gas valve body is a very thin casting that can take any limited
external force. Never apply a pipe wrench to the body of the gas
valve when installing piping. A wrench must be placed on the octagon 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
operation and/or the valve to leak.
Unitary Products Group
HIGH ALTITUDE GAS ORIFICE CONVERSION
The gas orifices on this furnace must be changed in order to maintain
proper and safe operation, when the furnace is installed in a location
where the altitude is greater than 2,000 ft. (610 m) above sea level on
natural gas or the altitude is greater than 4,000 ft. (1219 m) above sea
level on propane (LP) gas. Refer to Table 7 or the instructions in the
high altitude conversion kit for the proper gas orifice size.
HIGH ALTITUDE PRESSURE SWITCH CONVERSION
FIGURE 9: Downflow Gas Piping
GAS
PIPE
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 factory-supplied LP conversion kit. Follow the instructions supplied with
the LP kit. Refer to Table 6 or the instructions in the propane (LP) conversion kit for the proper gas orifice size.
The unit may also be converted for altitudes up to 10,000 ft. (3048 m)
on natural and propane (LP) gas with additional derate as shown in
Table 6 or refer to ANSI Z223.1 NFPA 54 National Fuel Gas Code or in
Canada CAN/CGA-B149.1-00 Natural Gas and Propane Installation
Code.
GROUNDED JOINT UNION
MAY BE INSTALLED
INSIDE OR OUTSIDE UNIT.
GAS
PIPE
GAS ORIFICE CONVERSION FOR PROPANE (LP)
This furnace is constructed at the factory for natural gas-fired operation
at 0 – 2,000 ft. (0 m – 610 m) above sea level.
EXTERNAL MANUAL
SHUTOFF VALVE
DRIP
LEG
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 2 dimensions.
For installation in locations where the altitude is less than 4,500 feet
(1372 m), it is not required that the pressure switch be changed, provided the maximum vent/intake pipe lengths are adjusted as shown in
Table 9. For altitudes above 4,500 feet (137 m), refer to Instructions in
the Accessory High Altitude Kit.
TABLE 6: HIigh Alititude Pressure Switch Application
Input (MBH)
Upflow Models
Output
(MBH)
4,500 To
10,000 Ft.
60/1200
80/1200
80/1600
100/1600
100/2000
120/2000
55
74
74
93
93
112
1PS0901
1PS0902
1PS0903
1PS0901
1PS0901
1PS0901
TABLE 7: High Altitude Conversion
Type
Of Gas
Orifice at
Sea Level
2,000 ft.
(610 m)
3,000 ft.
(914 m)
4,000 ft.
(1219 m)
Natural
Propane
#45
#55
#46
#55
#47
#55
#47
#55
Type
Of Gas
5,000 ft.
(1524 m)
6,000 ft.
(1829 m)
7,000 ft.
(2134 m)
8,000 ft.
(2438 m)
Natural
Propane
#47
#56
#48
#56
#48
#56
#49
#56
Type
Of Gas
9,000 ft.
(2743 m)
10,000 ft.
(3048 m)
Natural
Propane
#49
#56
#50
#57
9
035-19939-002 Rev. B (0904)
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 propane (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. 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.
SECTION V: ELECTRICAL POWER
TABLE 8: Electrical and Performance Data
Input
MBH
60
80
80
100
100
120
kW
18
23
23
29
29
35
Output
MBH
kW
55
16.1
74
21.7
74
21.7
93
27.3
93
27.3
112
32.8
kW
18
23
23
29
29
35
Max. Outlet
Air Temp.
°F
°C
170
76.7
165
76.7
170
76.7
165
79.4
165
79.4
165
76.7
Input
MBH
60
80
80
100
100
120
Nominal Airflow
CFM
m3/min
1200
34.0
1200
34.0
1600
45.3
1600
45.3
2000
56.6
2000
56.6
Cabinet Width
In.
mm
17-1/2
444
17-1/2
444
21
533
21
533
21
533
24-1/2
622
AFUE
%
91
91
91
91
91
91
Blower
Blower Size
Total Unit
HP
1/2
1/2
3/4
3/4
1
1
Amps
7.0
7.0
10.2
10.2
12.7
12.7
In.
11 x 8
11 x 8
11 x 10
11 x 10
11 x 11
11 x 11
mm
279 x 203
279 x 203
279 x 254
254 x 254
279 x 279
279 x 279
Amps
9
9
12
12
14
14
Air Temp. Rise
°F
°C
40 - 70
22 - 39
35 - 65
19 - 36
40 - 70
22 - 39
35 - 65
19 - 36
35 - 65
19 - 36
35 - 65
19 - 36
Max.
Over-current
Protect
20
20
20
20
20
20
Min. Wire Size
(awg) @ 75 ft.
One Way
14
14
14
14
12
12
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.
* Wire size and overcurrent protection must comply with the National Electric Code.
NOTES:
1. For altitudes above 2000 ft. (609 m) reduce capacity 4% for each 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).
ELECTRICAL POWER CONNECTIONS
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
wire when installed in accordance with instructions. Refer to Table 7 in
these instructions for specific furnace electrical data.
3.
Use copper conductors only.
SUPPLY VOLTAGE CONNECTIONS
1.
2.
10
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 convenience 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 in this instruction.
Remove the screws retaining the wiring 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 junction 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-wiring label on the inside of the blower compartment door or the wiring schematic in this section. 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 method 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. Refer to Figure
10.
The furnace's control system requires correct polarity of the power
supply and a proper ground connection. Refer to Figure 11.
IMPORTANT: The power connection leads and wiring box may be relocated 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 fasten using holes provided.
BLOWER
COMPARTMENT
COMBUSTION
AIR
VENT PIPE
CLASS 2 SYSTEM
CONTROL WIRING
TO THERMOSTAT
IGNITION
MODULE
TRANSFORMER
(BLK) LI (HOT)
(WHT) N
(GRN)GND
JUNCTION
BOX
FIGURE 11: Electrical Wiring
Unitary Products Group
035-19939-002 Rev. B (0904)
LOW VOLTAGE CONTROL WIRING CONNECTIONS
ELECTRONIC AIR CLEANER CONNECTION
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 12. Electronic thermostats may require the common wire to be connected as shown with the
dashed line in Figure 12. Apply strain relief to thermostat wires passing
through cabinet. If air conditioning equipment is installed, use thermostat wiring to connect the Y and C terminals on the furnace control
board to the yellow and brown wires on the condensing unit (unit outside). Refer to Figure 12.
Two 1/4” (0.64 cm) spade terminals (NEUTRAL) for electronic air
cleaner connections are located on the control board. The terminals
provide 115 VAC (1.0 amp maximum) during circulating blower operation.
IMPORTANT: Set the heat anticipator in the room thermostat to 0.10
amps. Setting it lower will cause short cycles. Setting it higher will cause
the room temperature to exceed the set points.
BLK
BLK (HOT)
WHT
WHT (NEUTRAL)
GRN
GRN
NOMINAL
120 VOLT
FIGURE 12: Polarity Wiring Connections
ROOM
THERMOSTAT
R
W
G
Y
C
FURNACE
CONTROL
CONDENSING
UNIT
TO AIR CONDITIONER
CONTROLS
R
W
G
Y
C
COMMON T’STAT CONNECTION
HUMIDIFIER CONNECTION
Two 1/4” (0.64 cm) spade terminals (NEUTRAL) for humidifier 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 control
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 circulating 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 simultaneously.
FIGURE 13: Heating and Cooling Thermostat Connections
IMPORTANT: Some electronic thermostats 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.
ACCESSORY CONNECTIONS
The furnace control will allow power-switching control of various accessories. Refer to Figure 13, for connection details.
115 VOLT
HUMIDIFIER
HUM. HOT
BLK
WHT
EAC SWITCHED
CIRCUITS
HUM
EAC HOT
BLK
115 VOLT
ELECTRONIC WHT
AIR CLEANER
EAC
HUM
FIGURE 14: Accessory Connections
Unitary Products Group
NEUTRALS
Before installing the relay and wiring, disconnect electrical power to
both furnaces. Failure to cut power could result in electrical shock
or equipment damage.
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.
TWINNING DUCT SYSTEM
Twinned furnaces must 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 single return air plenum, common to both furnaces must be used. It is suggested that a return platform be utilized, with bottom air entrance into
each furnace. If a side entrance returns system is used, the common
return duct must be divided equally so as to supply each furnace with
an equal amount of return air.
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 14.
If furnace staging is desired with two single stage furnaces on a common 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 furnaces 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.
11
035-19939-002 Rev. B (0904)
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.
VENT PIPE
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.
COMBUSTION
AIR PIPES
GAS SUPPLY
(BOTH SIDES)
ELECTRICAL
SUPPLY
FURNACE 1 CONTROL BOARD
1 COIL FOR
EACH FURNACE
CO
SU MM
PL PPL ON
EN Y
UM
SUPPLY
AIR
FURNACE 2 CONTROL BOARD
W
W
G
G
C
C
R TWIN
R TWIN
Y
Y
ISOLATION
RELAY
FIGURE 15: Typical Twinned Furnace Application
IMPORTANT: When two furnaces are twinned, typical system total airflow will be approximately 85% of additive individual furnaces, i.e., two
2000 CFM (56.6 m3/m) units will yield a total 3400 CFM (96.3 m3/m).
GAS PIPING
Furnace gas supplies must be provided as specified with these instructions. 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.
Single-Wire Twinning Instructions
Connect the control wiring as shown in the diagram below.
1.
2.
3.
Connect the low voltage wiring from the wall thermostat to the terminal strip on the control board of Furnace #1.
Connect a wire from the TWIN terminal of Furnace #1 to the TWIN
terminal of Furnace #2.
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 furnaces 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.
12
TO A/C
W G
R
Y
WALL THERMOSTAT
FIGURE 16: 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 function of this board ensures that both blowers turn on and off simultaneously, 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 staging 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 communication makes the second furnace blower come on at the same time, and
on the same speed, as the first furnace blower.
Single-Wire Staging Instructions
Connect the control wiring as shown in the Figure 16.
1.
2.
3.
Connect the low voltage wiring from the wall thermostat to the terminal strip on the control board of Furnace #1. For staging applications, 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.
Connect a wire from the TWIN terminal of Furnace #1 to the TWIN
terminal of Furnace #2.
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.
Unitary Products Group
035-19939-002 Rev. B (0904)
Single-Wire Staging Operation
Heating - On a call for first-stage heat (W1 signal) from the wall thermostat, 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 satisfied, 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.
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 subjected to freezing temperatures such as routing through unheated
areas or through an unused chimney.
COMBUSTION AIR/VENT PIPE SIZING
Cooling - On a call for cooling (Y signal) from the wall thermostat, both
furnace blowers will come on at the same time. When the thermostat is
satisfied, both blowers will stay on for 60 seconds, then will shut off at
the same time.
Select the correct size from Table 9. The size will be determined by a
combination of furnace model, total length of run, and the number of
elbows required. The following rules must also be observed.
1.
Long radius (sweep) elbows are required for all units.
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.
2.
Elbows are assumed to be 90 degrees. Two 45-degree elbows
count as one 90-degree elbow.
3.
Elbow count refers to combustion air piping and vent piping separately. For example, if the table allows for 5 elbows, this will allow a
maximum of 5 elbows in the combustion air piping and a maximum
of 5 elbows in the vent piping.
4.
Three vent terminal elbows (two for vent pipe and one for air
intake pipe) are already accounted for as vent termination.
5.
Combustion air and vent piping must be of the same diameter.
6.
All combustion air/vent pipe and fittings must conform to American
National Standards Institute (ANSI) standards and American Society for Testing and Materials (ASTM) standards D1785 (Schedule
40 PVC), D2665 (PVC-DWV), F891 (PVC-DWV Cellular Core).
D2241 (SDR-21 and SDR-26 PVC), D2261 (ABS-DWV), or F628
(Schedule 40 ABS. Pipe cement and primer must conform to
ASTM Standards D2564 (PVC) or D2235 (ABS).
7.
The use of flexible connectors or no hub connectors in the vent
system is not allowed. This type connection is allowed in the combustion air pipe near the furnace for air conditioning coil accessibility.
8.
Sidewall horizontal vent terminals and roof mounted vertical terminals may be field fabricated. Standard PVC/SRD fittings may be
used. Terminal configuration must comply as detailed in this section.
FURNACE 2 CONTROL BOARD
FURNACE 1 CONTROL BOARD
W
W
G
G
C
C
R TWIN
R TWIN
Y
Y
ISOLATION
RELAY
W G
TO A/C
R
Y
W2
WALL THERMOSTAT
FIGURE 17: 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 residential application. It may be installed without modification to the condensate system in a basement, garage, equipment room, alcove, attic
or any other indoor location provided the space temperature is 32 °F
(0°C) 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 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.
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 L vent
or vent connector, and not connected to any portion of a factorybuilt or masonry chimney
The furnace shall not be connected to a chimney flue serving a separate appliance designed to burn solid fuel.
Unitary Products Group
IMPORTANT: For the minimum vent length see Table 10.
For the maximum vent length see Table 10.
TABLE 9: Combustion Air Intake and Vent Connection Size at Furnace
(All Models)
FURNACE VENT CONNECTION SIZES
Furnace Input
40 - 120 MBH
(11.72-35.17 kW)
Intake Pipe Size
2” (5.08 cm)
Vent Pipe Size
2” (5.08 cm)
*. Vent pipe size must be increased to 3” diameter after connection to furnace on this model.
IMPORTANT: Accessory concentric vent / intake termination kits
1CT0302 and 1CT0303 are available and approved for use with these
furnaces.
IMPORTANT: Furnace vent pipe connections are sized for 2” (5.08 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 45º (degree) elbows will be required for plenum clearance
when the vent is increased to 3” (7.62 cm).
13
035-19939-002 Rev. B (0904)
TABLE 10: Combustion Air Supply and Vent Piping
MAXIMUM ELBOWS AND VENT LENGTHS
Models Input
BTUH (kW)
60,000 (17.6)
60,000 (17.6)
60,000 (17.6)
80,000 (23.4)/1200
80,000 (23.4)/1200
80,000 (23.4)/1600
80,000 (23.4)/1600
100,000 (29.3)
100,000 (29.3)
120,000 (35.1)
Pipe Size
Inches (mm)
1-1/2 (38)
2 (51)
3 (76)
2 (51)
3 (76)
2 (51)
3 (76)
2 (51)
3 (76)
3 (76)
1
15
60
85
60
85
60
85
25
80
55
2
10
55
80
55
80
55
80
20
75
50
Maximum Number of Elbows*
3
4
5
6
N/A
N/A
N/A
N/A
50
45
40
35
75
70
65
60
50
45
40
35
75
70
65
60
50
45
40
35
75
70
65
60
15
10
N/A
N/A
70
65
60
55
45
40
35
25
7
N/A
25
50
25
50
25
50
N/A
45
15
8
N/A
15
40
15
40
15
40
N/A
35
N/A
Minimum
Length
1.5
1.5
10
1.5
10
1.5
10
1.5
1.5
1.5
*. Elbow count does not include the elbows required for the termination. See Step 4 under Combustion Air/Vent Pipe Sizing.
NOTE: NOTE: If installing furnace at altitudes between 2000 - 4500 ft.,
(1609.6 - 1371.6 m) intake and vent pipe length must be
reduced by 10 ft. (3.05 m) If the installation requires the maximum allowable intake and vent pipe length, the furnace must be
converted for high altitude operation.
COMBUSTION AIR AND VENT PIPING ASSEMBLY
The final assembly procedure for the combustion air and vent piping is
as follows:
1.
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.
Cut piping to the proper length beginning at the furnace.
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.
2.
Deburr the piping inside and outside.
7.
All joints must provide a permanent airtight and watertight seal.
3.
Chamfer (bevel) the outer edges of the piping.
8.
4.
Dry-fit the vent piping assembly from the furnace to the outside termination 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:
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.
14
A.
Sealed combustion air systems from the furnace to the outside termination.
COMBUSTION AIR / VENT CLEARANCES
B.
Ventilated combustion air systems from the furnace to the
attic or crawl space termination.
IMPORTANT: The vent must be installed with the following minimum
clearances, and must comply with local codes and requirements.
Unitary Products Group
035-19939-002 Rev. B (0904)
VENT CLEARANCES
G
V
A
V
VENT TERMINAL
X
AIR SUPPLY
H
D
V
FIXED
CLOSED
E
B
B
B
L
V
B
I
C
V
V
X
AREA WHERE TERMINAL IS NOT PERMITTED
V
K
V
F
M
V
X
V
B
B
J
FIXED
CLOSED
OPERABLE
FIGURE 18: Home Layout
Canadian Installations1
A.Clearance above grade, veranda, porch, deck,
or balcony
B.Clearance to window or door that may be opened
C.Clearance to permanently closed window
D.Vertical clearance to ventilated soffit located
above the terminal within a horizontal distance
of 2 feet (61 cm) from the center line of the terminal
E.Clearance to unventilated soffit
F. Clearance to outside corner
G.Clearance to inside corner
H.Clearance to each side of center line extended
above meter/regulator assembly
I. Clearance to service regulator vent outlet
J. Clearance to nonmechanical air supply inlet to
building or the combustion air inlet to any othe
appliance
K.Clearance to a mechanical supply inlet
L. Clearance above paved sidewalk or paved driveway
located on public property
M.Clearance under veranda, porch, deck, or balcony
Dryer Vent
Plumbing Vent Stack
Gas Appliance Vent Terminal
Vent Termination from any Building Surface
Above Any Grade Level
Above anticipated snow depth
Any forced air inlet to the building.
The vent shall extend above the highest point where
it passes through the roof, not less than
Any obstruction within a horizontal distance
US Installation2
12 inches (30 cm)
12 inches (30 cm)
6 inches (15 cm) for applications ≤ 10,000 Btuh (3kW),
12 inches (30 cm) for appliances > 10,000 Btuh (3kW)
and ≤ 100,000 Btuh (30kW) , 36 inches (91 cm)
for appliances > 100,000 Btuh (30kW)
“
6 inches (15 cm) for applications ≤ 10,000 Btuh (3kW),
9 inches (23 cm) for appliances > 10,000 Btuh (3kW)
and ≤ 50,000 Btuh (15kW) , 12 inches (30 cm)
for appliances > 50,000 Btuh (30kW)
“
“
“
“
“
4 feet (122 cm)
3 feet (91 cm) within a height 15 feet (4.5 m) above the
meter/regulator assembly
3 feet (91 cm)
6 inches (15 cm) for applications ≤ 10,000 Btuh (3kW),
12 inches (30 cm) for appliances > 10,000 Btuh (3kW)
and ≤ 100,000 Btuh (30kW) , 36 inches (91 cm)
for appliances > 100,000 Btuh (30kW)
6 feet (1.83 m)
“
“
4 feet (122 cm)
“
“
6 inches (15 cm) for applications ≤ 10,000 Btuh (3kW)
9 inches (23 cm) for appliances > 10,000 Btuh (3kW)
and ≤ 50,000 Btuh (15kW) , 12 inches (30 cm)
for appliances > 50,000 Btuh (30kW)
3 feet (91 cm) above if witin 10 feet (3 cm) horizontally
7 feet (2.13 m) †
12 inches (30 cm)
3 ft (91.44 cm)
3 ft (91.44 cm)
3 ft (91.44 cm) *
12" (30.4 cm)
12" (30.4 cm)
12" (30.4 cm)
10 ft (304.8 cm)
“
‡
“
3 ft (91.44 cm)
3 ft (91.44 cm)
3 ft (91.44 cm) *
12" (30.4 cm)
12" (30.4 cm)
12" (30.4 cm)
10 ft (304.8 cm)
18" (46 cm)
18" (46 cm)
Not less than 18" (46 cm)
Not less than 18" (46 cm)
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 / NFPA 54, National Gas Code.
† Avent shall not erminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings.
‡ Permitted only if veranda , porch, deck, or balcony is fully open on a minimum of two sides beneath the floor. For clearance not specified in ANSI Z223.1 / NFPA 54 or CSA B149.1-00.
Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer’s Installation Manual.
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 adjecent to windows where steam may cause fogging.
A terminus of a vent shall be either:
Fitted with a cap in accordance with the vent manufacturer’s installation instructions, or In accordance with the installation instructions for a special venting system.
* Does not apply to multiple installations of this furnace model. Refer to "VENTING MULTIPLE UNITS" in this section of these instructions.
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 corrosive 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 recommended 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
15
035-19939-002 Rev. B (0904)
VENT SYSTEM
HORIZONTAL VENT ASSEMBLY
This furnace is certified to be installed with one of two possible vent
configurations.
Horizontal Left Vent Assembly
1.
Horizontal vent system. This vent system can be installed completely horizontal or combinations of horizontal, vertical, or offset
using elbows.
2.
Vertical vent system. This vent system can be installed completely
vertical or a combination of horizontal, vertical, or offset using
elbows.
When selecting the location for a horizontal combustion air / vent termination, the following should be considered:
Observe all clearances listed in vent clearances in these instructions.
Termination should be positioned where vent vapors will not damage 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 objectionable.
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).
A vent drain is required when vent passes through any unconditioned space such as an attic or crawl space in order to prevent
the accumulation of excess condensate in the inducer motor during operational cycles, refer to Figure 19, 20 and 23.
• Sealed combustion air systems must be installed so the vent
and the combustion air pipes terminate in the same atmospheric zone. Refer to Figures 21, 22, 23, 24 & 25.
2.
3.
4.
5.
6.
7.
Place the 2” (5.08 cm) 45° PVC street elbow on the vent connection 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.
3.
Refer to the “DOWNFLOW/HORIZONTAL CONDENSATE INTERNAL DRAIN CONFIGURATIONS” for futher details.
Horizontal Right Vent Assembly
HORIZONTAL VENT APPLICATIONS AND
TERMINATION
1.
1.
1.
Place the 2” (5.08 cm) 45° PVC street elbow on the vent connection 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.
3.
Refer to the “DOWNFLOW/HORIZONTAL CONDENSATE INTERNAL DRAIN CONFIGURATIONS” for futher details.
EXTERNAL HORIZONTAL VENT DRAIN
(Field Supplied)
When installing the furnace with a horizontal vent configuration that will
predominately be in a low ambient condition it is recommended that an
external vent drain be installed in the horizontal portion of the venting
system. The external vent drain is also recommended for extremely
long horizontal vent applications. This is recommended to prevent
accumulation of excess condensate in the inducer motor during operational cycles. Refer to Figure 19 for recommended external vent drain
configuration and connections.
VENT PIPE
FIELD SUPPLIED
EXTERNAL VENT
DRAIN
COMBUSTION
AIR PIPE
3” MINIMUM
LOOP DIAMETER
MANUFACTURER
SUPPLIED PVC
WYE AND VENT DRAIN
DOWNFLOW VENT ASSEMBLY
1.
Place the 2” (5.08 cm) 45° PVC street elbow on the vent connection 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.
3.
Locate the rubber condensate hose in front of the blower access
panel.
4.
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.
RETURN
AIR
2” PVC
45°
STELL
TEE
VENT DRAIN
FIGURE 20: External Horizontal Vent Drain
2” (5.08 cm)
VENT PIPE
RETURN
AIR
2” PVC
WYE
FURNACE
VENT PIPE
DOWNFLOW
VENT TRAP
MAINTAIN 12” MINIMUM CLEARANCE
ABOVE HIGHEST ANTICIPATED SNOW
LEVEL. MAXIMUM 24” ABOVE ROOF.
HORIZONTAL LEFT
12” MIN.
12” MIN.
RETURN
AIR
BARBED
FITTING
HORIZONTAL RIGHT
FIGURE 19: Downflow/Horizontal Vent Assembly
FIGURE 21: Termination Configuration - 1 Pipe
16
Unitary Products Group
035-19939-002 Rev. B (0904)
6.
12” VERTICAL SEPARATION
BETWEEN COMBUSTION AIR
AND VENT
MAINTAIN 12”
MINIMUM
CLEARANCE
ABOVE HIGHEST
ANTICIPATED
SNOW LEVEL.
12” MINIMUM
BELOW
OVERHANG
12” SEPARATION
BETWEEN BOTTOM
OF COMBUSTION
AIR PIPE AND
BOTTOM OF VENT
MAINTAIN 12”
MINIMUM CLEARANCE
ABOVE HIGHEST
ANTICIPATED SNOW
LEVEL OR GRADE,
WHICHEVER IS
HIGHER
A vent drain is required when vent passes through any unconditioned space such as an attic or crawl space in order to prevent
the accumulation of excess condensate in the inducer motor during operational cycles. See Figure 19 & 23.
VENTING MULTIPLE UNITS
Only the sealed combustion system can be used for installations requiring 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 24 or 25.
VENT
FIGURE 22: Termination Configuration - 2 Pipe
12” SEPARATION BETWEEN BOTTOMOF
COMBUSTION AIR PIPE AND TOP OF VENT.
MAINTAIN 12” MIN. CLEARANCE ABOVE
HIGHEST ANTICIPATED SNOW LEVEL.
12” MIN.
COMBUSTION AIR
12” MIN.
2”
FIGURE 25: Double Horizontal Sealed Combustion Air and Vent
Termination
6”
FIGURE 23: Termination Configuration - 2 Pipe Horizontal
12” MINIMUM
BELOW
OVERHANG
12” SEPARATION
BETWEEN BOTTOM
OF COMBUSTION
AIR PIPE AND
BOTTOM OF VENT
VENT DRAIN
MAINTAIN 12”
MINIMUM CLEARANCE
ABOVE HIGHEST
ANTICIPATED SNOW
LEVEL OR GRADE,
WHICHEVER IS
HIGHER
FIGURE 24: 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 instructions.
2.
Termination should be positioned where vent vapors are not objectionable.
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 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).
Unitary Products Group
FIGURE 26: 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 editions.
This furnace is certified to be installed with one of three possible combustion air intake configurations.
1.
2.
3.
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 models. Refer to
Figure 27.
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 20
& 27 for vent terminations. Refer to “AIR SOURCE FROM INSIDE
THE BUILDING” and “VENT AND SUPPLY AIR SAFETY CHECK”
for proper installation.
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 terminated in the same atmospheric zone. Refer to Figure 29 for fror
crawl space and attic termination. Only the combustion air intake
may terminate in the attic. The vent must terminate outside.
17
035-19939-002 Rev. B (0904)
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 21, 22 & 23) 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 21, 22 &
23) is the furnace vent pipe.
INSTALL PROVIDED
2” DIAMETER
RUBBER SLEEVE
A confined space is an area with less than 50 cu.ft (1.42 m3) 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 combustion and ventilation in confined spaces.
AMBIENT
COMBUSTION
AIR FLOW
VENT PIPE PASSES
THROUGH TOP PANEL
2” (5.08 cm)
VENT
CONNECTION
2” (5.08 cm)
COMBUSTION
AIR INTAKE
CONNECTION
FIGURE 28: Combustion Airflow Path Through The Furnace Casing to
the Burner Box
Combustion Air Source From Outdoors
FIGURE 27: Sealed Combustion Air Intake Connection and Vent
Connection
The combustion 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 “Outdoor Air Contaminants.”
The provided 2” diameter rubber sleeve should be installed on the combustion air pipe sticking through the furnace top, when making connection with the outdoor combustion air pipe. This, in combination with the
rubber sleeve installed inside the furnace, will facilitate removal of fresh
air pipe in front of the blower housing.
The blocking effects of louvers, grilles and screens must be given consideration in calculating free area. If the free area of a specific louver or
grille is not known, refer to Table 10, to estimate free area.
1.
The free area of a supply air opening shall be calculated by subtracting the blockage area of all fixed louvers grilles or screens
from the gross area of the opening.
Ambient Combustion Air Supply
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 louvers shall be interlocked so that the main burner cannot operate
unless either the damper or the louver is in the fully open position.
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
upflow 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 20 & 27.
This type of installation requires that the supply air to the appliance(s) be of a sufficient 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 create 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 appliance to soot and generate dangerous levels of CARBON MONOXIDE, which can lead to serious injury, property damage and / or
death.
An unconfined space is not less than 50 cu.ft (1.42 m3) 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 appliances are considered part of the unconfined space, if openings are furnished with doors.
18
TABLE 11: Estimated Free Area
Wood or Metal
Louvers or Grilles
Screens+
*
+
Wood 20-25%*
Metal 60-70% *
1/4” (0.635 cm)
mesh or larger 100%
Do not use less than 1/4” (0.635 cm) mesh
Free area or louvers and grilles varies widely; the installer should follow louver or grilles
manufacturer’s instructions.
Dampers, Louvers and Grilles (Canada Only)
TABLE 12: Free Area
Minimum Free Area Required for Each Opening
Vertical Duct or
Round Duct
Horizontal Duct
Openingto Outside
(4,000 BTUH)
(2,000 BTUH)
(4,000 BTUH)
60,000
30 sq. in. (76 cm)
15 sq. in. (38 cm)
5” (13 cm)
80,000
40 sq. in. (102 cm) 20 sq. in. (51 cm)
5” (13 cm)
100,000
50 sq. in. (102 cm) 25 sq. in. (64 cm)
6” (15 cm)
120,000
60 sq. in. (152 cm) 30 sq. in. (76 cm)
7” (18 cm)
EXAMPLE: Determining Free Area.
Appliance
1Appliance
2Total Input
100,000 + 30,000 = (130,000 ÷ 4,000) = 32.5 Sq. In. Vertical
Appliance
1Appliance
2Total Input
100,000 + 30,000 = (130,000 ÷ 2,000) = 65 Sq. In. Horizontal
BTUH Input
Rating
TABLE 13: Unconfined Space Minimum Area in Square Inch
BTUH Input Rating Minimum Free Area Required for Each Opening
60,000
375 (953 cm2)
80,000
500 (1270 cm2)
100,000
625 (1588 cm2)
120,000
750 (1905 cm2)
EXAMPLE: Square feet is based on 8 foot ceilings.
28,000 BTUH X 50 Cubic Ft. =
1,400
= 175 Sq. Ft.
1,000
8’ Ceiling Height
Unitary Products Group
035-19939-002 Rev. B (0904)
SOFFIT
VENT
VENTILATED
ATTIC
TOP ABOVE
INSULATION
OUTLET
AIR (a)
GAS
WATER
HEATER
FURNACE
OPTIONAL
INLET (a)
AIR SUPPLY OPENINGS AND DUCTS
4. 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 largest input.
GAS
VENT
GABLE
VENT
5. A square or rectangular shaped duct shall only be used
when the required free area of the supply opening is
2
2
9 in (58.06 cm ) or larger. When a square or rectangular
duct is used, its small dimensionshall not be less than
3 in (7.6 cm).
VENTILATED
ATTIC
TOP ABOVE
INSULATION
INLET
AIR (b)
GAS
WATER
HEATER
FURNACE
6. An air inlet supply from outdoors shall be equipped with SOFFIT
a means to prevent the direct entry of rain and wind.
VENT
Such means shall not reduce the required free area of
the air supply opening.
An air supply inlet opening from the outdoors shall
be located not less than 12” (30.5 cm) above the
outside grade level.
INLET
AIR (b)
OUTLET
AIR (a)
GAS
WATER
HEATER
INLET
AIR (a)
COMBUSTION AIR SOURCE FROM OUTDOORS
VENTILATED
CRAWL SPACE
7.
GAS
VENT
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 CHECK” in these instructions for
additional information and safety check procedure.
OUTLET
2. The duct shall be either metal, or a material meeting the class 1
AIR (b)
requirements of CAN4-S110 Standard for Air Ducts.
The
duct
shall
be
least
the
same
cross-sectional
area
as
the
free
3.
area of the air supply inlet opening to which it connects.
FURNACE
GAS
VENT
GABLE
VENT
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.
2. 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:
a. 1 square in per 3000 Btu per hour (6.45 cm2 0.879 kW) of the total
input rating of all equipment located in the enclosure.
b. Not less 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.
FIGURE 29: Outside and Ambient Combustion Air
Vent and Supply (Outside) Air Safety Check Procedure
Follow the procedure in ANSI Z223.1 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 Propane 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 procedure below. This procedure is designed to detect an inadequate ventilation 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 and 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.
3.
Turn on 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.
If 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 condition must be corrected before the
appliance can function safely.
8.
Any corrections to the venting system and / or to the supply (outside) air system must be in accordance with the National Fuel Gas
Code Z223.1 or CAN/CGA 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 and refer to Table 9 of these instructions.
Ventilated Combustion Air
The ventilated attic space or a crawl space from which the combustion
air is taken must comply with the requirements specified in “AIR
SOURCE FROM OUTDOORS” in this instruction or in Section 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 ventilated 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 building. Refer to
Table 10 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 ventilated attic space or
crawl space. DO NOT terminate vent pipe in an Attic or Crawl Space.
Ventilated Combustion Air Termination
Refer to Figure 29 for required attic termination for the combustion air
intake pipe. For attic termination, 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.
12” MINIMUM BETWEEN
BOTTOM OF BELOW AND
ANY MATERIAL
12”
MIN.
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.
FIGURE 30: Attic Combustion Air Termination
Unitary Products Group
19
035-19939-002 Rev. B (0904)
CONDENSATE DRAIN TRAP AND DRAIN FREEZE
PROTECTION
Specially Engineered Installations
The above requirements shall be permitted to be waived where special
engineering, approved by the authority having jurisdiction, provides an
adequate supply of air for combustion, ventilation and dilution of flue
gases.
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 protected. Use a 3 to 6 watt per foot (0.003 to 0.006 kW per meter) at 115
vac, 40º F (4.4° C) self-regulating, 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.
Be sure to instruct the owner not to block this intake pipe.
SECTION VIII: CONDENSATE PIPING
CONDENSATE DRAIN HOSE PART NUMBERS
TABLE 14: Condensate Drain Hose
Part
Number
Hose
Number
028-15156-000
028-15176-000
Description
Drain tube - Condensate pan (Down flow)
Drain tube - Inducer (Horizontal RT.)
-Vent system Down flow)
028-15168-000
#3
Drain tube - Inducer (Down flow)
028-15176-000
#4
Drain tube - Rain gutter (Down flow & Horizontal RT.)
028-15176-000
#5
Drain tube - After Tee (Down flow)
028-15196-000
#6
Drain tube – Upper rain gutter (Horizontal LT.)
028-15169-001
#7
Drain tube - After Tee (Horizontal RT.)
028-13309-004
#8
Drain tube - P-trap (All models)
028-15158-000
#9
Drain tube - Vent system (Horizontal LT.)
- Before Tee (Horizontal RT.)
Drain tube – Condensate pan (Horizontal –
028-15197-000
#10
drain closer to the front of the furnace, both LT & RT)
Hoses #2, #4, #5, along with a barbed nipple, and a barbed tee are part of
condensate hose assembly 028-15176-000.
CONDENSATE DRAIN TUBE 5/8” (1.59 cm)
FIGURE 31: Condensate Drain Internal Hose Routing
SECTION IX: CONDENSATE PIPING
CONDENSATE DRAIN
The condensate drain connection is provided in the furnace for field
installation. It consists of the hoses shown below, a NPT male connection, 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 configuration. Refer to Figures 30, 31, 32 & 33 for the condensate hose sizes
for condensate drain connections.
#1
#2
DOWNFLOW/HORIZONTAL CONDENSATE
INTERNAL DRAIN CONFIGURATIONS
IMPORTANT: The condensate drain from the furnace may be connected in common with the drain from an air conditioning coil if allowed
by local code.
Downflow
Furnace is shipped with one end of condensate hose #2 left open in the
furnace. If the provided 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 elbow 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.
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.
HOSE #9
3/4”
1-5/8”
3/4”
33”
HOSE #2 (if drain aligned
above the hole in
furnace top)
1”
HOSE #8*
2-3/4”
SPRING CLAMP
1”
DOG-LEG
22-1/8”
HOSE #4 (with 3/8”
barbed nipple)
HOSE #2
17-1/2”
DOG-LEG
HOSE #5
SPRING CLAMP
1”
HOSE #1
3/8”
SPRING CLAMP
3/4”
3/8” BARBED TEE
*USED AFTER
CONDENSATE
TRAP
HOSE #5
3/4”
SPRING CLAMP
3/4”
HOSE #3
2-3/4”
HOSE #1
DOGLEG
9”
8-1/8”
2”
3/4”
SPRING CLAMP
1-1/8”
5/8”
SPRING CLAMP
HOSE #4
HOSE #3
1/2”
3-3/8”
FIGURE 32: Downflow Condensate Drain Hose Configuration
20
Unitary Products Group
035-19939-002 Rev. B (0904)
Horizontal Left Air Flow (Inducer Low)
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 it's bracket from inside the furnace, 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 #3. Some lubricant may have to be used to facilitate this
installation as the hose is designed as a tight fit over the condensate drain. The other, shorter, dogleg end of hose #10 should be
installed 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.
7.
Switch the blocked condensate hose to the condensate tap on the
bottom of the condensate pan (close to the inducer).
8.
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.
9.
Remove all condensate hoses off the 3/8" barbed tee.
10. 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.
11. 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.
12. 1Install hose #6 between the top drain of the rain gutter of the
inducer and the remaining open end of 3/8" barbed tee.
13. 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.
THIS TUBE FOR THE BLOCKED
CONDENSATE SWITCH MUST
BE RELOCATED FROM ITS
ORIGINAL FACTORY
INSTALLED LOCATION
BEHIND THE COMBUSTION
AIR PIPE TO THE TAP BEHIND
THE DRAFT INDUCER.
BLOCKED
CONDENSATE
TAP
2”
HOSE #4
3/4”
SPRING CLAMP
1/2”
25/32”
60°
HOSE #6
1-3/8”
70°
1-5/16”
HOSE #9
HOSE #6
1”
HOSE #8*
3/8” BARBED
TEE
3/8” BARBED
NIPPLES
HOSE #4
CUT FROM
HOSE #1 (4-1/2” long)
DOG-LEG
22-1/8”
HOSE #10
HOSE #10
3/8” BARBED
TEE
*USED AFTER
CONDENSATE
TRAP
2-3/4”
SPRING CLAMP
1”
5-1/4”
1/2”
2-3/4”
HOSE #6
90°
90°
3-13/16”
HOSE #4
RECOMMENDED
CONDENSATE
TRAP ORIENTATION
1-1/2” PIECE
OF 3/8” HOSE
13-16”
HOSE #9
3/4”
1-5/8”
3/4”
33”
FIGURE 33: Horizontal Left Condensate Drain Hose Configuration
Unitary Products Group
21
035-19939-002 Rev. B (0904)
Horizontal Right Air Flow (Inducer High)
3.
Remove the condensate trap and it's bracket from inside the furnace, saving the screws for use later.
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 #3. Some lubricant may have to be used to facilitate this
installation as the hose is designed to be a tight fit over the condensate drain. The other, smaller, dogleg end of hose #10 should
be installed 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.
7.
Install the dogleg end of hose #9 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.
8.
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.
9.
Install one end of hose #7 on the 3/8" barbed tee inside the furnace. Guide the other end of hose #7 towards the condensate
trap, and install it on the tap on the condensate trap. See figure.
Installation without condensate trap bracket:
1.
Remove the 2" knockout on the casing side, away from the
inducer motor.
2.
Remove the condensate trap and it's bracket from the furnace,
saving the screws for use later.
3.
Remove all the condensate hoses inside the furnace and remove
the 2" knockout on the side of the casing.
4.
Remove the condensate trap from the bracket
5.
Remove the large condensate cap from the side of the condensate
pan, close to the knockout, and install it on the middle of the condensate pan, from where hose #1 was removed.
6.
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.
7.
Remove cap from the rain gutter and insert 3/8" barbed nipple into
the rain gutter. Place the cap, just removed, to the other side of
the rain gutter on the inducer.
8.
Install the condensate trap to the 2" hole on the side of the casing,
lining up the condensate pan opening with the larger opening on
the condensate trap.
9.
Install the dogleg end of hose #9 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.
10. 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. See figure.
10. 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, as shown in the figure.
11. 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.
11. Install one end of hose #7 on the 3/8" barbed tee inside the furnace. Guide the other end of hose #7 towards the condensate
trap, and install it on the tap on the condensate trap. See figure.
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.
12. 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. See figure.
13. 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.
Ensure all condensate hoses are pushed all the way down on the
condensate trap, and barbed fittings
Installation with condensate trap bracket:
1.
Remove the 2" knockout on the casing side, away from the
inducer motor.
2.
Remove all the condensate hoses inside the furnace, leaving the
3/8" barbed nipple, factory installed, in the rain gutter.
22
Plug all unused condensate trap, condensate pan and inducer drain
connection points using plugs provided.
Unitary Products Group
035-19939-002 Rev. B (0904)
2”
HOSE #4
3/4”
HOSE #7
3/4”
3/4”
SPRING CLAMP
HOSE #9
21”
3/8” BARBED TEE
1/2”
HOSE #4
17-1/2”
HOSE #2
3/8”
SPRING CLAMP
3/4”
HOSE #2
DOG-LEG
HOSE #8*
1”
2-3/4”
SPRING CLAMP
1”
DOG-LEG
22-1/8”
SPRING CLAMP
1”
HOSE #7
CUT FROM
HOSE #1
(4-1/2” long)
HOSE #1
HOSE #7
THIS TUBE FOR THE
BLOCKED CONDENSATE
SWITCH HAS BEEN
FACTORY INSTALLED
FOR THIS POSITION.
HOSE #2
* USED AFTER
CONDENSATE
TRAP
2-3/4”
HOSE #1
CUT
4-1/2”
PIECE
DOGLEG
8-1/8”
RECOMMENDED
CONDENSATE
TRAP ORIENTATION
HOSE #9
3/4”
1-5/8”
3/4”
33”
FIGURE 34: Horizontal Right Condensate Drain Hose Configuration
CONDENSATE DRAIN TERMINATION
BLOWER DOOR SAFETY SWITCH
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 condensate.
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.
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 disconnect.
Blower and burner must never be operated without the blower
panel in place.
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 condensate trap has been properly piped to a drain connection using the procedure 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 X: SAFETY CONTROLS
CONTROL CIRCUIT FUSE
A 3-amp fuse is provided on the control circuit board to protect the 24volt transformer from overload caused by control circuit wiring errors.
This is an ATO 3, automotive type fuse and is located on the control
board.
ROLLOUT SWITCH CONTROLS
These controls are mounted on the burner box assembly. If the temperature 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-energizes the ignition control module and the gas valve if any of the following conditions are present. Refer to Figure 35 for tubing connections.
1.
2.
3.
4.
Unitary Products Group
Blockage of combustion air piping or terminal.
Blockage of vent piping or terminal.
Failure of combustion air blower motor.
Blockage of condensate drain piping.
23
035-19939-002 Rev. B (0904)
DOWNFLOW/HORIZONTAL
FIGURE 35: Pressure Switch Tubing Routing
• 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 (1PK0602) 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 cm) length x 1/8” (0.3 cm) diameter tubing
• 1 - 5/16” (0.8 cm) tee
• 1 – 5/16” (0.8 cm) x 1/8” (0.3 cm) reducing coupling
• 1 – 1/8” (0.3 cm) adapter
• 1 - Dwyer – Manometer
These items are required in order to properly perform the required startup procedure.
LIMIT CONTROLS
IGNITION SYSTEM SEQUENCE
There is high temperature limit control located on the furnace vestibule
panel near the gas valve. This is an automatic reset control that provides over temperature protection due to reduced airflow, that may be
caused by a dirty filter, or if the indoor fan motor should fail. The control
module will lockout if the limit trips 5 consecutive times. Control will
reset and try ignition again after 1 hour.
1.
Turn the gas supply ON at external valve and main gas valve.
2.
Set the thermostat above room temperature to call for heat.
SECTION XI: START-UP AND
ADJUSTMENTS
The initial start-up of the furnace requires the following additional
procedures:
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.
c.
After flame is established, the supply air blower will start in
about 30 seconds.
IMPORTANT: All electrical connections made in the field and in the factory 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.
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.
Call 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 (38.8 MJ /
m³).
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 measuring equipment to the gas valve pressure ports.
There is an accessory kit (1PK0601) available from Source 1, which
has the following items:
• 1 - 12” (30 cm) length x 1/8” (0.3 cm) diameter tubing
• 2 – pieces of 4” (10 cm) length x 1/8” (0.3 cm) diameter tubing
• 1 - 5/16” (0.8 cm) tee
24
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 explosion may result causing
property damage, personal injury or loss of life.
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 locking out.
With furnace in operation, check all of the pipe joints, gas valve connections 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 natural gas with a heating value of 1050 BTU/Ft3 (39.12 MJ/m3). If
the heating 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.
2. At the gas meter, measure the time (with a stop watch) it takes to
use 2 cubic ft. (0.0566 m3.) of gas.
3. Calculate the furnace input by using one of the following equations.
Unitary Products Group
035-19939-002 Rev. B (0904)
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/m3), 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 MJm3), times 1 cubic ft. (0.028 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 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/f3 x 2 cu.ft. x 0.960 x 3600
Seconds it took to measure the 2 cu.ft. of gas
NATURAL GAS INPUT CALCULATION
EXAMPLE:
1030 x 2 x 0.960 x 3600
90.5
Natural Gas
BTU/SCF 1030
=
BTU/H
=
79,997.38
BTU/f3 x 2 cu.ft. x 0.960 x 3600
Seconds it took to measure the 2 cu.ft. of gas
PROPANE (LP) GAS INPUT CALCULATION
EXAMPLE:
2500 x 1 x 0.960 x 3600
108
Propane Gas
BTU/SCF 2500
=
BTU/H
=
80,000.00
In Canada you will use the following formula to calculate the furnace input if you are using a cubic foot gas meter.
For Natural Gas multiply the Heat content of the gas MJ/m3 (or Default 39.2), times 2 cubic ft. of gas x 0.02831 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/m3 (or Default 93.14), times 1 cu. ft. of gas x 0.02831 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/m3 x (2 cu.ft. x 0.028) x 0.960 x 3600
Seconds it took to measure the 2 cu.ft. of gas
NATURAL GAS INPUT CALCULATION
EXAMPLE:
39.2 x (2 x 0.028) x 0.960 x 3600
90.5
Natural Gas
BTU/SCF 1030 = 39.2 MJ/m3
PROPANE (LP) GAS INPUT CALCULATION
EXAMPLE:
93.15 x (1 x 0.028) x 0.960 x 3600
108
Propane Gas
BTU/SCF 2500 = 93.15 MJ/m3
=
MJ/H
x
0.2777
=
kW
x
3412.14
=
BTU/H
=
84.83
x
0.2777
=
23.28
x
3412.14
=
79,433
=
84.41
x
0.2777
=
23.45
x
3412.14
=
80,000.00
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/m3 (or Default 39.2), times 0.0566 m3 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 it took to measure 2 cubic ft. (0.0566 m3) of gas from the
gas meter.
For Propane (LP) Gas multiply the Heat content of the gas MJ/m3 (or Default 93.14), times 0.00283 m3 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 it took to measure 1 cubic ft. (0.0283 cm) of gas
from the gas meter.
The formula for metric input calculation using a cubic foot gas meter:
MJ/m3 x m3 x 0.960 x 3600
Seconds it took to measure the 2 cu.ft. of gas
NATURAL GAS INPUT CALCULATION
EXAMPLE:
39.2 x 0.1 x 0.960 x 3600
160
Natural Gas
BTU/SCF 1030 = 39.2 MJ/m3
PROPANE (LP) GAS INPUT CALCULATION
EXAMPLE:
93.15 x 0.028 x 0.960 x 3600
107.97
Propane Gas
BTU/SCF 2500 = 93.15 MJ/m3
=
MJ/H
x
0.2777
=
kW
x
3412.14
=
BTU/H
=
84.67
x
0.2777
=
23.51
x
3412.14
=
80,231
=
84.48
x
0.2777
=
23.18
x
3412.14
=
79,107
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 orifice spuds with the gas orifice spuds of the proper size for the type of gas you are using.
For altitudes above 2,000 ft. (610 m) the furnace input MUST BE DERATED. Refer to the GAS CONVERSION FOR PROPANE (LP) AND HIGH
ALTITUDES IN SECTION IV for information on high altitude conversions.
Unitary Products Group
25
035-19939-002 Rev. B (0904)
For altitudes above 2,000 ft. (610 m) the furnace input MUST BE DERATED. Refer to the GAS CONVERSION FOR PROPANE (LP) AND
HIGH ALTITUDES IN SECTION IV for information on high altitude conversions.
Be sure to relight any gas appliances that were turned off at the
start of this input check.
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 atmospheric pressure. Refer to Figure 36 for connection details.
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 35 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 15: Inlet Gas Pressure Range
INLET GAS PRESSURE RANGE
Natural Gas
Propane (LP)
Minimum
4.5” W.C. (1.12 kPa)
8.0” W.C. (1.99 kPa)
Maximum
10.5” W.C. (2.61 kPa)
13.0” (3.24 kPa) W.C.
IMPORTANT: The inlet gas pressure operating range table specifies
what the minimum and maximum gas line presures must be for the furnace to operate safely. The gas line pressure MUST BE
TABLE 16: Nominal Manifold Pressure
NOMINAL MANIFOLD PRESSURE
• 7” W.C. (1.74 kPA) for Natural Gas
• 11” W.C. (2.74 kPA) 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.
The 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 turning it 1 turn counter clockwise. DO NOT REMOVE THE SET
SCREW FROM THE PRESSURE PORT.
Read the inlet gas pressure using either of the two methods below.
WRENCH
BOSS
INLET
PRESSURE
PORT
26
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 pressure 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 positive side of the manometer to the gas valve pressure reference port. Refer to Figure 36 for connection details.
VENT PORT
OUTLET
FF
O
N
O
ON/OFF SWITCH
(Shown in ON position)
MAIN REGULATOR
ADJUSTMENT
FIGURE 36: Gas Valve
IMPORTANT: If gas valve regulator is turned in (clockwise), manifold
pressure is increased. If screw is turned out (counterclockwise), manifold 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 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.
Reading the gas pressure with the burner box cover in place:
A.
10.0" w.c. (2.488 kPa)
INLET
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 measured with the burner box cover removed. Follow the appropriate section in the instructions below. Refer to Figure 38 for a drawing of the
locations of the pressure ports on the gas valve.
1.
3.5" w.c. (0.87 kPa)
Propane (LP) Gas
OUTLET
PRESSURE
PORT
ADJUSTMENT OF MANIFOLD GAS PRESSURE
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.
Natural Gas
The manifold pressure must be checked with the screw-off cap for
the gas valve pressure regulator in place. If not, the manifold pressure setting could result in an over-fire condition. A high manifold
pressure will cause an over-fire condition, which could cause premature 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 cap is in place and burner box to
gas valve pressure reference hose is connected.
Unitary Products Group
035-19939-002 Rev. B (0904)
WITH BURNER BOX COVER IN PLACE
TEE
FITTING
WITH BURNER BOX COVER REMOVED
GAS
VALVE
GAS VALVE
BURNER BOX
PRESSURE
REFERENCE
HOSE
BURNER BOX
PRESSURE
REFERENCE
HOSE
U-TUBE
MANOMETER
6
5
4
3
2
1
0
1
2
3
4
5
6
3.5 IN
WATER COLUMN
GAS PRESSURE
SHOWN
6
5
4
3
2
1
0
1
2
3
4
5
6
U-TUBE
MANOMETER
3.5 IN
WATER COLUMN
GAS PRESSURE
SHOWN
FIGURE 37: Reading Gas Pressure
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.
All direct-drive blowers have multi-speed motors. The blower motor
speed taps are located in the control box in the blower compartment.
Refer to Figure 37, and the unit-wiring label to change the blower
speed. To use the same speed tap for heating and cooling, the heat terminal 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.
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 seconds. 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 37.
RED - LOW SPEED
YELLOW - MED. LOW SPEED
HUM
L1
XFMR
HEAT
EAC
HI COOL
PARK
BLACK - HIGH SPEED
BLUE - MED. HIGH SPEED
PARK
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 Table 7 “ELECTRICAL AND PERFORMANCE
DATA”.
The supply air temperature cannot exceed the “Maximum Supply
Air Temperature” specified in these instructions and on the furnace 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, a fire hazard, personal injury, property damage, and/or
death.
ADJUSTMENT OF FAN CONTROL SETTINGS
NEUTRALS
ADJUSTMENT OF TEMPERATURE RISE
FIGURE 38: Typical Heat/Cool Speed Tap Connections
Do not energize more than one motor speed at a time or damage to
the motor will result.
Unitary Products Group
27
035-19939-002 Rev. B (0904)
TABLE 17: Blower Performance CFM
AIRFLOW WITH TOP RETURN
MODELS
Input/
Output/
Airflow/
cabinet
Speed
Tap
High
60/55/
1200/B
80/75/
1200/B
0.1 (0.025)
0.2 (0.050)
0.3 (0.075)
EXTERNAL STATIC PRESSURE, INCHES W.C. (kPa)
0.4 (0.099)
0.5 (0.124)
0.6 (0.149)
0.7 (0.174)
0.8 (0.199)
0.9 (0.224)
1.0 (0.249)
CFM m3/min CFM m3/min CFM m3/min CFM m3/min CFM m3/min CFM m3/min CFM m3/min CFM m3/min CFM m3/min CFM m3/min
1687
48
1652
47
1631
46
1595
45
1557
44
1511
43
1456
41
1382
39
1313
37
1211
34
Medium High 1193
34
1183
33
1173
33
1162
33
1142
32
1115
32
1076
30
1036
29
982
28
950
27
Medium Low 933
26
933
26
921
26
911
26
902
26
872
25
825
23
793
22
771
22
712
20
Low
752
21
745
21
731
21
718
20
698
20
652
18
602
17
580
16
536
15
496
14
High
1686
48
1658
47
1623
46
1572
44
1534
43
1465
41
1391
39
1305
37
1202
34
1091
31
Medium High 1257
36
1223
35
1218
34
1203
34
1177
33
1142
32
1094
31
1026
29
939
27
874
25
Medium Low 977
28
982
28
976
28
955
27
934
26
899
25
843
24
791
22
738
21
686
19
Low
775
22
777
22
757
21
733
21
698
20
663
19
627
18
584
17
549
16
490
14
High
2071
59
2026
57
1981
56
1935
55
1864
53
1796
51
1713
48
1625
46
1532
43
1401
40
80/75/ Medium High 1583
1600/C Medium Low 1256
45
1590
45
1569
44
1554
44
1532
43
1502
43
1457
41
1409
40
1327
38
1221
35
36
1275
36
1275
36
1288
36
1275
36
1265
36
1232
35
1187
34
1126
32
1023
29
Low
937
27
939
27
936
26
945
27
942
27
936
26
912
26
874
25
810
23
726
21
High
1996
56
1961
56
1938
55
1896
54
1836
52
1779
50
1707
48
1625
46
1531
43
1399
40
100/95/ Medium High 1449
1600/C Medium Low 1167
41
1480
42
1495
42
1488
42
1488
42
1449
41
1417
40
1368
39
1299
37
1208
34
33
1192
34
1192
34
1187
34
1202
34
1192
34
1182
33
1140
32
1097
31
1018
29
Low
932
26
900
25
871
25
840
24
805
23
761
22
710
20
663
19
641
18
623
18
High
2404
68
2320
66
2225
63
2138
61
2034
58
1924
54
1816
51
1692
48
1559
44
1422
40
100/95/ Medium High 2018
2000/C Medium Low 1626
57
1955
55
1883
53
1815
51
1750
50
1670
47
1586
45
1497
42
1394
39
1246
35
46
1581
45
1531
43
1488
42
1418
40
1363
39
1291
37
1225
35
1123
32
964
27
21
Low
1336
38
1291
37
1249
35
1205
34
1155
33
1091
31
1018
29
951
27
884
25
759
High
2520
71
2432
69
2353
67
2251
64
2152
61
2042
58
1947
55
1815
51
1701
48
1525
43
120/112/ Medium High 2018
2000/D Medium Low 1586
57
1979
56
1945
55
1911
54
1863
53
1779
50
1705
48
1599
45
1493
42
1353
38
Low
1321
45
1545
44
1501
42
1457
41
1407
40
1351
38
1287
36
1216
34
1081
31
926
26
37
1266
36
1213
34
1163
33
1111
31
1071
30
987
28
864
24
763
22
700
20
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.
FILTER PERFORMANCE
The airflow capacity data published in Table 17 represents blower performance WITHOUT filters. To determine the approximate blower performance of the system, apply the filter drop value for the filter being
used or select an appropriate value from the Table 18.
NOTE: The filter pressure drop values in Table 18 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 manufacturers.
TABLE 18: Filter Performance - Pressure Drop Inches W.C. and (kPa)
FILTER TYPE
AIRFLOW RANGE
MINIMUM
OPENING SIZE
DISPOSABLE
COARSE FIBER
WASHABLE1*
PLEATED
CFM
m3/m
in2
cm2
In W.C.
kPA
In W.C.
kPA
In W.C..
kPA
0 - 750
0 - 21.4
230
584.2
0.01
0.00249
0.01
0.00249
0.15
0.03736
751 - 1000
21.25 - 28.32
330
838.2
0.05
0.01245
0.05
0.01245
0.20
0.04982
1001 - 1250
28.33 - 35.40
330
838.2
0.10
0.02491
0.10
0.02491
0.20
0.04982
1251 - 1500
35.41 - 42.48
330
838.2
0.10
0.02491
0.10
0.02491
0.25
0.06227
1501 - 1750
42.49 - 49.55
380
965.2
0.15
0.03736
0.14
0.03487
0.30
0.07473
1751 - 2000
49.56 - 56.63
380
965.2
0.19
0.04733
0.18
0.04484
0.30
0.07473
2001 & Above
56.64 - Above
463
1176.0
0.19
0.04733
0.18
0.04484
0.30
0.07473
1. Coarse Fiber Filters are the type supplied with furnace (if supplied).
28
Unitary Products Group
035-19939-002 Rev. B (0904)
APPLYING FILTER PRESSURE DROP TO
DETERMINE SYSTEM AIRFLOW
To determine the approximate airflow of the unit with a filter in place, follow the steps below:
1.
Select the filter type.
2.
Determine the External System Static Pressure (ESP) without the
filter.
3.
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 3 to determine the total system static.
4.
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.
5.
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 5 or calculate
the airflow by using the following example.
Example: For a 130,000 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 values at 0.50" & 0.60" ESP.
Airflow @ 0.50": 2125 CFM
Airflow @ 0.60": 2035 CFM
2.
Subtract the airflow @ 0.50" from the airflow @ 0.60" to obtain airflow difference.
2035 - 2125 = -90 CFM
3.
Subtract the total system static from 0.50" and divide this difference by the difference in ESP values in the table, 0.60" - 0.50", to
obtain a percentage.
4.
Multiply percentage by airflow difference to obtain airflow reduction.
5.
Subract airflow reduction value to airflow @ 0.50" to obtain actual
airflow @ 0.58" ESP.
(0.8) x (-90) = -72
2125 - 72 = 2053
Field Installed Accessories - Non-Electrical
MODEL NO.
DESCRIPTION
USED WITH
1NP0347
PROPANE (LP)
CONVERSION KIT
ALL MODELS
1CT0302
CONCENTRIC
INTAKE/VENT 2”
60, 80, 100 INPUT MBH
1CT0303
CONCENTRIC
INTAKE/VENT 3”
120 MBH
HIGH ALTITUDE
PRESSURE SWITCH KIT
(Does Not Include Orifices)
FOR APPLICATION
INFORMATION
SEE FORM
035-14447-000
1PS0901
1PS0902
1PS0903
1BR0417
1BR0421
17-1/2” CABINETS
EXTERNAL BOTTOM
FILTER RACK
1BR0424
21” CABINETS
24-1/2” CABINETS
1NK0301
CONDENSATE
NEUTRALIZER KIT
ALL MODELS
1TK0917
1TK0921
1TK0924
TRANSITION KITS FOR
COIL MOUNTING
17 1/2” cabinet
21” cabinet
24 1/2” cabinet
(0.58 - 0.50) / (0.60 - 0.50) = 0.8
Unitary Products Group
29
035-19939-002 Rev. B (0904)
SECTION XII: WIRING DIAGRAM
FIGURE 39: Wiring Diagram
30
Unitary Products Group
035-19939-002 Rev. B (0904)
NOTES
Unitary Products Group
31
NOTES
Subject to change without notice. Printed in U.S.A.
Copyright © by York International Corp. 2004. All rights reserved.
Unitary
Product
Group
035-19939-002 Rev. B (0904)
Supersedes: 035-19939-002 Rev. A (0704)
5005
York
Drive
Norman
OK
73069