Inst Manual P3HU 32-104 Output

INSTALLATION MANUAL

HIGH EFFICIENCY

TUBULAR HEAT EXCHANGER SERIES

MODELS: P*HU / G8T-UH / FL8-UH / L8T-UH

(Single Stage Upflow / LoNOx)

40 - 130 MBH INPUT

(11.72 - 38.10 KW) INPUT

EFFICIENCY

RATING

CERTIFIED

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

TWINNING AND STAGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

VENT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . .19

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

LIST OF FIGURES

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Furnace Base Rectangular Perforated Panel . . . . . . . . . . . . . . . . . . . 6

Typical Attic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Typical Suspended Furnace / Crawl Space Installation . . . . . . . . . . . . 7

Furnace Filter Slot Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Filter Retainer Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Side Return Cutout Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Line Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Heating and Cooling Thermostat Connections . . . . . . . . . . . . . . . . . 11

Accessory Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Typical Twinned Furnace Application . . . . . . . . . . . . . . . . . . . . . . . . 11

Single Stage Twinning Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . 12

Two-Stage Twinning Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 13

Vent Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Vent Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Typical Sidewall Vent Application . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Typical Sidewall Vent and Termination Configuration . . . . . . . . . . . .14

Home Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Combustion Airflow Path Through The Furnace Casing to the Burner Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Atlernate Air Intake, Air Outlet and Chimney Connections . . . . . . . . .16

Air Inlet, Outlet and Chimney Connections . . . . . . . . . . . . . . . . . . . . .16

Typical Chimney Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Horizontal Air Inlet, Outlet and Chimney Connections . . . . . . . . . . . .17

Outside and Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . .17

Pressure Switch Tubing Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Typical Heat/Cool Speed Tap Connections . . . . . . . . . . . . . . . . . . . .22

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

LIST OF TABLES

Unit Clearances to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Minimum Duct Sizing For Proper Airflow . . . . . . . . . . . . . . . . . . . . . . . 4

Round Duct Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Cabinet and Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Filter Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

High Altitude Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Ratings & Physical / Electrical Data - Upflow Models . . . . . . . . . . . . 10

Roof Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Horizontal Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Unconfined Space Minimum Area in Square Inch . . . . . . . . . . . . . . .17

Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Filter Performance - Pressure Drop Inches W.C. and (kPa) . . . . . . . .22

Blower Performance CFM - Upflow (without filter) . . . . . . . . . . . . . . .23

Field Installed Accessories - Non Electrical . . . . . . . . . . . . . . . . . . . .23

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.

035-19656-001 Rev. B (0404)

035-19656-001 Rev. B (0404)

SPECIFIC SAFETY RULES AND PRECAUTIONS

1.

Only Natural gas or Propane (LP) gas are approved for use with this furnace.

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 SEC-

TION VII of these instructions.

FIRE OR EXPLOSION HAZARD

Failure to follow the safety warnings exactly could result in serious injury, death or property damage.

Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life.

6.

Test 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

• 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 APPLI-

ANCE 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 duct system termination must be located external to the building and in an area where there will be no exposure to the substances listed above.

2 Unitary Products Group

035-19656-001 Rev. B (0404)

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.

Where a minimum amount of air intake/vent piping and elbows will be required.

2.

As centralized with the air distribution as possible.

3.

Where adequate combustion air will be available (particularly when the appliance is not using outdoor combustion air).

4.

Where it will not interfere with proper air circulation in the confined space.

5.

Where the outdoor vent terminal will not be blocked or restricted.

Refer to “VENT CLEARANCES” located in SECTION VII of these instructions. These minimum clearances must be maintained in the installation.

6.

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.

TABLE 1: Unit Clearances to Combustibles

Installation in freezing temperatures:

1.

Furnace shall be installed in an area where ventilation facilities provide for safe limits of ambient temperature under normal operating conditions. Ambient temperatures may fall below 32° F (0° C) providing the flue temperature does not fall below 260° F (127° C) at any point in the flue pipe between the furnace and the chimney or a B-Vent. The flue products will condense in the vent pipe if the flue temperature falls below 260° F (127° C) causing the vent pipe to deteriorate rapidly.

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.

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 an unconditioned space and an extended power failure occurs, there will be potential damage to the internal 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.

Installation in a residential garage:

1.

A gas-fired furnace for installation in a residential garage must be installed so the burner(s) and the ignition source are located not less than 18 inches (46 cm) above the floor, and the furnace must be located or protected to avoid physical damage by vehicles.

APPLICATION

TOP FRONT REAR LEFT SIDE RIGHT SIDE FLUE

In. (cm) In. (cm) In. (cm) In. (cm)

UPFLOW

UPFLOW B-VENT

HORIZONTAL

1 (25.4) 6 (15.24) 0 (0.0)

1 (25.4) 3 (7.62) 0 (0.0)

3

2 6 (15.24) 0 (0.0)

HORIZONTAL B-VENT 0 (0.0) 3 (7.62) 0 (0.0)

0 (0.0)

0 (0.0)

1 (25.4)

1 (25.4)

In. (cm)

3 (7.62)

1

0 (0.0)

0 (0.0)

0 (0.0)

In. (cm)

FLOOR/

BOTTOM

6 (15.24) COMBUSTIBLE




CLOSET ALCOVE ATTIC

LINE

CONTACT

YES

YES

NO

NO

YES

YES

YES

YES

YES

YES

YES

YES

NO

NO

YES

3

YES

3

1.

14-1/2” cabinet models only. All other units “0” clearance.

2.

14-1/2” cabinet left airflow applications only. All other units and right hand airflow applications “0” clearance.

3.

Line contact only permitted between lines formed by the intersection of the rear panel and side panel (top in horizontal position) of the furnace jacket and building joists, studs or framing.

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.

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.

4.

Complete a path for heated or cooled air to circulate through the air conditioning and heating equipment and to and from the conditioned space.

Unitary Products Group 3

035-19656-001 Rev. B (0404)

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 8 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.

DUCTWORK INSTALLATION AND SUPPLY PLENUM

CONNECTION

Attach the supply plenum to the furnace outlet duct connection 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 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.

TABLE 2: Minimum Duct Sizing For Proper Airflow

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. 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.

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.

Ex. The furnace input is 80,000 BTUH and 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 38.4, multiply by 2 for two round ducts which equals 76.8 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 300.8 square inch. This exceeds the recommended 280 square inch of duct.

In this example, the duct system attached to the plenum has a sufficient area so that the furnace operates at the specified external static pressure and within the air temperature rise specified on the nameplate.

Input Airflow Return

1

Rectangular

2

Round

2

Supply

3

BTU/H(kW)

40,000(11.72)

60,000 (17.58)

80,000 (23.44)

80,000 (23.44)

80,000 (23.44)

100,000 (29.31)

100,000 (29.31)

CFM(m³)

1,200(33.98)

1,200 (33.98)

1,200 (33.98)

1,600 (45.31)

2,000 (56.63)

1,200 (33.98)

1,600 (45.31)

In² (cm²)

280 (711)

280 (711)

280 (711)

360 (914)

440 (1,118)

320 (813)

360 (914) in. x in.(cm x cm)

14 x 20 (35.6 x 50.8)

14 x 20 (35.6 x 50.8)

14 x 20 (35.6 x 50.8)

18 x 20 (45.7 x 50.8)

20 x 22 (50.8 x 55.8)

16 x 20 (40.6 x 50.8)

18 x 20 (45.7 x 50.8) in. (cm) dia.

18 (45.7)

18 (45.7)

18 (45.7)

22 (55.8)

24 (60.9)

20 (50.8)

22 (55.8))

In²(cm²)

216 (549)

216 (549)

216 (549)

280 (711)

390 (991)

336 (853)

280 (711)

100,000 (29.31)

115,000 (35.17)

115,000 (35.17)

130,000 (41.03)

2,000 (56.63)

1,600 (45.31)

2,000 (56.63)

2,000 (56.63)

440 (1,118)

360 (914)

440 (1,118)

440 (1,118)

20 x 22 (50.8 x 55.8)

18 x 20 (45.7 x 50.8)

20 x 22 (50.8 x 55.8)

20 x 22 (50.8 x 55.8)

24 (60.9)

22 (55.8))

24 (60.9)

24 (60.9)

390 (991)

280 (711)

390 (991)

390 (991)

NOTE: This chart does not replace proper duct sizing calculations 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 m

3

/ minute).

2.

Example return main trunk duct minimum dimensions.

3.

Maximum supply air velocity in rigid duct @ 900 feet per minute (25.49 m

3

/ minute).

TABLE 3: Round Duct Size

Round Duct Size inches (cm)

5 (13)

6 (15)

7 (18)

8 (20)

9 (23)

10 (25)

11 (28)

12 (30)

13 (33)

14 (36)

Calculated Area For Each Round Duct Size

Sq.in (cm

2

)

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)

1.

The Air Temperature Rise is determined by subtracting the Return

Air Temperature Reading from the Supply Air Temperature Reading.

2.

The External Static Pressure is determined by adding the Supply

Duct Static Pressure reading to the Return Duct Static Pressure reading, adding the pressure across any addlied a-coil and the drop across the return air filter.


035-19656-001 Rev. B (0404)

TABLES 2 & 3 is 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 & 3 IS 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: The minimum plenum height is 12” (30.5 cm). The furnace will not operate properly on a shorter plenum height. The minimum recommended rectangular duct height is 4 inches (10 cm) attached to the plenum.

IMPORTANT: The air temperature rise should be taken only after the furnace has been operating for at least 15 minutes. Temperatures and external static pressures should be taken 6” (15 cm) past the first bend from the furnace in the supply duct and the return duct. If an external filter box or an electronic air cleaner is installed, take the return air readings before the filter box or air cleaner.

If a matching cooling coil is used, it may be placed directly on the furnace outlet and sealed to prevent leakage. Follow the coil instructions for installing the supply plenum. 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.

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.

B

A

FRONT

40

3/4

B

20

13-3/4

GAS INLET

1-1/4 x 2-1/2

28-1/2

LEFT SIDE

D

(VENT CONNECTIONS)

POWER WIRING

7/8” HOLE

5-3/8

2-1/2

32-1/2

ACCESS

WIRING

7/8” K.O.

2

14

16

8-3/4

14-3/4

23-1/2

RIGHT SIDE

T’STAT WIRING

7/8” K.O.

A

C

1-1/8

2-1/4

20

VENT

CONNECTION

(Vent Size)

D

28-1/2

23

(WITH K.O.

REMOVED)

E

F

3/4”

FLANGE

TOP IMAGE

(FRONT)

BOTTOM IMAGE

(FRONT)

All dimensions are in inches and are approximate.

FIGURE 1: Dimensions

TABLE 4: Cabinet and Duct Dimensions

BTUH (kW)

Input/Output

40/32 (11.71/9.38)

60/48 (17.6/14.07)

CFM (m

3

/min)

Cabinet

Size

1200 (33.98)

1200 (33.98)

80/64 (23.42/18.76) 1200 (33.98)

80/64 (23.42/18.76) 1600 (45.31)

A

A

A

B

(23.42/18.76) 2200 C

100/80 (29.28/23.42) 1200 (33.98)

100/80 (29.28/23.42) 1600 (45.31)

B

B

(29.28/23.42) 2000 C

(33.70/26.96) 1600 C

(33.70/26.96) 2000 C

130/104 (38.09/30.48) 2000 (56.63) D

Cabinet Dimension

A A (cm) B B (cm) C C (cm) D D (cm) F F (cm) E E (cm)

14 1/2 36.8 13 1/4 33.6 10 1/8 25.7 4.0 10.2 10 1/8 25.7 3 3/4 9.5

14 1/2 36.8 13 1/4 33.6 10 1/8 25.7 4.0 10.2 10 1/8 25.7 3 3/4 9.5

14 1/2 36.8 13 1/4 33.6 10 1/8 25.7 4.0 10.2 10 1/8 25.7 3 3/4 9.5

17 1/2 44.4 16 1/4 41.3 13 1/8 33.3 4.0 10.2 11 5/8 29.5 3 3/4 9.5

17 1/2

17 1/2

24 1/2

44.4

44.4

62.2

16 1/4

16 1/4

23 1/4

41.3

41.3

59.1

13 1/8

13 1/8

20 1/8

33.3

33.3

51.1

4.0

4.0

4.0

10.2

10.2

10.2

11 5/8

11 5/8

15 1/8

29.5

29.5

27.6

3 3/4

3 3/4

3 3/4

9.5

9.5

9.5


035-19656-001 Rev. B (0404)

RESIDENTIAL AND NON HUD MODULAR HOME

UPFLOW RETURN PLENUM CONNECTION

Return air may enter the furnace through the side(s) or bottom depending on the type of application. Return air may not be connected into the rear panel of the unit. In order to achieve the airflow indicated, it is recommended those applications over 1800 CFM (57 m³/min) use return air from two sides, one side and the bottom or bottom only. For single return application, see data and notes on blower performance data tables in this manual.

BOTTOM RETURN AND ATTIC INSTALLATIONS

Bottom return applications normally pull return air through a base platform or return air plenum. Be sure the return platform structure or return air plenum is suitable to support the weight of the furnace.

The furnace base is equipped with a rectangular perforated panel that can be removed by performing the following steps:

1.

Lay the furnace on its back.

2.

Push the panel out from inside the blower compartment.

3.

Bend the 3/4”(1.9 cm) flanges that will be used to attach the return air plenum using the scribe marks in the furnace base. Refer to

Figure 1 “Bottom Image Return End” and Figure 2 for flange locations.

4.

Be sure to seal the furnace to plenum connections to prevent air leakage. Refer to Figure 1 for unit and plenum dimensions.

Attic installations must meet all minimum clearances to combustibles and have floor support with required service accessibility.

There are 8 Tabs to be cut along this seam around the rectangular panel.

Removable rectangular base panel.

Scribe marks in base panel.

Bend sheet metal down on these marks to form the 3/4” flanges.

FIGURE 2: Furnace Base Rectangular Perforated Panel

IMPORTANT: If an external mounted filter rack is being used see the instructions provided with that accessory for proper hole cut size.

HORIZONTAL MODELS

Horizontal Installations With a Cooling Coil Cabinet

The furnace should be installed with coil cabinet part number specifically intended for Horizontal application. If a matching cooling coil is used, it may be placed directly on the furnace outlet and sealed to prevent leakage. Follow the coil instructions for installing the supply plenum. For details of the coil cabinet dimensions and installation requirements, refer to the installation instructions supplied with the coil cabinet

The perforations in the wrapper flanges must be bent away from the heat exchanger to create duct flanges so the air conditioning coil can be properly seated on the furnace.

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 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 air conditioning coil can overheat and melt.

Refer to the installation instructions supplied with the air conditioning coil for additional information.

Horizontal Installations Without a Cooling Coil Cabinet

When installing this appliance, the furnace must be installed so as to create a closed duct system, the supply duct system must be 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.

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.

Residential and Non Hud Modular Home Horizontal Return

Plenum Connections

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 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.

ATTIC INSTALLATION

SUPPLY AIR

LINE CONTACT ONLY PERMISSIBLE

BETWEEN LINES FORMED BY THE

INTERSECTION OF FURNACE TOP

AND TWO SIDES AND BUILDING

JOISTS, STUDS OR FRAMING

FILTER RACK

MUST BE A MINIMUM

DISTANCE

OF 18” (45.7 cm)

FROM THE

FURNACE

GAS PIPING

12”

VENT (Maintain required clearances to combustibles)

SHEET METAL

IN FRONT OF

FURNACE

COMBUSTION AIR

OPENINGS IS

RECOMMENDED

30” MIN.

WORK AREA

RETURN AIR SEDIMENT

TRAP

FIGURE 3: Typical Attic Installation


This appliance is design certified for line contact when the furnace is installed in the horizontal left or right position. The line contact is only permissible between lines that 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.

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.

SUSPENDED FURNACE / CRAWL SPACE

INSTALLATION

The furnace can be hung from floor joists 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 platform constructed of plywood or other building material secured to the floor joists. Refer to Figure 4 for typical crawl space installation.

ANGLE IRON

BRACKET

SUPPORT

ROD

1” MAX. BETWEEN

ROD & FURNACE

6” MIN BETWEEN

ROD & FURNACE

1” MAX. BETWEEN

ROD & FURNACE

FIGURE 4: Typical Suspended Furnace / Crawl Space Installation

035-19656-001 Rev. B (0404)

TABLE 5: Filter Sizes

BTU/H (kW)

Input / Output

CFM

(m³/min)

40/32

(11.71/9.38)

60/48

(17.57/14.07)

80/64

(23.42/18.76)

80/64

(23.42/18.76)

80/64

(23.42/18.76)

100/80

(29.28/23.42)

100/80

(29.28/23.42)

100/80

(29.28/23.42)

115/92

(33.70/26.96)

115/92

(33.70/26.96)

130/104

(38.09/30.48)

1200

(33.98)

1200

(33.98)

1200

(33.98)

1600

(45.31)

2200

(62.30)

1200

(33.98)

1600

(45.31)

2000

(56.63)

1600

(45.31)

2000

(56.63)

2000

(56.63)

Cabinet

Size

A

A

A

B

C

B

B

C

C

C

D

Side

(in)

(2)

16 x 25

(2)

16 x 25

Side

(cm)

(2)

40.6 x 63.5

(2)

40.6 x 63.5

(2)

40.6 x 63.5

(2)

40.6 x 63.5

Bottom

(in)

Bottom

(cm)

16 x 25 40.6 x 63.5 14 x 25 35.6 x 63.5

16 x 25 40.6 x 63.5 14 x 25 35.6 x 63.5

16 x 25 40.6 x 63.5 14 x 25 35.6 x 63.5

16 x 25 40.6 x 63.5 16 x 25 40.6 x 63.5

16 x 25 40.6 x 63.5 16 x 25 40.6 x 63.5

16 x 25 40.6 x 63.5 16 x 25 40.6 x 63.5

16 x 25 40.6 x 63.5 20 x 25 50.8 x 63.5

(2)

16 x 25

(2)

16 x 25

INTERNAL INSTALLATION

20 x 25 50.8 x 63.5

20 x 25 50.8 x 63.5

20 x 25 50.8 x 63.5

22 x 25 55.9 x 63.5

1.

Select desired filter position (left/right side, and/or bottom).

Remove the corresponding cabinet cutouts per instructions provided.

2.

Install snap-in retainer clips into the corresponding slots from the outside rear of the cabinet (Refer to Figure 5.) To prevent cabinet air leaks, install snap-in plugs (provided) into the unused slots at the outside rear of the cabinet.

CABINET

SLOT

LEFT

SIDE

SLOTS

FILTER SUPPORT

CLIPS ( provided)

RIGHT

SIDE

SLOTS

BOTTOM SLOTS

FIGURE 5: Furnace Filter Slot Locations

POSITION WIRE RETAINER

(IF PROVIDED) UNDER FLANGE

PLUG UNUSED

CABINET SLOTS

WITH PLUGS

(provided)

In any application where temperatures below freezing are possible, see “BELOW FREEZING LOCATIONS”.

SECTION III: FILTERS

FILTER INSTALLATION

All applications require the use of an internal or external filter. Filter(s) and the filter retainer are not provided on all models Some models are shipped with a high velocity filter that must be field installed. A field-supplied internal or external filter and filter retainer hardware must be provided if the filter and the filter retainer are not shipped with the furnace.

Refer to Table 4 for the recommended filter size.

CLIPS

IF FILTER

PROVIDED

RIGHT SIDE

INSTALLATION

SHOWN

FIGURE 6: Filter Retainer Placement

FURNACE

FRONT


035-19656-001 Rev. B (0404)

3.

Install the wire retainer inside the cabinet (if provided). Insert the open ends of the wire retainer into the clip loops at the rear of the blower compartment. The retainer wire should pivot freely like a hinge, on the clips at the rear of the cabinet. (Refer to Figure 6).

4.

Install the filter(s) if provided. Cut filter if necessary to match air opening in cabinet. Filter should extend beyond opening edge as much as possible to prevent air from bypassing the filter. DO NOT remove stiffening rods from inside the filter. Shorten the rods, if necessary, to match final filter size.

5.

Position the filter between the wire retainer and the cabinet wall (or floor) so it completely covers the cabinet air opening and secure the filter in place at the front of the cabinet by fastening the closed

(looped) end of the retainer wire under the flanged edge of the cabinet. When properly installed the filter should fit flush with all four sides of the cabinet wall.

NOTE: Air velocity through throwaway type filters may not exceed 300 feet per minute (91.4 m/min). All velocities over this require the use of high velocity filters.

SIDE RETURN - EXTERNAL INSTALLATION

Locate and knock out the square corner locators. These indicate the size of the cutout to be made in the furnace side panel. Refer to Figure 7.

All installations must have a filter installed.

FRONT OF

FURNACE

CORNER

MARKINGS

FIGURE 7: Side Return Cutout Markings

Install the side filter rack following the instructions provided with that accessory. If a filter(s) is provided at another location in the return air system, the ductwork may be directly attached to the furnace side panel. An accessory filter rack is available for mounting the filter external to the cabinet.

IMPORTANT: Some accessories such as electronic air cleaners and pleated media may require a larger side opening. Follow the instructions supplied with that accessory for side opening requirements. Do not cut the opening larger than the dimensions shown in Figure 1.

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” (45.7 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.

SECTION IV: GAS PIPING

GAS SAFETY

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.

OUTLET

PRESSURE

PORT

INLET

VENT PORT

OUTLET

WRENCH

BOSS

INLET

PRESSURE

PORT

OFF

ON

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.

The pressure ports on the gas valve are marked OUT P and IN

P.

2.

The manifold pressure must be taken at the port marked OUT P.

3.

The inlet gas supply pressure must be taken at the port marked

IN P.

4.

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.

5.

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.

6.

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 6: Inlet Gas Pressure Range

INLET GAS PRESSURE RANGE

Minimum

Maximum

Natural Gas

4.5” W.C. (1.12 kPa)

10.5” W.C. (2.61 kPa)

Propane (LP)

8.0” W.C. (1.99 kPa)

13.0” (3.24 kPa) W.C.

IMPORTANT: The inlet gas pressure operating range table specifies what the minimum and maximum gas line pressures must be for the furnace to operate safely. The gas line pressure MUST BE a minimum of:

• 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.


035-19656-001 Rev. B (0404)

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.

EXTERNAL MANUAL

SHUTOFF VALVE

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 1 dimensions.

GAS ORIFICE CONVERSION FOR PROPANE (LP)

This furnace is constructed at the factory for natural gas-fired operation, but may be converted to operate on propane (LP) gas by using a factory-supplied LP conversion kit. Follow the instructions supplied with the LP kit. Refer to Table 7 or the instructions in the propane (LP) conversion kit for the proper gas orifice size.

DRIP

LEG

TO GAS

SUPPLY

GROUNDED JOINT UNION

MAY BE INSTALLED

INSIDE OR OUTSIDE UNIT.

TO GAS

SUPPLY

FIGURE 9: 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 cannot take any external pressure. 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.

TABLE 7: High Altitude Conversion

Type

Of Gas

Natural

Propane

Orifice at

Sea Level

#45

#55

2,000 ft.

(610 m)

#46

#55

3,000 ft.

(914 m)

#47

#55

4,000 ft.

(1219 m)

#47

#55

5,000 ft.

(1524 m)

#47

#56

LoNOx furnaces requiring propane (LP) gas must have the LoNOx screens removed prior to installation and operation. See propane instructions 035-14445-000 or the start up procedure at the back of these instructions on proper removal of the NOx screens.

HIGH ALTITUDE GAS ORIFICE CONVERSION

This furnace is constructed at the factory for natural gas-fired operation at 0 – 2,000 ft. (0 m – 610 m) above sea level.

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.

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 7 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.

HIGH ALTITUDE PRESSURE SWITCH CONVERSION

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. For altitudes above 4,500 feet (137 m), refer to Instructions in the Accessory High Altitude Kit.

6,000 ft.

(1829 m)

#48

#56

7,000 ft.

(2134 m)

#48

#56

8,000 ft.

(2438 m)

#49

#56

9,000 ft.

(2743 m)

#49

#56

10,000 ft.

(3048 m)

#50

#57

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.


035-19656-001 Rev. B (0404)

SECTION V: ELECTRICAL POWER

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 8 in these instructions for specific furnace electrical data.

TABLE 8: Ratings & Physical / Electrical Data - Upflow Models

Use copper conductors only.

Input Output Nominal Cabinet Width Air Temp. Rise

MBH kW MBH kW CFM cmm In. cm AFUE

40 11.7 32 9.4 1200 34.0 80.0

60 17.6 48 14.1 1200 34.0 80.0

80 23.5 64 18.8 1200 34.0 80.0

17 80.0

80 23.0 64 18.8 2200 62.3 21 53.3 80.0

100 29.3 80 23.4 1200 34.0 17 80.0

100 29.3 80 23.4 1600 45.3 17 80.0

100 29.3 80 23.4 2000 56.6 21 53.3 80.0

115 33.7 92 26.9 1600 45.3 21 53.3 80.0

115 33.7 92 26.9 2000 56.6 21 53.3 80.0

130 38.1 104 30.5 2000 56.6 24-1/2 62.2 80.0

Input

Max. Outlet

Air Temp

Blower

Blower

Size

Total

Unit

°F

25-55

25-55

35-65

25-55

25-55

40-70

35-65

25-55

35-65

30-60

35-65

Max Over-current

Size (awg) @ 75 ft.

MBH kW

40 11.7

60

80

17.6

23.5

80

80

23.5

23.0

100 29.3

100 29.3

100 29.3

115 33.7

115 33.7

130 38.1

°F

155

155

170

155

165

170

165

155

170

170

165

°C Hp Amps In.

68.3

1/3 6.2 cm

10 x 7 25.4 x 17.7 amps

9.0

68.3

76.7

1/3

1/3

6.2

6.2

10 x 7 25.4 x 17.7

10 x 7 25.4 x 17.7

9.0

9.0

68.3

73.9

76.7

73.9

3/4

1.0

1/2

1/2

11.5

12.2

7

10.4

11 x 8 27.9 x 20.3

11 x 10 27.9 x 25.4

10 x 8 25.4 x 20.3

10 x 10 25.4 x 25.4

12.0

14.0

12.0

12.0

68.3

76.7

76.7

73.9

1.0

1/2

1.0

1.0

12.2 11 x 10 27.9 x 25.4 14.0

10.4 10 x 10 25.4 x 25.4 12.0

12.2 11 x 10 27.9 x 25.4 14.0

12.2 11 x 10 27.9 x 25.4 14.0 protect

20

20

20

20

20

20

20

20

20

20

20

°C

13-31

13-31

19-36

13-31

13-31

22-39

19-36

13-31

19-36

17-33

19-36

Min.

Wire

Operation

WGT.

14

14

14

14

12

14

14

12

14

12

12

105

110

117

126

140

128

134

145

145

147

158

Operation

WGT.

Kg

47.6

49.9

53.1

57.2

63.5

58.1

60.8

65.8

65.8

66.7

71.7

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.

SUPPLY VOLTAGE CONNECTIONS

1.

Provide a power supply separate from all other circuits. Install overcurrent protection and disconnect switch per local/national electrical codes. The switch should be close to the unit for 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.

BLK/BLK

WHT/WHT

GRN/GRN

JUNCTION

BOX

2.

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” (5.1 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.

3.

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

DOOR SWITCH

TRANSFORMER

IGNITION MODULE

Y W RGC

BURNER COMPARTMENT

FIGURE 10: Electrical Wiring

L1

HOT

N

GND

BLK

WHT

GRN

CLASS 2 SYSTEM

CONTROL WIRING

TO THERMOSTAT

LOW VOLTAGE CONTROL WIRING CONNECTIONS

Install the field-supplied thermostat by following the instructions that come with the thermostat. With the thermostat set in the OFF position and the main electrical source disconnected, connect the thermostat wiring from the wiring connections on the thermostat to the terminal board on the ignition module, as shown in Figure 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.


035-19656-001 Rev. B (0404)

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

WHT

GRN

BLK (HOT)

WHT (NEUTRAL)

GRN

NOMINAL

120 VOLT

FIGURE 11: Line Wiring Connections

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.

ROOM

THERMOSTAT

R

W

G

Y

C

FURNACE

CONTROL

R

W

G

Y

C

UNIT

TO AIR CONDITIONER

CONTROLS

CONDENSING

COMMON T’STAT CONNECTION

Before installing the relay and wiring, disconnect electrical power to both furnaces. Failure to cut power could result in electrical shock or equipment damage.

FIGURE 12: 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

HUMIDIFER

BLK

WHT

EAC

HUM

SWITCHED

CIRCUITS

EAC HOT

115 VOLT

ELECTRONIC

AIR CLEANER

BLK

WHT

NEUTRALS

FIGURE 13: Accessory Connections

ELECTRONIC AIR CLEANER CONNECTION

Two 1/4” (6.4 mm) spade terminals (EAC and EAC N) for electronic air cleaner connections are located on the control board. The terminals provide 115 VAC (1.0 amp maximum) during circulating blower operation.

HUMIDIFIER CONNECTION

Two 1/4” (0.64 cm) spade terminals (HUM and HUM N) 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: There are two different integrated control modules that can be used on these models. They are part # 031-01933-000 and 031-

01267-001.

You can twin two 031-01933-000 integrated control modules or two 031-01267-001 integrated control modules. You cannot

twin one 031-01933-000 integrated control module and one

031-01267-001 integrated control module. The two integrated control modules do not communicate with each other so they will not work in a twinning application.

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 return 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.

VENT PIPE

ELECTRICAL

SUPPLY

COMMON

SUPPL

PLENUM

Y

GAS SUPPLY

(both sides)

1 COIL FOR

EACH FURNACE

SUPPLY

AIR

FIGURE 14: Typical Twinned Furnace Application


035-19656-001 Rev. B (0404)

IMPORTANT: When two furnaces are twinned, typical system total airflow will be approximately 85% of additive individual furnaces, i.e., two

2000 CFM units will yield a total 3400 CFM.

FURNACE 1 CONTROL BOARD

C

R

Y

W

G

TWIN

ISOLATION

RELAY


R

Y

W

G

C

TWIN

If a return duct is connected to only one furnace (with a connection between the two furnaces) an imbalance in the airflow will occur and the furnace furthest from the return plenum will overheat.

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.

Connect the low voltage wiring from the wall thermostat to the terminal strip on the control board of Furnace #1.

2.

Connect a wire from the TWIN terminal of Furnace #1 to the TWIN terminal of Furnace #2.

3.

Install a separate 24V relay as shown in the diagram below. Use of this relay is required, as it ensures that the transformers of the two furnaces are isolated, thus preventing the possibility of any safety devices being bypassed.

Single-Wire Twinning Operation

Heating - On a call for heat (W signal) from the wall thermostat, both furnaces will start the ignition sequence and the burners on both 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.

Cooling - On a call for cooling (Y signal) from the wall thermostat, both furnace blowers will come on at the same time in cooling speed. When the thermostat is satisfied, both blowers will stay on for 60 seconds, then will shut off at the same time.

Continuous Fan - On a thermostat call for continuous fan (G signal), both furnace blowers will come on at the same time in cooling speed and will stay on until the G signal is removed.

TO A/C W G R Y

WALL THERMOSTAT

FIGURE 15: 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 Figure 16.

1.

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.

2.

Connect a wire from the TWIN terminal of Furnace #1 to the TWIN terminal of Furnace #2.

3.

Install a separate 24V relay as shown in the diagram below. Use of this relay is required, as it ensures that the transformers of the two furnaces are isolated, thus preventing the possibility of any safety devices being bypassed.

Single-Wire Staging Operation

Heating - On a call for first-stage heat (W1 signal) from the wall 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.

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.


035-19656-001 Rev. B (0404)

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.


W

R

Y

G

C

TWIN

ISOLATION

RELAY


W

G

C

R

Y

TWIN

TO A/C

WALL OR

PARAPET

RIDGE

W1 G

WALL THERMOSTAT

FIGURE 16: Two-Stage Twinning Wiring Diagram

SECTION VII: VENT SYSTEM

VENT SAFETY

This Category I, furnace is designed for residential application. It may be installed without modification in a basement, garage, equipment room, alcove, attic or any other indoor location where all required clearance to combustibles and other restrictions are met.

MORE THAN

10 FT (3.0 M)

R Y W2

3 FT (0.9 m)

MIN.

NOTE: NO

HEIGHT ABOVE

PARAPET REQUIRED

WHEN DISTANCE

FROM WALLS OR

PARAPET IS MORE

THAN 10 FT (3.0 m).

CHIMNEY

MORE THAN

10 FT (3.0 M)

2 FT(0.6 m)

MIN

HEIGHT ABOVE ANY

ROOF SURFACE WITHIN

10 FT (3.0 m) HORIZONTALLY

3 FT (0.9 m)

MIN

CHIMNEY

FIGURE 17: Vent Termination

LOWEST DISCHARGE OPENING

LISTED CAP

LISTED GAS

VENT

12

X

ROOF PITCH

IS X/12

H (min) - MINIMUM HEIGHT FROM ROOF

TO LOWEST DISCHARGE OPENING

FIGURE 18: Vent Termination

TABLE 9: Roof Pitch

ROOF PITCH H(min) ft m

Flat to 6/12

6/12 to 7/12

Over 7/12 to 8/12

Over 8/12 to 9/12

Over 9/12 to 10/12

Over 10/12 to 11/12

Over 11/12 to 12/12

Over 12/12 to 14/12

Over 14/12 to 16/12

Over 16/12 to 18/12

Over 18/12 to 20/12

Over 20/12 to 21/12

1.0

1.25

1.5

2.0

2.5

3.25

4.0

5.0

6.0

7.0

7.5

8.0

0.30

0.38

0.46

0.61

0.76

0.99

1.22

1.52

1.83

2.13

2.27

2.44

CATEGORY 1 - 450 F. MAX. VENT TEMP.

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.

The furnace shall be connected to any type of B, BW or L vent connector, and shall be connected to a factory-built or masonry chimney. The furnace shall not be connected to a chimney flue serving a separate appliance designed to burn solid fuel.

The furnace rating plate lists the maximum vent gas temperature. This temperature must be used to select the appropriate venting materials and clearances.

It is recommended that the appliance is installed in a location where the space temperature is 32 °F (0°C) or higher. If the appliance is installed in a location where the ambient temperature is below 32 °F (0°C), the combustion byproducts could condense causing damage to the appliance heat exchanger.

IMPORTANT: The “VENT SYSTEM” must be installed as specified in these instructions for Residential and Non HUD Modular Homes.

This appliance may be common vented with another gas appliance for residential installations as allowed by the codes and standards listed in these instructions.

Non-HUD approved Modular Homes must be vented with an approved roof jack and may not be common vented with other appliances.

VENTING

Category I venting consists of vertically venting one or more appliances in B-vent or masonry chimney (as allowed), using single wall metal pipe or B-vent connectors. Type B-vent system extends in a general vertical direction and does not contain offsets exceeding 45 degrees. A vent system having not more than one 60 degree offset is permitted.

If installing furnace at altitudes between 2000 - 4500 ft. (610 – 1372 m), vent pipe length must be reduced by 10 ft. (3.05 m). If the installation requires the maximum allowable vent pipe length, the furnace must be converted for high altitude operation. Refer to SECTION IV “GAS PIP-

ING” of these instructions and the proper high altitude application instruction for details.

VENTING INTO AN EXISTING CHIMNEY

For Category I installations, the furnace shall be connected to a factory built chimney or vent complying with a recognized standard, or a masonry or concrete chimney lined with a material acceptable to the authority having jurisdiction. Venting into an unlined masonry chimney or concrete chimney is prohibited.

Whenever possible, B-1 metal pipe should be used for venting. Where use of an existing chimney is unavoidable, the following rules must be followed:

1.

The masonry chimney must be built and installed in accordance with nationally recognized building codes or standards and must be lined with approved fire clay tile flue liners or other approved liner material that will resist corrosion, softening, or cracking from flue gases. THIS FURNACE IS NOT TO BE VENTED INTO AN

UNLINED MASONRY CHIMNEY.


035-19656-001 Rev. B (0404)

2.

This furnace must be vented into a fire clay tile lined masonry chimney only if a source of dilution air is provided, such as by common venting with a draft hood equipped water heater. If no source of dilution air is available, Type B vent must be used, or masonry chimney vent kit 1CK0603 or 1CK0604 must be used. Refer to the instructions with the kit to properly apply these masonry chimney kits.

3.

The chimney must extend at least 3 ft (0.91 m) above the highest point where it passes through a roof of a building and at least two feet higher than any portion of the building with a horizontal distance of ten feet.

4.

The chimney must extend at least 5 ft (1.5 m) above the highest equipment draft hood or flue collar.

HORIZONTAL SIDEWALL VENTING

For applications where vertical venting is not possible, the only approved method of horizontal venting is the use of an auxiliary power vent. Approved power venters are Fields Controls Model SWG-4Y or

Tjernlund Model GPAK-JT. Follow all application and installation details provided by the manufacturer of the power vent.

FAN ASSISTED FURNACE

& WATER HEATER

FAN ASSISTED

FURNACES

EXTERIOR

VENT HOOD

FURNACE

VENT

PIPE

OPTIONAL

SIDEWALL

VENT SYSTEM

(field supplied)

HOT

WATER

TANK

VENT PIPE

VENT

DAMPER

FLUE

PIPE

TOP

COVER

OPTIONAL

SIDEWALL

VENT SYSTEM

(field supplied)

CELLAR

WALL

BURNER

ACCESS

PANEL

FIGURE 20: Typical Sidewall Vent and Termination Configuration

VENT PIPING ASSEMBLY

The final assembly procedure for the vent piping is as follows:

1.

Cut piping to the proper length beginning at the furnace.

2.

Deburr the piping inside and outside.

3.

Dry-fit the vent piping assembly from the furnace to the termination checking for proper fit support and slope. Piping should be supported with pipe hangers to prevent sagging. The maximum spacing between hangers is 5 feet (1.5 m).

4.

Assemble the vent piping from the furnace to the termination securing the pipe connections with screws.

VENT CLEARANCES

IMPORTANT: The vent must be installed with the following minimum clearances as shown in Figures 17 & 18, must comply with local codes and requirements.

FIGURE 19: Typical Sidewall Vent Application

TABLE 10: Horizontal Venting

Heating

Input

BTU/H

40,000

60,000

80,000

80,000

80,000

100,000

100,000

100,000

115,000

115,000

130,000

Heating

Input kW

11.72

17.58

23.44

23.44

23.44

29.31

29.31

29.31

33.70

33.70

38.10

Heating

Output

BTU/H

32,000

48,000

64,000

64,000

64,000

80,000

80,000

80,000

92,000

92,000

104,000

Heating

Output kW

9.38

14.07

18.76

18.76

18.76

23.45

23.45

23.45

26.96

26.96

30.48

Furnace

Airflow

CFM

1200

1200

1200

1600

2200

1200

1600

2000

1600

2000

2000

Furnace

Airflow cm/m

33.98

33.98

33.98

45.31

62.30

33.98

45.31

56.63

45.31

56.63

56.63

4

4

4

4

4

4

4

4

Horizontal Vent Length Ft (m) with 4 Elbows

Pipe Size

Min. Vent Length Max. Vent Length

Inches cm

4 10.16

Feet

4.5

meters

1.37

Feet

34.5

meters

10.82

4

4

10.16

10.16

10.16

10.16

10.16

10.16

10.16

10.16

10.16

10.16

4.5

4.5

4.5

4.5

4.5

4.5

4.5

4.5

4.5

4.5

1.37

1.37

1.37

1.37

1.37

1.37

1.37

1.37

1.37

1.37

34.5

34.5

34.5

34.5

34.5

34.5

34.5

34.5

34.5

34.5

10.82

10.82

10.82

10.82

10.82

10.82

10.82

10.82

10.82

10.82


035-19656-001 Rev. B (0404)

VENT CLEARANCES

A

V

G

V

VENT TERMINAL

D

V

E

L

V

B

FIXED

CLOSED

C

F

B

V

V

H

B

B

B

V

I

B

V

V

J

X

OPERABLE

M

V

K

X

FIXED

CLOSED

X AIR SUPPLY

AREA WHERE TERMINAL IS NOT PERMITTED

FIGURE 21: Home Layout

Canadian Installations

1

A. Clearance above grade, veranda, porch, deck, or balcony

B. Clearance to window or door that may be opened

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)

“ 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 other appliance

“

“

“

“

3 feet (91 cm) within a height 15 feet (4.5 m) above the meter/regulator assembly

3 feet (91 cm)


≤ 10,000 Btuh (3kW),



K. Clearance to a mechanical supply inlet 6 feet (1.83 m)

L. Clearance above paved sidewalk or paved driveway located on public property 7 feet (2.13 m) †

M.Clearance under veranda, porch, deck, or balcony 12 inches (30 cm)

‡

Dryer Vent 3 ft (91.44 cm)

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

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)

Not less than 18" (46 cm)

US Installation

2

12 inches (30 cm)


≤ 10,000 Btuh (3kW),



“

“

“

“

“

“

“


≤ 10,000 Btuh (3kW),



3 feet (91 cm) above if within 10 feet (3 cm) horizontally

“

“

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)

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.

† A vent shall not terminate 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 adjacent 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 corrosion resistant material to protect against combustion product corrosion. Consideration must be given to wind direction in order to prevent flue products and/or condensate from being blown against the building surfaces. If a metal shield is used it must be a stainless steel material at a minimum dimension of 20 inches. It is 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.

HORIZONTAL VENT APPLICATIONS AND

TERMINATION

When selecting the location for a horizontal combustion air / vent termination, the following should be considered:

1.

Observe all clearances listed in vent clearances in these instructions.

2.

Termination should be positioned where vent vapors will not damage plants or shrubs or air conditioning equipment.

3.

Termination should be located where it will not be affected by wind gusts, light snow, airborne leaves or allow recirculation of flue gases.

4.

Termination should be located where it will not be damaged or exposed to flying stones, balls, etc.

5.

Termination should be positioned where vent vapors are not objectionable.

6.

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).

FAN-ASSISTED COMBUSTION SYSTEM

An appliance equipped with an integral mechanical means to either draw or force products of combustion through the combustion chamber and/or heat exchanger.


035-19656-001 Rev. B (0404)

Ambient Combustion Air Supply

This type installation will draw the air required for combustion from within the space surrounding the appliance and from areas or rooms adjacent to the space surrounding the appliance. This may be from within the space in a non-confined location or it may be brought into the furnace area from outdoors through permanent openings or ducts. 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.

COMBUSTION AIR VENT PIPE CEMENTS

INTO SOCKET JUST

ABOVE TOP PANEL

CHIMNEY OR

GAS VENT

VENTILATION LOUVERS

(each end of attic)

OUTLET

AIR

INLET AIR DUCT

[ends 1 ft (30 cm) above floor]

FIGURE 22: Combustion Airflow Path Through The Furnace Casing to the Burner Box

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 MONOX-

IDE, which can lead to serious injury, property damage and / or death.

An unconfined space is not less than 50 cu.ft (1.42 m

3

) 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.

A confined space is an area with less than 50 cu.ft (1.42 m

3

) 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.

CHIMNEY OR

GAS VENT

VENTILATION LOUVERS

(each end of attic)

FIGURE 24: Air Inlet, Outlet and Chimney Connections

Combustion Air Source From Outdoors

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 11, to estimate free area.

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 of louvers and grille varies widely; the installer should follow louver or grille manufacturer’s instructions.

Dampers, Louvers and Grilles (Canada Only)

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.

2.

Apertures in a fixed louver, a grille, 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.

CHIMNEY OR

GAS VENT

OPENING

OUTLET

AIR

INLET

AIR

ALTERNATE

AIR INLET

VENTILATION LOUVERS FOR UNHEATED CRAWL SPACE

FIGURE 23: Atlernate Air Intake, Air Outlet and Chimney Connections

FIGURE 25: Typical Chimney Connections

OPENING


OUTLET

AIR DUCT

INLET

AIR DUCT

FIGURE 26: Horizontal Air Inlet, Outlet and Chimney Connections

When a Category I furnace is removed or replaced, the original venting system may no longer be correctly sized to properly vent the attached appliances.

An improperly sized vent system can cause CARBON MONOXIDE to spill into the living space causing personal injury, and or death.

035-19656-001 Rev. B (0404)

TABLE 12: Free Area

BTUH Input

Rating

40,000

Minimum Free Area Required for Each Opening

Vertical Duct or

Horizontal Duct

(2,000 BTUH)

Opening to Outside

(4,000 BTUH)

Round Duct

(4,000 BTUH)

20 in

2

(129 cm

2

) 10 in

2

(64 cm

2

) 4” (10 cm)

60,000

80,000

100,000

30 in

2

(193 cm

2

)

40 in

2

(258 cm

2

)

50 in

2

(322 cm

2

)

60 in

2

(387 cm

2

)

15 in

20 in

2

25 in

2

2

(97 cm

2

(129 cm

2

(161 cm

2

)

)

)

5” (13 cm)

5” (13 cm)

6” (15 cm)

120,000

130,000 65 in

2

(419 cm

2

)

EXAMPLE: Determining Free Area.

30 in

2

(193 cm

2

)

33 in

2

(213 cm

2

)

7” (18 cm)

7” (18 cm)

Appliance 1Appliance

100,000 + 30,000 = (130,000

÷ 4,000) = 32.5 Sq. In. Vertical

Appliance 1Appliance

100,000 + 30,000 = (130,000

÷ 2,000) = 65 Sq. In. Horizontal

TABLE 13: Unconfined Space Minimum Area in Square Inch

BTUH Input Rating

40,000

60,000

80,000

100,000

120,000

130,000

Minimum Free Area in Square Feett

Required for Each Opening

250 (23.23 m

2

)

375 (34.84 m

2

)

500 (46.45 m

2

)

625 (58.06 m

2

)

750 (69.68 m

2

)

813 (75.53 m

2

)

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

SOFFIT

VENT

GABLE

VENT

OPTIONAL

INLET (a)

VENTILATED

ATTIC

TOP ABOVE

INSULATION

OUTLET

AIR (a)

GAS

VENT

AIR SUPPLY OPENINGS AND DUCTS

1.

An opening may be used in lieu of a duct to provide to provide the outside air

2.

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.

The duct shall be either metal, or a material meeting the class 1 requirements of CAN4-S110 Standard for Air Ducts.

OUTLET

AIR (b)

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.

GAS

VENT

OUTLET

AIR (a)

GAS

WATER

HEATER

VENTILATED

CRAWL SPACE

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.

5. A square or rectangular shaped duct shall only be used when the required free area of the supply opening is duct is used, its small dimensionshall not be less than

3 in (7.6 cm).

6. An air inlet supply from outdoors shall be equipped with a means to prevent the direct entry of rain and wind.

Such means shall not reduce the required free area of the air supply opening.

7.

An air supply inlet opening from the outdoors shall be located not less than 12” (30.5 cm) above the outside grade level.

SOFFIT

VENT

INLET

AIR (b)

GABLE

VENT

VENTILATED

ATTIC

TOP ABOVE

INSULATION

GAS

WATER

HEATER

GAS

VENT

INLET

AIR (b)

GAS

WATER

HEATER

INLET

AIR (a)

INLET

AIR (a)

COMBUSTION AIR SOURCE FROM OUTDOORS

1. Two permanent openings, one within 12 in (30.5 mm) of the top and one within 12 in (30.5 mm) of bottom of the confined space, permanent openings,

Two 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.

b.

input rating of all equipment located in the enclosure.

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.

4. The blocking effects of louvers, grilles and screens must be given consideration in calculating free area. If the free area of a specific louver aor grille is not known.

FIGURE 27: Outside and Ambient Combustion Air


035-19656-001 Rev. B (0404)

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 COM-

BUSTION 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.

Vent and Supply (Outside) Air Safety Check Procedure

For Category I furnaces, vent installations shall be in accordance with

Parts 7 and 11 of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, and or Section 7 and Appendix B of the CSA B149.1, Natural Gas and

Propane Installation Codes, the local building codes, furnace and vent manufacture's instructions.

Multi-story or common venting systems are permitted and must be installed in accordance with the National Fuel Gas Code, ANSI Z223.1/

NFPA 54 and / or the CSA B149.1, Natural Gas and Propane Installation Codes, local codes, and the manufacture's instructions.

Vent connectors serving Category I furnaces shall not be connected into any portion of mechanical draft systems operating under positive pressure.

Horizontal portions of the venting system shall be supported to prevent sagging using hangers or perforated straps and must slope upwards not less than 1/4" per foot (0.635 cm/m) from the furnace to the vent terminal.

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.

CARBON MONOXIDE POISONING HAZARD

Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbonmonxide poisoning or death.

The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances connected to the venting system are not in operation:

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.

NOTE: An unsafe condition exists when the CO reading exceeds 40 ppm and the draft reading is not in excess of - 0.1 in. W.C. (-25 kPa) with all of the appliance(s) operating at the same time.

8. 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.

SECTION VIII: 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.

BLOWER DOOR SAFETY SWITCH

This unit is equipped with an electrical interlock switch mounted in the blower compartment. This switch interrupts all power at the unit when the panel covering the blower compartment is removed.

Electrical supply to this unit is dependent upon the panel that covers the blower compartment being in place and properly positioned.

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.

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.


035-19656-001 Rev. B (0404)

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 28 for tubing connections.

1.

Blockage of vent piping or terminal.

2.

Failure of combustion air blower motor.

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.

IGNITION SYSTEM SEQUENCE

1.

Turn the gas supply ON at external valve and main gas valve.

2.

Set the thermostat above room temperature to call for heat.

3.

System start-up will occur as follows: a.

The induced draft blower motor will start and come up to speed. Shortly after inducer start-up, the hot surface igniter will glow for about 17 seconds.

b.

After this warm up, the ignition module will energize (open) the main gas valve.

c.

After flame is established, the supply air blower will start in about 30 seconds.

FIGURE 28: Pressure Switch Tubing Routing

LIMIT CONTROLS

There is a 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 3 consecutive times. Control will reset & try ignition again after 1 hour.

SECTION IX: START-UP AND

ADJUSTMENTS

The initial start-up of the furnace requires the following additional procedures:

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. 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”

(10.0 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

• 1 – 5/16” (0.8 cm) x 1/8” (3.175 mm) reducing coupling

• 1 – 1/8” (0.3 cm) adapter

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/Ft

3

(39.12 MJ/m

3

). 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 m

3

.) of gas.

3.

Calculate the furnace input by using one of the following equations.


035-19656-001 Rev. B (0404)

In the USA use the following formula to calculate the furnace input.

For natural gas multiply the heat content of the gas BTU/SCF (or Default 1030 BTU/SCF (38.4 MJ/m

3

), 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 MJm

3

), 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/f

3

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/f

3

x 2 cu.ft. x 0.960 x 3600


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/m

3

(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/m

3

(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/m

3

x (2 cu.ft. x 0.028) x 0.960 x 3600



EXAMPLE:

39.2 x (2 x 0.028) x 0.960 x 3600

90.5

Natural Gas

BTU/SCF 1030 = 39.2 MJ/m

3


EXAMPLE:

93.15 x (1 x 0.028) x 0.960 x 3600

108

Propane Gas

BTU/SCF 2500 = 93.15 MJ/m

3

=

=

=

MJ/H

84.83

84.41

x x x

0.2777

0.2777

0.2777

=

=

= kW

23.28

23.45

x x x

3412.14

3412.14

3412.14

=

=

BTU/H

79,433

= 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/m

3

(or Default 39.2), times 0.0566 m

3

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 m

3

) of gas from the gas meter.

For Propane (LP) Gas multiply the Heat content of the gas MJ/m

3

(or Default 93.14), times 0.00283 m

3

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/m

3

x m

3 x 0.960 x 3600



EXAMPLE:

39.2 x 0.1 x 0.960 x 3600

160

Natural Gas

BTU/SCF 1030 = 39.2 MJ/m

3


EXAMPLE:

93.15 x 0.028 x 0.960 x 3600

107.97

Propane Gas

BTU/SCF 2500 = 93.15 MJ/m

3

=

=

=

MJ/H

84.67

84.48

x x x

0.2777

0.2777

0.2777

=

=

= kW

23.51

23.18

x x x

3412.14

3412.14

3412.14

=

=

=

BTU/H

80,231

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.


035-19656-001 Rev. B (0404)

Be sure to relight any gas appliances that were turned off at the start of this input check.

TABLE 14: Inlet Gas Pressure Range

Minimum

Maximum

INLET GAS PRESSURE RANGE

Natural Gas

4.5” W.C. (1.12 kPa)

10.5” W.C. (2.61 kPa)

Propane (LP)

8.0” W.C. (1.99 kPa)

13.0” (3.24 kPa) W.C.

IMPORTANT: The inlet gas pressure operating range table specifies what the minimum and maximum gas line pressures 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.

ADJUSTMENT OF MANIFOLD GAS PRESSURE

Manifold gas pressure may be measured by connecting the “U” tube manometer to the gas valve with a piece of tubing and on an adapter.

Follow the appropriate section in the instructions below. Refer to Figure

26 for a drawing of the locations of the pressure ports on the gas valve.

Turn gas off at the ball valve or gas cock on gas supply line before the gas valve. Find the pressure ports on the gas valve marked Out Pressure Tap and Inlet Pressure Tap.

1.

The manifold pressure must be taken at the port marked OUT

Pressure Tap.

2.

The gas line pressure must be taken at the port marked Inlet Pressure Tap.

Using a screw driver, remove the cap that covers the manifold pressure set screw.

Read the inlet gas pressure

Connect the positive side of the manometer to the adapter previously installed in the Out pressure Tap on the gas valve. Do not connect any tubing to the negative side of the manometer, as it will reference atmospheric pressure. Refer to Figure 27 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.

NOTE: The regulated outlet pressures, both low and high, have been calibrated at the factory. Additional pressure adjustment should not be necessary. If adjustment is necessary, set to the following specifications. After adjustment, check for gas leakage.

1.

Refer to Figure 29 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: Nominal Manifold Pressure

NOMINAL MANIFOLD PRESSURE

Natural Gas

Propane (LP) Gas

3.5" w.c. (0.87 kPa)

10.0" w.c. (2.488 kPa)

OUTLET

PRESSURE

PORT

INLET

VENT PORT

OUTLET

WRENCH

BOSS

INLET

PRESSURE

PORT

OFF

ON

ON/OFF SWITCH

(Shown in ON position)

MAIN REGULATOR

ADJUSTMENT

FIGURE 29: 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 tighten the pressure tap plug using the 3/32” (2.4 mm)

Allen wrench.

6.

Turn the electrical and gas supplies back on, and with the burners in operation, check for gas leakage around the gas valve pressure port for leakage using an approved gas detector, a non-corrosive leak detection fluid, or other leak detection methods.

The manifold pressure must be checked with the screw-off cap for the gas valve pressure regulator in place. If not, the manifold 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.

FLAME

SENSOR

MAINFOLD PRESSURE “U” TUBE CONNECTION

GAS VALVE

OUTLET

PRESSURE TAP

1/4” TUBING

MAINIFOLD

PIPE

GAS

BURNERS

U-TUBE

MANOMETER

FIGURE 30: Reading Gas Pressure

3.5 IN

WATER

COLUMN

GAS

PRESSURE

SHOWN


035-19656-001 Rev. B (0404)

ADJUSTMENT OF TEMPERATURE RISE

The temperature rise, or temperature difference between the return air and the supply (heated) air from the furnace, must be within the range shown on the furnace rating plate and within the application limitations shown in Table 8 “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.

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 8.

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 31, 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.

ADJUSTMENT OF FAN CONTROL SETTINGS

This furnace is equipped with a time-on/time-off heating fan control. The fan on delay is fixed at 30 seconds. The fan off delay has 4 settings (60,

90, 120 and 180 seconds). The fan off delay is factory set to 120 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 31.

60

180

BLK

BLU

RED

RED-LOW SPEED

BLU-MEDIUM SPEED

BLK-HIGH SPEED

COOL

HEAT

PARK

PARK

LINE

XM

MOTOR LEADS

FAN OFF

ADJUSTMENT

SWITCHES

FIGURE 31: Typical Heat/Cool Speed Tap Connections

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 16.

The filter pressure drop values in Table 16 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.

Do not energize more than one motor speed at a time or damage to the motor will result.

TABLE 16: Filter Performance - Pressure Drop Inches W.C. and (kPa)

Filter Type

Minimum Opening Size

Airflow Range

CFM

0 - 750

Cm/m

0 - 21.24

1 Opening 2 Openings 1 Opening 2 Openings 1 Opening 2 Openings 1 Opening 2 Openings

In³ m³

230 0.0038

751 - 1000 21.27 - 28.32

330 0.0054

In³ m³ inwc kPa

0.01 0.0025

0.05 0.0125

inwc kPa inwc kPa

0.01 0.0025

0.05 0.0125

inwc kPa inwc

0.15 0.0374

0.2

kPa

0.0498

inwc kPa

1001 - 1250 28.35 - 35.40

330 0.0054

1251 - 1500 35.42 - 42.47

330 0.0054

0.1

0.1

0.0249

0.0249

0.1

0.1

0.0249

0.0249

0.2

0.0498

0.25 0.0623

1501 - 1750 42.50 - 49.55

380 0.0062 658 0.0108 0.15 0.0374 0.09 0.0224 0.14 0.0349 0.08 0.0199

0.3

0.0747 0.17 0.0423

1751 - 2000 49.58 - 56.63

380 0.0062 658 0.0108 0.19 0.0473 0.11 0.0274 0.18 0.0448

0.1

0.0249

0.3

0.0747 0.17 0.0423

2001 & Above 56.66 & Above 463 0.0076 658 0.0108 0.19 0.0473 0.11 0.0274 0.18 0.0448

0.1

0.0249

0.3

0.0747 0.17 0.0423

* Hogs Hair Filters are the type supplied with furnace (if supplied).

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.

Select the number of return air openings or calculate the return opening size in square inches to determine the proper filter pressure drop.

3.

Determine the External System Static Pressure (ESP) without the filter.

4.

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.

5.

If total system static matches a ESP value in the airflow table (i.e.

0.20 w.c. (50 Pa), 0.60 w.c. (150 Pa), etc,) the system airflow corresponds to the intersection of the ESP column and Model/Blower

Speed row.

6.

If the total system static falls between ESP values in the table (i.e.

0.58 w.c. (144 Pa), 0.75 w.c. (187 Pa), 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.


035-19656-001 Rev. B (0404)

Example: For a 130,000 BTUH (38.06 kW) furnace with 2 return openings and 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:

Obtain the airflow values at 0.50 w.c. (125 Pa) & 0.60 w.c. (150 Pa)

ESP.

Airflow @ 0.50”: 2125 CFM (60.17 m

3

/min)

Airflow @ 0.60”: 2035 CFM (57.62 m

3

/min)

Subtract the airflow @ 0.50 w.c. (125 Pa) from the airflow @ 0.60 w.c.

(150 Pa) to obtain airflow difference.

TABLE 17: Blower Performance CFM - Upflow (without filter)

2035 - 2125 = -90 CFM (2.55 m

3

/min)

Subtract the total system static from 0.50 w.c. (125 Pa) and divide this difference by the difference in ESP values in the table, 0.60 w.c.

(150 Pa) - 0.50 w.c. (125 Pa), to obtain a percentage.

(0.58 - 0.50) / (0.60 - 0.50) = 0.8

Multiply percentage by airflow difference to obtain airflow reduction.

(0.8) X (-90) = -72

Subtract airflow reduction value to airflow @ 0.50 w.c. (125 Pa) to obtain actual airflow @ 0.58 inwc (144 Pa) ESP.

2125 - 72 = 2053

MODELS

Input/Output/

Airflow/cabinet

Speed

Tap

EXTERNAL STATIC PRESSURE, INCHES WC (kPa)

0.1 (0.025) 0.2 (0.050) 0.3 (0.075) 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 cm/m cfm cm/m cfm cm/m cfm cm/m cfm cm/m cfm cm/m cfm cm/m cfm cm/m cfm cm/m cfm cm/m

HIGH 1580 44.7 1530 43.3 1470 41.6 1405 39.8 1330 37.7 1245 35.3 1150 32.6 1045 29.6 890 25.2 650 18.4

40/32/1200/"A" †

60/48/1200/"A" †

80/64/1200/"A" †

80/64/1600/"B" †

100/80/1200/"B" †

100/80/1600/"B" †

115/92/1600/"C"

80/64/2000/"C"

100/80/2000/"C" †

115/92/2000/“C" †

130/104/2000/"D" †

MED-LOW 845 23.9 840 23.8 830 23.5 815 23.1 790 22.4 750 21.2 670 19.0 595 16.8 480 13.6 320 9.1

LOW 675 19.1 665 18.8 660 18.7 645 18.3 620 17.6 585 16.6 530 15.0 455 12.9 360 10.2 255 7.2

HIGH 1970 55.8 1935 54.8 1900 53.8 1850 52.4 1795 50.8 1735 49.1 1660 47.0 1590 45.0 1495 42.3 1395 39.5

MED 1445 40.9 1435 40.6 1425 40.4 1415 40.1 1405 39.8 1375 38.9 1350 38.2 1300 36.8 1240 35.1 1160 32.8

LOW 1245 35.3 1235 35.0 1225 34.7 1215 34.4 1205 34.1 1190 33.7 1170 33.1 1135 32.1 1090 30.9 995 28.2

HIGH 1675 47.4 1645 46.6 1595 45.2 1530 43.3 1465 41.5 1385 39.2 1280 36.2 1155 32.7 1025 29.0 810 22.9

MED 1270 36.0 1260 35.7 1250 35.4 1240 35.1 1215 34.4 1185 33.6 1125 31.9 1035 29.3 910 25.8 695 19.7

LOW 955 27.0 950 26.9 945 26.8 935 26.5 920 26.1 905 25.6 865 24.5 810 22.9 685 19.4 510 14.4

HIGH 2050 58.0 1990 56.4 1935 54.8 1860 52.7 1770 50.1 1680 47.6 1580 44.7 1490 42.2 1370 38.8 1255 35.5

MED 1630 46.2 1615 45.7 1600 45.3 1585 44.9 1550 43.9 1510 42.8 1445 40.9 1355 38.4 1270 36.0 1135 32.1

LOW 1340 37.9 1325 37.5 1310 37.1 1295 36.7 1285 36.4 1270 36.0 1245 35.3 1195 33.8 1125 31.9 1005 28.5

HIGH 2040 57.8 1975 55.9 1925 54.5 1855 52.5 1780 50.4 1695 48.0 1610 45.6 1505 42.6 1380 39.1 1225 34.7

MED 1725 48.8 1685 47.7 1650 46.7 1610 45.6 1555 44.0 1500 42.5 1425 40.4 1340 37.9 1220 34.5 1075 30.4

LOW 1365 38.7 1355 38.4 1325 37.5 1290 36.5 1265 35.8 1250 35.4 1210 34.3 1140 32.3 1045 29.6 940 26.6

HIGH 2533 71.7 2442 69.1 2355 66.7 2279 64.5 2193 62.1 2110 59.7 2009 56.9 1895 53.7 1790 50.7 1670 47.3

80/64/2200/"C"

100/80/2000/"C" †

115/92/2000/"C" †

130/104/2000/"D" †

MED-HIGH 1978 56.0 1942 55.0 1906 54.0 1869 52.9 1819 51.5 1754 49.7 1694 48.0 1617 45.8 1521 43.1 1402 39.7

MED-LOW 1566 44.3 1544 43.7 1514 42.9 1475 41.8 1443 40.9 1419 40.2 1377 39.0 1317 37.3 1245 35.3 1141 32.3

LOW 1281 36.3 1262 35.7 1243 35.2 1198 33.9 1168 33.1 1135 32.1 1103 31.2 1047 29.6 988 28.0 912 25.8

HIGH 2400 68.0 2320 65.7 2275 64.4 2200 62.3 2115 59.9 2025 57.3 1930 54.7 1825 51.7 1700 48.1 1570 44.5

MED 2050 58.0 2025 57.3 1980 56.1 1930 54.7 1855 52.5 1805 51.1 1720 48.7 1635 46.3 1530 43.3 1400 39.6

LOW 1690 47.9 1675 47.4 1660 47.0 1630 46.2 1610 45.6 1560 44.2 1500 42.5 1430 40.5 1330 37.7 1225 34.7

HIGH 2380 67.4 2330 66.0 2270 64.3 2205 62.4 2120 60.0 2025 57.3 1920 54.4 1815 51.4 1705 48.3 1565 44.3

MED 2040 57.8 2010 56.9 1980 56.1 1920 54.4 1875 53.1 1790 50.7 1705 48.3 1610 45.6 1515 42.9 1385 39.2

LOW 1690 47.9 1680 47.6 1655 46.9 1630 46.2 1590 45.0 1530 43.3 1490 42.2 1425 40.4 1350 38.2 1235 35.0

NOTE: Data below reflects airflows with two return openings - two sides or one side and bottom

HIGH 2405 68.1 2340 66.3 2275 64.4 2210 62.6 2130 60.3 2050 58.0 1955 55.4 1840 52.1 1725 48.8 1600 45.3

MED 2005 56.8 1990 56.4 1965 55.6 1935 54.8 1880 53.2 1815 51.4 1725 48.8 1635 46.3 1535 43.5 1410 39.9

LOW 1655 46.9 1640 46.4 1625 46.0 1610 45.6 1585 44.9 1540 43.6 1485 42.1 1420 40.2 1340 37.9 1235 35.0

HIGH 2385 67.5 2335 66.1 2275 64.4 2195 62.2 2120 60.0 2040 57.8 1935 54.8 1820 51.5 1700 48.1 1555 44.0

MED 2005 56.8 1980 56.1 1955 55.4 1905 53.9 1845 52.2 1775 50.3 1700 48.1 1610 45.6 1500 42.5 1370 38.8

LOW 1640 46.4 1635 46.3 1620 45.9 1605 45.4 1575 44.6 1540 43.6 1480 41.9 1400 39.6 1330 37.7 1225 34.7

NOTES:

1. Airflow expressed in standard cubic feet per minute (CFM) and in cubic meters per minute (m

3

/min).

2. Return air is through side opposite motor (left side).

3. Airflows above 1800 CFM (50.97 m

3

/min) require either return from two sides or one side plus bottom.

4. Motor voltage at 115 V.

* Input / Output / CFM / Cabinet Width (A=14-1/2, B=17-1/2, C=21, D=24-1/2)

† Indicates model available in LoNOx.

TABLE 18: Field Installed Accessories - Non Electrical

MODEL NO.

1NP0805

1NP0806

1LN0802

1FF0110

1FF0112

1HA0802

DESCRIPTION

PROPANE (LP) CONVERSION KIT

PROPANE (LP) CONVERSION KIT

LOW NOX KIT

FILTER FRAME KIT

FILTER FRAME KIT

HIGH ALTITUDE INSTRUCTION PACKET (DOES NOT INCLUDE ORIFICES)

USED WITH

08, 12

16, 20

ALL MODELS

08 thru 12

16 thru 20

ALL MODELS


SECTION X: WIRING DIAGRAM

FIGURE 32: Wiring Diagram

Subject to change without notice. Printed in U.S.A.

Copyright © by York International Corp. 2004. All rights reserved.

Unitary

Product

Group

5005

York

Drive

035-19656-001 Rev. B (0404)

Supersedes: 035-19656-001 Rev. A (0304)

Norman

OK

73069

Inst Manual P3HU 32-104 Output

INSTALLATION MANUAL

HIGH EFFICIENCY

TUBULAR HEAT EXCHANGER SERIES

TABLE OF CONTENTS

LIST OF FIGURES

LIST OF TABLES

SECTION I: SAFETY

035-19656-001 Rev. B (0404)

035-19656-001 Rev. B (0404)

SPECIFIC SAFETY RULES AND PRECAUTIONS

SAFETY REQUIREMENTS

COMBUSTION AIR QUALITY

(LIST OF CONTAMINANTS)

2 Unitary Products Group

035-19656-001 Rev. B (0404)

INSPECTION

FURNACE LOCATION AND CLEARANCES

SECTION II: DUCTWORK

DUCTWORK GENERAL INFORMATION

Unitary Products Group 3

035-19656-001 Rev. B (0404)

DUCTWORK INSTALLATION AND SUPPLY PLENUM

CONNECTION

4 Unitary Products Group

035-19656-001 Rev. B (0404)

Unitary Products Group 5

035-19656-001 Rev. B (0404)

RESIDENTIAL AND NON HUD MODULAR HOME

UPFLOW RETURN PLENUM CONNECTION

BOTTOM RETURN AND ATTIC INSTALLATIONS

HORIZONTAL MODELS

Horizontal Installations With a Cooling Coil Cabinet

Horizontal Installations Without a Cooling Coil Cabinet

Residential and Non Hud Modular Home Horizontal Return

Plenum Connections

ATTIC INSTALLATION

6 Unitary Products Group

SUSPENDED FURNACE / CRAWL SPACE

INSTALLATION

035-19656-001 Rev. B (0404)

INTERNAL INSTALLATION

SECTION III: FILTERS

FILTER INSTALLATION

Unitary Products Group 7

035-19656-001 Rev. B (0404)

SIDE RETURN - EXTERNAL INSTALLATION

HORIZONTAL APPLICATION

Horizontal Filters

SECTION IV: GAS PIPING

GAS SAFETY

CHECKING THE GAS PRESSURES

8 Unitary Products Group

035-19656-001 Rev. B (0404)

GAS PIPING INSTALLATION

GAS ORIFICE CONVERSION FOR PROPANE (LP)

HIGH ALTITUDE GAS ORIFICE CONVERSION

HIGH ALTITUDE PRESSURE SWITCH CONVERSION

Unitary Products Group 9

035-19656-001 Rev. B (0404)

SECTION V: ELECTRICAL POWER

Electrical Power Connections

SUPPLY VOLTAGE CONNECTIONS

LOW VOLTAGE CONTROL WIRING CONNECTIONS

10 Unitary Products Group

035-19656-001 Rev. B (0404)

ACCESSORY CONNECTIONS

ELECTRONIC AIR CLEANER CONNECTION

HUMIDIFIER CONNECTION

SECTION VI: TWINNING AND STAGING

TWINNING DUCT SYSTEM

Unitary Products Group 11

035-19656-001 Rev. B (0404)

GAS PIPING

TWINNING

Single-Wire Twinning

Single-Wire Twinning Instructions

Single-Wire Twinning Operation

STAGING

Single-Wire Staging