INSTALLATION MANUAL

HIGH EFFICIENCY

TUBULAR HEAT EXCHANGER SERIES

MODELS: P*DD / G8D-DN

(Two Stage Downflow)

57 - 120 MBH IN

(16.70 - 55.17 KW) IN

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

VENT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . .15

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

LIST OF FIGURES

Combustible Floor Base Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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

Downflow Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Return Filter Grill and Return Duct Installation . . . . . . . . . . . . . . . . . . . 6

Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Line Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Field Wiring for Single Stage Thermosta . . . . . . . . . . . . . . . . . . . . . . . 9

Field Wiring for Two Stage Thermostat . . . . . . . . . . . . . . . . . . . . . . . . 9

Accessory Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Vent Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Vent Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Typical Sidewall Vent Application . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Typical Sidewall Vent and Termination Configuration . . . . . . . . . . . .10

Home Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Combustion Airflow Path Through The Furnace Casing to the Burner

Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Atlernate Air Intake, Air Outlet and Chimney Connections . . . . . . . . .12

Air In0let, Outlet and Chimney Connections . . . . . . . . . . . . . . . . . . . .12

Typical Chimney Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Horizontal Air Inlet, Outlet and Chimney Connections . . . . . . . . . . . .13

Outside and Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . .13

Pressure Switch Tubing Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

High Altitude Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Ratings & Physical / Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Roof Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Horizontal Sidewall Venting Clearances . . . . . . . . . . . . . . . . . . . . . . .10

Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Unconfined Space Minimum Area in Square Inch . . . . . . . . . . . . . . .13

Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Replacement PSC Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Blower Performance CFM-Upflow (without filter) . . . . . . . . . . . . . . . .19

Filter Performance - Pressure Drop Inches W.C. and (kPa) . . . . . . . .20

Field Installed Accessories - Non-Electrical . . . . . . . . . . . . . . . . . . . .20

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.

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.

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.

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.

035-19930-001 Rev. A (0404)

035-19930-001 Rev. A (0404)

SPECIFIC SAFETY RULES AND PRECAUTIONS

1.

Only Natural gas or Propane (LP) gas are approved for use with this furnace. Refer to the furnace rating plate or Section IV of these instructions.

2.

Install this furnace only in a location and position as specified in

SECTION I of these instructions.

3.

A gas-fired furnace for installation in a residential garage must be installed as specified in SECTION I of these instructions.

4.

Provide adequate combustion and ventilation air to the furnace space as specified in SECTION VII of these instructions.

5.

Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only, as specified in 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

035-19930-001 Rev. A (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” (0.64 cm) slope side-to-side and front-to-back to provide proper condensate drainage.

Installation in freezing temperatures:

1.

Furnace shall be installed in an area where ventilation facilities provide for safe limits of ambient 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)

TABLE 1: Unit Clearances to Combustibles 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.

Downflow furnaces for installation on combustible flooring only when installed on the accessory combustible floor base on wood flooring only and shall not be installed directly on carpeting, tile or other combustible material.

Check the rating plate and power supply to be sure that the electrical characteristics match. All models use nominal 115 VAC, 1

Phase 60Hz power supply.

Furnace shall be installed so the electrical components are protected from water.

Installation in 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) In. (cm) In. (cm)

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

DOWNFLOW B-VENT 1 (25.4) 3 (7.62) 0 (0.0)

0 (0.0)

0 (0.0)

3 (7.62)*

0 (0.0)

6 (15.24)

1 (25.4)

1.

Special floor base or air conditioning coil required for use on combustible floor.

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

FLOOR/

BOTTOM

1 (25.4)

1

1 (25.4)

1

CLOSET ALCOVE ATTIC

YES

YES

YES

YES

YES

YES

LINE

CONTACT

NO

NO 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.

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.

Unitary Products Group 3

035-19930-001 Rev. A (0404)

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.

FLOOR BASE AND DUCTWORK INSTALLATION

Downflow Combustible Floor Base

Installations on combustible material or floors must use a combustible floor base shown in Figure 1. The perforations in the wrapper flanges must be bent in towards the heat exchanger to allow for the coil duct flange to recess into the furnace Follow the instructions supplied with the combustible floor base accessory. This combustible floor base can be replaced with a matching cooling coil, properly sealed to prevent leaks. Follow the instructions supplied with the cooling coil cabinet for installing the cabinet to the duct connector. Refer to the installation instructions for additional information.

Downflow Duct Connectors

All downflow installations must use a suitable duct connector approved by the furnace manufacturer for use with this furnace. The duct connectors are designed to be connected to the rectangular duct under the floor and sealed. Refer to the instructions supplied with the duct connector for proper installation. Refer to the separate accessory parts list at the end of these instructions for the approved accessory duct connectors.

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.

The duct system is a very important part of the installation. If the duct system is improperly sized the furnace will not operate properly.

The ducts attached to the furnace plenum, should be of sufficient size so that the furnace operates at the specified external static pressure and within the air temperature rise specified on the nameplate.

Table 2 is a guide for determining whether the rectangular duct system that the furnace is being connected to be of sufficient size for proper furnace operation.

Use the Example below to help you in calculating the duct area to determine whether the ducts have sufficient area so that the furnace operates at the specified external static pressure and within the air temperature rise specified on the nameplate.

Example: The furnace input is 80,000 BTUH, 1,200 CFM. The recommended duct area is 280 sq.in, there are two 8 x 14 rectangular ducts attached to the plenum and there are two 7 inch round ducts attached to the furnace.

1.

Take 8 x 14, which equals 112 sq.in. X 2, which equals 224 square inch then go to round duct size located in Table 3.

2.

The square inch area for 7 inch round pipe is 38.4, 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.

TABLE 2: Minimum Duct Sizing For Proper Airflow

Input Airflow Return

1

Rectangular

2

Round

2

Supply

3

Rectangular

2

Round

2

BTU/H

(kW)

40000

(11.72)

60000

(17.58)

80000

(23.44)

CFM

(m³)

1,000

(28.32)

1,200

(33.98)

1,200

(33.98)

In²

(cm²)

240

(610)

280

(711)

280

(711) in. x in.

(cm x cm)

12 x 20

(30.5 x 50.8)

14 x 20

(35.6 x 50.8)

14 x 20

(35.6 x 50.8) in. (cm) dia.

18

45.7)

18

(45.7)

18

(45.7)

In²

(cm²)

180

(457)

216

(549)

216

(549) in. x in.

(cm x cm)

10 x 18

(25.4 x 45.7)

12 x 18

(30.5 x 45.7)

12 x 18

(30.5 x 45.7) in. (cm) dia.

16

(40.6)

16

(40.6)

16

(40.6)

80000

(23.44)

100000

(29.31)

1,600

(45.31)

2,000

(56.63)

360

(914)

440

(1,118)

18 x 20

(45.7 x 50.8)

20 x 22

(50.8 x 55.8)

22

(55.8)

24

(60.9)

280

(711)

390

(991)

14 x 20

(35.6 x 50.8)

16 x 22

(40.6 x 55.8)

18

(45.7)

22 (

55.8)

120000

(35.17)

2,000

(56.63)

440

(1,118)

20 x 22

(50.8 x 55.8)

24

(60.9)

390

(991)

16 x 22

(40.6 x 55.8)

22

(55.8)

NOTE: This chart does not replace proper duct sizing 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 and adding the pressure drop across any applied a-coil and return air filter.

TABLES 2 AND 3 are to be used as a guide only to help the installer determine if the duct sizes are large enough to obtain the proper air flow

(CFM) through the furnace. TABLES 2 and 3 ARE NOT to be used to design ductwork for the building where the furnace is being installed.

There are several variables associated with proper duct sizing that are not included in the tables. To properly design the ductwork for the building, Refer to the ASHRAE Fundamentals Handbook, Chapter on

“DUCT DESIGN” or a company that specializes in Residential and Modular Home duct designs.

IMPORTANT: If the supply air duct is being connected to the furnace without the use of an accessory duct connector, then a transition duct must be installed with flanges or tabs that are securely attached and sealed to the supply air duct and to the base of the furnace. The transition duct must have insulation between the transition duct and any combustible material.

The transition duct must be the same dimensional size as the rectangular opening in the base of the furnace.

4 Unitary Products Group

035-19930-001 Rev. A (0404)

DOWNFLOW

FURNACE

WARM AIR PLENUM

WITH 1” FLANGES

FIBERGLASS

INSULATION

FIBERGLASS TAPE

UNDER FLANGE

COMBUSTIBLE FLOOR

BASE ACCESSORY

FIGURE 1: Combustible Floor Base Accessory

Downflow Air Conditioning Coil Cabinet

The furnace should be installed with coil cabinet part number specifically intended for downflow application. If a matching cooling coil is used, it may be placed directly on the furnace outlet and sealed to prevent leakage. 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 air conditioning coil cabinet to the duct connector, and then position the furnace on top of the coil cabinet. The connection to the furnace, air conditioning coil cabinet, duct connector, and supply air duct must be sealed to prevent air leakage.

IMPORTANT: On all installations without a coil, a removable access panel is recommended in the outlet duct such that smoke or reflected light would be observable inside the casing to indicate the presence of leaks in the heat exchanger. This access cover shall be attached in such a manner as to prevent leaks.

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

3/4

20

T'STAT WIRING

7/8" K.O.

D

(Vent Connection)

A

FRONT

FIGURE 2: Dimensions

40

GAS INLET

1-1/4" X 2-1/2"

2-1/2

28-1/2

LEFT SIDE

31-1/8

5-3/4

ALT. GAS INLET

1-1/4" X 2-1/2"

RIGHT SIDE

B

20

Power

Wiring

7/8" K.O.

Vent Connection

(vent size)

D

1-7/8

5

E

FRONT

TOP IMAGE

F

1-1/8

A

1-1/8

20

C

7-3/8

FRONT

BOTTOM IMAGE

TABLE 4: Cabinet and Duct Dimensions

MBH

Input kW

Output

MBH kW

CFM

(m³/min)

57 / 42 16.7 / 12.3 46 / 34 13.5 / 10.0 1200 (33.98)

80 / 59 23.4 / 17.3 64 / 48 18.8 / 14.1 1200 (33.98)

80 / 59 23.4 / 17.3 64 / 48 18.8 / 14.1 1600 (45.31)

100 / 65 29.3 / 19.1 80 / 53 23.4 / 15.5 1200 (33.98)

120 / 78 35.2 / 22.9 96 / 64 28.1 / 18.8 2000 (56.63)

Cabinet

Size

CABINET DIMENSION

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

A

A

B

B

C

14 1/2 36.8 13 1/4 33.6 12 1/4 31.1

14 1/2 36.8 13 1/4 33.6 12 1/4 31.1

17 1/2 44.4 16 1/4 41.3 15 1/4 38.7

17 1/2 44.4 16 1/4 41.3 15 1/4 38.7

21 53.3 19 3/4 50.2 18 3/4 47.6

4.0

4.0

4.0

4.0

4.0

10.2 10 1/8 25.7

10.2 10 1/8 25.7

10.2 11 5/8 29.5

10.2 11 5/8 29.5

10.2 13 3/8 34

3 3/4

3 3/4

3 3/4

3 3/4

3 3/4

9.5

9.5

9.5

9.5

9.5

RESIDENTIAL AND NON HUD MODULAR HOME

DOWNFLOW RETURN PLENUM CONNECTION

The return duct system must be connected to the furnace inlet and the return duct system must terminate outside the space containing the furnace. When replacing an existing furnace, if the existing plenum is not the same size as the new furnace then the existing plenum must be removed and a new plenum installed that is the proper size for the new furnace.

Attach the return plenum to the furnace inlet duct flanges. This is typically through the use of S cleat material when a metal plenum is used.

The use of an approved flexible duct connector is recommended on all 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.

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

Unitary Products Group 5

035-19930-001 Rev. A (0404)

SECTION III: FILTERS

DOWNFLOW APPLICATION

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.

TABLE 5: Filter Sizes

Cabinet Size

A

B

C

C

Top Return (in) Top Return (cm)

(2) 14 x 20 (2) 35.6 x 50.8

All except 2,000

(2) 14 x 20

(2) 14 x 20

(2) 35.6 x 50.8

(2) 35.6 x 50.8

All except 2,000

All except 2,000

(2) 20 x 20 (2) 50.8 x 50.8

2,000 Only

FILTER RACK

(factory supplied with some furnaces)

RACK AND FILTERS SECURED

INSIDE BLOWER SECTION

FOR SHIPMENT

CASING SIZE DIMENSION FH

16-1/4” 12-3/4”

22-1/4”

26-1/4”

11”

8-1/4”

DUCTWORK

NOTE: FILTER ACCESS THROUGH

DUCTWORK MUST BE PROVIDED

FOR REMOVAL AND CLEANING

FILTERS

FILTER

RACK

FH

BRANCH

DUCTS

IMPORTANT: For easier filter access in a downflow configuration, a removable access panel is recommended in the vertical run of the return air plenum immediately above the furnace.

ELECTRICAL

SUPPLY

CLOSET

RETURN

AIR

VENT

PIPE

AIR

FILTERS

GAS SUPPLY

(EITHER SIDE)

FIGURE 4: Return Filter Grill and Return Duct Installation

Accessory External Filter Installation

1.

Install the return filter rack on the top of the furnace return air opening. Secure the filter rack to the front and back flanges with screws. The return air plenum can be placed over the filter rack and the branch ducts (rectangular ducts and / or round ducts) can be attached to the plenum. Route the combustion air and the vent

PVC pipes around the access panels for the filters.

2.

Install the filter(s) provided or you may install Permanent washable filters. Filter should extend through the entire length of the filter rack to prevent air from bypassing the filter. Make sure that any air filter that is installed in the furnace does not cause an excessive amount of pressure drop. Refer to Table 18 for air filter performance and pressure drops.

IMPORTANT: Air velocity through throwaway type filters must not exceed 300 feet per minute (1.52 m/m). All velocities over this require the use of high velocity filters. Refer to Table 18.

CROSS SECTION A-A

(with Plenum and filters)

FIGURE 3: Downflow Filter

Downflow Filters

A top return filter rack is supplied with the furnace. Two standard filters are supplied with each unit. Downflow furnaces typically are installed with the filters located above the furnace, extending into the return air plenum or duct. Any branch duct (rectangular or round duct) attached to the plenum must attach to the vertical plenum above the filter height.

Refer to Figure 3 for proper installation.

Filter(s)) may be located in the duct system external to the furnace using an external duct filter box attached to the furnace plenum or at the end of the duct in a return filter grille(s). The use of straps and / or supports is required to support the weight of the external filter box. Refer to

Figures 3 & 4.

If the accessory electronic air cleaner is installed, be sure the air cleaner is designed to accommodate the furnace CFM (cm/m) and the air cleaner is installed so it does not obstruct the return airflow. Consideration should be given when locating the air cleaner for maintenance and temperatures should the indoor fan motor fail to operate. The use of straps and / or supports is required to support the weight of the electronic air cleaner. It is recommended that the air cleaner not be located within 12 inches (30.5 cm) from the top of the return air opening on the furnace. Refer to the instructions supplied with the electronic air cleaner.

If pleated media air filters or any filter that has a large pressure drop is installed in the return air duct system be sure that the pressure drop caused by the air filter will not prevent the furnace from operating within the rise range specified on the rating plate. If the furnace does not operate within the specified rise range then a larger air filter or an air filter that has a lower pressure drop must be installed. Refer to figure 3 and furnace accessories for accessory external filter kit options.

All installations must have a filter installed.

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.

INLET

WRENCH

BOSS

O

F

F

ON

PM

C

HI

P

E

P

E

L L

A

C

E

SCRE

W

OUTLET

HIGH FIRE

REGULATOR

ADJUSTMENT

SEAL SCREW

ON / OFF SWITCH

FIGURE 5: 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.

6 Unitary Products Group

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

Natural Gas

4.5” W.C. (1.12 kPa)

Propane (LP)

8.0” W.C. (1.99 kPa)

Maximum 10.5” W.C. (2.61 kPa) 13.0” (3.24 kPa) W.C.

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

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 6.

EXTERNAL MANUAL

SHUTOFF VALVE

TO GAS

SUPPLY

TO GAS

SUPPLY

035-19930-001 Rev. A (0404)

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.

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.

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.

DRIP

LEG

GROUNDED JOINT UNION

MAY BE INSTALLED

INSIDE OR OUTSIDE UNIT.

FIGURE 6: Gas Piping

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

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.

5,000 ft.

(1524 m)

6,000 ft.

(1829 m)

7,000 ft.

(2134 m)

8,000 ft.

(2438 m)

9,000 ft.

(2743 m)

#47 #48 #48

#56 #56 #56 #56 #56

SECTION V: ELECTRICAL POWER

Electrical Power Connections

#49 #49

10,000 ft.

(3048 m)

#50

#57

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.

Use copper conductors only.

Unitary Products Group 7

035-19930-001 Rev. A (0404)

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.

TABLE 8: Ratings & Physical / Electrical Data

MBH

Input kW

MBH

Input kW

MBH

Output kW

57/42 16.7/12.3 46/34 13.5/10.0 1200 34.0

14-1/2

80/59 23.4/17.3 64/48 18.8/14.1 1200 34.0

14-1/2

80/59 23.4/17.3 64/48 18.8/14.1 1600 45.3

17 1/2

100/65 29.3/19.1 80/53 23.4/15.5 1200 34.0

17 1/2

120/78 35.2/22.9 96/64 28.1/18.8 2000 56.6

MBH

Output kW

Nominal

CFM cmm

Blower

Hp Amps

Cabinet Width

In.

cm

36.8

36.8

44.5

44.5

21 53.3

Blower Size

In.

cm

57/42 16.7/12.3 46/34 13.5/10.0

1/3 6.2

80/59 23.4/17.3 64/48 18.8/14.1

1/3 6.2

10 x 8 25.4 x 20.3

10 x 8 25.4 x 20.3

80/59 23.4/17.3 64/48 18.8/14.1

3/4 11.0

11 x 10 27.9 x 25.4

100/65 29.3/19.1 80/53 23.4/15.5

1/2 7.0

10 x 8 25.4 x 20.3

120/78 35.2/22.9 96/64 28.1/18.8

1.0

12.2

11 x 10 27.9 x 25.4

AFUE

80.0

80.0

80.0

80.0

80.0

Total Unit

Amps

9.0

9.0

12.0

12.0

14.0

Air Temp. Rise

°F °C

20-50

25-55

11-28

13-31

20-50

25-55

25-55

11-28

13-31

13-31

Max

Over-Current

Protect

Min wire size

(awg) @ 75 ft. one way

20

20

20

20

20

14

14

14

14

12

Max. Outlet Air Temp

°F °C

160

160

71.1

71.1

160

170

160

71.1

76.7

71.1

Oper.

Wgt.

LBS

Oper.

Wgt.

Kg

110

120

130

125

150

49.9

54.4

59.0

56.7

68.0

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.

Annual Fuel Utilization Efficiency (AFUE) numbers are determined in accordance with DOE Test procedures.

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.

L1

(HOT)

N

GND

HUM (HOT)

WIRING INSIDE

JUNCTION BOX

EAC (HOT)

GRN

WHT

BLK/BLK

WHT/WHT

GRN/GRN

BLK

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

7.

3.

The furnace's control system requires correct polarity of the power supply and a proper ground connection. Refer to Figure 8 or

"FURNACE CONTROL DIAGONSICS" for symptoms of reversed power supply polarity.

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

IGNITION MODULE

TRANSFORMER

DOOR

SWITCH

BURNER COMPARTMENT

FIGURE 7: Electrical Wiring

VENT PIPE

CLASS 2 SYSTEM

CONTROL WIRING

TO THERMOSTAT

FLUE

CHASE

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 strip on the cfm timer board, as shown in Figure 9 for single stage or

Figure 10 for two stage. Electronic thermostats may require the common wire to be connected to the "C" terminal as shown in Figures 9 &

10. 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 cfm timer board to the yellow and brown wires on the condensing unit (unit out side) as shown in Figure 10.

8 Unitary Products Group

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 8: Line Wiring Connections

SINGLE-STAGE THERMOSTAT CONNECTION DIAGRAM

ROOM

THERMOSTAT

24 V COM (if req.)

C

FAN

G

RH

24 V POWER

FURNACE

CONTROL

B

G

R

RC

Y1

W1

COOLING

HEAT

Y

W1

W2

BLUE

WHITE

COMMON

THERMOSTAT

CONNECTION

TO AIR CONDITIONER

CONDENSING UNIT

DELAY

TIMER

FIGURE 9: Field Wiring for Single Stage Thermosta

TWO-STAGE THERMOSTAT CONNECTION DIAGRAM

ROOM

THERMOSTAT

C

24 V COM (if req.)

FAN

FURNACE

CONTROL

G

B

G

24 V POWER

RH R

TO AIR CONDITIONER

CONDENSING UNIT

RC

Y1

COOLING

Y

HEAT (LOW)

W1

W2

HEAT (HIGH)

W1

W2

BLUE

WHITE

COMMON

THERMOSTAT

CONNECTION

DELAY

TIMER

FIGURE 10: Field Wiring for Two Stage Thermostat

Set the heat anticipator in the room thermostat as shown below. Setting it lower will cause short cycles. Setting it higher will cause the room temperature to exceed the setpoint.

Two-Stage Thermostat

First Stage

Second Stage

Single Stage Thermostat

.4 Amps

.1 Amps

.4 Amps

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 11, for connection details.

115 VOLT

HUMIDIFER

HUM. HOT

BLK

WHT

EAC

HUM

SWITCHED

CIRCUITS

EAC HOT

115 VOLT

ELECTRONIC

AIR CLEANER

BLK

WHT

FIGURE 11: Accessory Connections

Unitary Products Group

NEUTRALS

ELECTRONIC AIR CLEANER CONNECTION

Two 1/4” (0.64 cm) 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: 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)

FIGURE 13: Vent Termination

TABLE 9: Roof Pitch

ROOF PITCH

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

035-19930-001 Rev. A (0404)

3 FT (0.9 m)

MIN.

WALL OR

PARAPET

RIDGE

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 12: 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

H(min) ft

1.0

1.25

1.5

2.0

2.5

3.25

4.0

5.0

6.0

7.0

7.5

8.0

m

0.30

0.38

0.46

0.61

0.76

0.99

1.22

1.52

1.83

2.13

2.27

2.44

9

035-19930-001 Rev. A (0404)

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 by-products 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.

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.

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 2 ft

(0.61 higher than any portion of the building with a horizontal distance of 10 ft (3.1 m).

TABLE 10: Horizontal Sidewall Venting Clearances

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

FURNACE

VENT

PIPE

OPTIONAL

SIDEWALL

VENT SYSTEM

(field supplied)

HOT

WATER

TANK

FAN ASSISTED

FURNACES

EXTERIOR

VENT HOOD

FIGURE 14: Typical Sidewall Vent Application

VENT PIPE

VENT

DAMPER

FLUE

PIPE

TOP

COVER

CELLAR

WALL

OPTIONAL

SIDEWALL

VENT SYSTEM

(field supplied)

BURNER

ACCESS

PANEL

FIGURE 15: 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 pre-vent sagging. The maximum spacing between hangers is 4 ft (1.22 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 12, 13 & 16, and must comply with local codes and requirements.

Heating

Input

BTU/H

60,000

80,000

80,000

100,000

120,000

Heating

Input kW

17.58

23.44

23.44

29.31

35.20

Heating

Output

BTU/H

48,000

64,000

64,000

80,000

96,000

Heating

Output kW

14.07

18.76

18.76

23.45

28.10

Furnace Furnace

Airflow Airflow

CFM

1200 cm/m

33.98

1200

1600

1200

2000

33.98

45.31

33.98

56.63

Horizontal Vent Length Ft (m) with 4 Elbows

Pipe Size

Min. Vent Length Max. Vent Length

Inches cm

4

4

4

4

4

10.16

10.16

10.16

10.16

10.16

Feet

4.5

4.5

4.5

4.5

4.5

meters

1.37

1.37

1.37

1.37

1.37

Feet

34.5

34.5

34.5

34.5

34.5

meters

10.82

10.82

10.82

10.82

10.82

10 Unitary Products Group

035-19930-001 Rev. A (0404)

VENT CLEARANCES

D

V

E

L

V

B

V

G

FIXED

CLOSED

C

F

B

V

V

A

H

B

B

B

V

I

B

V

V

J

X

OPERABLE

M

V

K

X

FIXED

CLOSED

V

VENT TERMINAL

X AIR SUPPLY

AREA WHERE TERMINAL IS NOT PERMITTED

FIGURE 16: 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

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

“

J. Clearance to nonmechanical air supply inlet to building or the combustion air inlet to any other appliance

3 feet (91 cm)

6 inches (15 cm) for applications

≤ 10,000 Btuh (3kW),

12 inches (30 cm) for appliances > 10,000 Btuh (3kW) and

≤ 100,000 Btuh (30kW), 36 inches (91 cm) for appliances > 100,000 Btuh (30kW)

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

Dryer Vent

Plumbing Vent Stack

Gas Appliance Vent Terminal

Vent Termination from any Building Surface

Above Any Grade Level

Above anticipated snow depth

Any forced air inlet to the building.

The vent shall extend above the highest point where it passes through the roof, not less than

Any obstruction within a horizontal distance

12 inches (30 cm)

‡

3 ft (91.44 cm)

3 ft (91.44 cm)

3 ft (91.44 cm) *

12" (30.4 cm)

12" (30.4 cm)

12" (30.4 cm)

10 ft (304.8 cm)

18" (46 cm)

Not less than 18" (46 cm)

US Installation

2

12 inches (30 cm)

6 inches (15 cm) for applications

≤ 10,000 Btuh (3kW),

9 inches (23 cm) for appliances > 10,000 Btuh (3kW) and

≤ 50,000 Btuh (15kW), 12 inches (30 cm) for appliances > 50,000 Btuh (30kW)

“

“

“

“

“

“

“

6 inches (15 cm) for applications

≤ 10,000 Btuh (3kW),

9 inches (23 cm) for appliances > 10,000 Btuh (3kW) and

≤ 50,000 Btuh (15kW), 12 inches (30 cm) for appliances > 50,000 Btuh (30kW)

3 feet (91 cm) above if 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.

Unitary Products Group 11

035-19930-001 Rev. A (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 17: 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 19: Air In0let, 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 or 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 18: Atlernate Air Intake, Air Outlet and Chimney Connections

12

FIGURE 20: Typical Chimney Connections

OPENING

Unitary Products Group

035-19930-001 Rev. A (0404)

OUTLET

AIR DUCT

INLET

AIR DUCT

FIGURE 21: Horizontal Air Inlet, Outlet and Chimney Connections

TABLE 12: Free Area

BTUH Input

Rating

57,000

Minimum Free Area Required for Each Opening

Horizontal Duct

(2,000 BTUH)

30 in

2

(193 cm

2

)

Vertical Duct or

Opening to Outside

(4,000 BTUH)

15 in

2

(97 cm

2

)

Round Duct

(4,000 BTUH)

5” (13 cm)

TABLE 12: Free Area

80,000

100,000

40 in

2

(258 cm

2

)

50 in

2

(322 cm

2

)

20 in

2

(129 cm

2

)

25 in

2

(161 cm

2

)

5” (13 cm)

6” (15 cm)

120,000 60 in

2

(387 cm

2

) 30 in

2

(193 cm

2

) 7” (18 cm)

EXAMPLE: Determining Free Area.

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 Minimum Free Area Required for Each Opening

57,000 375 (34.84 m

2

)

80,000

100,000

500 (46.45 m

2

)

625 (58.06 m

2

)

120,000 750 (69.68 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

GABLE

VENT

OPTIONAL

INLET (a)

SOFFIT

VENT

VENTILATED

ATTIC

TOP ABOVE

INSULATION

OUTLET

AIR (a)

GAS

WATER

HEATER

VENTILATED

CRAWL SPACE

GAS

VENT

4. The duct shall terminate within 12” (cm) above, and within 24” (609.6 mm) 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 dimension shall not be less than 3” (76 mm).

Minimum One Inlet and One Outlet Supply is required

May be in and combustion shown

GAS

VENT

1. An opening may be used in lieu of a duct to provide to provide the outside air supply to an appliance unless otherwise permitted by the authority having jurisdiction. The opening shall be located within 12” (30 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.

2. 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.

INLET

AIR (b)

GAS

VENT

GABLE

VENT

VENTILATED

ATTIC

TOP ABOVE

INSULATION

7.

GAS

WATER

HEATER

An air supply inlet opening from the outdoors shall be located not less than 12” (30 cm) above the outside grade level.

SOFFIT

VENT

OUTLET

AIR (a)

INLET

AIR (a)

Inlet air opening must be within 12” (30 cm) of floor

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.

INLET

AIR (b)

GAS

WATER

HEATER

INLET

AIR (a)

Outlet air opening must be within 12” (cm) of ceiling

2

(a) 1 in per 4000 BTUH (1.17 kW)

FIGURE 22: Outside and Ambient Combustion Air

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.

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. Follow all notes, procedures and required materials in the SEALED COMBUS-

TION 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.

Unitary Products Group 13

035-19930-001 Rev. A (0404)

Multistory 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 carbon monoxide 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 at the furnace vent 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 VII: 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.

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 25 for tubing connections.

1.

Blockage of combustion air supply to furnace:

• Low fire (1LP)

• High fire (2LP)

2.

Blockage of vent piping or terminal.

• Low fire (1LP)

• High fire (2LP)

3.

Failure of combustion air blower motor.

• Low fire (1LP)

• High fire (2LP)

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.

14

FIGURE 23: Pressure Switch Tubing Routing

LIMIT CONTROLS

There is high temperature limit control located on the furnace vestibule panel near the gas valve. This is an automatic reset control that 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 and try ignition again after 1 hr.

Unitary Products Group

035-19930-001 Rev. A (0404)

SECTION VIII: 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.

NOx SCREEN REMOVAL (Lo-NOx Models Only)

1.

Make sure that the electrical power to the unit is turned off and that the gas supply is turned off at the shutoff valve.

2.

Remove the blower compartment and burner compartment access doors.

3.

Disconnect the gas supply piping at the union to permit removal of the entire burner and gas control assembly from the vestibule panel. Use the wrench boss on the gas valve when removing or installing the piping.

4.

Unplug the ignitor from the wire harness. Disconnect the flame sensor wires located on top of the air shield. Unplug the gas valve from the wiring harness.

5.

Remove the ignitor and ignitor bracket. Handle the ignitor very carefully since it is fragile and easily broken.

6.

Remove the screws holding the burner assembly to the vestible panel. It may be necessary to remove the rollout switch bracket(s) to gain access to one or more of these screws.

7.

Remove the burner assembly. It should be possible to swing the burner assembly out of the way without disconnecting the remaining wires.

8.

With the burner assembly out of the way, simply slide the NOx screens out of the heat exchanger tubes and discard the screens.

9.

Replace all components in reverse order. Reconnect all wiring.

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

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.

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.

Unitary Products Group 15

035-19930-001 Rev. A (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, times 2 cubic ft. 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 mea-

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

=

=

BTUH/H

79,997.38

sure 2 cubic ft. of gas from the gas meter.

For propane (LP) gas multiply the heat content of the gas BTU/SCF (or

Default 2500 BTU/SCF, times 1 cubic ft. 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. of gas from the 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

PROPANE (LP) GAS INPUT CALCULATION

EXAMPLE:

2500 x 1 x 0.960 x 3600

108

Propane Gas

BTU/SCF 2500

=

=

BTUH/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 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

The formula for metric input calculation using a cubic foot gas meter:

MJ/m

3

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

Seconds it took to measure the 2 cu.ft. of gas

NATURAL GAS INPUT CALCULATION

EXAMPLE:

39.2 x 2 x 0.960 x 3600

90.5

Natural Gas

BTU/SCF 1030 = 39.2 MJ/m

3

PROPANE (LP) GAS INPUT CALCULATION

EXAMPLE:

93.15 x 1 x 0.960 x 3600

108

Propane Gas

BTU/SCF 2500+93.15 MJ/m

3

=

=

=

MJ/H

84.76

84.41

x x x time it took to measure 2 cu.ft. 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 cu.ft. of gas from the gas meter.

0.2777

0.2777

0.2777

=

=

= kW

23.54

23.45

x x x

3412.14

3412.14

3412.14

= BTUH/H

= 80,312.62

= 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 0.0566 m

3

of gas from the

The formula for metric input calculation using a cubic foot gas meter:

MJ/m

3

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

Seconds it took to measure the 2 cu.ft. of gas

NATURAL GAS INPUT CALCULATION

EXAMPLE:

39.2 x 2 x 0.960 x 3600

90.5

Natural Gas

BTU/SCF 1030 = 39.2 MJ/m

3

PROPANE (LP) GAS INPUT CALCULATION

EXAMPLE:

93.15 x 1 x 0.960 x 3600

108

Propane Gas

BTU/SCF 2500+93.15 MJ/m

3

=

=

=

MJ/H

84.76

84.41

x x x 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 0.0283 cm of gas from the gas meter.

0.2777

0.2777

0.2777

=

=

= kW

23.54

23.45

x x x

3412.14

3412.14

3412.14

= BTUH/H

= 80,312.62

= 80,000.00

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 DER-

ATED. Refer to the GAS CONVERSION FOR PROPANE (LP) AND

HIGH ALTITUDES IN SECTION IV for information on high altitude conversions.

16 Unitary Products Group

035-19930-001 Rev. A (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 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.

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.

TABLE 15: Nominal Manifold Pressure

NOMINAL MANIFOLD PRESSURE

Natural Gas (High Fire)

Natural Gas (Low Fire)

Propane (LP) Gas (High Fire)

Propane (LP) Gas (Low Fire)

3.5" w.c. (0.87 kPa)

1.6" w.c. (0.40 kPa)

10.0" w.c. (2.488 kPa)

4.0" w.c. (0.99 kPa)

High Outlet Pressure Adjustment

1.

Turn off all electrical power to the system at main fuse or circuit breaker.

2.

Attach a manometer to the outlet pressure tap of the valve.

3.

Turn on power and energize main and redundant (P.M.) solenoids as well as the HI terminal.

4.

Remove high adjustment seal screw to expose the 3/32”. See Figure 24.

5.

To increase outlet pressure, turn the 3/32” set screw clockwise. To decrease outlet pressure, turn the set screw counterclockwise.

Adjust regulator until pressure shown on manometer matches the pressure specified on the appliance rating plate.

6.

Replace low adjustment seal screw and tighten securely. Cycle the valve several times to verify regulator setting.

7.

Remove manometer and replace the outlet pressure tap plug.

Low Outlet Pressure Adjustment

1.

Turn off all electrical power to the system at main fuse or circuit breaker.

2.

Attach a manometer to the outlet pressure tap of the valve.

3.

Turn on power and energize main and redundant (P.M.) solenoids.

Do not energize HI terminal.

4.

Remove low adjustment seal screw. See Figure 24.

5.

To increase outlet pressure, turn the 3/32” set screw below the low adjustment seal screw clockwise. To decrease outlet pressure, turn the set screw counterclockwise. Adjust regulator until pressure shown on manometer matches the pressure specified on the appliance rating plate.

6.

Replace high adjustment seal screw and tighten securely. Cycle the valve two and three times to verify regulator setting.

7.

Remove manometer and replace the outlet pressure tap.

IMPORTANT: If gas valve regulator is turned in (clockwise), manifold pressure is increased. If screw is turned out (counterclockwise), manifold pressure will decrease.

8.

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)”.

9.

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 re-install the plug in the Out Pressure Port using a compound (on the threads) resistant to the action of LP gases.

Replace the burner box front cover (if it was removed) and replace the pressure reference hose.

10. 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 non-corrosive gas leak detection fluid, or other non-flammable leak detection methods.

INLET

WRENCH

BOSS

O

F

F

ON

PM

C

HI

P

E

L

P

E

L

A

C

E

SCRE

W

OUTLET

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.

ON / OFF SWITCH

FIGURE 24: Gas Valve

Unitary Products Group 17

035-19930-001 Rev. A (0404)

MAINFOLD PRESSURE “U” TUBE CONNECTION

FLAME

SENSOR

GAS VALVE

GAS

BURNERS

O

F

F

ON

PM

C

HI

CE

A

SCRE

W

U-TUBE

MANOMETER

MAINIFOLD

PIPE

1/4” TUBING

3.5 IN

WATER

COLUMN

GAS

PRESSURE

SHOWN

FIGURE 25: Reading Gas Pressure

DIRECT DRIVE MOTORS

Adjustment of Fan-Off Control Settings

This furnace is equipped with a time-on/time-off heating fan control. The fan-on is fixed at 30 seconds. The fan-off delay is factory set to 60 seconds; however, it is field-adjustable to 90, 120 or 180 seconds. The fanoff setting must be long enough to adequately cool the furnace, but not so long that cold air is blown into the heated space. The continuous fan speed dip switch (switch 3) on the ignition control has no affect on setting and should be left in the off position, as continuous fan speed is determined by the variable speed motor program.

Direct Drive Motors (Only Applies to PSC Replacement)

The temperature rise, or temperature difference between the return air and the heated air from the furnace, must be within the range shown on the furnace rating plate. Application limitations are shown in Table 8.

After the temperature rise has been determined, the CFM can be calculated. 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 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. You may select a heating speed and a cooling speed. They may be the same speed or a different 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.

Installation PSC Motor

1.

Install the PSC direct drive motor into motor mount.

2.

Slide motor in motor mount insuring there is no interference between moving and stationary parts. Position wire leads downward. Tighten motor mount band screw to 30 in. lbs.

3.

Center the blower wheel in the blower housing and align the shaft flat with the blower wheel set screw. Tighten setscrew to 30 in. lbs.

4.

Replace blower assembly and fasten with 5 screws

5.

Strap motor capacitor to electric panel. Refer to Table 16, for proper capacitor selection.

6.

Fasten electric panel to blower housing.

7.

Remove red wire from Circ. input terminal. Plug jumper wire

(attach to motor power harness) on 120-volt line terminal on ignition control and jumper to Circ. Input. Connect brown door switch wire to jumper.

8.

Connect white main harness lead to Line neutral.

9.

Connect motor leads to cool, heat lo and heat high per electrical wire diagram table in the Installation manual.

10. Connect brown capacitor leads from motor to capacitor and cover terminals with boot supplied.

POWER SUPPLY POLARITY - Ignition Control: If the power supply polarity is reversed, the following unit operation will occur. On a call for heat, the inducer will run, the HSI will glow and the gas valve will energize and the burners will ignite. The burners will immediately extinguish and the unit will recycle. This will occur 3 times and then the unit will lockout. A “7” flash code will be displayed. This code means the flame could not be established. This occurs because the control cannot sense flame with the power supply polarity reversed.

TABLE 16: Replacement PSC Motor

Low Fire

Heating Input

Low Fire

Heating Output

High Fire

Heating Input

High Fire

Heating Output

Furnace

Airflow

Motor Part

Number

BTU/H kW BTU/H kW BTU/H kW BTU/H kW CFM cm/m

39,000 11.43

36,000 10.55

60,000 17.58

55,000 16.12 1200 33.98 024-23271-000

52,000 15.24

48,000 14.07

80,000 23.45

75,000 21.98 1600 45.31 024-26002-000

65,000 19.05

60,000 17.58

100,000 29.31

95,000 27.84 2000 56.63 024-23288-001

Motor

Horsepower

1/2

3/4

1

Capacitor

Part Number

Capacitor

Rating

024-20045-000 7.5 µf

024-20046-000 10.0 µf

024-20446-000 15.0 µf

78,000 22.86

72,000 21.10

120,000 35.17

112,000 32.82 2000 56.63 024-23238-001 1 024-20446-000 15.0 µf

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

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 dip switches on the

Integrated Control as shown in Figure 26.

18 Unitary Products Group

035-19930-001 Rev. A (0404)

ADJUSTMENT OF TEMPERATURE RISE

INDOOR FAN OFF

DELAY DIP SWITCHES

FIGURE 26: White Rodgers Integrated Control

Continuous Blower

The Integrated (Ignition) Control does not control the operation of the blower when it is run in the continuous mode. The CFM / timer Board controls the blower in the continuous mode through the “G” terminal on the thermostat. When the thermostat fan-switch is set to the ON position a circuit is completed between “R” and “G”. This will cause the blower to operate continuously at 63% of the high cool speed.

If more airflow is desired, you must locate the green wire labeled “G

Cool Speed” which is located in the wire bundle near the Integrated

(Ignition) Control. After the wire has been located, connect it to the “G” terminal on the Integrated (Ignition) Control. This will cause the blower to operate at the HIGH COOL speed. Dip switch 3 must be in the OFF position.

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

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.

MODELS

Input/Output

BTU (kw)

57/48 (16.7/14.1)

80/64 (23.4/18.8)

80/64 (23.4/18.8)

100/80 (29.3/

23.4)

115/96 (33.7/

28.1)

CFM

(m

3

/m)

1200

(34.0)

1600

(45.3)

1200

(34.0)

2000

(56.6)

EXTERNAL STATIC PRESSURE, INCHES WC (kPa)

Cabinet

Size

A

Speed

Tap

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 1540 43.6 1475 41.8 1405 39.8 1305 37.0 1230 34.8 1130 32.0 1015 28.7 855 24.2 695 19.7

MED-HIGH 1140 32.3 1120 31.9 1110 31.4 1075 30.4 1035 29.3 980 27.8 920 26.1 815 23.1 700 19.8 570 16.1

MED-LOW 870 24.6 860 24.4 840 23.8 815 23.1 770 21.8 725 20.5 675 19.1 600 17.0 530 15.0 425 12.0

LOW 695 19.7 675 19.1 655 18.5 635 18.0 610 17.3 575 16.3 530 15.0 470 13.3 400 11.3 290 8.2

B

B

C

HIGH 2110 59.7 2050 58.0 1995 56.5 1910 54.1 1840 52.1 1780 50.4 1690 47.9 1610 45.6 1515 42.9 1415 40.1

MED 1895 53.7 1860 52.7 1825 51.7 1765 50.0 1700 48.1 1630 46.2 1560 44.2 1495 42.3 1410 39.9 1310 37.1

LOW 1690 47.9 1675 35.0 1660 47.0 1605 45.4 1550 43.9 1490 42.2 1440 40.8 1360 38.5 1280 36.2 1200 34.0

HIGH 1775 50.3 1720 48.7 1660 47.0 1585 44.9 1510 42.8 1420 40.2 1315 37.2 1195 33.8 1055 29.9 865 24.5

MED 1380 39.1 1360 38.5 1350 38.2 1240 37.7 1280 36.2 1230 34.8 1150 32.6 1050 29.7 920 26.1 760 21.5

LOW 1030 29.2 1015 28.7 1000 28.3 985 27.9 965 27.3 950 26.9 895 25.3 805 22.8 710 20.1 595 16.8

HIGH 2515 71.2 2440 69.1 2355 66.7 2265 64.1 2190 62.0 2100 59.5 1990 56.4 1875 53.1 1740 49.3 1600 45.3

MED 2085 59.0 1615 58.6 2040 57.8 1585 56.6 1925 54.5 1850 52.4 1765 50.0 1660 47.0 1555 44.0 1430 40.5

LOW 1720 48.7 1710 48.4 1695 48.0 1685 47.7 1625 36.4 1580 44.7 1515 42.9 1440 40.8 1345 38.1 1215 34.4

Airflow expressed in standard cubic feet per minute (f

3

/m) and in cubic meters per minute (m

3

/min).

NOTES:

Motor voltage at 115 V.

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

Unitary Products Group 19

035-19930-001 Rev. A (0404)

FILTER PERFORMANCE

The airflow capacity data published in Table 18 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.

TABLE 18: Filter Performance - Pressure Drop Inches W.C. and (kPa)

AIRFLOW

RANGE

MINIMUM OPENING SIZE

0 - 750

751 - 1000

1001 - 1250

1251 - 1500

1501 - 1750

1751 - 2000

2001 & Above

1 Opening

Sq. in. m

2

.15

230

330

330

330

380

380

463

.21

.21

.21

.25

.25

.30

2 Openings

Sq. in.

m

2

658

658

658

.42

.42

.42

NOTE: 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.

DISPOSABLE

1 Opening 2 Opening

In w.c.

Pa In w.c.

0.01

0.04

0.08

0.08

0.14

0.17

0.17

Pa

2.5

10

20

20

35

42

42

0.08

0.09

0.09

20

22

22

In w.c.

0.01

0.03

0.07

0.07

0.13

0.15

0.15

FILTER TYPE

HOGS HAIR*

1 Opening 2 Opening

In w.c.

Pa Pa

2.5

7.5

17

17

32

37

37

0.06

0.07

0.07

15

17

17

PLEATED

1 Opening 2 Opening

In w.c.

Pa In w.c.

0.15

0.20

0.20

0.25

0.30

0.30

0.30

Pa

62

75

75

75

37

50

50

0.17

0.17

0.17

42

42

42

* 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.

TABLE 19: Field Installed Accessories - Non-Electrical

MODEL NO.

1NP0480

1PS0301

1PS0302

1PS0311

1PS0312

1BR0314

1BR0317

1BR0321

1BR0324

1CB0314

1CB0317

1CB0321

1CB0324

1SR0302

DESCRIPTION

PROPANE (LP) CONVERSION KIT

HIGH ALTITUDE PRESSURE SWITCH KIT

(Does Not Include Orifices)

EXTERNAL BOTTOM RETURN FILTER

COMBUSTIBLE FLOOR BASE FOR DOWNFLOW UNITS

EXTERNAL SIDE FILTER RACK - WITH FILTER RACK (6 pack)

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.

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

USED WITH

ALL MODELS

SEE TABLE BELOW

14-1/2” (“A”) CABINETS

17-1/2” (“B”) CABINETS

21” (“C”) CABINETS

24-1/2” (“D”) CABINETS

14-1/2” (”A”) CABINETS

17-1/2” (“B”) CABINETS

21” (“C”) CABINETS

24-1/2” (“D”) CABINETS

ALL MODELS

20 Unitary Products Group

SECTION IX: WIRING DIAGRAM

035-19930-001 Rev. A (0404)

FIGURE 27: Wiring Diagram

Unitary Products Group 21

035-19930-001 Rev. A (0404)

NOTES

22 Unitary Products Group

035-19930-001 Rev. A (0404)

Unitary Products Group 23

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

035-19930-001 Rev. A (0404)

Supersedes: 035-17429-000 Rev. B (0801)

Norman

OK

73069