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Inst Manual PV9DH 06..

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2. INJWIGYODOVY 30 3AWVSHOVIOD INVNDVIG NOLLOANNOD CAAdS WISVINIVA 3 9V ILIS OMLI MO TONAMOG 06 579 un 310N LONGNI 0 313313400S 30 CI 83MO 19 0 09 1 511 ALON 335 09 1 611 ATddAS YIMOd LYFANO LN3A31VWHON 791790 T o y 314909 183A 11389 NUS NAYS NMONG TONY TE JLIHM CINQ VEO 01134 13 3908 03 038 3018 ng CON Wn 6 42v 18 39113 fig YNAINOD 30 4009 NOIL23NNOO 1915 1 WOOY 9NI 1002 39VIS Z 39715 2 STOY LNOD YINOILIGNOD OL e e JOVIS 578 IQ VH HOIH gn31v2l 3 QINWRH W d 2313 381113 2v3 YOLOW dd AINO 1300W 0002 0091 y NOILVIN3WI Sa ALVSNAQNOD 39VvIS O N 31184 30 YNILVLAWWOD HOLIMS YOOd MS O N JYIVINIWI13 3AWVHOVIG INVHDVIG 151 D iring W FIGURE 39 39 Unitary Products Group NOTES Subject to change without notice Printed in U S A 271041 UIM A 0407 Copyright by York International Corp 2007 All rights reserved Supersedes 167811 UIM B 0706 Unitary 5005 Norman Product York OK Group Drive 73069
3. 5 yea eDeis 1514 LWM 002 5 puooeg e DBuis CA A 005 eDeis 1514 LA UOWWOD 43335 3 18VIHVA uoneoyipiunueq 10 S3A ul 15 031002 W40 uo 1ejsipiung pue 23 eui ul aq 15 d e3 9 sn 01 NO 01195 15 nus 1957 jejsouueu jo 91 deis DLS ILIN 01195 15 nuayy 195 5 jo deis jejsipitung WH 14617 jejsipiunnueq cM 1eoH eDeis 1514 LW3 1000 5 puooes CA 000 eDeis 1514 LA UOUJUJO2 3OA vZ LVLSOWYSAHL A63AX A69AX A83JAX A89AX AG 8 1 D 6 8 7 4 6 8Ad peeds ejqeueA 1019S 9 15 Zz 0107 Z SIN 01 Jes eq 1snui nue N Jes sowy jo deis euondo si UOWLUOD Jeureuue 34 JO 5 1eoH eDeis 1514 LW3 10H HOA vC 10H d d 002 puooes CA 000 eDeis 1514 LA UOWWOD 2 vcL0Zneedad LVLSOWYSHL si 3 OA vz Jeureuue
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5. 15 Filter Performance Pressure Drop Inches and kPa 38 Field Installed Accessories Non Electrical 38 SECTION SAFETY A This is a safety alert symbol When you see this symbol on A WARNING labels or in manuals be alert to the potential for personal injury Improper installation may create a condition where the operation of the product could cause personal injury or property damage Understand and pay particular attention to the signal words DANGER Improper installation adjustment alteration service or mainte WARNING or CAUTION nance can cause injury or property damage Refer to this manual DANGER indicates an imminently hazardous situation which if not for assistance or for additional information consult a qualified con avoided will result in death or serious injury WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury A CAUTION tractor installer or service agency CAUTION indicates a potentially hazardous situation which if not This product must be installed in strict compliance with the installa avoided may result in minor or moderate injury It is also used to tion instructions and any applicable local state and national codes alert against unsafe practices and hazards involving only property dam including but not limited to building electrical and mechanical age
6. 1888 828 343 1686 105 _ _________ __ 47 All are shown at 0 5 w c external static pressure These units have variable speed motors that automatically adjust to provide constant from 0 0 to 0 6 w c static pressure From 0 6 to 1 0 static pressure CFM is reduced by 2 per 0 1 increase in static Operation on duct systems with greater than 1 0 w c external static pressure is not recommended NOTE At some settings LOW COOL and or LOW HEAT airflow may be lower that what is required to operate an airflow switch on certain models of electronic air cleaners Consult the instructions for the electronic air cleaner for further details The ADJ tap should not be used Unitary Products Group 3 2 1041 UIM A 0407 FILTER PERFORMANCE The airflow capacity data published in Table 18 represents blower per formance WITHOUT filters To determine the approximate blower per formance of the system apply the filter drop value for the filter being used or select an appropriate value from the Table 19 NOTE The filter pressure drop values in Table 19 are typical values for the type of filter listed and should only be used as a guideline Actual pressure drop ratings for each filter type vary between filter manufactur ers TABLE 19 Filter Performance Pressure Drop Inches W C and kPa Filter Type Washable Fiber Pleated 0 00249 0 15 0 03736 Min
7. 22 1 4 25 3 8 26 1 2 27 1 8 30 1 8 LEFT SIDE I 19 14 1 1 4 BOTTOM IMAGE SUPPLY END FIGURE 3 Dimensions BTUH kW Input 60 17 6 1200 34 0 80 24 80 23 4 1600 45 3j 100 29 3 2000 56 6 120 35 1 2000 56 6 RESIDENTIAL AND NON HUD MODULAR HOME DOWNFLOW AND HORIZONTAL RETURN PLENUM CONNECTION The return duct system must be connected to the furnace inlet and the return duct system must terminate outside the space containing the fur nace When replacing an existing furnace if the existing plenum is not the same size as the new furnace then the existing plenum must be removed and a new plenum installed that is the proper size for the new furnace Attach the return plenum to the furnace inlet duct flanges This is typi cally through the use of S cleat material when a metal plenum is used The use of an approved flexible duct connector is recommended on all installations The connection of the plenum to the furnace and all the ducts connecting to the plenum must be sealed to prevent air leakage The sheet metal should be crosshatched to eliminate any popping of the sheet metal when the indoor fan is energized The duct system is a very important part of the installation If the duct system is improperly sized the furnace will not operate properly The ducts attached to the furnace must be of sufficient size so that the fur nace operates at the specified external static pr
8. 9114 Nid 91 65 6 Qquvog 1OHINOO 3OVNufj NO 13420S 9 9114 Nid ZI 15 1 nid NOLIVIN3AI 1 YNOd SUNIL ONOFSIG S31 ZAISSINYNOG 38431 N3 3SIW N31 3813 1100 1N3W3OV dWi4 30 31NVSOdWOO 31101 AYAIND 30 113 YNOd 531139 530 1NiWi1n1S CO SOI 4 122 SNIOW S3univuddwil 530 v 93151534 LNVANOd XN 1100 11 LNOL N3 fO 3lH1Vd N3 30V dNW3H X Vdl2INON 13 XNVDO1 53009 NO LA 232 NilIQVNVO 2313 3002 8 n0 13 N30 2313 3002 V NO13S M S310N 03123108Ud 53119415 Y4MOd 11V q3auNnouo9 A143dOUd 38 LSNW SING VIYSLVW NA 23AV 3413 1 3813 1100 39V113 31 IS 3I INVHO 39v1I4 LAOL AlLN3H3HNI SYOLOW 03 SLO3NNOOSIQ 3iQIAOUd NOdWOD LIN3W39Y1d3 11 KINO SYOLONGNOD 83880 03 JISVLIAS SYOLIANNOD 09 601 3 122 19931 30 ONILVY 34nivuddWil V 9NIAVH TWIYSLVW HLIM 032vV1d3H 38 LSAW 11 d49V1d34 38 LSAW JOVNYNA JHL HLIM 031 14415 SV 3UIM 3002 4112 YO 1V201 2 YO ONV 230 3402 9414 NVIOVNVO 8 YO ONV 93 3002 9414 IVNOIIVN V FHL 30 3 u3d ONIYIM 013414 117 SALON 38831 and 034 ON dil 321AN3S 31 23AV 3032084 30 LNVAY SYNFLONOPSIG S31 Z3HAfO 38831 N3 NOTIDV23Md LINN SIHL 9NI2IAU3S 380438 SLOANNODSIG 11 N3idO NOLLNVD 0002 0081 318VIUuVA 355311 v 13 SAVE 31 YWd JATILNGA 539715 V JSIVNYNO4 06
9. OU JO uonoeuuoo puooes cM 1eoH 1514 M 002 puooes CA 002 eDeis 1514 A UOWLUOD 3OA vZ 1005 LVLSOWYSAHL eDeijsniniw 1009 9 c 8 01195 15 0210 19 dnjes Je e1su 1e1s0uu9u L pesn euondo si JOA vz leureuue BU JO uonoeuuo9 puooes yeaH 1514 LWA HINAX 1009 OH HINAX 1 10H H 002 eBeis ZA 00D eDeis 1514 10 2 LVLSOWYSAHL 01195 15 uonooejoJg JOSSEIGWOD JequinN dnjas 1ej eisu Je SOWIOY 005 9 01195 15 ed uieis S JequinN dnies 19118154 12 50 194 Seuageq euondo si UOWLUOD eureuue 94 9 yeaH 95 cM 1eoH eDeis 1514 LW3 HINJX 1009 10H OH HNX 19H 10H H 1000 5 puooes ZA 000 eDeis 1514 D 0 LVLSOWYSHL Thermostat Chart AC FIGURE 11 Unitary Products Group 12 2 1041 UIM A 0407 yeay dnyoeg S Wy Jang Isso4 0 01195 1
10. Crawl Space Termination Configuration 2Pipe 18 Reading Gas Pressure 34 Double Horizontal Sealed Combustion Air and Vent Termination 18 Furnace Control Board 34 Double Vertical Sealed Combustion Air and Vent Termination 18 Wiring DISOFGITI Ea ere eire 39 LIST OF TABLES Unit Clearances to Combustibles 4 Combustion Air Intake and Vent Connection Size at Furnace Minimum Duct Sizing For Proper Airflow 5 nul vec m 15 Hound DUC SIZE 5 Estimated Free Area 19 Recommended Filter Sizes 7 PlCe fon beta aoe eee ae E 19 Nominal Manifold Pressure High Fire 10 Unconfined Space Minimum Area in Square Inch 19 Nominal Manifold Pressure Low Fire 10 Condensate Drain Hose 21 Electrical and Performance Data 11 Inlet Gas Pressure Range 33 Maximum Equivalent Pipe Length 15 Nominal Manifold Pressure 33 Equivalent Length of Fittings 15 nt hau Wa ob d a bred 37 Elbow Dimensions
11. INSTALLATION The furnace can be hung from floor hoists or installed on suitable blocks or pad Blocks or pad installations shall provide adequate height to ensure the unit will not be subject to water damage Units may also be suspended from rafters or floor joists using rods pipe angle supports or straps Angle supports should be placed at the supply air end and near the blower deck Do not support at return air end of unit All four sus pension points must be level to ensure quite furnace operation When suspending the furnace use a secure a platform constructed of plywood or other building material secured to the floor joists Refer to Figure 6 for typical crawl space installation Unitary Products Group 4 SUPPORT BRACKET ANGLE IRON BRACKET 1 MAX BETWEEN 6 MIN BETWEEN ROD amp FURNACE 1 MAX BETWEEN ROD amp FURNACE FIGURE 6 Typical Suspended Furnace Crawl Space Installation A CAUTION In any application where temperatures below freezing are possible see BELOW FREEZING LOCATIONS SECTION IV GAS PIPING GAS SAFETY ADANGER An overpressure protection device such as a pressure regulator must be installed in the gas piping system upstream of the furnace and must act to limit the downstream pressure to the gas valve so it does not exceed 0 5 PSI 114 w c 3 48 kPa Pressures exceed ing 0 5 PSI 14 w c 8 48 kPa at the gas valve will cause damage
12. a circuit is completed between the R and W terminals The indoor fan motor is energized through the W1 heat terminal and runs on the speed selected on the HEAT tap of the control board Unitary Products Group 2 1041 UIM A 0407 Humidistat When a humidistat is installed in the system the Humidistat Installed jumper on the control board should be moved to the YES position The cooling CFM will then be reduced by 1596 whenever the humidistat indi cates high humidity FURNACE CONTROL DIAGNOSTICS The furnace has built in self diagnostic capability If a system problem occurs a blinking LED shows a fault code The LED can flash red green or amber to indicate various conditions is located behind a clear view port in the blower compartment door The control continuously monitors its own operation and the operation of the system If a failure occurs the LED will indicate the failure code If the failure is internal to the control the light will stay on continuously In this case the entire control should be replaced as the control is not field repairable Flash sequence codes 1 through 10 are as follows LED will turn for 1 4 second and off for 1 4 second This pattern will be repeated the number of times equal to the code For example six on flashes equals a number 6 fault code All flash code sequences are broken by a 2 sec ond off period SLOW GREEN FLASH Normal operation SLOW AMBER FLASH Normal
13. codes 271041 UIM A 0407 2 1041 UIM A 0407 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 Install this furnace only in a location and position as specified in SECTION I of these instructions A gas fired furnace for installation in a residential garage must be installed as specified in SECTION of these instructions Provide adequate combustion and ventilation air to the furnace space as specified in SECTION VI of these instructions Combustion products must be discharged outdoors Connect this furnace to an approved vent system only as specified in SEC TION VI of these instructions FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in serious injury death or property damage Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for detection of leaks to check all connections A fire or explosion may result causing prop erty damage personal injury or loss of life Tests for gas leaks as specified in SECTION IX of these instruc tions Always install the furnace to operate within the furnace s intended temperature rise range Only connect the furnace to a duct system which has an external static pressure within the allowable range as specified on the furnace rating plate Whe
14. 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 HIGH STAGE REGULATOR ADJUSTMENT OUTLET PRESSURE el PORT lt VENT J sl E WRENCH BOSS mmi c INLET SX jO PRESSURE I I PORT ON OFF SWITCH LOW STAGE REGULATOR ADJUSTMENT FIGURE 7 Gas Valve IMPORTANT Plan your gas supply before determining the correct gas pipe entry Use 90 degree service elbow s or short nipples and con ventional 90 degree elbow s to enter through the cabinet access holes GAS PIPING INSTALLATION Properly sized wrought iron approved flexible or steel pipe must be used when making gas connections to the unit If local codes allow the use of a flexible gas appliance connection always use a new listed con nector Do not use a connector that has previously serviced another gas appliance Some utility companies or local codes require pipe sizes larger than the minimum sizes listed in these instructions and in the codes The furnace rating plate and the instructions in this section specify the type of gas approved for this furnace only use those approved gases The instal lation of a drip leg and ground union is required Refer to Figure 8 Unitary Products Group 2 1041 UIM A 0407 EXTERNAL MANUAL SHUT
15. velocity filters 2 2 C __ EE 2 2 1041 UIM A 0407 Downflow Filters Downflow furnaces typically are installed with the filters located above the furnace extending into the return air plenum or duct Any branch duct rectangular or round duct attached to the plenum must attach to the vertical plenum above the filter height Refer to Figure 4 for proper installation Filters s may be located in the duct system external to the furnace using an external duct filter box attached to the furnace plenum or at the end of the duct in a return filter grille s The use of straps and or sup ports is required to support the weight of the external filter box If the accessory electronic air cleaner is installed be sure the air cleaner is designed to accommodate the furnace CFM cm m and the air cleaner is installed so it does not obstruct the return airflow Consid eration should be given when locating the air cleaner for maintenance and temperatures should the indoor fan motor fail to operate The use of straps and or supports is required to support the weight of the elec tronic air cleaner It is recommended that the air cleaner not be located within 12 inches 30 5 cm from the top of the return air opening on the furnace Refer to the instructions supplied with the electronic air cleaner All loose accessories shipped with the furnace must be removed from the blower compartment prio
16. 0407 TABLE 18 Air Flow Data A B B B 30389 708 99 6 B B D B8 86 87 242 164 b Co A B B B 1699 1140 2045 1363 481 ES 1033 1661 B A 4834 93 ao 98 1527 1047 1884 120 C 14 98 159 392 B 6 b B uM NEN NN o 6 6 108 120 000 put Ton CFM Jumper Settings 120 000 Input 5 Ton mein 7 High tow COOL Tap ADJTap High iow 388 83 383 y SSS 1904 3229 __ ON 89 38 S 2140 3404 606 398 3700 3096 4 39 8 3287 s3 s3 3 amp 3 _ Od 5 382 99 __ uM 348 82 gt 241 34944 95 483 268 7 7 p 364 1 29 1 3837 82 p 378 227 183 68 c 32 189 HIGH LOW HEAT CFM WITHOUT FILTERS Low 272 gt gt gt gt B ay 25 3 24 0 D Any 217 100 000 Input 5 lon CFM 80 000 Input 4 Ton m3 min 100 000 Input 5 Ton m3 min HEAT ADJ B Ay D Ay 120 000 Input 5 Ton CFM JumperSetngs 120000 Input 5 Tonm mim 7 Hgh tw Hgh tw fT 2288 145 684 415 3094 Bry
17. 3SOH FIGURE 32 Horizontal Right Condensate Drain Hose Configuration Option 1 Front of Casing 27 Unitary Products Group 2 1041 UIM A 0407 HOSE 2 uo sl aS S 3 WAY TRANSITION Shown Provided with some furnaces CUT FROM 2 1 2 long HOSE 1 3 8 BARBED TEE HOSE 4 BLOCKED CONDENSATE SWITCH HAS BEEN FACTORY INSTALLED FOR THIS POSITION THIS TUBE FOR THE HOSE 7 FIGURE 33 Horizontal Right Condensate Drain Hose Configuration Option 2 Back of Casing 28 Unitary Products Group 2 1041 UIM A 0407 I lt e N LL 0 lt 2 I LLI I 3 22s L a 2O0mr lt 5 o T y E 2 a o HOSE 9 EL SPRING CLAMP DOGLEG SPRING CLAMP HOSE 8 3 8 BARBED NIPPLE HOSE 2 HOSE 1 HOSE 7 HOSE 9 RECOMMENDED CONDENSATE TRAP ORIENTATION LLI o L FIGURE 34 Horizontal Right Condensate Drain Hose Configuration Option 2 Back of Casing Unitary Products Group 29 2 1041 UIM A 0407 CONDENSATE DRAIN TERMINATION DO NOT terminate condensate drain in a chimney or where the drain line may freeze The line must terminate at an inside drain to prevent freezing of the condensate and possible property damage DO NOT trap the drain line at any other location than at the condensate drain trap supplied with the furnace A condensate sump
18. 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 FOR FURNACES INSTALLED IN THE COMMON WEALTH OF MASSACHUSETTS ONLY For all side wall horizontally vented gas fueled equipment installed in every dwelling building or structure used in whole or in part for resi dential purposes including those owned or operated by the Com monwealth and where the side wall exhaust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following require ments shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back up is installed on the floor level where the gas equipment is to be installed In addition the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling building or structure served by the side wall horizontal vented gas fueled equipment It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detec
19. Fuel Gas Code Refer to the section on the Recommended Procedure for Safety Inspection of an Existing Appliance or in Canada B149 1 00 Natural Gas and Pro pane Installation Code section on Venting Systems and Air Supply for Appliances and all local codes In addition to the procedure specified in ANSI Z223 1 It is recommended that you follow the venting safety pro cedure below This procedure is designed to detect an inadequate ven tilation system that can cause the appliances in the area to operate improperly causing unsafe levels of Carbon Monoxide or an unsafe condition to occur 1 Inspect the venting system for proper size 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 p
20. Horizontal nius 60 120 MBH INPUT SE 17 6 35 17 KW INPUT LIST OF CONTENTS SAFELY d 2a 374 ood REO 1 COMBUSTION AIR AND VENT SYSTEM 14 DUCTWORK 23d aod n ade dT E aC d a da eee 4 CONDENSATE PIPING 24 06 ink rmi mac RR RR RO 21 PIETERS a LA ardet a dO ER oa Eo aad ac od uA 7 SAFETY CONTROLS wawa a d d RENAL Mace ut 30 GAS PIPING xax ace te dees dive tows eee ee CR CERE AC 9 START UP AND ADJUSTMENTS 30 ELECTRICAL POWER peat aka ci sous RC era wane 10 WIRING DIAGRAM 39 LIST OF FIGURES Combustible Floor Base Accessory 5 Sealed Combustion Air Intake Connection and Vent Connection 18 Transition Kit Assembly 6 Combustion Airflow Path Through The Furnace DIMENSIONS P eee eee eh eee ee re 7 Casing to the Burner Box 19 Return Filter Grill and Return Duct Installation 8 Outside and Ambient 20 Typical Attic Installation 8 Attic Combustion Air Termination 20 Typical Suspended Furnace Crawl Space Installation 9 Condensate Drain Internal Hose Routing 21 VAG MP hinds Bas Pee hee eRe 9 Dow
21. SETTINGS Heating Indoor Fan Off Delay This furnace is equipped with a time on time off heating fan control The fan on delay is fixed at 30 seconds The fan off delay has 4 settings 60 90 120 and 180 seconds The fan off delay is factory set to 120 sec onds The fan off setting must be long enough to adequately cool the furnace but not so long that cold air is blown into the heated space The fan off timing may be adjusted by positioning the jumper on two of the four pins as shown in Figure 38 CONTINUOUS FAN SPEED JUMPER BLOWER OFF DELAY JUMPER COOLING PROFILE JUMPER BLOWER SPEED JUMPERS Unitary Products Group Heating and Cooling Airflow The heating and the cooling airflows are preset at the factory The heat ing airflow is set to the maximum CFM The cooling airflow is set to pro vide 90 percent of the maximum CFM The heating and cooling airflows must be field adjusted to match the HVAC system at installation See Table 18 for the HEAT COOL and ADJ jumper settings to use for spe cific airflows CFM Board Delay Taps Selection The set of jumper pins on the control board labeled DELAY are used to set the delay profiles for the furnace These can be chosen so as to maximize the comfort and sound levels for various regions of the coun try Tap A is the default profile It provides a 30 second ramp up from zero airflow to full capacity and a 30 second ramp down from full capacity back to zero airflow Whene
22. Unitary Products Group 2 1041 UIM A 0407 ACCESSORY CONNECTIONS The furnace control will allow power switching control of various acces sories Refer to Figure 13 for connection details HUM HOT 115 VOLT HUMIDIFIER SWITCHED CIRCUITS 115 VOLT ELECTRONIC AIR CLEANER NEUTRALS FIGURE 13 Accessory Connections ELECTRONIC AIR CLEANER CONNECTION Two 1 4 0 64 cm spade terminals NEUTRAL for electronic air cleaner connections are located on the control board The terminals provide 115 VAC 1 0 amp maximum during circulating blower opera tion HUMIDIFIER CONNECTION Two 1 4 0 64 cm spade terminals NEUTRAL for humidifier connec tions are located on the control board The terminals provide 115 VAC 1 0 amp maximum during heating system operation TWINNING These furnaces are not to be twinned If more than one furnace is needed in an application each furnace must have its own complete duct system and its own wall thermostat SECTION VI COMBUSTION AIR AND VENT SYSTEM COMBUSTION AIR AND VENT SAFETY This Category IV dual certified direct vent furnace is designed for resi dential application It may be installed without modification to the con densate system in a basement garage equipment room alcove attic or any other indoor location provided the space temperature is 32 F 090 or higher and where all required clearance to combustibles and other restrictions are met The combustion air and the v
23. being connected to the furnace without the use of an accessory duct connector then a transition duct must be installed with flanges or tabs that are securely attach and sealed to the supply air duct and to the base of the furnace The transi tion duct must have insulation between the transition duct and any com bustible material The transition duct must be the same dimensional size as the rectangu lar opening in the base of the furnace Unitary Products Group 5 2 1041 UIM A 0407 Downflow Air Conditioning Coil Cabinet The Cooling Coil Cabinet can be used in place of the combustible floor base for downflow installations on combustible materials The furnace should be installed with the cooling coil cabinet specifically intended for downflow applications The cooling coil cabinet must be secured to the floor A supply air duct plenum is installed through the opening pro vided The supply air duct is then secured to the duct system with screws and sealed to prevent leaks If a matching cooling coil is used it may be placed directly on the furnace outlet using the accessory transi tion kit and sealed to prevent leakage The transition kit must be used to secure the cooling coil cabinet to the furnace casing when installed in a downflow configuration This transition kit may be installed in one of two ways The transition kit may be installed and secured to either the furnace or the cooling coil cabinet by the use of screws and then it m
24. due to reduced airflow that may be caused by a dirty filter or if the indoor fan motor should fail The control module will lockout if the limit trips 5 consecutive times Control will reset and try ignition again after 1 hour SECTION IX START UP AND ADJ USTMENTS The initial start up of the furnace requires the following additional procedures IMPORTANT electrical connections made in the field and in the fac tory should be checked for proper tightness When the gas supply is initially connected to the furnace the gas piping may be full of air In order to purge this air it is recommended that the ground union be loosened until the odor of gas is detected When gas is detected immediately retighten the union and check for leaks Allow five minutes for any gas to dissipate before continuing with the start up A CAUTION Perform the following procedures only after the condensate trap has been properly piped to a drain connection using the procedure in this instruction Be sure proper ventilation is available to dilute and carry away any vented gas Unitary Products Group TOOLS AND INFORMATION THAT WILL BE REQUIRED IN ORDER TO PROPERLY PERFORM THE FURNACE STARTUP PROCEDURE 1 the local gas supplier to obtain heating value of the natural gas If you cannot obtain the heating valve of the gas from the gas supplier you may use a default value of 1030 BTU SCF 38 8 MJ 2 You will need a thermometer or porta
25. equivalent feet 40 equivalent feet 72 equivalent feet of 3 pipe This is less than the 90 foot maximum equivalent length of 3 pipe allowed for that model and is thus acceptable STANDARD ELBOW LONG SWEEP ELBOW FIGURE 14 Dimensions Unitary Products Group 2 1041 UIM A 0407 TABLE 10 Elbow Dimensions Elbow A Dimension 2 Standard 2 5 16 3 Standard 3 1 16 2 Sweep 3 1 4 eie Dimensions are those required in Standard ASTM D 3311 NOTE Sidewall vent terminal may be used for sidewall vent termina tions Refer to part list in the back of the USERS INFORMATION AND SERVICE AND MAINTENANCE MANUAL for the terminal part number TABLE 11 Combustion Air Intake and Vent Connection Size at Furnace All Models FURNACE VENT CONNECTION SIZES 60 100 MBH 120 MBH 17 5 29 3 kW 35 2 kW 2 5 1 3 7 6 2 5 1 3 7 6 Furnace Input Intake Pipe Size Vent Pipe Size Vent pipe size must be increased to 3 diameter after connection to furnace on this model IMPORTANT Accessory concentric vent intake termination kits 1CT0302 and 1CT0303 are available and approved for use with these furnaces Horizontal sidewall vent terminations kits 1HT0901 1 0902 are also approved for use with these furnaces IMPORTANT Furnace vent pipe connections are sized for 2 5 1 cm pipe Any pipe size change must be made outside the furnace casing in a vertical pipe
26. operation with call for heat RAPID RED FLASH Twinning error incorrect 24V phasing Check twinning wiring RAPID AMBER FLASH Flame sense current is below 1 5 microamps Check and clean flame sensor Check for proper gas flow 4 AMBER FLASHES The control board is recieving a Y signal from the thermostat without a signal indicating improper thermostat wir ing 1 RED FLASH This indicates that flame was sensed when there was not a call for heat With this fault code the control will turn on both the inducer motor and supply air blower A gas valve that leaks through or is slow closing would typically cause this fault 2 RED FLASHES This indicates that the normally open pressure switch contacts are stuck in the closed position The control confirms these contacts are open at the beginning of each heat cycle This would indicate a faulty pressure switch or miswiring 3 RED FLASHES This indicates the normally open pressure switch contact did not close after the inducer was energized This could be caused by a number of problems faulty inducer blocked vent pipe bro ken pressure switch hose or faulty pressure switch 4 RED FLASHES This indicates that a primary or auxiliary limit switch has opened its normally closed contacts With this fault code the control will operate the supply air blower and inducer This condition may be caused by dirty filter improperly sized duct system incorrect blower speed setting incorrect firing
27. or in accordance with local installation codes and the requirements of the gas supplier 12 inches 30 cm or in accordance with local installation codes and the requirements of the gas supplier 3 feet 91 cm Above a meter regulator assembly within 3 feet 91 cm horizontally of the vertical center line of the regula tor vent outlet to a maximum vertical distance of 15 feet 4 5 cm above the meter regulator assembly 3 feet 91 cm or in accordance with local installation codes and the requirements of the gas supplier Two pipe direct vent applications 9 inches 23 cm models 50 000 BTUH 15 kW 12 inches 30 cm for models 250 000 BTUH 15 kW 3 feet 91 cm above if within 10 feet 3 cm horizontally 7 feet 2 13 m or in accordance with local installation codes M the requirements of the gas supplier 12 inches 30 cm or in accordance with local installa tion codes and the requirements of the gas supplier 1 2 3 T Avent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings tt 12inches 30 cm up from the bottom edge of the structure for Two pipe direct vent applications per ANSI Z223 1 54 National Gas Code i Permitted only if veranda porch deck or balcony is fully open on a minimum of two sides beneath the floor and the distance between the top of the vent termina tion and the underside of the vera
28. pump MUST be used if required by local codes or if no indoor floor drain is available The condensate sump pump must be approved for use with acidic con densate CONDENSATE DRAIN PRE START UP PROCEDURE The condensate trap must be filled with water before putting the furnace into operation Perform the following procedures only after the conden sate trap has been properly piped to a drain connection using the pro cedure in this instruction The recommended procedure is as follows 1 Disconnect the condensate drain hose from the induced draft blower discharge 2 Elevate this hose and fill with water using a funnel 3 Replace the condensate drain hose and clamps If this procedure is not followed the unit may not properly drain on initial start up SECTION VIII SAFETY CONTROLS CONTROL CIRCUIT FUSE A 3 amp fuse is provided on the control circuit board to protect the 24 volt transformer from overload caused by control circuit wiring errors This is an ATO 3 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 A CAUTION Main power to the unit must still be inter
29. rain gutter drain and insert the 3 8 barbed nipple removed above in the bottom rain gutter drain Place the cap just removed to the other side of the rain gut ter on the inducer Remove the condensate trap and it s bracket from inside the fur nace saving the screws for later use Remove the large condensate cap from the side of the condensate pan and install it on the middle drain of the condensate pan from where 1 hose was removed Do not remove condensate trap from the condensate trap bracket Cut 2 1 2 straight piece from hose 1 and install it through the knockout opening in the casing on the side of the condensate pan from where the cap was previously removed Insert the other end of the hose into the large recessed drain on the condensate trap Install the condensate trap bracket to the 2 inch hole on the side of casing using existing holes lining up the condensate pan open ing with the larger opening on the condensate trap Install the dogleg end of hose 9 on the Wye drain and route the hose through the opening on top of the furnace Install the other end of the 9 hose to the barbed tee inside the furnace Install the dogleg end of hose 4 on 3 8 barbed nipple in the rain gutter The other end of hose 4 should be installed on the 3 8 barbed tee Install one end of hose 7 on the 3 8 barbed tee inside the fur nace Guide the other end of hose 7 towards the condensate trap and install it on the tap on the con
30. rate or faulty blower motor 5 RED FLASHES This fault is indicated if the normally closed contacts in the rollout switch opens The rollout control is manually reset If it has opened check for proper combustion air proper inducer operation and primary heat exchanger failure or burner problem Be sure to reset the switch after correcting the failure condition 6 RED FLASHES This indicates that after the unit was operating the pressure switch opened 4 times during the call for heat If the main blower is in a Delay on mode it will complete it and any subsequent delay off period The furnace will lock out for one hour and then restart 7 RED FLASHES This fault code indicates that the flame could not be established This no light condition occurred 3 times 2 retries during the call for heat before locking out Low gas pressure faulty gas valve faulty hot surface ignitor or burner problem may cause this The furnace will lock out for one hour and then restart 8 RED FLASHES This fault is indicated if the flame is lost 5 times 4 recycles during the heating cycle This could be caused by low gas pressure or faulty gas valve The furnace will lock out for one hour and then restart 35 2 1041 UIM A 0407 9 RED FLASHES Indicates reversed line voltage polarity or grounding problem Both heating and cooling operations will be affected Check polarity at furnace and branch Check furnace grounding Check that flame probe is not shorted t
31. section to allow proper drainage of condensate An offset using two 45 degree elbows will be required for plenum clearance when the vent is increased to 3 7 6 cm COMBUSTION AIR AND VENT PIPING ASSEMBLY The final assembly procedure for the combustion air and vent piping is as follows 1 Cut piping to the proper length beginning at the furnace 2 Deburr the piping inside and outside Chamfer bevel the outer edges of the piping 4 Dry fitthe vent piping assembly from the furnace to the outside ter mination checking for proper fit support and slope 5 Dry fit the combustion air piping assembly checking for proper fit support and slope on the following systems A Sealed combustion air systems from the furnace to the out side termination B Ventilated combustion air systems from the furnace to the attic or crawl space termination A CAUTION Solvent cements are flammable and must be used in well ventilated areas only Keep them away from heat sparks and open flames Do not breathe vapors and avoid contact with skin and eyes 6 Disassemble the combustion air and vent piping apply cement primer and the cement per the manufactures instructions Primer and cement must conform to ASTM D2564 for PVC or ASTM D2235 for ABS piping 7 All joints must provide a permanent airtight and watertight seal 8 Support the combustion air and vent piping such that it is angled a minimum of 1 4 per foot 0 635 cm m
32. sleeve installed inside the furnace will facilitate removal of fresh air pipe in front of the blower housing 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 is not piped directly into the burner box For downflow models combustion air is brought into the furnace through the unit top panel opening Do not install a pipe into the combustion air pipe at the top of the furnace Refer to Figure 24 If a 3 way transition is provided the side or bottom openings can also be used for the same purpose This type of installation requires that the supply air to the appli ance 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 cre ate conditions requiring special attention to avoid unsatisfactory operation of gas appliances A venting problem or a lack of supply air will result in a hazardous condition which can cause the appli ance to soot and generate dangerous levels of CARBON MONOX IDE which can lead to serious injury property damage and or death An unconfined space
33. the furnace model the total length of pipe required and the number of elbows required Table 8 lists the maximum equivalent length of pipe allowed for each model of furnace The equivalent length of elbows is shown in Table 9 The equivalent length of the vent system is the total length of straight pipe PLUS the equivalent length of all of the elbows The following rules must also be followed 1 Long radius sweep elbows are recommended Standard elbows may be used but since they have a longer equivalent length they will reduce the total length of pipe that will be allowed Short radius plumbing vent elbows are not allowed The standard dimensions of the acceptable elbows are shown below 2 The maximum equivalent length listed in Table 8 is for the vent pip ing and the air intake piping separately For example if the table allows 65 equivalent feet for a particular model then the vent can have 65 equivalent feet of pipe AND the combustion air intake can have another 65 equivalent feet of pipe 3 Three vent terminal elbows two for the vent and one for the com bustion air intake are already accounted for and need not be included in the equivalent length calculation 4 All combustion air and vent pipe must conform to American National Standards Institute ANSI and American Society for Test ing and Materials ASTM standards D1785 Schedule 40 PVC D2665 PVC DWV F891 PVC DWV Cellular Core 02261 ABS DWV or F628 Sche
34. 07 6 JSOH v ASOH 2 4315 SLIVLIMNOVA OL SHL NO GSTIVLSNI SI 3SOH TIVINS V YSONGNI LAVYGC GNIH39 dVL JHL OL 3dld HIV NOILSNENWOD NOLLVOO1 GATIVLSNI AYOLOVA IWNIDINO Q31VOO 3M LSNW HOLIMS J1VSN3QNOO Q342018 JHL 3801 SIHL Z L L ISOH 10 9 ASOH JIVSN3QNOO Qq35320 seoeuunj eulos u 5 NOLLISNV L ddld NOILSNENOO div Horizontal Left Condensate Drain Hose Configuration FIGURE 29 23 Unitary Products Group 2 1041 UIM A 0407 v 3SOH ASOH 8 6 cli v ASOH 331 8 6 Sa lddIN qa3gsva 8 6 9 ISOH LED D dI AV IO 9NISdS S ASOH v dSOH 931 41 JIVSN3QNOO Yslav 19 8 ISOH dI AV IO 9NISdS it CN 9 ISOH dVal ALVSNAGNOO Q3GaNalWNWO23H sert qagasva 8 6 qagsva 8 6 JSOH 8 6 JO JOald 1 ISOH FIGURE 30 Horizontal Left Condensate Drain Hose Configuration Unitary Products Group 24 Horizontal Right Air Flow Inducer High Refer to Figures 31 34 Installation with condensate trap bracket Front of casing Refer to Figure 31 and 32 1 2 Remove the 2 knockout on the casing side away from the inducer motor Remove all the condensate hoses inside the furnace inclu
35. 30 9 2 100 000 29 3 85 25 9 120 000 29 3 3 7 6 60 18 3 TABLE 9 Equivalent Length of Fittings Equivalent Length 5 feet of 2 pipe 2 1 2 feet of 2 pipe 10 feet of 2 pipe 5 feet of 2 pipe 2 90 sweep elbow 2 45 sweep elbow 2 90 standard elbow 2 45 standard elbow 3 90 sweep elbow 3 45 sweep elbow 3 90 standard elbow 3 45 standard elbow 5 feet of 3 pipe 2 1 2 feet of 3 pipe 10 feet of 3 pipe 5 feet of 3 pipe 2 corrugated connector 10 feet of 2 pipe 10 feet of 3 pipe 3 corrugated connector Example An 80 000 BTUH furnace requires 32 feet of pipe and four 90 elbows Using 2 pipe and standard elbows the total equivalent length will be 32 feet of 2 pipe 4 90 standard 2 elbows 4x10 Total 32 equivalent feet 40 equivalent feet 72 equivalent feet of 2 pipe This exceeds the 65 foot maximum equivalent length of 2 pipe allowed for that model and is thus not acceptable By using sweep elbows the total equivalent length will be 32 feet of 2 pipe 4 90 standard 2 elbows 4x5 Total 32 equivalent feet 20 equivalent feet 52 equivalent feet of 2 pipe This is less than the 65 foot maximum equivalent length of 2 pipe allowed for that model and is thus acceptable Alternatively using 3 pipe and standard elbows the total equivalent length will be 32 feet of 3 pipe 4 90 standard 2 elbows 4x5 Total 32
36. 5 115504 eU491X3 0120 JOQUINN dnies 1ej eisu 12 50 194 Jan 15904 si eounog yeaH dnyoeg JEOH 01195 aq 15 eounos jeep dnyoeg 0020 JequinN dnies 1ej eisu 12 50 194 uoneoyipiuunueg 10 uonisod SJA ui jsnui 2 W49 eui pue uonisod z3 eui eq1snu d z3 dung 01195 eq 15 nus 1951 sowy jo deis Buioo2 ul 9 jeuruue g O 0 01195 aq 15 uonejedo g O 0610 JequinN dnies 1ej eisu 1 50 194 NOILVOl1ddV SIHL NI NOILONNS ON IVNIINH3 L 3ON3IN3ANOO 1 000 z IeeH 01195 eq 15 ed 0410 dniss 1e eisu 1e1s0uu98U NO 01 1e9H uo 44 dund 29H 01 195 eq 1snu nue u sN sowy 10 deis Ayesseoeu ou 1215019 1 uo uo 9 330 9 led 195 YOUMS 23 13 SV9 Jo Hd3lJIdiWnaH E euondo 1euuog 108095 jeuuog WH eoH Aveyixny a6els 1514 1514 M LW3 LW3 asiy Aupiunp uo uedo uoneoyipiunueq 12151 jeisipiunp yeay eBeis 5 ZA Z
37. 5 3 42 3 4 vo gt jocis DOGLEG e ge HOSE 2 if drain aligned HOSE 4 SPRING CLAMP CUT ez 2 3 4 HOSE 1 HOSE 3 1 1 8 SPRING CLAMP HOSE 2 17 1 2 3 4 Ez SPRING CLAMP NS e Sr LEG USED AFTER CONDENSATE TRAP HOSE 8 22 1 8 SPRING CLAMP HOSE 9 Switch the blocked condensate hose to the condensate tap on the bottom of the condensate pan close to the inducer Install hose 9 between the external drain on the Wye and the condensate trap with the dogleg end installed on the protruded stub drain of the condensate trap The length of hose 9 may have to be trimmed to ensure proper condensate drainage Remove all condensate hoses off the 3 8 barbed tee Cut 1 1 2 length of straight 3 8 hose off of hose 5 and install it on the 3 8 barbed tee The other end of the 1 1 2 hose should be installed on the welled opening on the condensate trap Install one end of the 3 8 barbed tee on hose 4 as shown Ensure that hose 4 follows a gradual downward slope all the way to the barbed tee Install hose 6 between the top drain of the rain gutter of the inducer and the remaining open end of 3 8 barbed tee Ensure that all hoses are properly installed have no kinks and are draining properly All hoses on the condensate trap should be pushed all the way down to ensure against leakage Unitary Products Group 2 1041 UIM A 04
38. 8 cm 45 PVC street elbow on the vent connec tion 2 Place the 2 5 08 cm PVC WYE Y assembly on the 2 5 08 cm 45 PVC street elbow 3 Refer to the DOWNFLOW HORIZONTAL CONDENSATE INTER NAL DRAIN CONFIGURATIONS for further details MAINTAIN 12 MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL MAXIMUM 24 ABOVE ROOF FIGURE 17 Termination Configuration 1 Pipe 12 VERTICAL SEPARATION BETWEEN COMBUSTION AIR AND VENT 12 MINIMUM BELOW OVERHANG 12 MINIMUM SEPARATION BETWEEN BOTTOM OF COMBUSTION AIR PIPE AND BOTTOM OF VENT MAINTAIN 12 MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL MAINTAIN 12 MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE J WHICHEVER IS 12 MINIMUM SEPARATION BETWEEN BOTTOMOF COMBUSTION AIR PIPE AND TOP OF VENT MAINTAIN 12 MIN CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL FIGURE 19 Termination Configuration 2 Pipe Horizontal 17 2 1041 UIM A 0407 12 MINIMUM BELOW OVERHANG 12 MINIMUM SEPARATION BETWEEN BOTTOM OF COMBUSTION AIR PIPE AND BOTTOM OF VENT MAINTAIN 12 MINIMUM CLEARANCE Meri ABOVE HIGHEST E ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS HIGHER VENT DRAIN FIGURE 20 Crawl Space Termination Configuration 2Pipe VERTICAL VENT APPLICATIONS AND TERMINATION Roof mounted vertical terminals may be field fabricated Standard PVC SRD fittings may be used If install
39. 96 square inch x 2 192 square inches sure and within the air temperature rise specified on the nameplate then go to round duct size located in Table 3 Providing the return duct is properly sized as well 2 The square inch area for 7 inch round ducts 38 4 square inch x 2 76 8 square inches TABLE 2 Minimum Duct Sizing For Proper Airflow Input Cabinet Rectangular Round Supply Rectangular BTU KW minim em xem 60 B 17 6 1 200 34 0 280 1806 14 x 20 35 6 x 50 8 18 45 7 216 1394 12 x 18 30 5 x 45 7 16 40 6 80 B 23 4 1 200 34 0 280 1806 14 x 20 35 6 x 50 8 18 45 7 216 1394 12 x 18 30 5 x 45 7 23 4 40 6 16 40 6 1 500 453 22 558 16 45 7 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 O 700 feet per minute 213 m min 2 Example return main trunk duct minimum dimensions 3 Maximum supply air velocity in rigid duct 900 feet per minute 274m min TABLE 3 Round Duct Size Round Duct Size Calculated Area For Each Round Duct Size DOWNFLOW FURNACE WARM AIR PLENUM WITH 1 FLANGES FIBERGLASS INSULATION FIBERGLASS TAPE UNDER FLANGE 0 COMBUSTIBLE FLOOR ACCESSORY 1 The Air Temperature Rise is determined by subtracting the Return Air Temperat
40. A 1u6r1 14617 1u6r1 7 002 ui 1009 ui pezi amp ueu3 eA eA 002 ui pezi amp ueu3 eA eA Ayeyixny yeaH 5 95 puooes LNO 5 1514 eoH 15414 916115 JOH OA bz JOH HOA bz 10H 30A rZ d d d d d 002 5 puooes 1009 puooes ejBuis LNO cA CA A 1 1514 002 eDeis 1514 LA LA UOUJUJ02 3OA vZ UOWWOD HINAX 1009 10H OH eDeig 1514 1514 LA UOWWOD 9 5 1514 LA UOWWOD 10A v2 UOWWOD 10A vZ VeteZne dd 104 0 LV3H TOHLNOO 39VNHf LZnegdd ve LOLNCEdd 50715 43335 a3 18VIHVA LVLSOWYSAHL LVLSOWYSHL LVLSOWYSAHL YO Spo duing 5925 966 L0 LE0 M A63AX 6 e ASAAX A989AX A6 8 1 9 6 8 7 4 6 8Ad Apeeg 9 5 9 ejqeiueA M 3ZA GS H d H 9 15 OML 13 Thermostat Chart HP FIGURE 12
41. ERSION This furnace is constructed at the factory for natural gas fired operation at 0 8 000 feet 0 m 2 438 m above sea level The manifold pressure must be changed in order to maintain proper and safe operation when the furnace is installed in a location where the altitude is greater than 8 000 feet 2 438 m above sea level Refer to Tables 5 and 6 for proper manifold pressure settings HIGH ALTITUDE PRESSURE SWITCH CONVERSION For installation where the altitude is less than 8 000 feet 2 438 m it is not required that the pressure switch be changed For altitudes above 8 000 feet 2 438 m see Table 20 Field Installed Accessories High Altitude pressure Switch 2 1041 UIM A 0407 TABLE 5 Nominal Manifold Pressure High Fire Second Stage Manifold Pressures in wc Second Stage Manifold Pressures kpa iude 5 5 5 83e 35 385 s one 98 mum 82 785 TABLE 6 Nominal Manifold Pressure Low Fire First Stage Manifold Pressures in wc First Stage Manifold Pressures kpa Altitude feet Altitude m 0 7999 8000 8999 9000 9999 0 2437 2438 2742 2743 3048 ADANGER PROPANE AND HIGH ALTITUDE CONVERSION KITS It is very important to choose the correct kit and or gas orifices for the altitude and the type of gas for which the furnace is being installed Only use natural gas in furnaces designed for natural gas Only use propane LP gas for furnaces that h
42. OFF VALVE N GROUNDED JOINT UNION MAY BE INSTALLED INSIDE OR OUTSIDE UNIT MANUAL SHUT OFF a VALVE LEG GAS BURNERS GAS VALVE MANUAL SHUT OFF VALVE FIGURE 9 Horizontal Gas Piping IMPORTANT An accessible manual shut off valve must be installed upstream of the furnace gas controls and within 6 feet 1 8 m of the fur nace The furnace must be isolated from the gas supply piping system by closing its individual external manual shut off valve during any pressure testing of the gas supply piping system at pressures equal to or greater than 1 2 psig 3 5 kPa CAUTION Never apply a pipe wrench to the body of the gas valve when installing piping A wrench must be placed on the octagonal hub located on the gas inlet side of the valve Placing a wrench to the body of the gas valve will damage the valve causing improper oper ation and or the valve to leak Gas piping may be connected from either side of the furnace using any of the gas pipe entry knockouts on both sides of the furnace Refer to Figure 3 dimensions GAS ORIFICE CONVERSION FOR PROPANE LP This furnace is constructed at the factory for natural gas fired operation but may be converted to operate on propane LP gas by using a fac tory supplied LP conversion kit Follow the instructions supplied with the LP kit Refer to the instructions in the propane LP conversion kit for the proper gas orifice size HIGH ALTITUDE GAS ORIFICE CONV
43. Sealed Combustion Air and Vent Termination 18 FIGURE 22 Double Vertical Sealed Combustion Air and Vent Termination COMBUSTION AIR SUPPLY All installations must comply with Section 5 3 Air for Combustion and Ventilation of the National Fuel Gas Code ANSI Z223 1 or Sections 7 2 7 3 or 7 4 of CAN CGA B149 1 or 2 Installation Code latest edi tions This furnace is certified to be installed with one of three possible com bustion air intake configurations 1 OUTDOOR COMBUSTION AIR This is a sealed combustion air configuration where the combustion air is supplied through a PVC or ABS pipe that is connected to the PVC coupling attached to the burner box and is terminated in the same atmospheric zone as the vent This type of installation is approved on all models Refer to Figure 23 2 AMBIENT COMBUSTION AIR Combustion air is supplied from the area surrounding the furnace through the combustion air pipe in the furnace casing The combustion air and the vent pipes are not terminated in the same atmospheric zone Refer to Figure 24 for vent terminations Refer to AIR SOURCE FROM INSIDE THE BUILDING and VENT AND SUPPLY AIR SAFETY CHECK for proper installation 3 VENTILATED COMBUSTION AIR Combustion air is supplied through a PVC or ABS pipe that is connected to the PVC coupling attached to the burner box and is terminated in a ventilated attic or crawl space The combustion air and the vent pipes are not termi nated i
44. TE PIPING a c x d x S D CONDENSATE DRAIN TUBE 5 8 1 59 cm FIGURE 27 Condensate Drain Internal Hose Routing CONDENSATE DRAIN The condensate drain connection is provided in the furnace for field installation It consists of the hoses shown in Table 15 a NPT male con nection and a 1 2 1 27 cm female x 3 4 1 9 cm PVC slip coupling of the drain hoses will be needed to convert the condensate drain system when the furnace is installed in a horizontal left or right configu ration Refer to Figures 28 34 for the condensate hose sizes for con densate drain connections IMPORTANT The condensate drain from the furnace may be con nected in common with the drain from an air conditioning coil if allowed by local code IMPORTANT Condensate must be disposed of properly Follow local plumbing or wastewater codes The drain line must maintain a 1 4 per foot 0 635 cm per meter slope to the drain Unitary Products Group 2 1041 UIM A 0407 CONDENSATE DRAIN TRAP AND DRAIN FREEZE PROTECTION Special precautions MUST be made if installing furnace in an area which may drop below freezing This can cause improper operation or damage to the equipment If the furnace is installed in an area that has the potential of freezing the drain line and the drain trap must be pro tected Use a 3 to 6 watt per foot at 115 vac 40 F 4 4 C self regulat ing shielded and waterproof heat tape Wrap the drain trap an
45. TEM 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 Unitary Products Group 2 1041 UIM A 0407 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 lock ing out With furnace in operation check all of the pipe joints gas valve connec tions and manual valve connections for leakage using an approved gas detector a non corrosive leak detection fluid or other leak detection methods Take appropriate steps to stop any leak If a leak persists replace t
46. UIREMENTS 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 421 47 CSA 2 3 Refer to the unit rating plate for the furnace model number and then see the dimensions page of this instruction for return air ple num dimensions in Figure 3 The plenum must be installed according to the instructions Provide clearances from combustible materials as listed under Clearances to Combustibles in Table 1 Provide clearances for servicing ensuring that service access is allowed for both the burners and blower These models ARE NOT CSA listed or approved for installation into a HUD Approved Modular Home or a Manufactured Mobile Home This furnace is not approved for installation in trailers or recre ational vehicles Failure to carefully read and follow all instructions in this manual can result in furnace malfunction death personal injury and or property damage Furnaces for installation on combustible flooring shall not be installed directly on carpeting tile or other combustible material other than wood flooring Check the rating plat
47. With a Cooling Coil Cabinet The furnace should be installed with the cooling coil cabinet specifically intended for horizontal applications If a matching cooling coil is used it may be placed directly on the supply air side of the furnace and sealed to prevent leakage A warm air duct plenum with 1 2 54 cm is installed through the opening provided The supply air duct system is connected to the warm air plenum and sealed to prevent leaks IMPORTANT The furnace the cooling coil cabinet and all duct work MUST BE SEALED as needed to prevent leaks AND SECURED Refer to the assembly drawing in Figure 2 Attach the supply plenum to the air conditioning coil cabinet outlet duct flanges through the use of S cleat material when a metal plenum is used The use of an approved flexible duct connector is recommended on all installations The connection to the furnace air conditioning coil cabinet and the supply plenum should be sealed to prevent air leakage The sheet metal plenum should be crosshatched to eliminate any pop ping of the sheet metal when the indoor fan is energized The minimum plenum height is 12 30 5 cm If the plenum is shorter than 12 30 5 cm the turbulent air flow may cause the limit controls not to operate as designed or the limit controls may not operate at all Also the plastic drain pan in the under the air conditioning coil can overheat and melt Refer to the installation instructions supplied with the air conditioning
48. ator vent outlet to a maximum vertical distance of 15 feet 4 5 cm above the meter regulator assembly l Clearance to service regulator vent outlet 3 feet 91 cm H Clearance to each side of center line extended above meter regulator assembly J Clearance to nonmechanical air supply inlet to building or the combustion air inlet to any other appliance K Clearance to a mechanical supply inlet In accordance with the current CSA B149 1 00 Natural Gas and Propane Installation Code In accordance with the current ANSI Z223 1 NFPA 54 National Gas Code In accordance with the current ANSI Z21 47 CSA 2 3 American National Standard 12 inches 30 cm for models x100 000 BTUH 30 kW 36 inches 91 cm for models gt 100 000 BTUH 30 kW 12 inches 30 cm for models x100 000 BTUH 30 kW 36 inches 91 cm for models 100 000 BTUH 30 kW 6 feet 1 83 m L Clearance above paved sidewalk or paved 7 feet 2 13 m t driveway located on public property M Clearance under veranda porch deck or balcony 12 inches 30 VENT TERMINAL AIR SUPPLY AREA WHERE TERMINAL IS NOT PERMITTED 12 inches 30 cm US Installation Two pipe direct vent applications 9 inches 23 cm models 50 000 BTUH 15 kW 12 inches 30 cm for models 250 000 BTUH 15 kW tt 12 inches 30 cm 12 inches 30 cm or in accordance with local installation codes and the requirements of the gas sup plier 12 inches 30 cm
49. ave been properly converted to use pro pane LP gas Do not use this furnace with butane gas Incorrect gas orifices or a furnace that has been improperly converted will create an extremely dangerous condition resulting in premature heat exchanger failure excessive sooting high levels of carbon monoxide personal injury property damage a fire hazard and or death High altitude and propane LP conversions are required in order for the appliance to satisfactory meet the application An authorized distributor or dealer must make all gas conversions In Canada a certified conversion station or other qualified agency using factory specified and or approved parts must perform the conversion The installer must take every precaution to insure that the furnace has been converted to the proper gas orifice size when the furnace is installed Do not attempt to drill out any orifices to obtain the proper orifice size Drilling out a gas orifice will cause misalignment of the burner flames causing premature heat exchanger burnout high levels of carbon monoxide excessive sooting a fire hazard personal injury property damage and or death SECTION V ELECTRICAL POWER ELECTRICAL POWER CONNECTIONS A CAUTION Field wiring to the unit must be grounded Electric wires that are field installed shall conform to the temperature limitation of 63 F 85 C rise when installed in accordance with these instructions Refer to Table 7 in these instructions for spe
50. ble digital thermometer to read the supply and return air temperatures 3 You will need a U tube manometer or digital equipment that has the ability to read pressures between 0 15 in w c 0 3 73 kPa in order to measure the gas line and the manifold pressures 4 You will need a 3 32 Allen wrench for the pressure port plugs in the gas valve 5 You will need 2 pieces of 1 8 0 3 cm ID flexible tubing that is 12 30 cm in length 2 pieces of 1 8 0 3 cm tubing that are 4 10 1 cm in length a 1 8 0 3 cm tee and a 1 8 0 3 cm adapter to connect the U tube manometer or the digital pressure measur ing equipment to the gas valve pressure ports 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 e 1 5 6 0 8 cm x 1 8 3 175 mm reducing coupling e 1 1 8 0 3 cm adapter There is a accessory kit 1 0602 available from Source 1 which has the following items 12 30 cm length x 1 8 0 3 cm diameter tubing 2 pieces of 4 10 cm length x 1 8 0 3 cm diameter tubing e 1 5 16 0 8 cm tee e 1 5 16 0 8 cm x 1 8 0 3 cm reducing coupling e 1 1 8 0 3 cm adapter e 1 Dwyer Manometer These items are required in order to properly perform the required start up procedure IGNITION SYS
51. cific furnace electrical data BTU cu ft Gas Heating Value Gas Heating Value BTU cu ft Gas Heating Value Gas Heating Value Unitary Products Group TABLE 7 Electrical and Performance Data Output Input High Low High Low Nominal Airflow CFM m min 60738 56736 80 52 23 15 75 49 21 7 14 4 1600 45 3 zo 2 271041 UIM A 0407 Cabinet Width Total Unit EN Air Temp Rise e 35 55 19 36 8 e 35 85 19 36 70 80 752 70 Blower Size As m 11x8 11x8 11x10 27 9x 25 4 11 x 11 279x279 20 Max Min Wire Size Over current awg 75 ft Weight cm Protect One Way 279 203 Operating Annual Fuel Utilization Efficiency AFUE numbers are determined in accordance with DOE Test procedures Wire size and over current protection must comply with the National Electrical Code NFPA 70 latest edition and all local codes The furnace shall be installed so that the electrical components are protected from water Wire size and overcurrent protection must comply with the National Electric Code NOTES 1 For altitudes above 2000 ft 609 m reduce capacity 496 for each 1000 ft above sea level 2 Wire size based on copper conductors 140 F 60 C 3 voltage drop Continuous return air temperature must not be below 55 12 8 C SUPPLY VOLTAGE CONNECTIONS IMPORTANT The power connecti
52. coil for additional information Horizontal Installations Without a Cooling Coil Cabinet When installing this appliance the furnace must be installed so as to create a closed duct system the supply duct system must be con nected to the furnace outlet and the supply duct system must terminate outside the space containing the furnace When replacing an existing furnace if the existing plenum is not the same size as the new furnace then the existing plenum must be removed and a new plenum installed that is the proper size for the new furnace Attach the supply plenum to the furnace outlet duct flanges through the use of S cleat material when a metal plenum is used The use of an approved flexible duct connector is recommended on all installations This connection should be sealed to prevent air leakage The sheet metal should be crosshatched to eliminate any popping of the sheet metal when the indoor fan is energized On all installations without a coil a removable access panel is recommended in the outlet duct such that smoke or reflected light would be observable inside the casing to indicate the presence of leaks in the heat exchanger This access cover shall be attached in such a manner as to prevent leaks Unitary Products Group T STAT WIRING 7 8 K O HORIZONTAL CONDENSATE DRAIN OPENING 1 3 4 N DRAIN OPENING 2 JUNCTION BOX HOLE 7 8 GAS PIPE ENTRY 1 1 2 CONDENSATE DRAIN HOLE 7 8 SIDE PIPING HOLE 3 3 8 4
53. d pipe that extends from the furnace vent connection top right of unit to the exterior of the building Refer to Table 9 for intake pipe sizing allowable length and elbow usage 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 Ventilated Combustion Air Termination Refer to Figure 26 for required attic termination for the combustion air intake pipe For attic termination use two 90 elbows with the open end in a downward position Be sure to maintain 12 30 5 cm clearance above any insulation flooring or other material A crawl space combustion air installation consists of a straight pipe from the PVC coupling on the burner box that extends into the crawl space and terminates with a 1 4 0 63 cm mesh screen and no elbows 12 MINIMUM BETWEEN BOTTOM OF BELOW AND ANY MATERIAL FIGURE 26 Attic Combustion Air Termination Unitary Products Group Specially Engineered Installations The above requirements shall be permitted to be waived where special engineering approved by the authority having jurisdiction provides an adequate supply of air for combustion ventilation and dilution of flue gases A WARNING Be sure to instruct the owner not to block this intake pipe SECTION VII CONDENSA
54. d the drain line with the heat tape and secure with ties Follow the heat tape manufacturer s recommendations CONDENSATE DRAIN HOSE PART NUMBERS TABLE 15 Condensate Drain Hose Part Hose Number Number 028 15156 000 Drain tube Condensate pan Down flow 028 15176 000 Drain tube Inducer Horizontal RT Vent system Down flow 028 15168 000 Drain tube Inducer Down flow Drain tube Rain gutter 028 15176 000 4 Down flow amp Horizontal RT 028 15176 000 Drain tube After Tee Down flow Drain tube Upper rain gutter Horizontal LT 028 15169 001 7 Drain tube After Tee Horizontal RT 028 13309 004 Drain tube P trap All models 028 15158 000 Drain tube Vent system Horizontal LT Before Tee Horizontal RT Drain tube Condensate pan Horizontal 028 15197 000 10 drain closer to the front of the furnace both LT amp RT Hoses 2 4 5 along with a barbed nipple and a barbed tee are part of condensate hose assembly 028 15176 000 DOWNFLOW HORIZONTAL CONDENSATE INTERNAL DRAIN CONFIGURATIONS Downflow Refer to Figure 28 Description 028 15196 000 6 Furnace is shipped with one end of condensate hose 2 left open in the furnace If the provided Wye s drain is aligned with the opening in the top of the furnace hose 2 can be used If it is desired that the Wye and street elbow assembly point away from the opening in the casing top then the 2 hose will have to be rep
55. densate trap Install the dogleg end of hose 2 on the bottom drain of the inducer Guide the other end of hose 2 towards the condensate trap and install it on the small recessed drain in the condensate trap Ensure that all hoses are properly installed have no kinks and are draining properly All hoses on the condensate trap should be pushed all the way down to ensure against leakage All hoses on the condensate pan should be pulled all the way up to ensure proper operation 25 2 1041 UIM A 0407 HOSE 2 BLOCKED CONDENSATE SWITCH HAS BEEN FACTORY INSTALLED FOR THIS POSITION THIS TUBE FOR THE 3 8 BARBED TEE HOSE 4 HOSE 9 HOSE 7 FIGURE 31 Horizontal Right Condensate Drain Hose Configuration Option 1 Front of Casing 26 Unitary Products Group 2 1041 UIM A 0407 s ASOH L ISOH 119 amie dNV19 5 ol 77 9 1 T 7 E g c CJ gt Adi 06 y a 5 EZ 6 ISOH 01 ISOH a NOILWLNAIYO dVe L JIVSN3IQONOO QI3QdN3lNINOO3 4 vit ISOH ili i J lddIN N 8 2 vic ASOH vIe 87 02 gt 0LZ ISOH 931 900 9 m dWV10 7 HE 035 gt x acc 931 900 AC dI AV IO 5 dI AV IO NIHdS ile E v 3SOH cit ASOH ASOH 6
56. di tioned space such as an attic or crawl space in order to prevent the accumulation of excess condensate in the inducer motor dur ing operational cycles Refer to Figures 16 or 20 8 Sealed combustion air systems must be installed so the vent and the combustion air pipes terminate in the same atmospheric zone Refer to Figures 18 19 20 21 and 22 DOWNFLOW VENT ASSEMBLY 1 Place the 2 5 08 cm 45 PVC street elbow on the vent connec tion 2 Place the 2 5 08 cm PVC WYE assembly on the 2 5 08 cm 45 PVC street elbow 3 Locate the rubber condensate hose in front of the blower access panel 4 Slide the hose through the hole in the top cover and insert the hose on to the barbed fitting on the bottom of the 2 5 08 cm PVC WYE Y assembly RETURN 2 5 08 cm AIR y VENT PIPE RETURN 2 PVC pus WYE FURNACE VENT PIPE HORIZONTAL LEFT DOWNFLOW RETURN AIR gt BARBED FITTING HORIZONTAL RIGHT FIGURE 16 Downflow Horizontal Vent Assembly Unitary Products Group 2 1041 UIM A 0407 HORIZONTAL VENT ASSEMBLY Horizontal Left Vent Assembly 1 Place the 2 5 08 cm 45 PVC street elbow on the vent connec tion 2 Place the 2 5 08 cm PVC WYE assembly on the 2 5 08 cm 45 PVC street elbow 3 Refer to the DOWNFLOW HORIZONTAL CONDENSATE INTER NAL DRAIN CONFIGURATIONS for further details Horizontal Right Vent Assembly 1 Place the 2 5 0
57. ding the 3 8 barbed nipple factory installed in the rain gutter Remove the drain cap from the bottom rain gutter drain and insert the 3 8 barbed nipple removed above in the bottom rain gutter drain Place the cap just removed to the other side of the rain gut ter on the inducer Remove the condensate trap and its bracket from inside the fur nace saving the screws for later use Remove the large condensate cap from the side of the condensate pan and install it on the middle drain of the condensate pan from where 1 hose was removed Install longer dogleg end of hose 10 through the casing hole on to the side drain of the condensate pan where cap was removed in step 43 Some lubricant may have to be used to facilitate this installation as the hose is designed to be a tight fit over the con densate drain The other smaller dogleg end of hose 10 should be installed into the large recessed drain in the condensate trap Install the condensate trap bracket with the condensate trap on to the front side of the furnace using the screws removed in step 1 Install the dogleg end of hose 9 on Wye drain and route the hose through the opening on top of the furnace as shown Install the other end of the 9 hose to the barbed tee inside the furnace Install the dogleg end of hose 4 to the rain gutter on the inducer The other end of hose 4 should be installed on the 3 8 barbed tee Install one end of hose 7 on the 3 8 barbed t
58. dule 40 ABS Pipe cement and primer must conform to ASTM Standard D2546 PVC or D2235 ABS If ABS pipe is to be used any joint where ABS pipe is joined to PVC pipe must be glued with cement that is approved for use with BOTH materials Metallic materials must not be used for venting or air intake 5 flexible connector is used in the vent system it must be made of a material that is resistant to acidic exposure and to at least 225 F temperature Flexible connectors are also allowed in the combustion air pipe 6 All models are supplied with 2 vent connections When the pipe must be increased to 3 diameter the transition from 2 to 3 must be done as close to the furnace as possible For upflow models the transition from 2 to 3 should be done immediately above the furnace For downflow or horizontal models the transition from 2 to 3 pipe should be done immediately after the drain tee or drain elbow 7 n Canada vents shall be certified to ULC 5636 Standard for Type BH Gas Venting Systems IPEX System 636 PVC is certified to this standard 8 In Canada the first three feet 900 mm of the vent must be readily accessible for inspection Unitary Products Group TABLE 8 Maximum Equivalent Pipe Length Model Input BTUH kW Pipe Size Inches cm Maximum Equivalent length feet m 65 19 8 90 27 4 5 1 7 6 65 19 30 274 5 1 6 60 000 17 6 2 5 60 000 17 6 3 7 100 000 29 3
59. e and power supply to be sure that the elec trical 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 pro tected from water Installing and servicing heating equipment can be hazardous due to the electrical components and the gas fired components Only trained and qualified personnel should install repair or service gas heating equipment Untrained service personnel can perform basic maintenance functions such as cleaning and replacing the air filters When working on heating equipment observe precau tions in the manuals and on the labels attached to the unit and other safety precautions that may apply These instructions cover minimum requirements and conform to existing national standards and safety codes In some instances these instructions exceed certain local codes and ordinances especially those who have not kept up with changing residential and non HUD modular home construction practices These instructions are required as a minimum for a safe installation COMBUSTION AIR QUALITY LIST OF CONTAMINANTS The furnace will require OUTDOOR AIR for combustion when the fur nace is located in any of the following environments Restricted Environments Commercial buildings Buildings with indoor pools Furnaces installed in laundry rooms Furnaces insta
60. eat content of the gas BTU SCF or Default 2500 BTU SCF 93 13 MJ m times 1 cubic ft 0 028 m of gas mea sured at the gas meter times a barometric pressure and temperature correction factor of 0 960 times 3600 then divided by the time In seconds it took to measure 1 cubic ft 0 028 m of gas from the gas meter The formula for US input calculation using a cubic foot gas meter BTU ft x 2 cu ft x 0 960 x 3600 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 BTU H 8 666 90 Natural Gas BTU SCF 1030 BTU ft x 1 cu ft x 0 960 x 3600 Seconds it took to measure the 1 cu ft of gas PROPANE LP GAS INPUT CALCULATION EXAMPLE 2500 x 1 x 0 960 x 3600 80 000 00 108 Propane Gas BTU SCF 2500 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 or Default 38 4 times 2 cubic ft of gas x 0 028 to convert from cubic feet to cubic meters measured at the gas meter times a barometric pressure and temperature correction factor of 0 960 times 3600 then divided by the time it took to measure 2 cubic ft 0 056 m of gas from the gas meter For Propane LP Gas multiply the Heat content of the gas MJ m or Default 93 13 times 1 cu ft of gas x 0 028 to convert from cubic feet to cubic meters measured at the gas meter times a barometric p
61. ee inside the fur nace Guide the other end of hose 7 towards the condensate trap and install it on the tap on the condensate trap Install the dogleg end of hose 2 on the bottom drain of the inducer Guide the other end of hose 2 towards the condensate trap and install it on the small recessed drain in the condensate trap Ensure that all hoses are properly installed have no kinks and are draining properly All hoses on the condensate trap and conden sate pan should be pushed all the way down to ensure against leakage and performance Some hoses may have to be trimmed for proper fit NOTE The condensate trap can also be installed on the 2 knockout opening in this configuration using the provided condensate trap bracket Some modifications may however have to be made to the condensate hoses Unitary Products Group 2 1041 UIM A 0407 A CAUTION Ensure all condensate hoses are pushed all the way down on the condensate trap barbed fittings and condensate pan drains CAUTION Plug all unused condensate trap condensate pan and inducer drain connection points using plugs provided Installation with condensate trap bracket Back of casing Refer to Figure 33 and 34 1 2 Remove the 2 knockout on the casing side away from the inducer motor Remove all the condensate hoses inside the furnace including the 3 8 barbed nipple factory installed in the rain gutter Remove the drain cap from the bottom
62. eld provided 2 5 08 cm x 4 10 2 cm box and cover on the outside of the furnace Route the furnace leads into the box using a protective bushing where the wires pass through the furnace panel After making the wiring connections replace the wiring box cover and screws Unitary Products Group The furnace s control system requires correct polarity of the power supply and a proper ground connection If the power supply polar ity is reversed the control board will flash 9 times The furnace will not operate until the polarity is corrected Refer to Furnace Diag nostics section of the User s Information Maintenance amp Ser vice Manual provided with this furnace LOW VOLTAGE CONTROL WIRING CONNECTIONS Install the field supplied thermostat by following the instructions that come with the thermostat With the thermostat set in the OFF position and the main electrical source disconnected connect the thermostat wiring from the wiring connections on the thermostat to the terminal board on the ignition module as shown in Figures 11 and 12 Electronic thermostats may require the common wire to be connected as shown in Figures 11 and 12 Apply strain relief to thermostat wires passing through cabinet If air conditioning equipment is installed use thermo stat wiring to connect the Y and C terminals on the furnace control board to the proper wires on the condensing unit unit outside IMPORTANT Set the heat anticipator in the roo
63. emperature 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 7 HEAT HI HEAT DELAY DELAY JUMPER JUMPER DEHUMIDISTAT JUMPER LOW VOLTAGE TERMINALS 1v34 7000 2 8 v 3 8 v VX WHO O 3 oo rov FIGURE 38 Furnace Control Board 34 WITH BURNER BOX COVER REMOVED GAS VALVE BURNER BOX PRESSURE REFERENCE HOSE WATER COLUMN GAS PRESSURE SHOWN MANOMETER c oO 0 NM gt gt 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 VARIABLE SPEED MOTORS The variable speed motor must be configured so the blower will provide a sufficient airflow so that the furnace operates with in the temperature rise range on the rating plate and within the application limitations shown in Table 7 in these Instructions ADJ USTMENT OF FAN CONTROL
64. enting system must be installed in accordance with Section 5 3 Air for Combustion and Ventilation of the National Fuel Gas Code Z223 1 NFPA 54 latest edition or Sections 7 2 7 3 or 7 4 of CSA B149 1 National Gas and Propane Codes latest edition or applicable provisions of the local building code and these instructions IMPORTANT The VENT SYSTEM must be installed as specified in these instructions for Residential and Non HUD Modular Homes The sealed combustion air vent system is the only configuration that can be installed in a Non HUD Modular Home This furnace may not be common vented with any other appliance since it requires separate properly sized air intake and vent lines The furnace shall not be connected to any type of B BW or L vent or vent connector and not connected to any portion of a factory built or masonry chimney The furnace shall not be connected to a chimney flue serving a sep arate appliance designed to burn solid fuel 14 A CAUTION When combustion air pipe is installed above a suspended ceiling or when it passes through a warm and humid space the pipe must be insulated with 1 2 Armaflex or other heat resistant type insulation Vent piping must be insulated with 1 2 insulation if it will be sub Jected to freezing temperatures such as routing through unheated areas or through an unused chimney COMBUSTION AIRAVENT PIPE SIZING The size of pipe required will be determined by
65. enum above the filter height The use of straps and or supports is required to support the weight of the external filter box ATTIC INSTALLATION LINE CONTACT ONLY PERMISSIBLE BETWEEN LINES FORMED BY THE INTERSECTION OF FURNACE TOP AND TWO SIDES AND BUILDING COMBUSTION FILTER RACK JOISTS STUDS OR FRAMING Al R SUPPLY am T 4 RETURN IRI VENT PIPE maintain required clearances to 30 MIN combustible WORK AREA 12 CLEARANCE FOR SERVICE FIGURE 5 Typical Attic Installation This appliance is design certified for line contact when the furnace is installed in the horizontal left or right position The line contact is only permissible between lines are formed by the intersection of the top and two sides of the furnace and the building joists studs or framing This line may be in contact with combustible material IMPORTANT In either a horizontal left or right installation a minimum of 8 20 3 cm clearance is required beneath the furnace to allow for the installation of the condensate trap and drain pipe Refer to CON DENSATE PIPING section of this manual for more information When a furnace is installed in an attic or other insulated space keep all insulating materials at least 12 inches 30 5 cm away from furnace and burner combustion air openings If this furnace is installed over a finished space a condensate safety pan must be installed SUSPENDED FURNACE CRAWL SPACE
66. essure and within the air temperature rise specified on the nameplate Attic installations must meet all minimum clearances to combustibles and have floor support with required service accessibility CFM Cabinet 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 2 1041 UIM A 0407 T STAT WIRING 7 8 K O HORIZONTAL CONDENSATE DRAIN OPENING 1 3 4 p HORIZONTAL CONDENSATE DRAIN OPENING 1 3 4 JUNCTION BOX HOLE 7 8 GAS PIPE ENTRY 1 1 2 CONDENSATE DRAIN HOLE 7 8 22 24 5 8 26 1 2 21 118 RIGHT SIDE I 23 1 4 TOP IMAGE RETURN END Cabinet Dimension a RR sez ewe soi z2 64 3 75 mL rea eo aa 60_ SECTION 111 FILTERS FILTER INSTALLATION All applications require the use of a filter Replacement filter size is shown in Table 4 TABLE 4 Recommended Filter Sizes Input CFM Cabinet Top Return BTU H iat Size Filter in cm 80078 1200039 8 Gii4x2 5x5 80 oon 2 14 x 20 86 x 51 80 23 4 2 100 29 3 2000 57 14 x 20 36 x 51 120 35 1 2000 57 gt 2 14 x 20 36 x 51 NOTES Air velocity through throwaway type filters may not exceed 300 feet per minute 91 4 m min All velocities over this require the use of high
67. f CAN4 S110 Standard for Air Ducts supply to an appliance unless otherwise permitted by the authority having jurisdiction The opening shall be located within 12 30 5 cm horizontally from the burner level of the appliance Refer to AIR SOURCE FROM OUTDOORS AND VENT AND SUPPLY AIR SAFETY CHECK in these instructions for additional information and safety check procedure OUTLE AIR b The duct shall be least the same cross sectional area as the free area of the air supply inlet opening to which it connects The duct shall terminate within 12 in 30 5 cm above and within 24 in 61 cm horizontally from the burner level of the appliance having the largest input VENTILATED CRAWL SPACE Asquare or rectangular shaped duct shall only be used when the required free area of the supply opening is 9 58 06 cm or larger When a square or rectangular duct is used its small dimension shall not be less than 3 in 7 6 cm EI An air inlet supply from outdoors shall be equipped with SOFFIT a means to prevent the direct entry of rain and wind Such means shall not reduce the required free area of the air supply opening ATTIC TOP ABOVE 7 An air supply inlet opening from the outdoors shall be located not less than 12 30 5 cm above the outside grade level FIGURE 25 Outside and Ambient Combustion Air Vent and Supply Outside Air Safety Check Procedure Follow the procedure in ANSI Z223 1 National
68. furnace is equipped with memory that will store up to five error codes to allow a service technician to diagnose problems more easily This memory will be retained even if power to the furnace is lost This feature should only be used by a qualified service tech nician The control stores up to five separate error codes If more than five error codes have occurred since the last reset only the five most recent will be retained The furnace control board has a button labeled LAST ERROR that is used to retrieve error codes This function will only work if there are no active thermostat signals So any call for heating cooling or continuous fan must be terminated before attempting to retrieve error codes To retrieve the error codes push the LAST ERROR button The LED on the control will then flash the error codes that are in memory starting with the most recent There will be a two second pause between each flash code After the error codes have all been displayed the LED will resume the normal slow green flash after a five second pause To repeat the series of error codes push the button again If there are no error codes in memory the LED will flash two green flashes To clear the memory push the LAST ERROR button and hold it for more than five seconds The LED will flash three green flashes when the memory has been cleared then will resume the normal slow green flash after a five second pause Unitary Products Group 2 1041 UIM A
69. he component The furnace and its equipment shut off 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 shut off valve during any pressure testing of the gas supply piping system CALCULATING THE FURNACE INPUT NATURAL GAS NOTE Burner orifices are sized to provide proper input rate using natu ral gas with a heating value of 1030 BTU Ft 38 4 MJ m If the heat ing value of your gas is significantly different it may be necessary to replace the orifices NOTE Front door of burner box must be secured when checking gas input 1 Turn off all other gas appliances connected to the gas meter 2 At the gas meter measure the time with a stop watch it takes to use 2 cubic ft 0 0566 m of gas 3 Calculate the furnace input by using one of the following equa tions 31 2 1041 UIM A 0407 In the USA use the following formula to calculate the furnace input For natural gas multiply the heat content of the gas BTU SCF or Default 1030 BTU SCF 38 4 MJ m times 2 cubic ft 0 056 m of gas measured at the gas meter times a barometric pressure and temperature correction factor of 0 960 times 3600 then divided by the time In seconds it took to measure 2 cubic ft 0 056 m of gas from the gas meter For propane LP gas multiply the h
70. imum Opening Size Airflow Range 0 750 Disposable 0 21 4 230 1484 0 01 0 01 APPLYING FILTER PRESSURE DROP TO DETERMINE SYSTEM AIRFLOW To determine the approximate airflow of the unit with a filter in place fol low the steps below 1 Select the filter type 2 Determine the External System Static Pressure ESP without the filter TABLE 20 Field Installed Accessories Non Electrical 3 Selecta filter pressure drop from the table based upon the number of return air openings or return air opening size and add to the ESP from Step 2 to determine the total system static If total system static matches a ESP value in the airflow table i e 0 20 0 60 etc the system airflow corresponds to the intersection of the ESP column and Model Blower Speed row FIELD INSTALLED ACCESSORIES NON ELECTRICAL MODEL NO 1C T0302 1C T0303 1PS0507 1PS0508 1NK0301 1HT0902 1CB0317 1HT0901 SIDEWALL VENT TERMINATION KIT 3 38 DESCRIPTION PROPANE LP CONVERSION KIT CONCENTRIC INTAKE VENT 2 CONCENTRIC INTAKE VENT 3 CONDENSATE NEUTRALIZER KIT SIDEWALL VENT TERMINATION KIT 2 COMBUSTIBLE FLOOR BASE COIL TRANSITION KIT USED WITH ALL MODELS 100 120 MBH 60 1200 80 1200 80 1600 100 2000 120 2000 ALL MODELS ALL MODELS ALL MODELS 17 1 2 CABINET 21 CABINET 24 1 2 CABINET 17 1 2 CABINET HIGH ALTITUDE PRESSURE SWITCH KIT Does Not Include Orifices 21 CABINET 24 1 2 CABINET Unita
71. ing a vertical venting system through any unconditioned space such as an attic or crawl space it must be insulated 1 Observe all clearances listed in vent clearances in these instruc tions 2 Termination should be positioned where vent vapors are not objec tionable 3 Termination should be located where it will not be affected by wind gusts light snow or allow recirculation of flue gases 4 Termination should be located where it cannot be damaged plugged or restricted by tree limbs leaves and branches 5 Horizontal portions of the vent system must slope upwards and 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 6 A vent drain is required when vent passes through any uncondi tioned space such as an attic or crawl space in order to prevent the accumulation of excess condensate in the inducer motor dur ing operational cycles See Figure 16 VENTING MULTIPLE UNITS Only the sealed combustion system can be used for installations requir ing more than one furnace in a structure A separate sealed combustion air pipe and a separate vent pipe must be installed for each furnace Do not connect more than one furnace to a combustion air pipe or a vent pipe The combustion air and vent termination must be located as shown in Figures 21 or 22 COMBUSTIONAIR gt 2 4 FIGURE 21 Double Horizontal
72. ipe as close to the appliance as possible Use a combustion analyzer to check the CO2 and CO levels of each appliance Use a draft gauge to check for a downdraft or inadequate draft condition 6 After it has been determined that each appliance properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their normal condition 7 f improper venting is observed during any of the above tests a problem exists with either the venting system or the appliance does not have enough combustion air Supply Air from outside to complete combustion This condition must be corrected before the appliance can function safely NOTE An unsafe condition exists when the CO reading exceeds 40 ppm and the draft reading is not in excess of 0 1 in W C 25 kPa with all of the appliance s operating at the same time 20 VENTILATED INSULATION COMBUSTION AIR SOURCE FROM OUTDOORS 1 Two permanent openings one within 12 in 30 5 mm of the top and one within 12 in 30 5 mm of bottom of the confined space Two permanent openings shall communicate directly or by means of ducts with the outdoors crawl spaces or attic spaces One permanent openings commencing within 12 in 30 5 mm of the top of the enclosure shall be permitted where the equipment has clearances of at least 1 in 2 54 cm from the sides and back and 6 in 15 24 cm from the front of the appliance The
73. is not less than 50 cu ft 1 42 m per 1 000 Btu hr 0 2928 kW input rating for all of the appliances installed in that area Rooms communicating directly with the space containing the appli ances are considered part of the unconfined space if openings are not furnished with doors A confined space is an area with less than 50 cu ft 1 42 m per 1 000 Btu hr 0 2928 kW input rating for all of the appliances installed in that area The following must be considered to obtain proper air for combus tion and ventilation in confined spaces VENT PIPE PASSES COMBUSTION THROUGH TOP PANEL AIRFLOW COMBUSTION AIRFLOW 3 WAY TRANSITION Provided with some furnaces e FIGURE 24 Combustion Airflow Path Through The Furnace Casing to the Burner Box Unitary Products Group 271041 UIM A 0407 Combustion Air Source From Outdoors The blocking effects of louvers grilles and screens must be given con sideration in calculating free area If the free area of a specific louver or grille is not known refer to Table 12 to estimate free area TABLE 12 Estimated Free Area Wood or Metal Louvers or Grilles Wood 20 25 Metal 60 70 1 4 0 635 cm mesh or larger 100 Screens Do not use less than 1 4 0 635 cm mesh Free area or louvers and grilles varies widely the installer should follow lou ver or grilles manufacturer s instructions Dampers Louvers and Grilles Canada Only 1 The free area
74. l be installed in an area where ventilation facilities provide for safe limits of ambient temperature under normal oper ating conditions Ambient temperatures must not fall below 32 F 0 C unless the condensate system is protected from freezing 2 Do not allow return air temperature to be below 55 F 13 C for extended periods To do so may cause condensation to occur in the main heat exchanger leading to premature heat exchanger failure leading to premature heat exchanger failure A WARNING Improper installation in an ambient below 32 F 0 0 C could create a hazard resulting in damage injury or death 3 furnace is installed in any area where the ambient tempera ture may drop below 32 F 0 C a UL listed self regulated heat tape must be installed on any condensate drain lines It is required that self regulating heat tape rated at 3 watts per foot be used This must be installed around the condensate drain lines in the unconditioned space Always install the heat tape per the manu facturer s instructions Cover the self regulating heat tape with fiberglass Armaflex or other heat resistant insulating material 4 If this unit is installed in an unconditioned space and an extended power failure occurs there will be potential damage to the conden sate trap drain lines and internal unit components Following a power failure situation do not operate the unit until inspection and repairs are performed C
75. laced with provided 9 hose The dogleg end of hose 9 hose should be installed on the drain of the Wye 21 2 1041 UIM A 0407 above the hole in furnace top HOSE 7 4 with 3 8 barbed nipple 3 8 Barbed Tee HOSE 5 HOSE 1 HOSE 3 FIGURE 28 Downflow Condensate Drain Hose Configuration Horizontal Left Air Flow Inducer Low Refer to Figures 29 and 30 1 Remove all the condensate hoses inside the furnace leaving the 3 8 barbed nipple and hose 4 both factory installed in the rain gutter 2 Remove the condensate trap and its bracket from inside the fur nace saving the screws for use later 3 Remove the yellow cap from the top drain of the rain gutter and install loosely packed 3 8 barbed nipple in it 4 Remove the large condensate cap from the side of the condensate pan and install it on the middle drain of the condensate pan from where 1 hose was removed 5 Install longer dogleg end of hose 10 through the casing hole on to the side drain of the condensate pan where cap was removed in step 4 Some lubricant may have to be used to facilitate this installation as the hose is designed as a tight fit over the conden sate drain The other shorter dogleg end of hose 10 should be installed into the large recessed drain in the condensate trap 6 Install the condensate trap bracket with the condensate trap on to the front side of the furnace using the screws removed in step 1 22 HOSE
76. learances 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 clear ances for combustible materials where accessibility clearances are greater 2 1041 UIM A 0407 A WARNING Downflow Horizontal furnaces for installation on combustible floor ing only when installed on the accessory combustible floor base on wood flooring only and shall not be installed directly on carpeting tile or other combustible material Check the rating plate and power supply to be sure that the electri cal characteristics match All models use nominal 115 VAC 1 Phase 60Hz power supply Furnace shall be installed so the electrical components are pro tected from water TABLE 1 Unit Clearances to Combustibles Application In mm In mm Top From Rear Left Side Right Side Flue 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 le
77. lled in hobby or craft rooms Furnaces installed near chemical storage areas Chemical Exposure The furnace will require OUTDOOR AIR for combustion when the fur nace is located in an area where the furnace is being exposed to the fol lowing substances and or chemicals Permanent wave solutions Chlorinated waxes and cleaners Chlorine based swimming pool chemicals Water softening chemicals De icing salts or chemicals Carbon tetrachloride Halogen type refrigerants Cleaning solvents such as perchloroethylene Printing inks paint removers varnishes etc Hydrochloric acid Cements and glues Antistatic fabric softeners for clothes dryers Masonry acid washing materials When outdoor air is used for combustion the combustion air intake pipe termination must be located external to the building and in an area where there will be no exposure to the substances listed above Unitary Products Group The furnace area must not be used as a broom closet or for any other storage purposes as a fire hazard may be created Never store items such as the following on near or in contact with the fur nace 1 Spray or aerosol cans rags brooms dust mops vacuum cleaners or other cleaning tools 2 Soap powders bleaches waxes or other cleaning com pounds plastic items or containers gasoline kerosene ciga rette lighter fluid dry cleaning fluids or other volatile fluid 3 Paint thinners and other painting compounds
78. lve pressure port for leakage using an approved gas detector a non corrosive leak detection fluid or other leak detection methods AWARNING The manifold pressure must be checked with the screw off cap for the gas valve pressure regulator in place If not the manifold pres sure setting could result in an over fire condition A high manifold pressure will cause an over fire condition which could cause pre mature heat exchanger failure If the manifold pressure is too low sooting and eventual clogging of the heat exchanger could occur Be sure that gas valve regulator cap is in place and burner box to gas valve pressure reference hose is connected 33 2 1041 UIM A 0407 WITH BURNER BOX COVER IN PLACE BURNER BOX PRESSURE REFERENCE HEB gt U TUBE MANOMETER WATER COLUMN GAS PRESSURE FIGURE 37 Reading Gas Pressure ADJ USTMENT OF TEMPERATURE RISE The temperature rise or temperature difference between the return air and the supply heated air from the furnace must be within the range shown on the furnace rating plate and within the application limitations shown in Table 7 ELECTRICAL AND PERFORMANCE DATA The supply air temperature cannot exceed the Maximum Supply Air Temperature specified in these instructions and on the fur nace rating plate Under NO circumstances can the furnace be allowed to operate above the Maximum Supply Air Temperature Operating the furnace above the Maximum Supply Air T
79. ly air duct down stream of the furnace Cooled air may not be passed over the heat exchanger When the furnace is used in conjunction with a cooling coil the coil must be installed parallel with or in the supply air side of the furnace to avoid condensation in the primary heat exchanger When a parallel flow arrangement is used dampers or other means used to control airflow must be adequate to prevent chilled air from entering the furnace If manually operated the damper must be equipped with means to pre vent the furnace or the air conditioner from operating unless the damper is in full heat or cool position The duct system must be properly sized to obtain the correct airflow for the furnace size that is being installed Refer to Table 7 and the furnace rating plate for the correct rise range and static pressures If the ducts are undersized the result will be high duct static pres sures and or high temperature rises which can result in a heat exchanger OVERHEATING CONDITION This condition can result in premature heat exchanger failure which can result in personal injury property damage or death FLOOR BASE AND DUCTWORK INSTALLATION Downflow Combustible Floor Base Installations on combustible materials require the use a com bustible floor base shown in Figure 1 The floor base must be secured to the floor A supply air duct plenum with 1 2 54 cm flange is installed through the opening provided The
80. m thermostat to 0 45 amps Setting it lower will cause short cycles Setting it higher will cause the room temperature to exceed the set points 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 Using a Single Stage Heat Thermostat with the Furnace This two stage furnace may be used with a single stage thermostat Place the W2 Delay jumper in the 10 minute 15 minute or 20 minute position If the jumper is left on the OFF pins the furnace will operate only in low fire For additional connection diagrams for all UPG equipment refer to Low Voltage System Wiring document available online at www upgnet com in the Product Catalog Section 11 2 1041 UIM A 0407 HalJlIdiWnH Atz eoepelu uev 1ojuo2 JOH 1009 5 puooes cA 002 eDeis 1514 LA UOWWOD 9 OSNINOILLIQNOO 50715 NOILVOl1ddV SIHL NI NOILONN4 ON TVNIINH3 L 3ON3IN3ANOO 14617 uonounjrelw CVX 002 ui 9 eA eA O esty uo uedo WAH yeaH
81. n 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 fur nace casing and terminating outside the space containing the fur nace It is permitted to use the furnace for heating of buildings or struc tures under construction Installation must comply with all manu facturer s installation instructions including Proper vent installation e Furnace operating under thermostatic control Return air duct sealed to the furnace e Air filters in place Set furnace input rate and temperature rise per rating plate marking Means for providing outdoor air required for combustion Return air temperature maintained between 55 F 13 C and 80 F 27 C The air filter must be replaced upon substantial completion of the construction process Clean furnace duct work and components upon substantial completion of the construction process and verify furnace operating conditions including ignition input rate temperature rise and venting according to the manufacturer s instructions When installed in a Non HUD Approved Modular Home or building constructed on site combustion air shall not be supplied from occupied spaces The size of the unit should be based on an acceptable heat loss calculation for the structure ACCA Manual J or other approved methods may be used SAFETY REQ
82. n the same atmospheric zone Refer to Figure 26 for crawl space and attic termination Only the combustion air intake may terminate in the attic The vent must terminate outside Outdoor Combustion Air Combustion Air Intake Vent Connections This installation requires combustion air to be brought in from outdoors This requires a properly sized pipe shown in Figures 18 19 and 20 that will bring air in from the outdoors to the furnace combustion air intake collar on the burner box The second pipe shown in Figures 18 19 and 20 is the furnace vent pipe 2 5 08 cm VENT CONNECTION AIR INTAKE FIGURE 23 Sealed Combustion Air Intake Connection and Vent Connection Unitary Products Group The combustion air intake pipe should be located either through the wall horizontal or side vent or through the roof vertical vent Care should be taken to locate side vented systems where trees or shrubs will not block or restrict supply air from entering the terminal Also the terminal assembly should be located as far as possible from a swimming pool or a location where swimming pool chemicals might be stored Be sure the terminal assembly follows the outdoor clearances listed in Section 1 Outdoor Air Contaminants The provided 2 diameter rubber sleeve should be installed on the com bustion air pipe sticking through the furnace top when making connec tion with the outdoor combustion air pipe This in combination with the rubber
83. nda porch or deck is greater than 1 foot 30 cm as specified in CSA B149 1 00 A vent shall not terminate less than 1 foot 30 cm above a grade level Any fresh air or make up inlet for dryer or furnace area is considered to be forced air inlet Avoid areas where condensate drippage may cause problems such as above planters patios or adjacent to windows where steam may cause fogging A terminus of a vent shall be fitted with a cap in accordance with the vent manufacturer s installation instructions or in accordance with the installation instructions for a special venting system IMPORTANT Consideration must be given for degradation of building materials by flue gases Sidewall termination may require sealing or shielding of building surfaces with a corrosion resistant material to protect against combustion product corrosion Consideration must be given to wind direction in order to prevent flue products and or condensate from being blown against the building surfaces If a metal shield is used it must be a stainless steel material at a minimum dimension of 20 inches is rec ommended that a retaining type collar be used that is attached to the building surface to prevent movement of the vent pipe Responsibility for the provision of proper adequate venting and air supply for application shall rest with the installer Vent shall extend high enough above building or a neighboring obstruction so that wind from any direction will not create a posi
84. nflow Condensate Drain Hose Configuration 22 Downflow Gas Piping 9 Horizontal Left Condensate Drain Hose Configuration 23 Horizontal Gas Piping 9 Horizontal Left Condensate Drain Hose Configuration 24 mcus 11 Horizontal Right Condensate Drain Hose Configuration Thermostat Chart S earn 12 Option 1 Front of Casing 26 Thermostat Chart 13 Horizontal Right Condensate Drain Hose Configuration Accessory Connections 14 Option 1 Front of Casing 27 DIMENSIONS EEE TEEST ee ae ee eee 15 Horizontal Right Condensate Drain Hose Configuration Gavanue vehi E E E 16 Option 2 Back of Casing 28 Downflow Horizontal Vent Assembly 17 Horizontal Right Condensate Drain Hose Configuration Termination Configuration 1 Pipe 17 Option 2 Back of Casing 29 Termination Configuration 2 Pipe 17 Pressure Switch Tubing Routing 30 Termination Configuration 2 Pipe Horizontal 17 ads acus Rete xh ima E edere ee es 33
85. ng instructions to place the unit back in operation 3 Adjust manifold pressure by adjusting gas valve regulator screw for the appropriate gas per the following TABLE 17 Nominal Manifold Pressure NOMINAL MANIFOLD PRESSURE 3 5 w c 0 87 kPa 10 0 w c 2 488 kPa Natural Gas Propane LP Gas HIGH STAGE REGULATOR ADJUSTMENT OUTLET PRESSURE am o gt Le PRESSURE PORT LOW STAGE REGULATOR ADJUSTMENT ON OFF SWITCH FIGURE 36 Gas Valve IMPORTANT If gas valve regulator is turned in clockwise manifold pressure is increased If screw is turned out counterclockwise mani fold pressure will decrease 4 After the manifold pressure has been adjusted re calculate the furnace input to make sure you have not exceeded the specified input on the rating plate Refer to CALCULATING THE FURNACE INPUT NATURAL GAS 5 Once the correct BTU kW input has been established turn the gas valve to OFF and turn the electrical supply switch to OFF then remove the flexible tubing and fittings from the gas valve pressure tap and the pressure reference hose from the right side of the burner box and tighten the pressure tap plug using the 3 32 Allen wrench Replace the burner box front cover if it was removed and place the pressure reference hose back on the gas valve 6 Turn the electrical and gas supplies back on and with the burners in operation check for gas leakage around the gas va
86. o chassis 10 RED FLASHES Gas valve energized with no call for heat Check gas valve and gas valve wiring 11 RED FLASHES This indicates that a primary or auxiliary limit switch has opened its normally closed contacts and has remained open for more than five minutes This condition is usually caused by a failed blower motor or blower wheel 12 RED FLASHES This code indicates an open igniter circuit which could be caused by a disconnected or loose wire or by a cracked or bro ken igniter STEADY ON RED Control failure Replace control board 60 MINUTE AUTOMATIC RESET FROM LOCKOUT This control includes a watchdog type circuit that will reset from a lockout condition after 60 minutes Operational faults 6 7 8 will be reset This provides protection to an unoccupied structure if a temporary condition exists causing a furnace malfunction An example would be a low incoming gas supply pressure preventing unit operation When the gas pressure is restored at some point the watchdog would restart the unit and pro vide heat for the house NOTE If a flame is detected the control flashes the LED for 1 8 of a second and then enters a flame stabilization period IGNITION CONTROL Normal flame sense current is approximately 3 7 microamps DC Low flame signal warning starts at 1 5 microamps Low flame signal control lockout point is 0 1 microamps DC 36 DIAGNOSTIC FAULT CODE STORAGE AND RETRIEVAL The control in this
87. of a supply air opening shall be calculated by sub tracting the blockage area of all fixed louvers grilles or screens from the gross area of the opening 2 Apertures in a fixed louver a grilles or screen shall have no dimension smaller than 0 25 0 64 cm 3 A manually operated damper or manually adjustable louvers are not permitted for use 4 A automatically operated damper or automatically adjustable lou vers shall be interlocked so that the main burner cannot operate unless either the damper or the louver is in the fully open position TABLE 13 Free Area Minimum Free Area Required for Each Opening Horizontal Duct Round Duct 2 000 BTUH 4 000 BTUH 4 000 BTUH aL ALL EXAMPLE Determining Free Area Appliance 1Appliance 2 Total Input 100 000 30 000 130 000 4 000 32 5 Sq In Vertical Appliance 1Appliance 2 Total Input 100 000 30 000 130 000 2 000 65 In Horizontal BTUH Input Rating TABLE 14 Unconfined Space Minimum Area in Square Inch BTUH Input Rating Minimum Free Area Required for Each Opening 60 000 60 378 cm 80 000 80 516 cm 100 000 100 645 cm 120 000 120 774 cm 19 2 1041 UIM A 0407 AIR SUPPLY OPENINGS AND DUCTS 1 An opening may be used in lieu of a duct to provide to provide the outside air VENTILATED ATTIC INLET a TOP ABOVE E I I E EEE SOFFIT _ The duct shall be either metal or a material meeting the class 1 requirements o
88. ok to measure the 0 10 m of gas NATURAL GAS INPUT CALCULATION EXAMPLE 38 4 x 0 1 x 0 960 x 3600 160 MJ H 0 2777 kW X 3412 14 82 94 X 0 2777 23 03 X 3412 14 Natural Gas BTU SCF 1030 38 4 MJ m PROPANE LP GAS INPUT CALCULATION EXAMPLE 93 13 x 0 1 x 0 960 x 3600 387 3412 14 83 17 x 0 2777 23 09 X 78 805 20 Propane Gas BTU SCF 2500 93 13 MJ m DO NOT ADJUST the manifold pressure regulator if the actual input is equal to or within 896 less than the furnace input specified on the rating plate or if the furnace rise is above the specified rise range on the rating plate If the actual input is significantly higher than the furnace input specified on the rating plate then replace the gas orifices with the gas orifices of the proper size for the type of gas you are using For altitudes above 2 000 ft 610 m the furnace input MUST BE DERATED Refer to the GAS CONVERSION FOR PROPANE LP AND HIGH ALTITUDES IN SECTION IV for information on high altitude conversions 32 Unitary Products Group A CAUTION Be sure to relight any gas appliances that were turned off at the start of this input check TABLE 16 Inlet Gas Pressure Range INLET GAS PRESSURE RANGE _ 8 0 1 99 kPa 13 0 3 24 kPa W C 4 5 W C 1 12 kPa Maximum 10 5 W C 2 61 kPa IMPORTANT The inlet gas pressure operating range table specifies what the minimum and maximum gas line pressures m
89. on leads and wiring box may be relo cated to the left side of the furnace Remove the screws and cut wire tie holding excess wiring Reposition on the left side of the furnace and fas ten using holes provided BLOWER COMBUSTION COMPARTMENT AIR VENT PIPE CLASS 2 SYSTEM CONTROL WIRING TO THERMOSTAT IGNITION MODULE TRANSFORMER JUNCTION BOX BLK LI HOT WHT GRN GND FIGURE 10 Electrical Wiring 1 Provide a power supply separate from all other circuits Install overcurrent protection and disconnect switch per local national electrical codes The switch should be close to the unit for conve nience in servicing With the disconnect or fused switch in the OFF position check all wiring against the unit wiring label Refer to the wiring diagram shown in Figure 39 2 Remove the screws retaining the junction box cover Route the power wiring through the opening in the unit into the junction box with a conduit connector or other proper connection In the junc tion box there will be three wires a Black Wire a White Wire and a Green Wire Connect the power supply as shown on the unit wir ing label on the inside of the blower compartment door or Figure 10 The black furnace lead must be connected to the L1 hot wire from the power supply The white furnace lead must be connected to neutral Connect the green furnace lead equipment ground to the power supply ground An alternate wiring method is to use a fi
90. onds then will ramp up to full capacity At the end of the cooling cycle the motor will ramp down to 63 of full capac ity and will stay there for 30 seconds then will ramp down to zero In every case it will take the motor 30 seconds to ramp from one speed to another Continuous Blower Operation The blower will run continuously whenever the wall thermostat fan switch is in the ON position The furnace blower will run at the speed selected on the FAN SPEED jumpers on the main control board HI COOL LO COOL HI HEAT or LO HEAT When the jumper is in the VS G position the blower will run at 50 of the high cool speed Intermittent Blower Cooling On cooling heating thermostats with a fan switch when the fan switch is set in the auto position and the thermostat calls for cooling a circuit is completed between the R Y and G terminals The motor is energized through the Y1 cool terminal and runs on the speed selected on the COOL tap of the control board The fan off setting is fixed at 60 seconds for SEER enhancement The control board can accommodate two stage cooling When a two stage cool thermostat is connected to the Y1 and Y2 terminals on the board the blower will operate on LOW COOL speed when Y1 is energized and on HI COOL speed when Y1 and Y2 are energized Intermittent Blower Heating On cooling heating thermostats with a fan switch when the fan switch is set in the auto position and the thermostat calls for heating
91. opening shall communicate directly with the outdoors and shall have a minimum free area of a 1 square in per 3000 Btu per hour 6 45 cm per 0 879 kW of the total input rating of all equipment located in the enclosure b Notless than the sum of all vent connectors in the confined space The duct shall be least the same cross sectional area as the free area of the air supply inlet opening to which it connects The blocking effects of louvers grilles and screens must be given consideration in calculating free area If the free area of a specific louver aor grille is not known FURNACE 8 corrections to the venting system and or to the supply out side 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 refer to Table 8 of these instructions Ventilated Combustion Air The ventilated attic space or a crawl space from which the combustion air is taken must comply with the requirements specified in AIR SOURCE FROM OUTDOORS in this instruction or in Section 5 3 Air for Combustion and Ventilation of the National Fuel Gas Code ANSI Z223 1 latest edition This type installation requires two properly sized pipes One brings combustion air from a properly ventilated attic space or crawl space and a secon
92. r to installation If pleated media air filters or any filter that has a large pressure drop is installed in the return air duct system be sure that the pressure drop caused by the air filter will not prevent the furnace from operating within the rise range specified on the rating plate If the furnace does not oper ate within the specified rise range then a larger air filter or an air filter that has a lower pressure drop must be installed IMPORTANT For easier filter access in a downflow configuration a removable access panel is recommended in the vertical run of the return air plenum immediately above the furnace PL CLOSET COMBUSTION RETURN AIR Re Su AIR AIR FILTERS EITHER SIDE FIGURE 4 Return Filter Grill and Return Duct Installation IMPORTANT Air velocity through throwaway type filters must not exceed 300 feet per minute 1 52 m m All velocities over this require the use of high velocity filters Refer to Table 19 CAUTION All installations must have a filter installed HORIZONTAL APPLICATION Horizontal Filters All filters and mounting provision must be field supplied Filters s may be located in the duct system external to the furnace or in a return filter grille s Filters s may be located in the duct system using an external duct filter box attached to the furnace plenum Any branch duct rectan gular or round duct attached to the plenum must attach to the vertical pl
93. ressure and temperature correction factor of 0 960 times 3600 then divided by the time it took to measure 1 cubic ft 0 028 m of gas from the gas meter The formula for metric input calculation using a cubic foot gas meter MJ m x 2 cu ft x 0 028 x 0 960 x 3600 Seconds it took to measure the 2 cu ft of gas NATURAL GAS INPUT CALCULATION EXAMPLE 38 4 x 2 x 0 028 x 0 960 x 3600 90 5 X kW X 3412 14 X 22 80 X 3412 14 77 796 80 Natural Gas BTU SCF 1030 38 4 MJ m PROPANE LP GAS INPUT CALCULATION EXAMPLE 93 13 x 1 x 0 028 x 0 960 x 3600 108 3412 14 X 23 17 X 79 063 70 Propane Gas BTU SCF 2500 93 13 MJ m In Canada use the following formula to calculate the furnace input if you are using a gas meter that measures cubic meters For Natural Gas multiply the Heat content of the gas MJ m or Default 38 4 times 0 10 m of gas measured at the gas meter times a barometric pressure and temperature correction factor of 0 960 times 3600 then divided by the time it took to measure 0 10 m of gas from the gas meter For Propane LP Gas multiply the Heat content of the gas MJ m or Default 93 13 times 0 10 m of gas measured at the gas meter times a baro metric pressure and temperature correction factor of 0 960 times 3600 then divided by the time it took to measure 0 10 m of gas from the gas meter The formula for metric input calculation using a cubic foot gas meter MJ m x m x 0 960 x 3600 Seconds it to
94. rnace plenum should be of sufficient size so that the furnace plenum should be if sufficient size so that the fur nace operates at the specified external static pressure and within the air temperature rise specified on the nameplate Table 2 is a guide for determining whether the rectangular duct system that the furnace is being connected is of sufficient size for proper fur nace operation Use the Example below to help you in calculating the duct area to deter mine whether the ducts have sufficient area so that the furnace oper ates at the specified external static pressure and within the air temperature rise specified on the nameplate Unitary Products Group 2 1041 UIM A 0407 The following are general duct sizing guidelines that may not serve to 3 Then take the 192 square inch from the rectangular duct and add it requirements of every application to the 76 8 square inch of round duct The total square inch of duct Example The furnace input is 80 000 BTUH 1 200 CFM blower attached to the furnace supply plenum is 268 8 square inches requirement The recommended duct area is 216 sq in there are two 8 This exceeds the recommended 216 square inch of duct x 12 rectangular ducts attached to the plenum and there are two 7 inch In this example the duct system attached to the plenum has a sufficient round ducts attached to the furnace area so that the furnace operates at the specified external static pres 1 Take 8 x 12 which equals
95. rupted at the main power disconnect switch before any service or repair work is to be done to the unit Do not rely upon the interlock switch as a main power dis connect Blower and burner must never be operated without the blower panel in place ROLLOUT SWITCH CONTROLS These controls are mounted on the burner box assembly If the temper ature in the burner box exceeds its set point the ignition control and the gas valve are de energized The operation of this control indicates a malfunction in the combustion air blower heat exchanger or a blocked vent pipe connection Corrective action is required These are manual reset controls that must be reset before operation can continue 30 PRESSURE SWITCHES This furnace is supplied with a pressure switch which monitors the flow through the combustion air vent piping system This switch de ener gizes the ignition control module and the gas valve if any of the follow ing conditions are present Refer to Figure 35 for tubing connections 1 Blockage of combustion air piping or terminal 2 Blockage of vent piping or terminal 3 Failure of combustion air blower motor 4 Blockage of condensate drain piping DOWNFLOW HORIZONTAL FIGURE 35 Pressure Switch Tubing Routing LIMIT CONTROLS There is high temperature limit control located on the furnace vestibule panel near the gas valve This is an automatic reset control that pro vides over temperature protection
96. ry Products Group 2 1041 UIM A 0407 WIRING DIAGRAM SECTION X 1010 05 0112 JONVSSINd 30 un310V4 NG un3lvWHUOJSNVHl dd U3WHOJSNVHI YOLOVS H3MOd dd 1138VddV 13 U3IINVHO 39713 321A30 ONY ONINIM 01313 113uVddV 13 3NISQ 1 30 39713 YNIWYOISNYYL 11 NOISS3Yd 30 YNILYLNWWOD NOIIVSN3ONOO 30 1110094 416 VAO u3NHOJSNVHI LI 31VSN30NOO HOLIMS 391553094 dIE NOISS3Nd 30 YNFLVLNWNOD NG 3915 H3 WiHd 411 3BvI 1891105 9 3102 1N3Wi1nON YNFLVLAWNOD 3019 1431 HOLIMS 1 0 1308 2508 11080 3102 1N3W31nO0N YNILYLNWWOD 1809 3015 LHOIY HOLIMS LINO 1108 1508 NOILONGNI YNILOW 31 WI 1 30 YNFLVLNWNOD ZSI JIVdIONIYd 31INI 30 YNALVLAWNOD 151 NOILINO9I Q JIOYLNOD 30 FLLANOVId Y1 YAS 514 91 V 3l10Vlid3O3M 13 35149 65 64 HOLIMS LIWII YFONGNI 2S1 HOLIMS LINIT AYWWIYd 151 318314400S v1 0 31 snOd 514 6 V 310V143238 13 35184 85 84 HOIOM Y3M019 NO 133209 ond Nid 85 84 3193144105 v1 30 YNALOW 31 YNOd 514 91 312V1d3238 13 35188 95 94 wol HANOI WO L3NDOS Nid 91 99794 3dvdnOS v1 UNS 514 V 312V1d323H 13 35184 SS Sd Siu 134908 NOII20QNI Q YNFLOW 514 V 310V1d323N 13 35184 75 78 GLOW sssmoNi NO 134208 9 sg Nia JOVAUNS 30 NOILINOI G 514 V 312V1d323H 13 35184 S Ed MOLINO 32ViNDS LOH NO 135205
97. so that condensate will flow back towards the furnace Piping should be supported with pipe hangers to prevent sagging 9 Seal around the openings where the combustion air and or vent piping pass through the roof or sidewalls COMBUSTION AIR VENT CLEARANCES IMPORTANT The vent must be installed with the following minimum clearances and must comply with local codes and requirements 15 2 1041 UIM A 0407 VENT CLEARANCES OPERABLE FIGURE 15 Home Layout Direct Vent Terminal Clearances Canadian Installations A Clearance above grade veranda porch deck or 12 inches 30 cm balcony B Clearance to window or door that may be opened C Clearance to permanently closed window 12 inches 30 cm D Vertical clearance to ventilated soffit located 12 inches 30 cm or in accordance with local above the terminal within a horizontal distance installation codes and the requirements of the gas of 2 feet 61 cm from the center line of the terminal supplier 12 inches 30 cm or in accordance with local installation codes and the requirements of the gas supplier 12 inches 30 cm or in accordance with local installation codes and the requirements of the gas supplier E Clearance to unventilated soffit F Clearance to outside corner G Clearance to inside corner 3 feet 91 cm Above a meter regulator assembly within 3 feet 91 cm horizontally of the vertical center line of the regul
98. ss than 18 inches 46 cm above the floor and the furnace must be located or protected to avoid physical damage by vehicles Floor Bottom Line Closet In mm Contact 1 Combustible floor base or air conditioning coil required for use on combustible floor 2 Line contact only permitted between lines formed by the intersection of the rear panel top in horizontal position of the furnace jacket and building joists studs or framing SECTION Il DUCTWORK DUCTWORK GENERAL INFORMATION The duct system s design and installation must 1 Handle an air volume appropriate for the served space and within the operating parameters of the furnace specifications 2 installed in accordance with standards of NFPA National Fire Protection Association as outlined in NFPA pamphlets 90A and 90B latest editions or applicable national provincial or state and local fire and safety codes 3 Create a closed duct system For residential and Non HUD Modu lar Home installations when a furnace is installed so that the sup ply ducts carry air circulated by the furnace to areas outside the space containing the furnace the return air shall also be handled by a duct s sealed to the furnace casing and terminating outside the space containing the furnace 4 Complete a path for heated or cooled air to circulate through the air conditioning and heating equipment and to and from the condi A CAUTION The cooling coil must be installed in the supp
99. supply air duct is then secured to the duct system with screws and sealed to prevent leaks Do not shoot screws through the flanges of the supply air duct into the top of the combustible floor base Install the furnace on the combustible floor base so that the corners of the furnace are parallel with the corner brackets of the floor base Follow the instructions supplied with the combustible floor base accessory This combustible floor base can be replaced with a matching cooling coil properly sealed to prevent leaks Follow the instructions supplied with the cooling coil cabinet for installing the cabinet to the duct connec tor Refer to the installation instructions for additional information When replacing an existing furnace if the existing plenum is not the same size as the new furnace then the existing plenum must be removed and a new plenum installed that is the proper size for the new furnace Ductwork Installation NOTE When attaching duct flange do not shoot the screw down into the casing Use the formed flange intended for duct flange attachment A proper Heat Loss Gain Calculation should be done on all installations for proper application of equipment From this the ductwork sizing can be calculated ACCA Manual J and D and industry standards are help ful The duct system is a very important part of the installation If the duct system is improperly sized the furnace will not operate properly The ducts attached to the fu
100. tive pressure in the vicinity of the vent 168 itary Products Group VENT SYSTEM This furnace is certified to be installed with one of two possible vent configurations 1 Horizontal vent system This vent system can be installed com pletely horizontal or combinations of horizontal vertical or offset using elbows 2 Vertical vent system This vent system can be installed completely vertical or a combination of horizontal vertical or offset using elbows HORIZONTAL VENT APPLICATIONS AND TERMINATION When selecting the location for a horizontal combustion air vent termi nation the following should be considered 1 Observe all clearances listed in vent clearances in these instruc tions 2 Termination should be positioned where vent vapors will not dam age 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 objec tionable 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 7 vent drain is required when vent passes through any uncon
101. tors a n the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level b the event that the requirements of this subdivision can not be met at the time of completion of installation the owner shall have a period of thirty 30 days to comply with the above requirements provided however that during said thirty 30 day period a battery operated carbon mon oxide detector with an alarm shall be installed 2 APPROVED CARBON MONOXIDE DETECTORS Each car bon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI UL 2034 listed and IAS certified 3 SIGNAGE A metal or plastic identification plate shall be perma nently mounted to the exterior of the building at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUC TIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspector observes car bon monoxide detectors and signage installed in accordance
102. ure Reading from the Supply Air Temperature Read ing FIGURE 1 Combustible Floor Base Accessory 2 The External Static Pressure is determined by adding the Supply Duct Static Pressure reading to the Return Duct Static Pressure reading A WARNING TABLES 2 AND 3 are to be used as a guide only to help the installer i The supply air temperature MUST NEVER exceed the Maximum determine if the duct sizes are large enough to obtain the proper air flow Supply Air Temperature specified on the nameplate CFM through the furnace TABLES 2 and 3 ARE NOT to be used to desan da ebuild h the f ebena Operating the furnace above the maximum supply air temperature xe ees will cause the heat exchanger to overheat causing premature heat There are several variables associated with proper duct sizing that are exchanger failure Improper duct sizing dirty air filters incorrect not included in the tables To properly design the ductwork for the build manifold pressure incorrect gas orifice and or a faulty limit switch ing Refer to the ASHRAE Fundamentals Handbook Chapter on can cause the furnace to operate above the maximum supply air DUCT DESIGN or a company that specializes in Residential and Mod temperature Refer to sections IIl and IX for additional informa ular Home duct designs tion on correcting the problem IMPORTANT If the supply air duct is
103. ust be for the fur nace to operate safely The gas line pressure MUST BE 7 W C 1 74 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 ADJ USTMENT OF MANIFOLD GAS PRESSURE Manifold gas pressure may be measured by two different procedures It may be measured with the burner box cover in place or it may be mea sured with the burner box cover removed Follow the appropriate sec tion in the instructions below Refer to Figure 36 for a drawing of the locations of the pressure ports on the gas valve Turn gas off at the ball valve or gas cock on gas supply line before the gas valve Find the pressure ports on the gas valve marked OUT P and IN P 1 The manifold pressure must be taken at the port marked OUT P 2 The gas line pressure must be taken at the port marked IN P 3 Using a 3 32 2 4 mm Allen wrench loosen the setscrew by turn ing it 1 turn counter clockwise DO NOT REMOVE THE SET SCREW FROM THE PRESSURE PORT Read the manifold gas pressure using either of the two methods below Reading the gas pressure with the burner box cover in place A Disconnect the pressure reference hose from the right side of the burner box Using a tee fitting and a short piece of hose connect the negative side of the manometer to the burner box as described belo
104. ust be sealed to prevent leaks fthe transition kit has been installed on the cooling coil cabinet it must be secured to the cooling coil cabinet with screws The sup ply air side of the furnace is then placed on the cooling coil cabi net and then sealed for leaks e If the transition kit has been installed on the supply air side of the furnace it must be secured to the furnace with screws The fur nace and the transition kit are then placed on the cooling coil cab inet and then sealed for leaks NOTE Refer to instructions packed out with coil cabinet for securing and sealing to the furnace IMPORTANT The furnace transition kit and the cooling coil cabinet MUST BE SEALED as needed to prevent leaks AND SECURED Refer to the assembly drawing in Figure 2 IMPORTANT On all installations without a coil a removable access panel is recommended in the outlet duct such that smoke or reflected light would be observable inside the casing to indicate the presence of leaks in the heat exchanger This access cover shall be attached in such a manner as to prevent leaks TRANSITION DOWNFLOW FURNACE REFRIGERANT COOLING COIL CABINET ONNECTIONS a AIRFLOW 1 FA TRANSITION KIT AIRFLOW FIGURE 2 Transition Kit Assembly Horizontal Models IMPORTANT This furnace may be installed in a horizontal position on either side as shown above It must not be installed on its back Horizontal Installations
105. ver there is a change in airflow mode such as from low heat to high heat the motor will take 30 seconds to ramp from one speed to the other Tap B is the humid profile This profile is best suited for installations where the humidity is frequently very high during cooling season such as in the southern part of the country On a call for cooling the blower will ramp up to 50 of full capacity and will stay there for two minutes then will ramp up to 82 of full capacity and will stay there for five min utes and then will ramp up to full capacity where it will stay until the wall thermostat is satisfied In every case it will take the motor 30 sec onds to ramp from one speed to another Tap C is the dry profile This profile is best suited to parts of the country where excessive humidity is not generally a problem where the sum mer months are usually dry On a call for cooling the motor will ramp up to full capacity and will stay there until the thermostat is satisfied At the end of the cooling cycle the blower will ramp down to 50 of full capac ity where it will stay for 60 seconds Then it will ramp down to zero In every case it will take the motor 30 seconds to ramp from one speed to another Tap D is the normal profile best suited for most of the country where neither excessive humidity nor extremely dry conditions are the norm On a call for cooling the motor will ramp up to 63 of full capacity and will stay there for 90 sec
106. w B Remove one end the 5 16 0 8 cm ID flexible tubing over the pressure port on the burner box C Insert the end of the 5 16 0 8 cm tubing that has the 1 8 0 3 cm adapter at the end of the tube in to the 1 8 0 3 cm tee D Connect the 1 8 0 3 cm tee to the burner box adapter and to the negative side of a U tube manometer or digital pres sure measuring equipment with 2 1 8 0 3 cm tubes E Use the 5 16 0 8 cm x 1 8 0 3 cm reducing coupling and a 4 10 2 cm piece of 1 8 0 3 cm tubing to connect the posi tive side of the manometer to the gas valve pressure refer ence port Refer to Figure 37 for connection details Reading the gas pressure with the burner box cover removed Remove the screws securing the burner box front cover plate Remove the cover The gasket and may stick in place Connect the positive side of the manometer to the gas valve as described above There will be no second connection to the manometer as it will reference atmospheric pressure Refer to Figure 37 for connection details Unitary Products Group 2 1041 UIM A 0407 IMPORTANT The cap for the pressure regulator must be removed entirely to gain access to the adjustment screw Loosening or tightening the cap does not adjust the flow of gas 1 Refer to Figure 36 for location of pressure regulator adjustment cap and adjustment screw on main gas valve 2 Turn gas and electrical supplies on and follow the operati
107. with the provisions of 248 CMR 5 08 2 a 1 through 4 Unitary Products Group 2 1041 UIM A 0407 INSPECTION As soon as a unit is received it should be inspected for possible dam age during transit If damage is evident the extent of the damage should be noted on the carrier s freight bill A separate request for inspection by the carrier s agent should be made in writing Also before installation the unit should be checked for screws or bolts which may have loosened in transit There are no shipping or spacer brackets which need to be removed FURNACE LOCATION AND CLEARANCES The furnace shall be located using the following guidelines 1 Where a minimum amount of air intake vent piping and elbows will be required 2 As centralized with the air distribution as possible 3 Where adequate combustion air will be available particularly when the appliance is not using outdoor combustion air 4 Where it will not interfere with proper air circulation in the confined space 5 Where the outdoor combustion air vent terminal will not be blocked or restricted Refer to COMBUSTION AIR VENT CLEAR ANCES located in SECTION VI of these instructions These mini mum clearances must be maintained in the installation 6 Where the unit will be installed in a level position with no more than 1 4 6 4 mm slope side to side and front to back to provide proper condensate drainage Installation in freezing temperatures 1 Furnace shal

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