Coleman PxXU-V series, PxXU-G9V-UP series, PxXD-G9V-DH series, PxXD-V series Installation Instructions Manual

INSTALLATION

TWO-STAGE ULTRA

HIGH-EFFICIENCY GAS-FIRED

INSTRUCTIONS

TABLE OF CONTENTS

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . 2

SPECIFIC UNIT INFORMATION . . . . . . . . . . . . . . . . . . 3

DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

ELECTRICAL POWER CONNECTION . . . . . . . . . . . . 12

ELECTRICAL CONTROL CONNECTIONS . . . . . . . . . 13

COMBUSTION AIR AND VENT SYSTEM . . . . . . . . . . 14

CONDENSATE PIPING . . . . . . . . . . . . . . . . . . . . . . . . 22

SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . 24

START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . 25

VARIABLE SPEED FURNACES

MODELS

UPFLOW - P*XU - “V” / G9V-UP

60 To 120 MBH Input

DOWNFLOW/HORIZONTAL - P*XD-V / G9V-DH

80 To 120 MBH Input

FURNACE ACCESSORIES . . . . . . . . . . . . . . . . . . . . . 29

AIRFLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

OPERATION AND MAINTENANCE . . . . . . . . . . . . . . . 32

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 35

EFFICIENCY
RATING
CERTIFIED

CAUTION: READ ALL SAFETY GUIDES BEFORE YOU

START TO INSTALL YOUR FURNACE.

SAVE THIS MANUAL

035-17468-001 Rev. A (801)

IMPROPER INSTALLATION MAY CREATE A CON­DITION WHERE THE OPERATION OF THE
PRODUCT COULD CAUSE PERSONAL INJURY
OR PROPERTY DAMAGE.

IMPROPER INSTALLATION, ADJUSTMENT,
ALTERATION, SERVICE OR MAINTENANCE CAN
CAUSE INJURY OR PROPERTY DAMAGE.
REFER TO THIS MANUAL FOR ASSISTANCE OR
ADDITIONAL INFORMATION, CONSULT A QUALI­FIED INSTALLER, SERVICE AGENCY OR THE
GAS SUPPLIER.

THIS PRODUCT MUST BE INSTALLED IN STRICT
COMPLIANCE WITH THE ENCLOSED INSTALLA­TION INSTRUCTIONS AND ANY APPLICABLE
LOCAL, STATE, AND NATIONAL CODES INCLUD­ING BUT NOT LIMITED TO, BUILDING, ELECTRI­CAL AND MECHANICAL CODES.

035-17468-001 Rev. A (801)

GENERAL INFORMATION

DESCRIPTION

This Category IV, dual certified direct vent and 1-pipe vent
furnace is designed for residential or commercial application.
It may be installed without modification to the condensate
system in a basement, garage, equipment room, alcove, attic
or any other indoor location provided the space temperature
is 32 °F or higher and where all required clearance to com­bustibles and other restrictions are met. If the furnace is
being installed where the space temperature is below 32°F,
refer to BELOW FREEZING LOCATIONS on Page 4.

This furnace is constructed at the factory for natural gas-fired
operation from 0 - 4,500 ft. above sea level, but may be con­verted to operate on propane (LP) gas and at altitudes up to
10,000 ft. For applications at altitudes between 2,000 - 4,500
ft., see COMBUSTION AIR/VENT PIPE SIZING on Page 14,
for required vent length reductions. For application at alti­tudes greater than 4,500 feet, see high altitude instructions
035-14460-000.

High altitude and propane (LP) changes or conversions
required in order for the appliance to satisfactory meet the
application must be made by an authorized distributor or
dealer. In Canada, a certified conversion station or other
qualified agency, using factory specified and/or approved
parts, must perform the conversion.

The blower in this furnace is programmed to supply a con­stant volume of airflow to compensate for duct system static.

The furnace area must not be used as a broom
closet or for any other storage purposes, as a fire
hazard may be created. Never store items such as
the following on, near or in contact with the
furnace.

1. Spray or aerosol cans, rags, brooms, dust mops,

vacuum cleaners or other cleaning tools.

2. Soap powders, bleaches, waxes or other clean-

ing compounds; plastic items or
containers; gasoline, kerosene, cigarette lighter
fluid, dry cleaning fluids or other volatile fluid.

3. Paint thinners and other painting compounds.

4. Paper bags, boxes or other paper products

Never operate the furnace with the blower door
removed. To do so could result in serious personal
injury and/or equipment damage.

INSPECTION

As soon as a unit is received, it should be inspected for possi­ble damage during transit. If damage is evident, the extent of
the damage should be noted on the carrier's freight bill.

A separate request for inspection by the carrier's agent
should be made in writing. Also, before installation the unit
should be checked for screws or bolts which may have loos­ened in transit. There are no shipping or spacer brackets
which need to be removed.

NOTES, CAUTIONS & WARNINGS

The installer should pay particular attention to the words:

NOTE, CAUTION and WARNING. NOTES are intended to
clarify or make the installation easier. CAUTIONS are given
to prevent equipment damage. WARNINGS are given to alert
the installer that personal injury and/or equipment or property
damage may occur if installation procedures are not handled
properly.

The cooling coil must be installed in the supply air
duct. Cooled air may not be passed over the heat
exchanger.

2 Unitary Products Group

035-17468-001 Rev. A (801)

VENT SAFETY CHECK PROCEDURE

This furnace may not be common vented with any
other appliance, since it requires separate, properly­sized 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.

If this furnace is replacing a common-vented fur­nace, it may be necessary to resize the existing vent
line and chimney to prevent oversizing problems for
the new combination of units. Refer to the National
Gas Code (ANSI Z223.1) or CAN/CGA B149.1 or.2
Installation Code (latest editions).

The following steps shall be followed with each appliance
connected to the venting system placed in operation, while
any other appliances connected to the venting system are not
in operation:

1. Seal any unused openings in the venting system.

2. Inspect the venting system for proper size and horizontal
pitch, as required in the National Fuel Gas Code, ANSI
Z223.1, or the CAN/CGA B149 Installation Codes and
these instructions. Determine that there is no blockage
or restriction, leakage, corrosion or other deficiencies
which could cause an unsafe condition.

3. Insofar as is practical, close all building doors and win­dows and all doors between the space in which the appli­ance(s) is located and other spaces of the building. Turn
on clothes dryers. Turn on any exhaust fans, such as
range hoods and bathroom exhausts, so they shall oper­ate at maximum speed. Do not operate a summer
exhaust fan. Close fireplace dampers.

4. Follow the lighting instructions. Place the appliance
being inspected in operation. Adjust thermostat so the
appliance shall operate continuously.

5. Test for draft hood equipped appliance spillage at the
draft hood relief opening after 5 minutes of main burner
operation. Use the flame of a match or candle.

6. After it has been determined that each appliance con­nected to the venting system properly vents when tested
as outlined above, return doors, windows, exhaust fans,
fireplace dampers and any other gas burning appliance
to their previous conditions of use.

7. If improper venting is observed during any of the above
tests, the venting system must be corrected.

8. Any corrections to the common venting system must be
in accordance with the National Fuel Gas Code Z223.1
or CAN/CGA B149.1 or.2 Installation Code (latest edi­tions). If the common vent system must be resized, it
should be resized to approach the minimum size as
determined using the appropriate tables in Appendix G
of the above codes.

SPECIFIC UNIT INFORMATION

LIMITATIONS & LOCATION

This furnace should be installed in accordance with all
national and local building/safety codes and requirements, or
in the absence of local codes, with the National Fuel Gas
Code ANSI Z223.1 or CAN/CGA B149.1 or .2 Installation
Code (latest editions), local plumbing or waste water codes,
and other applicable codes.

CLEARANCES FOR ACCESS

Ample clearances should be provided to permit easy access
to the unit. The following minimum clearances are recom­mended:

1. Twenty-four (24) inches 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 at the side where access is
required for passage to the front when servicing or for
inspection or replacement of flue/vent connections.

NOTE: In all cases, accessibility clearances shall take prece­dence over clearances for combustible materials where
accessibility clearances are greater.

Do not install the furnace in an unconditioned space
or garage that could experience ambient tempera­tures of 32° F (0° C) or lower. For application in
below freezing locations, See “BELOW FREEZING
LOCATIONS” on page 4.

The furnace is not to be used for temporary heating
of buildings or structures under construction.

This unit must be installed in a level (1/4”) position
side-to-side and front-to-back to provide proper con­densate drainage.

Do not allow return air temperature to be below 55°F
for extended periods. To do so may cause conden­sation to occur in the maim fired heat exchanger.

Only use natural gas in furnaces designed for natu­ral gas. Only use propane (LP) gas for furnaces that
have been properly converted to use propane (LP)
gas. Do not use this furnace with butane. Using
wrong gas could create a hazard, resulting in dam­age, injury or death.

Unitary Products Group 3

Furnaces shall not be installed directly on carpeting,
tile or other combustible material other than wood
flooring. An accessory combustible floor base is
available to allow direct installation of downflow
models on combustible flooring.

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

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.

Refer to furnace rating plate for the type of gas approved for
this furnace - only use those approved gases.

Check the rating plate and power supply to be sure that the
electrical characteristics match. All models use nominal 115
VAC, 1 Phase, 60 Hertz power supply.

For installations above 2,000 feet, reduce input 4% for each
1,000 feet above sea level.

For installation between 2000 and 4500 feet, it is not required
that the pressure switch be changed, provided the maximum
vent/intake pipe lengths are adjusted as shown in the Note
from Tables 5 & 6 on Pages 15 & 19. For altitudes above
4,500 feet, refer to instructions 035-14460-000 for correct
pressure switch/orifice or other required conversion informa­tion.

The furnace shall not be connected to a chimney flue serving
a separate appliance designed to burn solid fuel.

A furnace installed in a residential garage shall be located so
that all burners and burner ignition devices are located not
less that 18" above the garage floor, and located or protected
to prevent damage by vehicles.

Allow clearances from combustible materials as listed under
Clearances to Combustibles, ensuring that service access is
allowed for both the burners and blower.

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, the dampers or
other means used to control air flow shall be adequate to pre­vent chilled air from entering the furnace, and if manually
operated, must be equipped with means to prevent operation
of either unit unless the damper is in the full heat or cool posi­tion.

035-17468-001 Rev. A (801)

The furnace shall be located using these guidelines:

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

2. As centralized with the air distribution system as possi­ble.

3. Where adequate combustion air will be available
(particularly when installing as 1-pipe system).

4. In an area where ventilation facilities provide for safe lim­its of ambient temperature under normal operating condi­tions. Ambient temperatures must not fall below 32°F
(0°C) unless the condensate system is protected from
freezing (Refer to BELOW FREEZING LOCATIONS
below).

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

6. Where the outdoor combustion air/vent terminal will not
be blocked or restricted.

CLEARANCES TO COMBUSTIBLES

Minimum clearances from combustible construction are
shown in Table 3, “UNIT CLEARANCES TO COMBUSTI­BLES,” on Page 6. These minimum clearances must be
maintained in the installation.

BELOW FREEZING LOCATIONS

If this furnace is installed in any area where the ambient tem­perature may drop below 32° F, a UL listed self regulated
heat tape must be installed on any condensate drain lines. It
is recommended that self regulating heat tape rated at 3
watts per foot be used. This must be installed around the con­densate drain lines in the unconditioned space. Always install
the heat tape per the manufacturer's instructions. Cover the
self-regulating heat tape with fiberglass or other heat resis­tant, insulating material.

If this unit is installed in an unconditioned space and
an extended power failure occurs, there could be
potential damage to the condensate trap, drain lines
and internal unit components. Following a power
failure situation, Do Not Operate the Unit Until

Inspection and Repair Are Performed.

4 Unitary Products Group

035-17468-001 Rev. A (801)

20

6-3/8

1-1/4

B

3-1/8

20

D
INTAKE
CONNECTION

OPTIONAL SIDE RETURN
CUT-OUT (EITHER SIDE)

CONDENSATE
DRAIN

28-1/2

B

FRONT

TOP IMAGE

E
VENT CONNECTION
(vent size)

28-1/2

2-3/4

6-1/8

T’ STAT
WIRING
7/8” K.G.

9-7/8

6-7/8

23

BOTTOM IMAGE

A

C

WITH K.O.
REMOVED

FRONT

4-1/8

45

20-5/8

A

MODELS

P*XU -V & G9V-UH

60 / 55 / 1200 /”B”

80 / 75 / 1600 /”C”

100 / 95 / 2000 /”C”

120 / 112 / 2000 /”D”

1. Vent pipe must be increased to 3” on this unit.

3/4”
FLANGE

6

1-3/4

A

17-1/2

21

21

24-1/2

1-3/4

14-1/2

16-1/4

19-3/4

19-3/4

23-1/4

8-7/8

22-3/4

B

CDE

13-1/8

16-5/8

16-5/8

20-1/8

3/4

2

2

2

2

2

2

3

1

2

FIGURE 1 : Dimensions - Upflow models

Table 1 : RATINGS & PHYSICAL / ELECTRICAL DATA - UPFLOW MODELS

P*XU-V/G9V—UH

INPU

OUTPUT

MBH

H/L

MBH

H/L

NOM.

CFM

AFUE

1

LOW
FIRE

TEMP.

RISE °F

HIGH

FIRE

TEMP.

RISE °F

MAX.

OUTLET

AIR

TEMP. °F

60/39 55/36 1200 93.5 45 - 75 45 - 75 175 1/2 1.7 11x8 9.6 20 14

80/52 75/48 1600 93.5 30 - 60 30 - 60 165 3/4 3.6 11x8 12.0 20 14

100/65 95/60 2000 94.0 30 - 60 30 - 60 160 1 4.3 11x10 14.5 20 12

120/78 112/72 2000 94.0 45 - 75 45 - 75 175 1 4.4 11x10 14.5 20 12

1.

AFUE numbers are determined in accordance with DOE test procedures

2.

Wire size and overcurrent protection must comply with the National Electrical Code (NFPA-70-latest edition).
For altitudes above 2,000 ft., reduce capacity 4% for each 1,000 ft. above sea level. Refer to instructions 035-14460-000.

·
Wire size based on copper conductors, 60°C, 3% voltage drop.

·
Continuous return air temperature must not be below 55°F.

·

BLOWER

HP AMPS SIZE

TOTAL

UNIT

AMPS

MAX.

OVER-CURRENT

PROTECT

2

MIN WIRE SIZE
(AWG) @ 75 FT.

ONE WAY

2

Unitary Products Group 5

035-17468-001 Rev. A (801)

20

1-7/8

B

20

3/4

T'STAT WIRING
7/8 K.O.

45

CONDENSATE
DRAIN ACCESS
3-1/4 x 3

AIR INTAKE
3-5/8 x 3-5/8
( CONN. SIZE/

G

PIPE SIZE)

GAS INLET
1-1/4 x 2-1/2

5-1/4

1-1/4

3-3/4

1-3/4

2-3/4

A

FRONT RIGHT SIDE

B

28-1/2

LEFT SIDE

A

D

VENT CONNECTION

35

18-1/2

16-3/4

7-1/2

6-1/4

4-1/8

3-3/4

1-1/4

ALT. GAS INLET
1-1/4 x 2-1/2

1-3/8

VENT CONNECTION

POWER
WIRING
7/8 K.O.

E F

TOP IMAGE

RETURN END

(VENT SIZE

5-3/8

19-1/4

C

H

FRONTFRONT

BOTTOM IMAGE

RETURN END

P*XD-V / G9V-DH

80/75/1200/B

120/112/2000/D

8

MODELS

ABCDEFG

17-1/2

16-1/4

24-1/2

23-1/4

14-3/4

21-3/4

2

2 (3)

1. VENT PIPE MUST BE INCREASED TO 3" ON THIS MODEL.

ALL DIMENSION ARE IN INCHES, AND ARE APPROXIMATE.

CONDENSATE
DRAIN ACCESS
3-1/4 x 3

AIR INTAKE
3-5/8 x 3-5/8
( CONN. SIZE/

G

PIPE SIZE)

6-5/8

1

10-1/8

2-1/4

2-1/423

FIGURE 2 : Dimensions - Downflow/Horizontal Models

Table 2 : RATINGS & PHYSICAL / ELECTRICAL DATA - DOWNFLOW/HORIZONTAL MODELS

P*XD-V/G9V-DH

INPU

OUTPUT

MBH

H/L

MBH

H/L

NOM.

CFM

CABINET

WIDTH

(INCHES)

AFUE

1

TEMP.

RISE °F

LOW
FIRE

HIGH

FIRE

TEMP.

RISE °F

MAX.

OUTLET

AIR

TEMP. °F

80/52 75/48 1200 17-1/2 92.0 35-65 35-65 165 1/2 1.7 11 x 8 12.0 20 14 128

120/78 112/72 2000 24-1/2 92.0 40-70 40-70 170 1 4.4 11 x 10 14.5 20 12 184

1.

AFUE numbers are determined in accordance with DOE test procedures

2.

Wire size and overcurrent protection must comply with the National Electrical Code (NFPA-70-latest edition).

•

For altitudes above 2,000 ft., reduce capacity 4% for each 1,000 ft. above sea level. Refer to Form 035-14460-000.

•

Wire size based on copper conductors, 60°C, 3% voltage drop.

•

Continuous return air temperature must not be below 55°F.

BLOWER

HP AMPS SIZE

TOTAL

UNIT

AMPS

MAX.

OVER-CURRENT

PROTECT

2

MIN WIRE SIZE
(AWG) @ 75 FT.

ONE WAY

2

OPERATING

WT. (LBS)

Table 3 : UNIT CLEARANCES TO COMBUSTIBLES

APPLICATION TOP FRONT REAR

LEFT

SIDE

RIGHT

SIDE

FLUE FLOOR/BOTTOM CLOSET ALCOVE ATTIC

UPFLOW MODELS (P*XU-V / G9V-UP)

UPFLOW 1 3 0 0 0 0 COMBUSTIBLE YES YES YES NO

DOWNFLOW / HORIZONTAL MODELS (P*XD-V / G9V-DH)

DOWNFLOW 1 3 0 0 0 0

HORIZONTAL 1 3 0 0

1.

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

2.

Minimum of 8” clearance required to install condensate removal system.

3.

Line contact only permitted between lines formed by the intersection of the rear panel and side panel (top in horizontal position) of

+

0

COMBUSTIBLE

0

COMBUSTIBLE

1

YES YES YES NO

2

NO YES YES

the furnace jacket and building joists, studs or framing.

LINE

CONTACT

YES

3

6 Unitary Products Group

035-17468-001 Rev. A (801)

DUCTWORK

The duct system's design and installation must:

1. Handle an air volume appropriate for the served space
and within the operating parameters of the furnace
specifications.

2. Be installed in accordance with standards of NFPA
(National Fire Protection Association) as outlined in
NFPA pamphlets 90A and 90B (latest editions) or appli­cable national, provincial, local fire and safety codes.

3. Create a closed duct system. The supply duct system
must be connected to the furnace outlet and the return
duct system must be connected to the furnace inlet. Both
supply and return duct systems must terminate outside
the space containing the furnace.

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

The cooling coil must be installed in the supply air
duct. Cooled air must 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, the dampers or
other means used to control air flow must be adequate to pre­vent chilled air from entering the furnace, and if manually
operated, must be equipped with means to prevent operating
of either unit unless the damper is in the full heat or cool
position.

UPFLOW MODELS

SUPPLY PLENUM CONNECTION

Attach the supply plenum to the fur­nace outlet duct connection flanges.
This is typically through the use of S
cleat material when a metal plenum is
used. The use of an approved flexible
duct connector is recommended on all
installations. This connection should be
sealed to prevent air leakage.

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

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

RETURN DUCT CONNECTION

Return air may enter the furnace through the side(s) or bot­tom depending on the type of application. Return air may
not be connected into the rear panel of the unit. Refer to
the "Filter Installation" section of this instruction for the type of
application desired for specific installation details.

NOTE: In order to achieve the airflow indicated in the table, it
is recommended those applications over 1800 CFM use
return air from two sides, one side and the bottom or bottom
only. For single return application, see data and notes on
blower performance data tables in this manual.

UPFLOW FILTER INSTALLATION

All applications require the use of a filter. A high velocity filter
and retainer are provided for field installation.

Internal Installation

1. Select desired filter position (left/right side, and/or bot­tom). Remove the corresponding cabinet cut-outs per
instructions provided.

2. Install snap-in retainer clips into the corresponding slots
from the outside rear of the cabinet (Refer to Figure 3.)
To prevent cabinet air leaks, install snap-in plugs (pro­vided) into the unused slots at the outside rear of the
cabinet.

3. Install the wire retainer inside the cabinet. Insert the
open ends of the wire retainer into the clip loops at the
rear of the blower compartment. The retainer wire should
pivot freely like a hinge, on the clips at the rear of the
cabinet. See Figure 4.

FURNACE
(REAR CABINET)

RIGHT
SIDE
SLOTS

BOTTOM SLOTS

CABINET
SLOT

FILTER SUPPORT
CLIPS (PROVIDED)

LEFT
SIDE
SLOTS

PLUG UNUSED
CABINET SLOTS
WITH PLUGS
(PROVIDED)

FIGURE 3 : Furnace Filter Slot Locations

Unitary Products Group 7

POSITION WIRE RETAINER
PROVIDED UNDER FLANGE

035-17468-001 Rev. A (801)

NOTE: Some accessories such as electronic air cleaners and
pleated media may require a larger side opening. Follow the
instructions supplied with the accessory for side opening
requirements.

FILTER

CLIPS

RIGHT SIDE
INSTALLATION
SHOWN

PROVIDED

FURNACE
FRONT

FIGURE 4 : Side Filter Retainer Placement

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

5. Position the filter between the wire retainer and the cabi­net wall (or floor) so it completely covers the cabinet air
opening and secure the filter in place at the front of the
cabinet by fastening the closed (looped) end of the
retainer wire under the flanged edge of the cabinet.
When properly installed the filter should fit flush with all
four sides of the cabinet wall.

NOTE: Air velocity through throw-away type filters may not
exceed 300 feet per minute. All velocities over this require the
use of high velocity filters.

Side Return - External Filter

Locate and knock out the square corner locators. These indi­cate the size of the cutout to be made in the furnace side
panel, See Figure 5.

FRONT OF

CORNER
MARKINGS

FURNACE

FIGURE 5 : Side Return Cutout Markings

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

All installations must have a filter installed.

The return duct may be attached to the furnace by S-cleat,
bend tabs or other approved methods. Be sure to seal the
duct to the furnace to prevent air leakage.

Where the return duct system is not complete, the return con­nection must run full size to a location outside the utility room
or basement. For further details, consult Section 5.3 (Air for
Combustion and Ventilation) of the National Fuel Gas Code,
ANSI Z223.1, or CAN/CGA B149.1 or.2, Installation Code ­latest editions.

Bottom Return

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

The bottom panel is equipped with a perforated opening for
easy removal. Tabs must be cut with sheet metal snips to
allow removing knock-out. Scribe marks are included for
forming flanges for attachment of the return air ductwork.

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

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

DOWNFLOW/HORIZONTAL MODELS

COOLING COIL TRANSITION

These furnace models are equipped with perforations in the
supply air wrapper flanges that allow for easy application of
air conditioning coil to the furnace without the use of sheet
metal transition pieces, These perforations can be bent in
either direction depending on the type of application - either
downflow or horizontal left and right. Refer to either the
“Downflow Application” or “Horizontal Application” section
below for specific instructions on how to install the coil.

Downflow Installations

For installation of air conditioning coil in a downflow applica­tion, the perforations in the wrapper flanges must be bent in
towards the heat exchanger to allow for the coil duct flange to
recess into the furnace. Refer to the installation instructions
supplied with the air conditioning coil for additional informa­tion and completion of the coil installation.

NOTE: Duct pliers or other suitable tool can be used to bend
perforations. To help bend flanges in a straight line, scribe a
line between the perforations prior to bending.

8 Unitary Products Group

035-17468-001 Rev. A (801)

Horizontal Installations

For installation of an air conditioning coil in a horizontal appli­cation, the perforations in the wrapper flanges must be bent
away from the heat exchanger to create duct flanges so the
air conditioning coil can be properly seated on the furnace.
Refer to the installation instructions supplied with the air con­ditioning coil for additional information and completion of the
coil installation.

NOTE: Duct pliers or other suitable tool can be used to bend
perforations. To help bend flanges in a straight line, scribe a
line between the perforations prior to bending.

DOWNFLOW APPLICATION

DOWNFLOW FILTERS

A top return filter rack is supplied with
the furnace. Two 14" x 20" permanent
washable filters are supplied with each
unit.

Downflow furnaces typically are
installed with the filters located above
the furnace, extending into the return
air duct. See Figure 6.

Any branch duct must attach to the ver­tical ductwork above the filter height
(FH).

The filter rack (provided) should be secured to the center of
the front and rear flanges at the furnace top. Drill a hole
through the front and rear duct flange into the filter rack and
secure it with a sheet metal screw.

Refer to the unit rating plate for furnace model then see the
dimensions page of this instruction for return air plenum
dimensions. Install the plenum following instructions under
Ductwork in this instruction

SUPPLY AIR DUCTS

Installations on combustible material or floors must use a
combustible floor base (shown in Figure 7 - 1CB0317 or
1CB0324) as specified on the rating plate or a matching cool­ing coil. Follow the instructions supplied with the combustible
floor base accessory.

This base can be replaced with a matching cooling coil, prop­erly sealed to prevent leaks. Follow the cooling coil instruc­tions for installing the plenum.

All downflow application supply duct systems must be
designed and installed in accordance with the standards of
NFPA 90A and 90B, and/or all local codes.

FILTER RACK

(FACTORY SUPPLIED)

A

DUCTWORK

A

NOTE: FILTER ACCESS THRU DUCT­WORK MUST BE PROVIDED FOR
REMOVALAND CLEANING

CROSS SECTION A-A

(WITH PLENUM AND FILTERS)

RACK AND FILTERS SECURED
INSIDE BLOWER SECTION
FOR SHIPMENT

CASING SIZE DIMENSION FH

16-1/4 12-3/4

22-1/4 11
26-1/4 8-1/4

FILTERS

FILTER
RACK

FIGURE 6 : DOWNFLOW FILTERS

COMBUSTIBLE FLOOR
BASE ACCE

BRANCH
DUCTS

FH

DOWNFLOW
FURNACE

ARM AIR PLENUM

W

ITH 1" FLANGES

W

FIBERGLASS
INSULATION

FIBERGLASS TAPE
UNDER FLANGE

SSORY

Unitary Products Group 9

FIGURE 7 : Combustible Floor Base Accessory

DOWNFLOW / HORIZONTAL MODELS ­HORIZONTAL APPLICATION

Downflow furnaces may be installed horizontally with the sup­ply airflow toward the left or right by laying the unit on the left
or right side panel.

LINE CONTACT ONLY PERMISSIBLE
BETWEEN LINES FORMED BY THE
INTERSECTION OF FURNACE TOP
AND TWO SIDES AND BUILDING
JOISTS, STUDS OR FRAMING

GAS PIPING

035-17468-001 Rev. A (801)

SUPPLY AIR

VENT (Maintain
required clearances
to combustibles)

SHEET METAL
IN FRONT OF
FURNACE
COMBUSTION AIR
OPENINGS IS
RECOMMENDED

12”

30” MIN.
WORK AREA

Do not install the unit on the rear panel.

After determining the best orientation, lay the unit on top of
the shipping carton to protect the finish. The appropriate elec­trical knock-outs for power wiring, control wiring and gas pip­ing should be removed at this time.

For horizontal application, return air may enter through the
bottom, left side or right side panel or any combination of
these openings. Return air may not be connected into the
rear panel of the unit.

HORIZONTAL FILTERS

All filters and mounting provision must be field supplied. Fil­ter(s) may be located in the duct system external to the fur­nace or in a return filter grille(s). Refer to furnace accessories
on Page 30 for External Filter Kit options.

ATTIC INSTALLATION

This appliance is design certified for line contact for furnaces
installed horizontally. The intersection of the furnace top and
sides form a line. This line may be in contact with combustible
material. Refer to Figure 8.

Secure a platform constructed of plywood or other building
material to the floor joists. Sheet metal, 12" in front of the fur­nace combustion air openings is recommended. (Refer to
Figure 8).

NOTE: The unit must be elevated to allow clearance to the
condensate trap and drain pipe. A minimum of 8” clearance is
required for this purpose.

RETURN AIR

SEDIMENT

TRAP

FIGURE 8 : Typical Attic Installation

When a furnace is installed in an attic or other insu­lated space, keep all insulating materials at least 12"
away from furnace and burner combustion air open­ings.

NOTE: See crawl space installation for suspending the fur­nace in attic installations.

CRAWL SPACE INSTALLATION

The furnace can be hung from floor hoists or installed on suit­able blocks or pad. Blocks or pad installations shall provide
adequate height to ensure the unit will not be subject to water
damage.

When suspending the furnace from rafters or floor joists using
rod, pipe or straps, refer to Physical Data and,Table 3, “UNIT
CLEARANCES TO COMBUSTIBLES,” on Page 6, for fur­nace weights to determine suitable means of suspension.

Angle supports should be placed at the supply air end and
near the blower deck. (Refer to Figure 9.) Do not support at

return air end of unit.

Units may also be suspended by using straps or other mate­rial at the same location. All four suspension points must be
level to ensure quiet furnace operation

If this furnace is installed over a finished space, a
condensate safety pan must be installed.

10 Unitary Products Group

035-17468-001 Rev. A (801)

ANGLE IRON
BRACKET

1” MAX. BETWEEN
ROD & FURNACE

6” MIN BETWEEN
ROD & FURNACE

1” MAX. BETWEEN
ROD & FURNACE

FIGURE 9 : Typical Furnace Installation Using

Suspension Materials

In any application where temperatures below freez­ing are possible, See “BELOW FREEZING LOCA­TIONS” on page 4.

GAS PIPING

SUPPORT
ROD

An overpressure protection device, such as a pres­sure regulator, which conforms to the National Fuel
Gas Code, ANSI Z223.1 (U.S.) or CAN-B149.1 or .2
(Canada) and acts to limit the downstream pressure
to a value that does not exceed 0.5 PSI (14” w.c.),
must be installed in the gas piping system upstream
of the furnace. Failure to do so may result in a fire or
explosion or cause damage to the furnace or some
of its components.

EXTERNAL MANUAL
SHUTOFF VALVE

GROUND JOINT UNION
MAY BE INSTALLED
INSIDE OR OUTSIDE UNIT

TO GAS
SUPPLY

DROP LEG

TO GAS
SUPPLY

The gas supply should be a separate line and must be
installed in accordance with the National Fuel Gas Code,
ANSI Z223.1 (latest edition), or the CAN/CGA B149.1 or .2
Installation Codes (latest edition) and all applicable local and
utility requirements.

Some utility companies or local codes require pipe sizes
larger than the minimum sizes listed in these instructions and
in the codes. Properly sized wrought iron, approved flexible
or steel pipe must be used when making gas connections to
the unit. The installation of a drop leg and ground union is
required (Refer to Figure 10).

Gas piping may be connected from either side of the furnace
using any of the gas pipe entry knockouts on both sides of
the furnace (Refer to Figure 1 for locations and dimensions).

NOTE: Plan your combustion air piping before determining
the correct gas pipe entry. Use 90 degree service elbow(s), or
short nipples and conventional 90 degree elbow(s) to enter
through the cabinet access holes.

INLET GAS PRESSURE RANGE

NATURAL GAS PROPANE (LP)

Minimum 4.5 In. W.C. 11 In. W.C.

Maximum 13.8 In. W.C. 13.8 In. W.C.

NOTE: An accessible manual shutoff valve must be installed
upstream of the furnace gas controls and within 6 feet of the
furnace.

GAS VALVE

FIGURE 10 : Gas Piping

NOTE: A 1/8” NPT plug is included in the inlet side of the gas

valve for measuring incoming gas pressure.

The furnace must be isolated from the gas supply piping sys­tem by closing its individual external manual shutoff valve
during any pressure testing of the gas supply piping system
at pressures equal to or less than 1/2 psig (3.48 kpa).

The furnace and its individual shutoff valve must be discon­nected from the gas supply piping system during any pres­sure testing of that system at test pressures in excess of 1/2
psig (3.48 kpa).

Never apply a pipe wrench to the body of the combi­nation automatic gas valve. A wrench must be
placed on the projection or wrench boss of the valve
when installing piping to it.

Unitary Products Group 11

Compounds used on threaded joints of gas piping
must be resistant to the action of liquefied petroleum
LP gases. After connections are made, leak-test all
pipe connections.

After all gas piping connections are completed, leak
test all joints, fittings and furnace connections with
rich soap and water solution, commercially available
bubble type leak detection fluid, or other approved
means.

Do not use an open flame or other source of
ignition for leak testing.

ELECTRICAL POWER CONNECTION

Field wiring to the unit must conform to and be grounded in
accordance with the provisions of the National Electrical
Code ANSI/NFPA No. 70-latest edition, Canadian Electric
Code C22.1 Part 1 - (latest edition) and/or local codes. Elec­tric wires which are field installed shall conform with the tem­perature limitation for 63°F / 35°C rise wire when installed in
accordance with instructions. Specific electrical data is given
for the furnace on its rating plate and in Table 1 on Page 5 or
Table 2 on Page 6.

Provide a power supply separate from all other circuits. Install
overcurrent protection and disconnect switch per local/
national electrical codes. The switch should be close to the
unit for convenience in servicing. With the disconnect switch
in the OFF position, check all wiring against the unit wiring
label. Also, see the wiring diagrams in this instruction.

NOTE: The furnace’s control system depends on correct
polarity of the power supply and a proper ground connection.
Refer to FURNACE CONTROL DIAGNOSTICS on Page 37,
for symptoms of reversed power supply polarity.

Use copper conductors only.

Connect the power supply as shown on the unit wiring label
on the inside of the blower compartment door and Figure 11
or 12 on Page 12. 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. Also, the green equip­ment ground wire must be connected to the power supply
ground.

Remove the screws retaining the wiring box cover. Route the
power wiring through the opening in the unit into the junction
box with a conduit connector or other proper connection.
Make wiring connections referring to Figure 11 or 12 and
replace the junction box cover and screws.

035-17468-001 Rev. A (801)

GND.

N

L1
(HOT)

WHT

GRN

BLK

JUNCTION BOX

DOOR SWITCH

CLASS 2 SYSTEM
CONTROL WIRING
TO THERMOSTAT

IGNITION MODULE

HUM (HOT)

EAC (HOT)

CFM/TIMER
BOARD

BLK/BLK
WHT/WHT
GRN/GRN

HUM

EAC

WIRING INSIDE
JUNCTION BOX

BURNER
COMPARTMENT

BLOWER

COMPARTMENT

FIGURE 11 : Electrical Wiring - Upflow Models

JUNCTION
BOX

BLOWER COMPARTMENT

IGNITION MODULE

TRANSFORMER

DOOR
SWITCH

BURNER COMPARTMENT

L1
(HOT)

BLK

N

WHT

HUM (HOT)

GND

GRN

EAC (HOT)

WIRING INSIDE
JUNCTION BOX

VENT PIPE

CLASS 2 SYSTEM
CONTROL WIRING
TO THERMOSTAT

BLK/BLK
WHT/WHT
GRN/GRN

FLUE
CHASE

FIGURE 12 : Electrical Wiring - Downflow / Horizontal

Models

An alternate wiring method is to use a field provided 2 x 4 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.

12 Unitary Products Group