Coleman UGAB100BUJ, UGAB075BUJ, UGAA075BUJ Installation Guide

......................................... I-I ', H', ,'1.-¢" 'l.I

HIGH EFFICIENCY
CLAM TUBE HEAT EXCHANGER SERIES

MODELS: UGAA/UGAB

ISO 9001

(Single Stage Multi-Position)

75- 100 MBH INPUT
(21.98 - 29.31 KW) INPUT

!

LIST OF SECTIONS

SAFETY ................................................ 1 TWINNING AND STAGING ................................ 15

DUCTWORK ............................................ 4 VENT/COMBUSTION AIR SYSTEM ......................... 16

FILTERS .............................................. 10 SAFETY CONTROLS .................................... 22

GAS PIPING ........................................... 11 START-UP AND ADJUSTMENTS ........................... 22

ELECTRICAL POWER ................................... 13 WIRING DIAGRAM ...................................... 29

LIST OF FIGURES

Upflow/Horizontal Configuration .............................. 5

Downflow/Horizontal Configuration ........................... 5

Vent Blower ............................................. 6

Top Cap ................................................ 6

Dimensions ............................................. 7

Combustible Floor Base Accessory ........................... 8

Typical Attic Installation .................................... 9

Typical Suspended Furnace ! Crawl Space Installation ............ 9

Side Return Cutout Markings ............................... 10

Horizontal Mount and Filter ................................ 10

Downflow Filter .......................................... 10

Return Filter Grill and Return Duct Installation .................. 11

Gas Valve .............................................. 11

Upflow Configuration ..................................... 11

Downflow Configuration ................................... 12

Gas Piping ............................................. 12

Burner Assembly ........................................ 12

Electrical Wiring - Upflow Position ........................... 14

Single Stage Heat Thermostat Connections ................... 14

Accessory Connections ................................... 14

Typical Twinned Furnace Application ......................... 15

Single Stage Twinning Wiring Diagram ....................... 16

Two-Stage Twinning Wiring Diagram ......................... 16

Vent Termination ........................................ 16

Vent Termination ........................................ 17

Alternate Air Intake, Air Outlet and Chimney Connections ......... 17

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

Typical Sidewall Vent Application ............................ 18

Typical Sidewall Vent and Termination Configuration ............ 18

Typical Chimney Connections .............................. 18

Horizontal Air Inlet, Outlet and Chimney Connections ............ 18

Home Layout ........................................... 19

Combustion Airflow Path Through The Furnace

Casing to the Burner Box .................................. 20

Outside and Ambient Combustion Air ......................... 21

Pressure Switch Tubing Routing ............................ 22

Gas Valve .............................................. 25

Reading Gas Pressure .................................... 25

Furnace Control Board .................................... 26

Wiring Diagram .......................................... 29

Certified Quality

Management System

LIST

Unit Clearances to Combustibles ............................. 4

Minimum Duct Sizing For Proper Airflow ....................... 6

External Static Pressure Range .............................. 7

Cabinet and Duct Dimensions ............................... 7

Recommended Filter Sizes ................................ 10

High Altitude Conversion .................................. 13

Ratings & Physical ! Electrical Data - Upflow Models ............ 14

Roof Pitch .............................................. 17

Horizontal Sidewall Venting Clearances ...................... 18

SECTION h SAFETY

This is a safety alert symbol. When you see this symbol on

labels or in manuals, be alert to the potential for personal
injury.

Understand and pay particular attention to the signal words DANGER,

WARNING, or CAUTION.
DANGER indicates an imminently hazardous situation, which, if not

avoided, will result in death or serious iniurv.
WARNING indicates a potentially hazardous situation, which, if not

avoided, could result in death or serious iniurv.
CAUTION indicates a potentially hazardous situation, which, if not

avoided mav result in minor or moderate iniurv. It is also used to

alert against unsafe practices and hazards involving only property dam-
age.

OF TABLES

Estimated Free Area ...................................... 20

Free Area .............................................. 20

Unconfined Space Minimum Area in Square Inches ............. 20

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

Inlet Gas Pressure Range ................................. 25

Nominal Manifold Pressure ................................. 25

Filter Performance - Pressure Drop Inches W.C. and (kPa) ........ 27

Blower Performance - CFM ................................ 28

_WARNING

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 mainte-
nance can cause injury or property damage. Refer to this manual
for assistance or for additional information, consult a qualified con-
tractor, installer or service agency.

CAUTION

This product must be installed in strict compliance with the installa-
tion instructions and any applicable local, state, and national codes
including, but not limited to building, electrical, and mechanical

codes.

288130-UIM-A-0407

288130-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.

2. Install this furnace only in a location and position as specified in
SECTION I of these instructions.

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

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

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

TION VII of these instructions.

_WARNING

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.

6. Test for gas leaks as specified in SECTION Xl of these instruc-
tions.

7. Always install the furnace to operate within the furnace's intended
temperature rise range. Only connect the furnace to a duct system

which has an external static pressure within the allowable range,
as specified on the furnace rating plate.

8. When a furnace is installed so that supply ducts carry air circulated
by the furnace to areas outside the space containing the furnace,

the return air shall also be handled by duct(s) sealed to the fur-
nace casing and terminating outside the space containing the fur-

nace.

9. 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;
Furnace operating under thermostatic control;

Return air duct sealed to the furnace;

• 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.

10. When installed in a Non-HUD-Approved Modular Home or building
constructed on-site, combustion air shall not be supplied from

occupied spaces.

11. The size of the unit should be based on an acceptable heat loss
calculation for the structure. ACCA, Manual J or other approved

methods may be used.

12. Mobile Home Installations:
This appliance must be installed with a vent terminating in the

same atmospheric zone, external to the building.

13. Modular and Manufactured (Mobile) Home Installations:
This appliance must be installed so that the vent pipe from the

vent connection on the furnace can be easily connected to a B
type vent that terminates outdoors. This appliance cannot be con-

nected to a vent that is serving another appliance. This appliance
shall be installed in an area where there is an adequate supply of

combustion air available to assure proper combustion and ambient
air temperatures are maintained within safe operating limits.

If an adequate supply of combustion air is not available to assure
proper combustion and ventilation air, outside air shall be intro-

duced to the space in which the appliance is located. An outside
combustion air duct may be used to provide the outside air to the

space. Refer to ANSI Z223.1 National Fuel Gas Code or in Can-
ada B149-00 National Gas and Propane Installation Code for

proper duct sizing and installation.

NOTE: Air for combustion must never be taken from occupied spaces.

Appliance combustion air must be provided from outdoors.

14. Modular Home Definition:
Factory-built home constructed to the state, local, or regional code

where the house will be located. The home is transported in one or
more modules and joined at the home site.

15. Mobile Home Definition:
Factory-built home constructed, transported, and installed under

the federal building code administered by the U.S. Department of
Housing and Urban Development (HUD Code), rather than to

building codes at their destination. The house is built, transported,
and installed on a non-removable chassis.

16. This furnace is not approved for installation in trailers or recre-
ational vehicles.

SAFETY REQUIREMENTS

• This furnace should be installed in accordance with all national
and local building/safety codes and requirements, local plumbing

or wastewater codes, and other applicable codes. In the absence
of local codes, install in accordance with the National Fuel Gas

Code ANSI Z223.1/NFPA 54, National Fuel Gas Code, and!or
CAN/CGA B149.1 Natural Gas and Propane Installation Code
(latest editions). Furnaces have been certified to the latest edition

of standard ANSI Z21-47 • CSA 2.3.

• A manufactured (mobile) home installation must conform with the

Manufactured Home Construction and Safety Standard, Title 24
CFR, Part 3280, or when such standard is not applicable, the

standard for Manufactured Home Installations (Manufactured

Home Sites, Communities, and Set-ups) ANSI/NCS A225.1, and/

or the Canadian Standard for CAN/CSA Z240 MH, Series M92

Mobile Homes. Furnaces have been certified to the latest edition

of standard ANSI Z21-47 • CSA 2.3.

Refer to the unit rating plate for the furnace model number, and

then see the dimensions page of this instruction for return air ple-

num dimensions in Figure 5. The plenum must be installed

according to the instructions.

Provide clearances from combustible materials as listed under
Clearances to Combustibles.

Provide clearances for servicing ensuring that service access is

allowed for both the burners and blower.

• These models ARE NOT CSA listed or approved for installation

into a HUD APProved Modular Home or a Manufactured

(Mobile) Home.

• This furnace is not approved for installation in trailers or 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.

2 Unitary Products Group

Furnaces for installation on combustible flooring shall not be
installed directly on carpeting, tile or other combustible material

other than wood flooring.

Check the rating plate and power supply to be sure that the 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 installed 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

If outdoor air is used for combustion, the combustion air intake duct sys-
tem termination must be located external to the building and in an area
where there will be no exposure to the substances listed above.

288130-UIM-A-0407

,&WARNING

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 foflowing 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.

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 detectors
a. In 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. In 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

with the provisions of 248 CMR 5.08(2)(a)1 through 4.

Unitary Products Group 3

288130-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, and any shipping or spacer brackets which

need to be removed.

FURNACE LOCATION AND CLEARANCES
The furnace shall be located usina the followina auidelines:

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

2. As centralized with the air distribution as possible.

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

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

5. Where the outdoor vent terminal will not be blocked or restricted.
Refer to "VENT CLEARANCES" located in SECTION VII of these

instructions. These minimum clearances must be maintained in
the installation.

6. Where the unit will be installed in a level position with no more than
1/4" (0.64 cm) slope side-to-side and front-to-back to provide

proper condensate drainage.

Installation in freezina temperatures:

1. Furnace shall be installed in an area where ventilation facilities
provide for safe limits of ambient temperature under normal oper-

ating conditions. Ambient temperatures falling below 32° F (0° C)
may result in the flue temperature falling below 260 ° F (127 ° C) at

any point in the flue pipe between the furnace and the chimney or
a B-Vent. The flue products will condense in the vent pipe if the

flue temperature falls below 260 ° F (127 ° C) causing the vent pipe
to deteriorate rapidly.

2. Do not allow return air temperature to be below 550 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.

TABLE 1: Unit Clearances to Combustibles

,&WARNING

Improper installation in an ambient below 32°F (0.0 ° C) could create

a hazard, resulting in damage, injury or death.

3. If this furnace is installed in an unconditioned space and an
extended power failure occurs, there will be potential damage to

the internal components. Following a power failure situation, do
not operate the unit until inspection and repairs are performed.

Clearances for access:
Ample clearances should be provided to permit easy access to the unit.

The following minimum clearances are recommended:

1. Twenty-four (24) inches (61 cm) between the front of the furnace
and an adjacent wall or another appliance, when access is

required for servicing and cleaning.

2. Eighteen (18) inches (46 cm) at the side where access is required
for passage to the front when servicing or for inspection or replace-

ment of flue/vent connections.

In all cases, accessibility clearances shall take precedence over clear-

ances for combustible materials where accessibility clearances are
greater.

,&WARNING

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

other combustible material.
Check the rating plate and power supply to be sure that the 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.

Installation in a residential aaraee:
A gas-fired furnace for installation in a residential garage must be

installed so the burner(s) and the ignition source are located not less
than (18) inches (46 cm) above the floor, and the furnace must be
located or protected to avoid physical damage by vehicles.

Application

Upflow 1 (2.5) 2 (5.1) 0 (0.0) 0 (0.0) 6(15.2)

Upflow B-Vent 1(2.5) 3 (7.6) 0 (0.0) 0 (0.0) 6 (15.2)

Horizontal 1 (2.5) 2 (5.1) 0 (0.0) 1 (5.08) 6 (15.2)

Horizontal B-Vent 1 (2.5) 3 (7.6) 0 (0.0) 0 (0.0) 6 (15.2)

Downflow 1 (2.5) 2 (5.1) 0 (0.0) 0 (0.0) 6(15.2)

Downflow B-Vent 1 (2.5) 3 (7.6) 0 (0.0) 0 (0.0) 6 (15.2)

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

SECTION Ih DUCTWORK

DUCTWORK GENERAL INFORMATION
The duct system's design and installation must:

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

2. Be installed in accordance with standards of NFPA (National Fire
Protection Association) as outlined in NFPA pamphlets 90A and

90B (latest editions) or applicable national, provincial, or state, and
local fire and safety codes or in Canada, refer to the Natural Gas

and Propane Installation Code B149.1-00.

Top Front Rear Sides Single Wall Vent

In, (cm) In, (cm) In, (cm) In, (cm) In, (cm)

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-

tioned space.

5. For manufactured (mobile) home and modular home return
duct system installation: The return air duct and the return air

plenum are required by the furnace manufacturer.

Floor/ Line

Bottom Contact

Combustible Yes Yes Yes No
Combustible Yes Yes Yes No

Combustible No Yes Yes Yes1

Combustible No Yes Yes Yes1
Non-Combustible Yes Yes Yes No
Non-Combustible Yes Yes Yes No

Closet Alcove Attic

4 Unitary Products Group

[,& CAUTION

The cooling coil must be installed in the supply 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.

AWARNING

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.

288130-UIM-A-0407

14. Remove the rectangular knockout in the center of the top cap. See
Figure 4.

15. Install the top cap at the same end of the furnace as the vent
blower, using the sheet metal screws saved earlier. See Figure 1.

16. Install the bottom cap on the bottom of the furnace using the sheet
metal screws saved earlier. See Figure 1.

17. The conversion is now complete. The furnace may now be
installed in the upflow position or in the horizontal position on

either side.

TRANSITION

TOP j_ VENT

EXTRA PRESSURE

SCREWS

GASKET /

CAP

_i : ::::: PAN

' k J/ ,b; =- = e

J HOSE

/i

PRESSURE

SWITCH

VENT

BLOWER

i

INSTALLATION POSITION

This furnace may be installed in an upflow, downflow or horizontal posi-
tion. Depending on the configuration shipped from the factory, it may be
necessary to convert the furnace from downflow to upflow or from
upflow to downflow configuration. Use conversion instructions in this

document.

CONVERSION INFORMATION

This furnace may be shipped in either the upflow or the downflow con-
figuration. To convert from upflow to downflow or vice-versa it is neces-
sary only to exchange the top and bottom casing caps and to rotate the
vent blower 180 degrees. Use the step by step instructions to perform

the conversion.

TO CONVERT FROM DOWNFLOW TO UPFLOW
CONFIGURATION

1. Lay the furnace on its back.

2. Remove the front door.

3. Remove the seven sheet metal screws that are used to fasten the
top cap to the casing. Remove the top cap and save the screws.

4. Remove the four sheet metal screws that are used to fasten the
bottom cap to the casing. Remove the bottom cap and save the

screws.

5. Unplug the vent blower wires.

6. Disconnect the pressure hose from the vent blower.

7. Remove the four machine screws that fasten the vent blower to
the vent pan and save the screws. Leave the gasket in place on

the pan.

8. Remove the two extra machine screws in the vent pan front and
save the screws.

9. Rotate the vent blower and transition 180° so that its outlet points
to the outlet air end of the furnaces as shown in Figure 1.

10. Line up the vent blower mounting holes with the holes in the vent
pan and screw it into place. Use the same machine screws that

held the vent blower in place previously.

11. Install the two extra machine screws in the two open holes in the
front of the vent pan See Figure 1.

12. Plug in the vent motor wires.

13. Plug the pressure hose into the vent blower.

BOTTOM

j CAP

FIGURE 1: Upflow/Horizontal Configuration

TOP

CAP

TRANSITION

BOTTOM

CAP \_

/ /

PRESSURE VENT EXTRA VENT

HOSE PAN SCREWS BLOWER

/

_GASKET

FIGURE 2: Downflow/Horizontal Configuration

TO CONVERT FROM UPFLOW TO DOWNFLOW
CONFIGURATION

1. Lay the furnace on its back.

2. Remove the front door.

3. Remove the seven sheet metal screws that are used to fasten the
top cap to the casing.

4. Remove the four sheet metal screws that are used to fasten the
bottom cap to the casing. Remove the bottom cap and save the

screws.

Unitary Products Group 5

288130-UIM-A-0407

5. Unplug the vent blower wires.

6. Disconnect the pressure hose from the vent blower.

7. Remove the four machine screws that fasten the vent blower to
the vent pan and save the screws. Leave the gasket in place on

the vent pan.

8. Remove the two extra machine screws in the vent pan front and
save the screws.

9. Install the cast aluminum transition on the vent blower, using the
three screws supplied on the vent blower. See Figure 3.

TRANSITION-

FIGURE 3: Vent Blower

10. Rotate the vent blower 1800so that its outlet points toward the inlet
air end of the furnace. See Figure 2.

11. Line up the vent blower mounting holes with the holes in the vent
pan and screw it into place. Use the same machine screws that
held the vent blower in place previously.

12. Install the two extra machine screws in the two open holes in the
front of the vent pan. See Figure 2.

13. Plug in the vent motor wires.

14. Plug the pressure hose into the vent blower.

15. Remove the round knockout at the right side of the top cap. See
Figure 4.

UPFLOW _ VENT

VENT _ _ .......... _C:.. OPENING

OPENING ...... ........._ .........

FIGURE 4: Top Cap

16. Install the top cap at the opposite end of furnace from the vent
blower, using the seven sheet metal screws saved earlier. See

Figure 2.

17. Install the bottom cap on the bottom of the furnace using the sheet
metal screws saved earlier. See Figure 2,

18. The conversion is now complete. The furnace may now be
installed in the downflow position or in the horizontal position on

either side.

DOWNFLOW

FLOOR BASE AND DUCTWORK INSTALLATION
Upflow Instructions

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 recom-
mended on all installations. This connection should be

sealed to prevent air leakage. The sheet metal should
be cross-hatched to eliminate any popping of the
sheet metal when the indoor fan is energized.

When replacing an existing furnace, if the existing plenum is not the
same size as the new furnace then the existing plenum must be
removed and a new plenum installed that is the proper size for the new
furnace. If the plenum is shorter than 12" (30.5 cm) the turbulent air flow
may cause the limit controls not to operate as designed, or the limit con-
trols may not operate at all.

The duct system is a very important part of the installation. If the duct
system is improperly sized the furnace will not operate properly.
The ducts attached to the furnace plenum, should be of sufficient size
so that the furnace operates at the specified external static pressure
and within the air temperature rise specified on the nameplate.

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

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

the furnace.

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

2. The square inch area for 7 inch round pipe is 38.4, multiply by 2 for
two round ducts which equals 76.8 square inch.

3. Then take the 224 square inch from the rectangular duct and add it
to the 76.8 sq.in, of round duct. The total square inch of duct

attached to the furnace plenum is 300.8 square inch. This exceeds
the recommended 280 square inch of duct.

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

Consideration should be given to the heating capacity required and also
to the air quantity (CFM) required. These factors can be determined by
calculating the heat loss and heat gain of the home or structure. If these
calculations are not performed and the furnace is over-sized, the follow-
ing may result:

1. Short cycling of the furnace.

2. Wide temperature fluctuations from the thermostat setting.

3. Reduced overall operating efficiency of the furnace.

The supply and return duct system must be of adequate size and
designed such that the furnace will operate within the designed air tem-
perature rise range and not exceed the maximum designed static pres-

sure. These values are listed Tables 2 and 3.
TABLE 2: Minimum Duct Sizing For Proper Airflow

Input Airflow Return I Rectangular 2 Round 2 Supply 3

BTU/H CFM In_ in. x in. in. In_

(kW) (m3) (cm 2) (cm x cm) (cm) dia. (cm2)
75,000 1,200 280 14 x 20 18 216
(21.98) (33.98) (1806) (35.6 x 50.8) (45.7) (1394)

75,000 1,600 360 18 x 20 22 280
(21.98) (45.31) (2322) (45.7 x 50.8) (55.8) (1806)

100,000 1,600 360 18 x 20 22 280

(29.31) (45.31) (2322) (45.7 x 50.8) (55.8) (1806)

NOTE: This chart does not replace properduct sizing calculationsor take into
account static pressure dropfor run length andfittings. Watch outfor thetemper-
ature rise and static pressures.

1. Maximum return air velocity in rigid duct @ 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 (274 m/min)

6 Unitary Products Group

288130-UIM-A-0407

TABLE 3: External Static Pressure Range

Input

MBH kW

75 22.0
75 22.0

100 29.3

TABLES 2 and 3 are to be used as a guide only to help the installer
determine if the duct sizes are large enough to obtain the proper air flow
(CFM) through the furnace. TABLES 2 and 3 ARE NOT to be used to
design ductwork for the building where the furnace is being installed.
There are several variables associated with proper duct sizing that are
not included in the tables. To properly design the ductwork for the build-
ing, Refer to the ASHRAE Fundamentals Handbook, Chapter on
"DUCT DESIGN" or a company that specializes in Residential and Mod-
ular Home duct designs.

IMPORTANT: The minimum plenum height is 12" (30.5 cm). The fur-
nace will not operate properly on a shorter plenum height. The mini-

mum recommended rectangular duct height is 4 inches (10 cm)
attached to the plenum.

Nominal
AirFlow

CFM cmm
1200 34.0

1600 45.3
1600 45.3

DOWNFLOW

Ext. Static Pressure

Minimum Maximum

In,W,C kPa In,W,C kPa

0.12 0.0299 0.50 0.1245

0.12 0.0299 0.50 0.1245

0.15 0.0374 0.50 0.1245

IMPORTANT: The air temperature rise should be taken only after the
furnace has been operating for at least 15 minutes. Temperatures and

external static pressures should be taken 6" (15 cm) past the first bend
from the furnace in the supply duct and the return duct. If an external fil-

ter box or an electronic air cleaner is installed, take the return air read-
ings before the filter box or air cleaner.

kWARNING

The supply air temperature MUST NEVER exceed the Maximum

Supply Air Temperature, specified on the nameplate.
Operating the furnace above the maximum supply air temperature
will cause the heat exchanger to overheat, causing premature heat
exchanger failure. Improper duct sizing, dirty air filters, incorrect
manifold pressure, incorrect gas orifice and/or a faulty limit switch
can cause the furnace to operate above the maximum supply air
temperature. Refer to sections II, III and IX for additional informa-
tion on correcting the problem.

If a matching cooling coil is used, it may be place 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 remov-
able 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.

UPFLOW

i 3%1/2

BOTTOM VIEW

FIGURE 5: Dimensions

TABLE 4: Cabinet and Duct Dimensions

BTUH (kW)

Input

75 (22.0)

75 (22.0

100 (29.3)

BTUH (kW)

Input

75 (22.0)
75 (22.0)

100 (29.3)

1. All models are supplied with 3" (7.62 cm) vent connections. An installer supplied transition to 4" (10.16 cm) or 5" (12.7 cm) must be used where necessary.
* Dimensions "B", "C", "D", and "E" are with duct flanges turned up. "F", "G", "H", & "J" are with flanges flat.

Nominal Cabinet Cabinet Dimension

CFM (m3/min) Size A(in.) A(cm) B(in.) B(cm) C(in.) C(cm) D(in.) D(cm) E(in.) E(cm)

1200 (34.0) B 17 1/2 44.5 16 1/2 41.9 20 3/8 51.8 20.0 50.8 16 40.6
1600 (45.3) C 21 53.3 20 50.8 20 3/8 51.8 20.0 50.8 19 1/2 49.5
1600 (45.3) C 21 53.3 20 50.8 20 3/8 51.8 20.0 50.8 19 1/2 49.5

Nominal Cabinet K Vent K Vent

CFM (m3/min) Size F(in.) F(cm) G(in.) G(cm) H(in.) H(cm) J(in.) J(cm) (in.) (cm)

1200 (34.0) B 14 3/4 37.46 18 3/4 47.62 15 1/8 38.4 19.0 48.2 41 10.161
1600 (45.3) C 18 1/4 46.35 18 3/4 47.62 18 5!8 47.3 19.0 48.2 41 10.161
1600 (45.3) C 18 1/4 46.35 18 3/4 47.62 18 5!8 47.3 19.0 48.2 41 10.161

BOTTOM VIEW

Unitary Products Group 7

288130-UIM-A-0407

RESIDENTIAL AND NON HUD MODULAR HOME
UPFLOW RETURN PLENUM CONNECTION

Return air may enter the furnace through the side(s) or bottom depend-
ing on the type of application. Return air may not be connected into the
rear panel of the unit. For single return application, see data and notes
on blower performance data tables in this manual.

BOTTOM RETURN AND ATTIC INSTALLATIONS

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

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

1. Lay the furnace on its back.

2. Remove the screws from the toe plate.

3. Remove the toe plate.

4. Pull the base plate out of the furnace base.

5. Reinstall the toe plate and secure with the screws that were
removed.

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

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

FLOOR BASE AND DUCTWORK INSTALLATION
Downflow Combustible Floor Base

Installations on combustible material or floors must

use a combustible floor base shown in Figure 6. The
perforations in the wrapper flanges must be bent in
towards the heat exchanger to allow for the coil duct
flange to recess into the furnace Follow the instruc-
tions supplied with the combustible floor base acces-
sory. This combustible floor base can be replaced with

a matching cooling coil, properly sealed to prevent
leaks. Follow the instructions supplied with the cooling coil cabinet for
installing the cabinet to the duct connector. Refer to the installation

instructions for additional information.

Downflow Duct Connectors

DOWNFLOW

FURNACE

iI WARM AIR PLENUM

J WITH 1" FLANGES

__ FIBERGLASS

INSULATION

FIBERGLASS TAPE

_/ UNDER FLANGE

-- COMBUSTIBLEFLOOR
BASEACCESSORY

FIGURE 6: Combustible Floor Base Accessory

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

nectors.
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.

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

Downflow Air Conditioning Coil Cabinet
The furnace should be installed with coil cabinet part number specifi-

cally intended for downflow application. If a matching cooling coil is
used, it may be placed directly on the furnace outlet and sealed to pre-
vent leakage. For details of the coil cabinet dimensions and installation
requirements, refer to the installation instructions supplied with the coil

cabinet.
The perforations in the wrapper flanges must be bent away from the

heat exchanger to create duct flanges so the air conditioning coil can be
properly seated on the furnace. Attach the air conditioning coil cabinet
to the duct connector, and then position the furnace on top of the coil
cabinet. The connection to the furnace, air conditioning coil cabinet,
duct connector, and supply air duct must be sealed to prevent air leak-
age.

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.

RESIDENTIAL AND NON HUD MODULAR HOME
DOWNFLOW RETURN PLENUM CONNECTION

The return duct system must be connected to the furnace inlet and the
return duct system must terminate outside the space containing the 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 pressure and within the air

temperature rise specified on the nameplate.
IMPORTANT: If an external mounted filter rack is being used see the

instructions provided with that accessory for proper hole cut size.

HORIZONTAL MODELS

//

Ls_f

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 With a Cooling Coil Cabinet
The furnace should be installed with coil cabinet part number specifi-

cally intended for Horizontal application. If a matching cooling coil is
used, it may be placed directly on the furnace outlet and sealed to pre-

vent leakage. Follow the coil instructions for installing the supply ple-
num. For details of the coil cabinet dimensions and installation

requirements, refer to the installation instructions supplied with the coil
cabinet

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

properly seated on the furnace.

8 Unitary Products Group

288130-UIM-A-0407

Attach the supply plenum to the air conditioning coil cabinet outlet duct
flanges through the use of S cleat material when a metal plenum is
used. The use of an approved flexible duct connector is recommended
on all installations. The connection to the furnace, air conditioning coil
cabinet and the supply plenum should be sealed to prevent air leakage.
The sheet metal should be crosshatched to eliminate any popping of
the sheet metal when the indoor fan is energized.

The minimum plenum height is 12" (30.5 cm). If the plenum is shorter
than 12" (30.5 cm) the turbulent air flow may cause the limit controls not
to operate as designed, or the limit controls may not operate at all. Also
the plastic drain pan in the air conditioning coil can overheat and melt.
Refer to the installation instructions supplied with the air conditioning

coil for additional information.

Horizontal Installations Without a Cooling Coil Cabinet

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

Residential and Non Hud Modular Home Horizontal Return
Plenum Connections

The return duct system must be connected to the furnace inlet and the
return duct system must terminate outside the space containing the 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 pressure and within the air

temperature rise specified on the nameplate.
Attic installations must meet all minimum clearances to combustibles
and have floor support with required service accessibility.

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

ATTIC INSTALLATION

LINE CONNECT ONLY PERMISSIBLE BETWEEN
LINES FORMED BY THE INTERSECTION OF
FURNACE TOP AND TWO SIDES AND BUILDING

JOISTS, STUDS, OR FRAMING

FILTER RACK MUST f , /; --_

BEAMINIMUM DISTANCE J .... (_ /_ _']

OF 18" (45.7 CM) FROM / I I t_ /

T.EFURNAOE ,, IV/

TRAP / ___Z2/PLYWOOD

FIGURE 7: Typical Attic Installation

This appliance is design certified for line contact when the furnace is
installed in the horizontal left or right position. The line contact is only
permissible between lines that are formed by the intersection of the top
and two sides of the furnace and the building joists, studs or framing.
This line may be in contact with combustible material.

"_-_-_ FLOOR

SHEET METAL IN FRONT OFFURNACE COMBUSTION
AIR OPENINGS IS RECOMMENDED

_WARNING

When a furnace is installed in an attic or other insulated space,
keep all insulating materials at least 12 inches (30.5 Cm) away from
furnace and burner combustion air openings.

SUSPENDED FURNACE / CRAWL SPACE
INSTALLATION

The furnace can be hung from floor joists or installed on suitable blocks
or pad. Blocks or pad installations shall provide adequate height to
ensure the unit will not be subject to water damage. Units may also be
suspended from rafters or floor joists using rods, pipe angle supports or
straps. Angle supports should be placed at the supply air end and near
the blower deck. Do not support at return air end of unit. All four sus-
pension points must be level to ensure quiet furnace operation. When
suspending the furnace use a secure platform constructed of plywood
or other building material secured to the floor joists. Refer to Figure 8
for typical crawl space installation.

\

BRACKETX-- II I I

II RT

1" MAN. BETWEEN 6" MIN BETWEEN 1" MAX.BETWEEN
ROD & FURNACE ROD & FURNACE ROD & FURNACE

FIGURE 8: Typical Suspended Furnace / Crawl Space Installation

Unitary Products Group 9

288130-UIM-A-0407

SECTION IIh FILTERS

FILTER INSTALLATION

All applications require the use of a filter.
TABLE 5: Recommended Filter Sizes

UPFLOW

Input

MBH

75
75

100

DOWN FLOW

MBH kW

75 22.0 B
75 22.0 C

100 29.3 C

NOTES:

1.Air velocity through throwaway type filters may not exceed 300 feet per minute.

2.Air flows above 1800 CFM require either return from two sides or one side plus

kW

22.0

22.0

29.3

In _ut

Air Flow

CFM m3/min
1200 34.0

1600 45.3
1600 45.3

Air Flow

CFM m3/min
1200 34.0

1600 45.3
1600 45.3

Cabinet

Size

B
C
C

Cabinet Size

Side

Return

in,

25x 16
25x 16
25x 16

Top Return (Downflow)

Cleanable Air Filters

in. cm

14 x 20 (2) 36 x 51
16x20 (2)41 x51
16x20 (2)41 x51

All velocities over this require the use of high velocity filters.
bottom.

cm

64 x41
64 x41
64 x41

in.

25x 16
25 x 20
25 x 20

Top Return (Downflow)

Disposable Air Filters

in. cm

(2) 14 x 20 (2) 36 x 51
(2) 16x20 (2)41 x51
(2) 16 x 20 (2) 41 x 51

Bottom/End

Return

cm

64 x41
64 x 51
64 x 51

SIDE RETURN/BOTTOM EXTERNAL INSTALLATION

Locate and knock out the square corner Iocators. These indicate the
size of the cutout to be made in the furnace side panel. Refer to Figure 9.

FURNACE

ER
INGS

FIGURE 9: Side Return Cutout Markings

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

nal to the cabinet.
Some accessories such as electronic air cleaners and pleated media

may require a larger side opening. Follow the instructions supplied with
that accessory for side opening requirements. Do not cut the opening
larger than the dimensions shown in Figure 5.

EXTERNAL INSTALLATION FOR
UPFLOW/HORIZONTAL CONFIGURATIONS

1. Select desired filter position for upflow/horizontal (left/right side,
side and bottom). Remove the corresponding cabinet cutouts per

instructions provided.

2. Install the external filter box to the side of the cabinet and secure
to the cabinet as specified in the instructions provided with the air

filter kit. If a side return is to be used, cut out the side of the casing
14" high by 16 1/4" wide using the lances in the casing side as a

guide. DO NOT CUT THE OPENING LARGER THAN 14" X 16 1!
4". It is not permissible to cut out the back of the furnace. For bot-

tom returns you place the external filter box between the return air
plenum and the base of the furnace. The casing bottom is

embossed to indicate where to bend the flanges. Refer to Figure 5
for the maximum return air opening sizes. Seal this connection to

prevent leaks.
Do not cut the opening larger than the dimensions shown in Figure

5.

3. Install the return air duct to the air filter box and secure with
screws. Seal this connection to prevent leaks.

4. Install the field provided filter. Refer to Table 5 for the recom-
mended filter size for your furnace.

NOTE: Air velocity must not exceed 300 feet per minute through low
velocity disposable filters. Air velocity must not exceed 650 feet per
minute through high velocity cleanable permanent filters. Use of a filter
that is too small will cause static pressure in the duct system to be too
high, which will have an adverse effect on heating and cooling opera-

tion.

RETURN
DUCT

AIR _lJ

FILTER

FIGURE 10: Horizontal Mount and Filter

I% N-,t

[]
[]
[]

[]
[]

[]
[]
[]

/_ FILTER RACK

FURNACE

Di

[]

RACK AND FILTERS SECURED

...... SECT,ON

NOTE: FILTERACCESS THROUGH (

_ DUCTWORK MUST BE PROVIDED _ BRANCH

/ FOR REMOVALAND CLEANING _ DUCTS

(
',, FILTERS

DUCTWORK

CROSS SECTION A-A

(with Plenum and filters)

FIGURE 11: Downflow Filter

10 Unitary Products Group

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 )lenum must attach to
the vertical plenum above the filter height. Refer to Figure 11 for proper

installation.
Filter(s) may be located in the duct system external to the furnace using

an external duct filter box attached to the furnace plenum or at the end
of the duct in a return filter grille(s). The use of straps and ! or supports
is required to support the weight of the external filter box. Refer to Fig-

ure 10.
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 (2.5 cm) from the top of the return air opening on the

furnace. Refer to the instructions supplied with the electronic air
cleaner.

If pleated media air filters or any filter that has a large pressure drop is
installed in the return air duct system be sure that the pressure drop
caused by the air filter will not prevent the furnace from operating within
the rise range specified on the rating plate. If the furnace does not 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. Refer to Table 13 and
the furnace accessories for accessory external filter kit options.

IMPORTANT: For easier filter access in a downflow configuration, a
removable access panel is recommended in the vertical run of the

return air plenum immediately above the furnace.

.-"" i "",. _ CLOSET

::. "-... RETURN

VENT_ T" " FILTERS
PIPE : _! :

288130-UIM-A-0407

kWARNING

For applications requiring more than 1800 CFM, it is required to use
both side returns or one side plus the bottom return.

Single side return is not approved on 5 Ton models.
18" minimum height for return air box for bottom return only or
Heating only appfications with furnace in the upflow configuration
24" minimum height for return air box for bottom return only on A.

C appfications with furnace in the upflow configuration.

SECTION IV: GAS PIPING

GAS SAFETY

This furnace is designed to operate on NATURAL GAS or PRO-
PANE GAS ONLY. Do not bum any other fuel in this furnace. Burn-
ing any fuel except NATURAL GAS or PROPANE GAS can cause
premature heat exchanger burnout, high levels of carbon monox-
ide, excessive sooting, a fire hazard, personal injury, property dam-
age and/or death.

kDANGER

An overpressure protection device, such as a pressure regulator,
must be installed in the gas piping system upstream of the furnace
and must act to limit the downstream pressure to the gas valve so it
does not exceed 0.5 PSI (14" w.c. (3.48 kPa). Pressures exceeding

0.5 PSI (14" w.c. (3.48 kPa) at the gas valve will cause damage to
the gas valve, resulting in a fire or explosion or cause damage to
the furnace or some of its components that will result in property
damage and loss of life.

OUTLET __

PRESSURE

PORT i

VENT PORT

I.

WRENCH J _

BOSS INLET// __

PRESSURE
PORT

FIGURE 13: Gas Valve

ON/OFF SWITCH
(Shownin ON position)

::i:':TO.

ADJUSTMENT

-,$j

FIGURE 12: Return Filter Grill and Return Duct Installation

Accessory External Filter Installation

1. Install the return filter rack on the top of the furnace return air
opening. Secure the filter rack to the front and back flanges with

screws. The return air plenum can be placed over the filter rack
and the branch ducts (rectangular ducts and ! or round ducts) can

be attached to the plenum. Route the combustion air and the vent
PVC pipes around the access panels for the filters.

2. Install the filter(s) provided or you may install Permanent washable
filters. Filter should extend through the entire length of the filter

rack to prevent air from bypassing the filter.

IMPORTANT: Air velocity through throwaway type filters must not
exceed 300 feet per minute (1.52 m/m). All velocities over this require
the use of high velocity filters. Refer to Table 16.

CAUTION

All installations must have a filter instafled.

Unitary Products Group 11

FIGURE 14: Upflow Configuration

288130-UIM-A-0407

4 ¸ • •i•

FURNACE
CONTROL\

BLOWER
DOOR \
SWITCH\'\

ROLL-OUT

BURNERS

HOT
SURFACE

IGNITOR

GAS ..........

VALVE

PRESSURE -j
SWITCH

FIGURE 15: Downflow Configuration

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 17.

EXTERNAL MANUAL
SHUTOFF VALVE

TOGAS _' "]_, TOGAL_

T .... VENT

VENTP,PE

i i TRANSITION

ii GAS

i4 ....... PIPE

3" DIAMETER
VENT PIPE

GAS

?_'- SHUT-OFF

VALVE

ROLUOUT

.... SWITCH

zz DIRT LEG

VENT

BLOWER

GAS ORIFICE CONVERSION FOR PROPANE (LP)

Refer toTable 7 for the proper gas orifice size.

A.WARNING

The conversion shaft be installed by a qualified service agency in
accordance with the manufacturer's instructions and all applicable
codes and requirements of the authority having jurisdiction. If the
information in these instructions is not followed exactly, a fire, an
explosion or production of carbon monoxide may result causing
property damage, personal injury or loss of life. The qualified ser-
vice agency is responsible for the proper installation. The installa-
tion is not proper and complete until the operation of the converted
appliance is checked as specified in the manufacturer's instruc-

tions.

A.WARNING

Improper installation may damage equipment, can create a shock
hazard, and will void the warranty.

IMPORTANT: These instructions are for the use of qualified individuals
specially trained, experienced and certified in the installation of this type

of equipment and related system components. Installation and service
personnel are required by some states to be licensed. Persons not

qualified shall not install this equipment nor interpret these instructions.
NOTE: The words "Shall" or "Must" indicate a requirement, which is

essential to satisfactory and safe product performance.

NOTE: The words "Should" or "May" indicate a recommendation or

advice which is not essential and not required but which may be
useful or helpful.

CONTENTS

1. Burner orifices for LP (propane) gas are located in bag attached to
the gas valve.

2. Conversion plate.

BURNER GASVALVE

DRIP/" MAY BE INSTALLED
LEG INSIDE OR OUTSIDE UNIT.

FIGURE 16: Gas Piping

IMPORTANT: An accessible manual shutoff valve must be installed
upstream of the furnace gas controls and within 6 feet (1.8 m) of the fur-

nace. Refer to Figures 14, 15, and 16.
The furnace must be isolated from the gas supply piping system by

closing its individual external manual shutoff valve during any pressure
testing of the gas supply piping system at pressures equal to or less
than 1/2 psig (3.5 kPa).

CAUTION]

Never apply a pipe wrench to the body of the gas valve when
installing piping. A wrench must be placed on the octagon hub
located on the gas inlet side of the valve. Placing a wrench to the
body of the gas valve will damage the valve causing improper 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 5 dimensions.

GAS
ORIFICE GAS

MANIFOLD

FIGURE 17: Burner Assembly

CONVERSION PROCEDURE

CAUTION

The gas supply must be shut off prior to disconnecting the electrical

power, before proceeding with the conversion.

AWARNING

SHOCK HAZARD - Turn off electrical supply to furnace

12 Unitary Products Group

288130-UIM-A-0407

1. Shut off gas supply at valve upstream from furnace or at meter as
required. Refer to Figures 9 and 10.

2. Disconnect as supply piping from gas valve on furnace.

3. Disconnect electrical wires from gas valve, nothing which wires
are connected to which terminals.

4. Remove the four screws that attach the gas manifold to the burner
support box. See Figure 11.

5. Remove and discard natural gas orifices.

6. Remove LP (Propane) orifices from the bag attached to the gas
valve.

7. Install the LP (Propane) gas orifices supplied with the furnace.
Tighten to 15 - 25 inch - pounds of torque.

8. Reinstall the manifold in the assembly by reversing the removal
process.

9. Reconnect the wires to the proper terminals on the gas valve.

10. Remove the regulator with the blue cap and turn it upside down so
the letters "LP" are upright. Place the blue cap on the opposite end

of the regulator.

11. Convert the gas valve for LP (propane) gas operation by following
the instructions. Remove the natural tag and replace with the pro-
pane tag supplied in the orifice bag to the gas burner mounting

plate to show that is has been converted.

12. Remove the blue conversion label on the furnace door after the
furnace has been converted.

13. Reconnect the gas supply piping to the gas valve and insure that
all gas connections are tight.

14. Remove pressure tap plugs from gas valve and connect water
gauge to the pressure tap ports. See Figure 8 for location of the

gas valve pressure taps and pressure regulator adjustment.

15. Turn on gas supply to furnace and check all gas connections with
suitable leak detector.

kWARNING

Never use an open flame to check for leaks. Fire or explosion could
occur. Since some leak solutions including soap and water may
cause corrosion or stress cracking, the piping must be rinsed with
water after testing unless it has been determined that the leak test

solution is non-corrosive.

HIGH ALTITUDE GAS ORIFICE CONVERSION

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

The gas orifices on this furnace must be changed in order to maintain
proper and safe operation, when the furnace is installed in a location
where the altitude is greater than 2,000 ft. (610 m) above sea level on
natural gas or the altitude is greater than 4,000 ft. (1219 m) above sea
level on propane (LP) gas. Refer to Table 7 for the proper gas orifice

size.
The unit may also be converted for altitudes up to 10,000 ft. (3048 m)

on natural and propane (LP) gas with additional derate as shown in
Table 7 or refer to ANSI Z223.1 NFPA 54 National Fuel Gas Code or in

Canada CAN/CGA-B149.1-00 Natural Gas and Propane Installation
Code.

kDANGER

PROPANE AND HIGH ALTITUDE CONVERSION KITS

It is very important to choose the correct kit and/or gas orifices for the altitude and the type of gas for which the furnace is being installed.
Only use natural gas in furnaces designed for natural gas. Only use propane (LP) gas for furnaces that have been properly converted to use 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.

TABLE 6: High Altitude Conversion

Type Orifice at 2,000 ft. 3,000 ft. 4,000 ft. 5,000 ft. 6,000 ft. 7,000 ft. 8,000 ft. 9,000 ft. 10,000 ft.

Of Gas Sea Level (610 m) (914 m) (1219 m) (1524 m) (1829 m) (2134 m) (2438 m) (2743 m) (3048 m)

Natural #42 #42 #43 #43 #43 #44 #44 #45 #46 #47

Propane #54 #54 #55 #55 #55 #55 #55 #56 #56 #56

SECTION V: ELECTRICAL POWER

ELECTRICAL POWER CONNECTIONS

Field wiring to the unit must be grounded. Electric wires that are field
installed shall conform to the temperature limitation for 63°F (35°C) rise

wire when installed in accordance with instructions. Refer to Table 7 in
these instructions for specific furnace electrical data.

Use copper conductors only.

CAUTION]

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288130-UIM-A-0407

TABLE 7: Ratings & Physical / Electrical Data - Upflow Models

Input

MBH kW

75 22.0
75 22.0

100 29.3

Input

MBH kW

75 22.0
75 22.0

100 29.3

Nominal external static pressure is 0.50" w.c. at furnace outlet ahead of cooling coils.
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-70qatest edition) and all local codes.

SUPPLY VOLTAGE CONNECTIONS

1. Provide a power supply separate from all other circuits. Install
overcurrent protection and disconnect switch per local/national

electrical codes. The switch should be close to the unit for 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 in this instruction.

2. Remove the screws retaining the wiring box cover. Route the
power wiring through the opening in the unit into the junction box

with a conduit connector or other proper connection. In the 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 the wir-

ing schematic in this section. The black furnace lead must be
connected to the L1 (hot) wire from the power supply. The white

furnace lead must be connected to neutral. Connect the green fur-
nace lead (equipment ground) to the power supply ground. An

alternate wiring method is to use a field provided 2" (51 mm) x 4"
(102 mm) 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 con-

nections replace the wiring box cover and screws. Refer to Figure

18.

3. The furnace's control system requires correct polarity of the power
supply and a proper ground connection. Refer to Figure 19.

BLK A BLK (HOT) o--E::::_<_----4_'_

WHT _WHT (NEUTRAL) f NOMINAL120VOLT

GRN #& GRN _L

Output

MBH kW

60 17.6
60 17.6

80 23.4

Max. Outlet

Air Temp

oF oc

165 73.9
160 71.1
170 76.7

Nominal Airflow

CFM m3min
1200 34.0

1600 45.3
1600 45.3

Blower

Hp Amps
1/2 7.0

1/2 10.4
1/2 10.4

Cabinet Width

In. cm

17-1/2 44.45

21 53.34
21 53.34

Blower

Size

In. cm

10 x 8 25.4 x 20.3
10x10 25.4 x 25.4
10x10 25.4 x 25.4

FIGURE 19: Single Stage Heat Thermostat Connections

IMPORTANT: Some electronic thermostats do not have adjustable heat
anticipators. They may have other type cycle rate adjustments. Follow

the thermostat manufacturer's instructions.
IMPORTANT: Set the heat anticipator in the room thermostat to 0.40

amps. Setting it lower will cause short cycles. Setting it higher will cause
the room temperature to exceed the set points.

The 24-volt, 40 VA transformer is sized for the furnace components
only, and should not be connected to power auxiliary devices such as

humidifiers, air cleaners, etc. The transformer may provide power for an
air conditioning unit contactor.

ACCESSORY CONNECTIONS

The furnace control will allow power-switching control of various acces-
sories. Refer to Figure 20 for connection details.

Total

Unit

Amps

8.0

11.4

11.4

Max

Over-current

protect

15
15
15

ROOM FURNACE CONDENSING
THERMOSTAT CONTROL UNIT

Min.Wire Size
(awg) @ 75 ft.

_[_ TO AIR CONDITIONER

.y _ ......................

.................. .........

115 VOLT
HUMIDIFIER

HUM. HOT

AFUE

80.0

80.0

80.0

one way

14
14
14

Air Temp. Rise

oF oc

35-65 19.4-36.1
30-60 16.7-33.3

40-70 22.2-38.9

Operation

Weight

LBS Kg

118 53.5
129 58.5
135 61.2

CONTROLS

FIGURE 18: Electrical Wiring - Upflow Position

IMPORTANT: The power connection 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.

LOW VOLTAGE CONTROL WIRING CONNECTIONS

Install the field-supplied thermostat by following the instructions that
come with the thermostat. With the thermostat set in the OFF position
and the main electrical source disconnected, connect the thermostat
wiring from the wiring connections on the thermostat to the terminal
board on the ignition module, as shown in Figure 19. Electronic thermo-
stats may require the common wire to be connected as shown with the
dashed line in Figure 19. 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 yellow and brown wires on the condensing unit (unit out-
side). Refer to Figure 19.

AtR CLEANER J""""""q_

FIGURE 20: Accessory Connections

ELECTRONIC AIR CLEANER CONNECTION

Two 1/4" (0.6 cm) spade terminals (EAC and 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.

EAC HOT _ --

115VOLT -- B_
ELECTRONIC I WHT

|

• /

14 Unitary Products Group

HUMIDIFIER CONNECTION

Two 1/4" (0.6 cm) spade terminals (HUM and NEUTRAL) for humidifier
connections are located on the control board. The terminals provide 115
VAC (1.0 amp maximum) during heating system operation.

SECTION Vh TWINNING AND STAGING

NOTE: You can twin two furnaces that have the same integrated control
module. Check the part number on the integrated control module. You
cannot twin two furnaces that have different integrated control module
part numbers. If the part numbers of the two integrated control modules
are different they may not communicate with each other so they will not
work in a twinning application.

In applications where more heating capacity or more airflow capacity is
needed than what one furnace can deliver, twinning can be used to
make two furnaces operate in tandem. When two furnaces are installed
using the same duct system, it is very important that the two furnace cir-
culating air blowers operate in unison. If one blower starts before the
second blower, the duct system will become pressurized and the blower
on the second furnace will turn backwards causing the second furnace
to overheat, resulting in damage to the furnace. Twinning is used to
make two furnaces operate in tandem, using one duct system, one
room thermostat and causing both furnaces to turn on and off simulta-
neously.

_WARNING

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

or equipment damage.

TWINNING DUCT SYSTEM

Twinned furnaces must only be applied on a common duct system. A
single air supply plenum must be used for both furnaces and coil(s).

Separate plenums and supply ducts systems cannot be utilized. A sin-
gle return air plenum, common to both furnaces must be used. It is sug-
gested that a return platform be utilized, with bottom air entrance into
each furnace. If a side entrance returns system is used, the common
return duct must be divided equally so as to supply each furnace with
an equal amount of return air.

Both furnaces must be identical models in both heating capacity and
CFM capacity. Both furnaces must be operated on the same motor
speed tap. See typical application, Figure 21.

If furnace staging is desired with two single stage furnaces on a com-
mon duct, where the gas burner on the first furnace operates on W1
and the gas burner on the second furnace operates on W2, then the
use of an air-mixing device in the plenum to mix the air from both fur-
naces is strongly recommended. The mixing device must be installed
before any ducts that supply air to occupied spaces. Twinning causes
both indoor fans to operate simultaneously. If a mixing device is not
used, any ducts that are connected down stream from the furnace that
operates on W2, will be supplying cold air in the Heating mode to the
occupied spaces unless W2 is energized.

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

2000 CFM units will yield a total 3400 CFM.

[ CAUTIONJ

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

288130-UIM-A-0407

VENT PIPE

ELECTRICAL
SUPPLY

FIGURE 21: Typical Twinned Furnace Application

GAS PIPING

Furnace gas supplies must be provided as specified with these instruc-
tions. Since the furnaces are side by side, with no space between, gas
supplies must enter on the right and left respectively. All gas piping
must be in accordance with the national fuel gas code, ANSI Z223.1,
latest edition, and/or all local code or utility requirements.

GAS SUPPLY
(both sides)

1COILFOR

_ EACHFURNACE

TWINNING

Single-Wire Twinning
The control in the furnace has the single-wire twinning feature. With this

feature, a single wire is connected between the TWIN terminal on one
furnace board to the TWIN terminal on the second furnace board. The

board then communicates the blower status from one furnace to the
other along this wire. This communication makes the second furnace

blower come on at the same time, and on the same speed, as the first
furnace blower.

Single-Wire Twinning Instructions

Connect the control wiring as shown in Figure 22.

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

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

3. Install a separate 24V relay as shown in the diagram below. Use of
this relay is required, as it ensures that the transformers of the two

furnaces are isolated, thus preventing the possibility of any safety
devices being bypassed.

NOTE: The twinned furnaces must be connected to the same leg of the
line voltage to prevent phasing error problems. If this is not done prop-
erly, the furnaces will not operate and the control board LEDs will flash
a rapid red flash to indicate the twinning error.

CAUTION]

The relaymust not be installedin any locationwhere itcould be
exposed to water.Ifthe relayhas been exposed to waterin any
way,itmust notbe used.

Unitary Products Group 15

288130-UIM-A-0407

Single-Wire Twinning Operation

Heating - On a call for heat (W signal) from the wall thermostat, both
furnaces will start the ignition sequence and the burners on both fur-
naces will light. About thirty seconds after the burners light, the blowers
on both furnaces will come on in heating speed. When the thermostat is
satisfied, the burners will all shut off and, after the selected blower off
delay time, both blowers will shut off at the same time. The twinned

controls ensure that both blowers come on and shut off at the same
time.

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

then will shut off at the same time.
Continuous Fan - On a thermostat call for continuous fan (G signal),

both furnace blowers will come on at the same time in cooling speed
and will stay on until the G signal is removed.

FURNACE 1 CONTROL BOARD FURNACE 2 CONTROL BOARD

i=\#C

TWIN

ISOLATION

/_C! :i 1 ,\_/R

RELAY

i '

TOA!C w G R Y

VVALL THERMOSTAT

Single-Wire Staging Operation
Heating - On a call for first-stage heat (W1 signal) from the wall thermo-

stat, Furnace #1 will start the ignition sequence and the burners will
light. About thirty seconds after the burners light, the blowers on both
furnaces will come on in heating speed. When the thermostat is satis-
fied, the burners will shut off and, after the selected blower off delay
time, both blowers will shut off at the same time. On a call for second
stage of heat, the burners of Furnace #2 will also light and both blowers
will run. The twinning control ensures that both blowers come on and

shut off at the same time.
Cooling - On a call for cooling (Y signal) from the wall thermostat, both

furnace blowers will come on at the same time. When the thermostat is
satisfied, both blowers will stay on for 60 seconds, then will shut off at

the same time.
Continuous Fan - On a thermostat call for continuous fan (G signal),

both furnace blowers will come on at the same time in cooling speed
and will stay on until the G signal is removed.

FURNACE 1 CONTROL BOARD FURNACE 2 CONTROL BOARD

TO A/C Wl G R Y W2

WALL THERMOSTAT

FIGURE 23: Two-Stage Twinning Wiring Diagram

FIGURE 22: Single Stage Twinning Wiring Diagram

STAGING

SECTION Vlh VENT/COMBUSTION AIR
SYSTEM

In applications where more heating capacity or more airflow capacity is
needed than what one furnace can deliver, twinning can be used to
make two furnaces operate in tandem, using one duct system and one
room thermostat. This control can also be used along with a two-stage
wall thermostat to stage two twinned furnaces, making them operate
like a single two-stage furnace. This allows only one furnace to supply
heat during times when the heat output from one furnace is sufficient to
satisfy the demand. When one duct system is used for two furnaces, it
is necessary that the two blowers operate in unison. The twinning func-

tion of this board ensures that both blowers turn on and off simulta-

VENT SAFETY

This Category I, furnace is designed for residential application. It may
be installed without modification in a basement, garage, equipment
room, alcove, attic or any other indoor location where all required clear-

ance to combustibles and other restrictions are met.

_1-_ MORE THAN ---4_

10 FT (3.0 M) " _T_---- 3_FT (0,9 m )

neously, and operate on the same blower speed. Even when only one
furnace is supplying heat, both furnace blowers must run.

Single-Wire Staging

The single-wire twinning feature of this board can also be used for stag-
ing of two furnaces. With this feature, a single wire is connected

between the TWIN terminal on one furnace board to the TWIN terminal
on the second furnace board. The board then communicates the blower

status from one furnace to the other along this wire. This communica-
tion makes the second furnace blower come on at the same time, and

on the same speed, as the first furnace blower.

Single-Wire Staging Instructions

Connect the control wiring as shown in the Figure 23.

1. Connect the low voltage wiring from the wall thermostat to the ter-

WALL OR

PARAPET

.°: :

I : I IPARAPETREQUIRED',

° _ WHEN DISTANCE ',

_." • FROM WALLS OR ,

_ PARAPET IS MORE _

THAN 10 FT (3.0 m). CHIMNEY

_4.__ MORE THAN

10FT 3.0M

2 FT(0.6 m),&

HEIGHT ABOVE ANY
ROOF SURFACE WITHIN

10 FT (3.0 m) HORIZONTALLY

3 FT (0.9 m)
MIN

minal strip on the control board of Furnace #1. For staging applica-
tions, the wire from thermostat W1 is connected to the W

connection on the board on Furnace #1. The wire from thermostat
W2 is connected to Furnace #2 through a separate relay, as

described below.

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

3. Install a separate 24V relay as shown in the diagram below. Use of
this relay is required, as it ensures that the transformers of the two

FIGURE 24: Vent Termination

CHIMNEY

furnaces are isolated, thus preventing the possibility of any safety
devices being bypassed.

16 Unitary Products Group

288130-UIM-A-0407

LOWEST DISCHARGE OPENING

LISTED CAP

LISTED GAS --
VENT

J

FIGURE 25: Vent Termination

TABLE 8: Roof Pitch

ROOF PITCH H(min) ft m

Flat to 6/12 1.0 0.30

6/12 to 7/12 1.25 0.38
Over 7/12 to 8/12 1.5 0.46
Over 8/12 to 9/12 2.0 0.61

Over 9/12 to 10/12 2.5 0.76
Over 10/12 to 11/12 3.25 0.99
Over 11/12 to 12/12 4.0 1.22
Over 12/12 to 14/12 5.0 1.52
Over 14/12 to 16/12 6.0 1.83
Over 16/12 to 18/12 7.0 2.13
Over 18/12 to 20/12 7.5 2.27
Over 20/12 to 21/12 8.0 2.44

ROOF PITCH
IS X/12

H (min) - MINIMUM HEIGHT FROM ROOF
TO LOWEST DISCHARGE OPENING

VENTING

Category I venting consists of vertically venting one or more appliances
in B-vent or masonry chimney (as allowed), using single wall metal pipe

or B-vent connectors. Type B-vent system extends in a general vertical
direction and does not contain offsets exceeding 45 degrees. A vent

system having not more than one 60 degree offset is permitted.

CHIMNEY OR
GAS VENT

ALTERNATE

VENTIALTION LOUVERS FOR UNHEATED CRAWL SPACE

VENTILATION LOUVERS
(Each end of attic)

OUTLET
AIR

INLET

FIGURE 26: Alternate Air Intake, Air Outlet and Chimney Connections

CHIMNEY OR

VENTILATION LOUVERS

Each end of attic)

OUTLET

AIR

CATEGORY 1 - 450 IF. MAX. VENT TEMP.
The venting system must be installed in accordance with Section 5.3,

Air for Combustion and Ventilation, of the National Fuel Gas Code
Z223.1/NFPA 54 (latest edition), or Sections 7.2, 7.3 or 7.4 of CSA
B149.1, National Gas and Propane Codes (latest edition) or applicable
provisions of the local building code and these instructions.

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

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

and clearances.
It is recommended that the appliance is installed in a location where the

space temperature is 32 °F (0°C) or higher. If the appliance is installed
in a location where the ambient temperature is below 32 °F (0°C), the
flue by-products could condense causing damage to the appliance heat
exchanger.

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

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

these instructions.
Non-HUD approved Modular Homes must be vented with a listed dou-

ble wall or B-vent system and may not be common vented with other
appliances.

INLETAIR DUCT

1 ft (30 cm)

above floor}

FIGURE 27: Air Inlet, Outlet and Chimney Connections

VENTING INTO AN EXISTING CHIMNEY

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

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

followed:

1. The masonry chimney must be built and installed in accordance
with nationally recognized building codes or standards and must

be lined with approved fire clay tile flue liners or other approved
liner material that will resist corrosion, softening, or cracking from

flue gases. THIS FURNACE IS NOT TO BE VENTED INTO AN
UNLINED MASONRY CHIMNEY.

2. This furnace must be vented into a fire clay tile lined masonry
chimney only if a source of dilution air is provided, such as by com-

mon venting with a draft hood equipped water heater. If no source
of dilution air is available, Type B vent must be used, or masonry

chimney vent kit 1CK0603 or 1CK0604 must be used. Refer to the
instructions with the kit to properly apply these masonry chimney
kits.

Unitary Products Group 17

288130-UIM-A-0407

3. The chimney must extend at least three feet above the highest
point where it passes through a roof of a building and at least two

feet higher than any portion of the building with a horizontal dis-
tance of ten feet.

4. The chimney must extend at least five feet above the highest
equipment draft hood or flue collar.

HORIZONTAL SIDEWALL VENTING

For applications where vertical venting is not possible, the only
approved method of horizontal venting is the use of an auxiliary power
vent. Approved power venters are Fields Controls Model SWG-4Y or
Tjernlund Model GPAK-JT. Follow all application and installation details
provided by the manufacturer of the power vent. Refer to Figures 28
and 29 for typical installation views.

FAN ASSISTED FURNACE
& WATER HEATER

OPTIONAL

.... I _1 VENT SYSTEM

FURNACE WATER

HOT

FAN ASSISTED
FURNACES

-- EXTERIOR

U

FIGURE 28: Typical Sidewall Vent Application

VENT PiPE

VENT

TABLE 9: Horizontal Sidewall Venting Clearances

Horizontal Vent Length Ft. (m) with 4 Elbows

Models Pipe Size Min. Vent Length Max. Vent Length

Inches cm Feet meters Feet meters

All Models 4 10.2 4.5 1.37 34.5 10.82

VENT PIPING ASSEMBLY

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

1. Cut piping to the proper length beginning at the furnace.

2. Deburr the piping inside and outside.

3. Dry-fit the vent piping assembly from the furnace to the termination
checking for proper fit support and slope. Piping should be sup-

ported with pipe hangers to prevent sagging. The maximum spac-
ing between hangers is 4 feet (1.22 m).

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

GAS VENT

FLUE

TOP

OPTIONAL
SIDEWALL

VENT SYSTEM

(field supplied)

.CELLAR ACCESS

WALL PANEL

FIGURE 29: Typical Sidewall Vent and Termination Configuration

FIGURE 30: Typical Chimney Connections

2_

FIGURE 31: Horizontal Air Inlet, Outlet and Chimney Connections

VENT CLEARANCES

IMPORTANT: The vent must be installed with the following minimum
clearances as shown in Figure 32, and must comply with local codes

and requirements.

18 Unitary Products Group

288130-UIM-A-0407

\

\

\

FIGURE 32: Home Layout

Canadian Installations I US Installation 2

A. Clearance above grade, veranda, porch, deck, or balcony 12 inches (30 cm) 12 inches (30 cm)

B. Clearance to window or door that may be opened 12 inches (30 cm) 4 Feet (1.22 m)
C. Clearance to permanently closed window 12 inches (30 cm) 12 inches (30 cm)

D. Vertical clearance to ventilated soffit located
above the terminal within a horizontal distance 4 Feet (1.22 m) 4 Feet (1.22 m)

of 2 feet (61 cm) from the center line of the terminal
E. Clearance to unventilated soffit 12 Inches (30 cm) 12 Inches (30 cm)
F. Clearance to outside corner 12 Inches (30 cm) 12 Inches (30 cm)
G. Clearance to inside corner 6 Feet (1.83 m) 6 Feet (1.83 m)

H. Clearance to each side of center line extended

3 feet (0.91 m) within a height 3 feet (0.91 m) within a height

15 feet (4.57 m) above the 15 feet (4.57 m) above the

above meter/regulator assembly meter/regulator assembly meter/regulator assembly
I. Clearance to service regulator vent outlet 3 feet (0.91 m) 3 feet (0.91 m)

J. Clearance to nonmechanical air supply inlet to 12 inches (30 cm) 4 Feet (1.22 m)
building or the combustion air inlet to any other appliance

K. Clearance to a mechanical supply inlet 6 feet (1.83 m) 10 feet (3.04 m) horizontally

_. Clearance above paved sidewalk or paved

driveway located on public property

7 feet (2.13 m) t 7 feet (2.13 m) t

M. Clearance under veranda, porch, deck, or balcony 12 inches (30 cm) 12 inches (30 cm)
Vent Termination from any Building Surface 12 inches (30 cm) 12 inches (30 cm)
Above anticipated snow depth 12 inches (30 cm) 12 inches (30 cm)

1. In accordance with the current CSA B149.1-00, Natural Gas and Propane Installation Code.

2. In accordance with the current ANSI Z223.1 / NFPA 54, National Gas Code.
1" A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings.

_: Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor. For clearance not specified in ANSI Z223.1 / NFPA

54 or CSA B149.1-00.

Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer's Installation Manual.
Any fresh air or make up inlet for dryer or furnace area is considered to be forced air inlet.
Avoid areas where condensate drippage may cause problems such as above planters, patios, or adjacent to windows where steam may cause fogging.

A terminus of a vent shall be either:
Fitted with a cap in accordance with the vent manufacturer's installation instructions, or In accordance with the installation instructions for a special venting system.

* Does not apply to multiple installations of this furnace model. Refer to "VENTING MULTIPLE UNITS" in this section of these instructions.
IMPORTANT: Consideration must be given for degradation of building materials by flue gases. Sidewall termination may require sealing or shielding of building surfaces
with a corrosion resistant material to protect against combustion product corrosion. Consideration must be given to wind direction in order to prevent flue products and/
or condensate from being blown against the building surfaces. If a metal shield is used it must be a stainless steel material at a minimum dimension of 20 inches. It is
recommended that a retaining type collar be used that is attached to the building surface to prevent movement of the vent pipe.
Responsibility for the provision of proper adequate venting and air supply for application shall rest with the installer.
Vent shall extend high enough above building, or a neighboring obstruction, so that wind from any direction will not create a positive pressure in the vicinity of the vent.

HORIZONTAL VENT APPLICATIONS AND

4. Termination should be located where it will not be damaged or

TERMINATION

When selecting the location for a horizontal combustion air / vent termi-

5. Termination should be positioned where vent vapors are not objec-

nation, the following should be considered:

1. Observe all clearances listed in vent clearances in these instruc-

6. Horizontal portions of the vent system must slope upwards and be

tions.

2. Termination should be positioned where flue products 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.

[] VENT TERMINAL

AIR SUPPLY

AREA WHERE TERMINAL IS NOT PERMITTED

3 feet (0.91 m) above if within

exposed to flying stones, balls, etc.

tionable.

supported to prevent sagging. The vent system may be supported
by the use of clamps or hangers secured to a permanent part of

the structure every 4 ft. (1.22 m).

Unitary Products Group 19

288130-UIM-A-0407

FAN-ASSISTED COMBUSTION SYSTEM

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

Ambient Combustion Air Supply

This type installation will draw the air required for combustion from
within the space surrounding the appliance and from areas or rooms
adjacent to the space surrounding the appliance. This may be from
within the space in a non-confined location or it may be brought into the
furnace area from outdoors through permanent openings or ducts. A
single, properly sized pipe from the furnace vent connector to the out-
doors must be provided. For upflow models combustion air is brought
into the furnace through the unit top panel opening.

VENT PIPE FITS
INTOSOCKET JUST --'_

COMBUSTION !-
AiR _ i:iii:ili:

ABOVE TOPPANEL

COMBUSTION

A,R

\

A confined space is an area with less than 50 cu.ft (1.42 m 3) per 1,000
Btu/hr (0.2928 kW) input rating for all of the appliances installed in that
area. The following must be considered to obtain proper air for combus-
tion and ventilation in confined spaces.

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 10, to estimate free area.

TABLE 10: Estimated Free Area

Wood or Metal Wood 20-25%*

Louvers or Grilles Metal 60-70% *

Screens+

• Do not use less than 1/4"(0.635 cm) mesh
+ Free area or louvers andgrille varies widely; theinstaller should follow lou-

ver or grillemanufacturer's instructions.

Dampers, Louvers and Grilles (Canada Only)

1. The free area 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 grille, or screen shall have no dimen-
sion smaller than 0.25" (0.635 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 11: Free Area

1!4" (0.635 cm)

mesh or larger 100%

UPFLOW DOWNFLOW

FIGURE 33: Combustion Airflow Path Through The Furnace Casing to

the Burner Box

_WARNING

This type of installation requires that the supply air to the appfi-
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 is not less than 50 cu.ft (1.42 m3) per 1,000 Btu/
hr (0.2928 kW) input rating for all of the appliances installed in that

area.
Rooms communicating directly with the space containing the appli-

ances are considered part of the unconfined space, if openings are fur-
nished with doors.

Minimum Free Area Required for Each Opening

BTUH Input Vertical Duct or

Rating Opening to Outside

75,000 38 in2 (245 cm 2) 19 in2 (123 cm2) 5" (13 cm)

100,000 50 in2 (322 cm 2) 25 in2 (161 cm2) 6" (15 cm)

EXAMPLE: Determining Free Area.

Appliance 1Appliance 2Total Input

100,000 + 30,000=(130,000+4,000)=32.5Sq. ln. Vertical

Appliance 1Appliance 2Total Input

100,000 + 30,000 = (130,000 + 2,000) = 65 Sq. In. Horizontal

TABLE 12: Unconfined Space Minimum Area in Square Inches

BTUH Input Rating Minimum Free Area Required for Each Opening

75,000 75 (484 cm 2)

100,000 100 (645 cm 2)

Horizontal Duct Round Duct

(2,000 BTUH) (4,000 BTUH) (4,000 BTUH)

20 Unitary Products Group

288130-UIM-A-0407

GAS

GABLE
VENT

OPTIONAL

VENTILATED E_

CRAWL SPACE

5. A square or rectangular shaped duct shall only be used
when the required free area of the supply opening is

9 in 2(58.06 cm 2)or larger. When a square or rectangular
duct is used, its small dimensionshall not be less than
3 in (7.6 cm).

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

Such means shall net reduce the required free area of
the air supply opening•

7. An air supply inlet opening from the outdoors shall
be located not less than 12" (30.5 cm) above the

outside grade level.

VENT

AIR SUPPLY OPENINGS AND DUCTS

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

supply to an appliance unless otherwise permitted by the authority having

jurisdiction. The opening shall be located within 12" (30.5 cm) horizontally from,

the burner level of the appliance. Refer to "AIR SOURCE FROM OUTDOORS
AND VENTAND SUPPLY AIR SAFETY CHECK" in these instructions for

additional information and safety check procedure. OUTLE_

2• The duct shall be either metal, or a material meeting the class 1 AIR (b)

requirements of CAN4-S 110 Standard for Air Ducts.

3• The duct shall be least the same cross-sectional area as the free

area of the air supply inlet opening to which it connects.

4 The 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.

GABLE VENT
VENT

WATER

HFATER INLET 4.

FIGURE 34: Outside and Ambient Combustion Air

kWARNING

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

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

Ventilated Combustion Air
The ventilated attic space or a crawl space from which the combustion

air is taken must comply with the requirements specified in "AIR
SOURCE FROM OUTDOORS" in this instruction or in Section 5.3, Air
for Combustion and Ventilation of the National Fuel Gas Code, ANSI
Z223.1 (latest edition). This type installation requires a pipe that
extends from the furnace vent connection (top right of unit) to the exte-
rior of the building. Follow all notes, procedures and required materials

in the COMBUSTION AIR SUPPLY section in these instructions when
installing the unit and into a ventilated attic space or crawl space. DO

NOT terminate vent pipe in an Attic or Crawl Space.

GAS

IIII

.W_TA_gR

INLET
AIR (b) _ --

COMBUSTION AIR SOURCE FROM OUTDOORS

GAS

l I l I-I lAIR(a)

1. Two permanent openings, one within 12 in (30•5 mm) of the top and
one within 12 in (30.5 mm) of bottom of the confined space, Two

permanent openings, shall communicate directly or by means of ducts

with the outdoors, crawl spaces or attic spaces•

2. One permanent openings, commencing within 12 in (30•5 mm)efthe
top of the enclosure shall be permitted where the equipment has
clearances of at least 1 in (2•54 cm) from the sides and back and

6 in (15•24 cm) from the front of the appliance• The opening shall
communicate directly with the outdoors and shall have a minimum

free area of:

a. 1 square in per 3000 Btu per hour (6•45 cm20.879 kW) of the total

input rating of all equipment located in the enclosure.

b. Not less than the sum of all vent connectors in the confined space.

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.

Vent and Supply (Outside) Air Safety Check Procedure
For Category I furnaces, vent installations shall be in accordance with

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

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

Multistory or common venting systems are permitted and must be
installed in accordance with the National Fuel Gas Code, ANSI Z223.1!

NFPA 54 and ! or the CSA B149.1, Natural Gas and Propane Installa-
tion Codes, local codes, and the manufacture's instructions.

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

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

minal.
It is recommended that you follow the venting safety procedure below.

This procedure is designed to detect an inadequate ventilation system
that can cause the appliances in the area to operate improperly causing

unsafe levels of Carbon Monoxide or an unsafe condition to occur.

t!I 1,,

t I I ] IJ AIR (a)

NLET

Unitary Products Group 21

288130-UIM-A-0407

_WARNING

CARBON MONOXIDE POISONING HAZARD
Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon

monoxide poisoning or death.

The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances

connected to the venting system are not in operation:

1. Inspect the venting system for proper size and horizontal pitch. Determine that there is no blockage, restriction, leakage, corrosion or other
deficiencies, which could cause an unsafe condition

2. Close all building doors and windows and all doors.

3. Turn on clothes dryers and TURN ON any exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum
speed. Open the fireplace dampers. Do not operate a summer exhaust fan.

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

5. Test each appliance (such as a water heater) equipped with a draft hood for spillage (down-draft or no draft) at the draft hood relief opening
after 5 minutes of main burner operation. Appliances that do not have draft hoods need to be checked at the vent pipe as close to the

appliance as possible. Use a combustion analyzer to check the CO2 and CO levels of each appliance. Use a draft gauge to check for a
downdraft or inadequate draft condition.

6. After it has been determined that each appliance properly vents when tested as outlined above, return doors, windows, exhaust fans, fire-
place dampers and any other gas burning appliance to their normal condition.

7. If improper venting is observed during any of the above tests, a problem exists with either the venting system or the appliance does not
have enough combustion air (Supply Air from outside) to complete combustion. This condition must be corrected before the appliance can

function safely.

NOTE: An unsafe condition exists when the CO reading at the furnace vent exceeds 40 ppm and the draft reading is not in excess of - 0.1 in.

W.C. (-25 kPa) with all of the appliance(s) operating at the same time.

8. Any corrections to the venting system and / or to the supply (outside) air system must be in accordance with the National Fuel Gas Code
Z223.1 or CAN/CGA B149.1-00 Natural Gas and Propane Installation Code (latest editions). If the vent system must be resized, follow the

appropriate tables in Appendix G of the above codes or for this appliance.

SECTION Vllh 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.

l CAUTIONI

Main power to the unit must still be interrupted at the main power
disconnect switch before any service or repair work is to be done to
the unit. Do not rely uoon the interlock switch as a main cower 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.

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.

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 due to reduced airflow, that may be
caused by a dirty filter, or if the indoor fan motor should fail. The control
module will lockout if the limit trips 3 consecutive times. Control will
reset and try ignition again after 1 hour.

SECTION IX: START-UP AND
ADJUSTMENTS

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

IMPORTANT: All electrical connections made in the field and in the 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
procedure. Be sure proper ventilation is available to dilute and carry
away any vented gas.

22 Unitary Products Group

288130-UIM-A-0407

TOOLS AND INFORMATION THAT WILL BE
REQUIRED IN ORDER TO PROPERLY PERFORM THE
FURNACE STARTUP PROCEDURE.

1. Call the local gas supplier to obtain heating value of the natural
gas. If you cannot obtain the heating valve of the gas from the gas
supplier, you may use a default value of 1030 BTU/SCF (38.4 MJ /

m3).

2. You will need a thermometer or portable digital thermometer to
read the supply and return air temperatures.

3. You will need a U-tube manometer or digital equipment that has
the ability to read pressures between 0 - 15" in.w.c (0 - 3.73 kPa)

in order to measure the gas line and the manifold pressures.

4. You will need a 3/32" Allen wrench for the pressure port plugs in
the gas valve.

5. You will need 2 pieces of 1/8" (0.3 cm) ID flexible tubing that is 12"
(30 cm) in length, 2 - pieces of 1/8" (0.3 cm) tubing that are 4"

(10.0 cm) in length, a 1/8" (0.3 cm) tee and a 1/8" (0.3 cm) adapter
to connect the U-tube manometer or the digital pressure 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
1 - 5/16" (0.8 cm) x 1/8" (0.3 cm) reducing coupling
1 - 1/8" (0.3 cm) adapter

There is a accessory kit (1PK0602) available from Source 1, which has
the following items:

12" (30 cm) length x 1/8" (0.3 cm) diameter tubing

2 - pieces of 4" (10 cm) length x 1/8" (0.3 cm) diameter tubing

1 - 5/16" (0.8 cm) tee
1 - 5/16" (0.8 cm) x 1/8" (0.3 cm) reducing coupling

1 - 1/8" (0.3 cm) adapter
1 - Dwyer- Manometer

These items are required in order to properly perform the required start-
up procedure.

IGNITION SYSTEM SEQUENCE

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

2. Set the thermostat above room temperature to call for heat.

3. System start-up will occur as follows:
a. The induced draft blower motor will start and come up to

speed. Shortly after inducer start-up, the hot surface ignitor
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.

_WARNING

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 the component.

The furnace and its equipment shutoff valve must be disconnected from
the gas supply piping system during any pressure testing of that system
at test pressures in excess of 1/2 PSI (3.45 kPa).

The furnace must be isolated from the gas supply piping system by
closing the equipment shutoff valve during any pressure testing of the
gas supply piping system.

CALCULATING THE FURNACE INPUT
(NATURAL GAS)

NOTE: Burner orifices are sized to provide proper input rate using natu-
ral gas with a heating value of 1030 BTU/Ft 3 (38.4 Mj/m3). 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 m3.) of gas.

3. Calculate the furnace input by using one of the following equa-
tions.

TABLE 13: Field Installed Accessories - Non Electrical

PART NO,

1FB0318
1FB0319

1FB0320
1BR0312
1BR0316
1BR0320

1PS0466

1PS0467

2802-321P

High Altitude Conversion Kit for Natural Gas

High Altitude Conversion Kit for Propane (LP) Gas

DESCRIPTION

Combustible Floor Sub-Base

Bottom Filter Rack

Vent Pipe Extension

USED WITH

50,7512

7516,10016

10020,125

50,7512

7516,10016

10020,125,150

All Models
All Models
All Models

Unitary Products Group 23

288130-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, times 2 cubic ft. of gas measured at the gas meter, times a

barometric pressure and temperature correction factor of 0.960; times 3600, then divided by the time (In seconds) it took to measure 2 cubic ft. of gas
from the gas meter.

For propane (LP) gas multiply the heat content of the gas BTU/SCF (or Default 2500 BTU/SCF, times 1 cubic ft. of gas measured at the gas meter,
times a barometric pressure and temperature correction factor of 0.960; times 3600, then divided by the time (In seconds) it took to measure 1 cubic

ft. of gas from the gas meter.
The formula for US input calculation using a cubic foot gas meter:

BTU/f 3x 2 cu.ft, x 0.960 x 3600

Seconds ittook to measure the 2 cu.ft,of gas
NATURAL GAS INPUTCALCULATION
EXAMPLE:

1030 x 2 x 0.960 x 3600

Natural Gas

In Canada you will use the following formula to calculate the furnace input if you are using a cubic foot gas meter.
For Natural Gas multiply the Heat content of the gas MJ/m 3 (or Default 39.2), times 2 cu. ft. of gas x 0.02831 to convert from cubic feet to cubic

meters measured at the gas meter, times a barometric pressure and temperature correction factor of 0.960; times 3600, then divided by the time it
took to measure 2 cu.ft, of gas from the gas meter.

For Propane (LP) Gas multiply the Heat content of the gas MJim 3 (or Default 93.14), times 1 cu. ft. of gas x 0.02831 to convert from cubic feet to
cubic meters measured at the gas meter, times a barometric pressure and temperature correction factor of 0.960; times 3600, then divided by the

time it took to measure 1 cu.ft, of gas from the gas meter.
The formula for metric input calculation using a cubic foot gas meter:

MJ/m 3 x (2 cu.ft, x Conv) x 0.960 x

Seconds ittook to measure the 2cu.ft, of gas
NATURAL GAS INPUTCALCULATION

EXAMPLE:

Natural Gas

PROPANE(LP) GAS INPUTCALCULATION

EXAMPLE:

Propane Gas

In Canada use the following formula to calculate the furnace input if you are using a gas meter that measures cubic meters.
For Natural Gas multiply the Heat content of the gas MJ/m 3 (or Default 39.2), times 0.0566 m 3 of gas measured at the gas meter, times a barometric

pressure and temperature correction factor of 0.960; times 3600, then divided by the time it took to measure 0.0566 m3 of gas from the gas meter.
For Propane (LP) Gas multiply the Heat content of the gas M Jim 3 (or Default 93.14), times 0.00283 m3 of gas measured at the gas meter, times a

barometric pressure and temperature correction factor of 0.960; times 3600, then divided by the time it took to measure 0.0283 cm of gas from the
gas meter.

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

MJ/m 3 x (2 cu.ft, x Conv) x 0.960 x

Seconds ittook to measure the 2cu.ft, of gas
NATURAL GAS INPUTCALCULATION

EXAMPLE:

Natural Gas

PROPANE (LP) GAS INPUTCALCULATION
EXAMPLE:

Propane Gas

90.5

BTU/SCF 1030

3600 = MJ/H x

39.2 X 2 X0.960 X 3600

90.5

BTU/SCF 1030 = 39.2 MJim 3

93.15 X 1 X0.960 X 3600
108

BTU/SCF 2500+93.15 MJim 3

3600 = MJ/H x

39.2 x 2 x 0.960 x 3600

90.5

BTU/SCF 1030 = 39.2 MJ/m 3

93.15 x 1 x 0.960 x 3600
108

BTU/SCF 2500+93.15 MJ/m 3

= BTUH/H

= 79,997.38

= 84.76 X

= 84.41 X

= 84.76 x

= 84.41 x

BTU/f 3 x 1 cu.ft, x 0.960 x 3600 =

Seconds ittook to measure the 2 cu.ft, of gas
PROPANE (LP)GAS INPUT CALCULATION

EXAMPLE:

2500 x 1 x 0.960 x 3600

108

Propane Gas

0.2777 = kW x 3412.14 = BTUH/H

0.2777 = 23.54 x 3412.14 =

0.2777 = 23.45 x 3412.14 =

0.2777 = kW x 3412.14 = BTUH/H

0.2777 = 23.54 x 3412.14 =

0.2777 = 23.45 x 3412.14 =

BTU/SCF 2500

BTUH/H

80,000.00

80,312.6

2

80,000.0

0

80,312.6

2

80,000.0

0

DO NOT ADJUST the manifold pressure regulator if the actual input is equal to or within 8% less than the furnace input specified on the rating plate
or if the furnace rise is above the specified rise range on the rating plate.

If the actual input is significantly higher than the furnace input specified on the rating plate then replace the gas orifice spuds with the gas ori-
fice spuds of the proper size for the type of gas you are using.

24 Unitary Products Group

,&CAUTION

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

TABLE 14: Inlet Gas Pressure Range

INLET GAS PRESSURE RANGE

Natural Gas Propane (LP)

Minimum 4.5" W.C. (1.12 kPa) 8.0" W.C. (1.99 kPa)

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

IMPORTANT: The inlet gas pressure operating range table specifies
what the minimum and maximum gas line pressures must be for the fur-

nace to operate safely. The gas line pressure MUST BE a minimum of

7" W.C. (1.74 kPA) for Natural Gas
11" W.C. (2.74 kPA) for Propane (LP) Gas

in order to obtain the BTU input specified on the rating plate and in
these instructions.

ADJUSTMENT OF MANIFOLD GAS PRESSURE

Manifold gas pressure may be measured at the gas valve.
Turn gas off at the ball valve or gas ¢o¢k 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 R

2. The gas line pressure must be taken at the port marked IN R

3. Using a 3/32" Allen wrench, loosen the setscrew by turning it 1
turn counter clockwise. DO NOT REMOVE THE SET SCREW

FROM THE PRESSURE PORT.

4. Use the 4" (10.2 cm) piece of 1/8" (0.3 cm) tubing to connect the
positive side of the manometer to the gas valve pressure refer-

ence port. Refer to Figure 37 for connection details.

IMPORTANT: The cap for the pressure regulator must be removed
entirely to gain access to the adjustment screw. Loosening or tightening

the cap does not adjust the flow of gas.

5. Refer to Figure 36 for location of pressure regulator adjustment
cap and adjustment screw on main gas valve.

6. Turn gas and electrical supplies on and follow the operating
instructions to place the unit back in operation.

7. Adjust manifold pressure by adjusting gas valve regulator screw
for the appropriate gas per the following:

TABLE 15: Nominal Manifold Pressure

Nominal Manifold Pressure

Natural Gas 3.5" w.c. (0.87 kPa)

Propane (LP) Gas 10.0" w.c. (2.488 kPa)

OUTLET ..... _'_

PRESSURErq ......f T"

PORT 1

WRENCH f _

oss

PRESSURE
PORT

FIGURE 36: Gas Valve

ON/OFF SWITCH
(Shown in ON position)

'_::7 VENT PORT

<--- OUTLET

MAIN REGULATOR
ADJUSTMENT

288130-UIM-A-0407

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

fold pressure will decrease.

8. After the manifold pressure has been adjusted, re-calculate the
furnace input to make sure you have not exceeded the specified

input on the rating plate. Refer to "CALCULATING THE FURNACE
INPUT (NATURAL GAS)".

9. Once the correct BTU (kW) input has been established, turn the
gas valve to OFF and turn the electrical supply switch to OFF; then

remove the flexible tubing and fittings from the gas valve pressure
tap and tighten the pressure tap plug using the 3/32" Allen wrench.

10. Turn the electrical and gas supplies back on, and with the burners
in operation, check for gas leakage around the gas valve pressure

port for leakage using an approved 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.

MAINFOLD PRESSURE "U" TUBE CONNECTION

_ OUTLET

_,_q_,_r__ _ PRESSURE TAP

GAS VALVE J "_ MANIFOLD PiPE

_ 1/4" TUBING

\ hLJ Ill-i-Ill± 3. ,N

\ {_ WATER

FLAME U-TUBE lU--,L--III COLUMN

SENSOR MANOMETER {m- __-_ GAS

MAINFOLD PRESSURE "U" TUBE CONNECTION

1/4"TUBING _e_ .... _rl SENSOR

OUTLET __N

PRESSURE

TAP MANIFOLD q_-_- _[

U-TUBE COLUMN

MANOMETER TGAS

FIGURE 37: Reading Gas Pressure

[_ ._ FLAME

PIPE _L_ _

WATER

PRESSURE
SHOWN

I_--_--ml I PRESSURE

' SHOWN

GASVALVE

Unitary Products Group 25

288130-UIM-A-0407

ADJUSTMENT OF TEMPERATURE RISE

,,DANGER

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 Temperature
will cause premature heat exchanger failure, high levels of Carbon
Monoxide, a fire hazard, personal injury, property damage, and/or

death.

The temperature rise, or temperature difference between the return air
and the heated supply air from the furnace, must be within the range
shown on the furnace rating plate and within the application limitations

as shown in Table 7.
After about 15 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.

FAN OFF
ADJUSTMENT_
JUMPER

TWAIN

oow

m_r

All direct-drive blowers have multi-speed motors. The blower motor
speed taps are located in the control box in the blower compartment.
Refer to Figure 38, and the unit wiring label to change the blower
speed. To use the same speed tap for heating and cooling, the heat ter-
minal and cool terminal must be connected using a jumper wire and

connected to the desired motor lead. Place all unused motor leads on
Park terminals. Two are provided.

[,& CAUTION

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

ADJUSTMENT OF FAN CONTROL SETTINGS

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

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

PARK PARK____ _

_------ YELLOW-MED. LOW

H_AT_L_.

EAC==_H

RED-LOW

BLACK-HI

BLUE-MED. HI

z

I OO ]

÷

FIGURE 38: Furnace Control Board

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. It 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 11 are as follows: LED will turn "on"
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 operation with call for heat.

26 Unitary Products Group

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. Verify that
current is greater than 1.5 microamps at flame current test pad.

4 AMBER FLASHES: The control board is recieving a "Y" signal from
the thermostat without a "G" 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.

HUM +

288130-UIM-A-0407

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 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 and cycle power (24 VAC) to the control after correcting the fail-

ure 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,
dirty or faulty flame sensor, 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, dirty or faulty flame sensor or faulty gas valve. The furnace

will lock out for one hour and then restart.
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 to chassis.

10 RED FLASHES: Gas flow 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. Cycle power (24 VAC) to the control to
reset the hard lockout condition after correcting the failure condition.

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 (pa)

Low flame signal warning starts at 1.5 microamps.

Low flame signal control lockout point is

0.1 microamps DC (pa)

DIAGNOSTIC FAULT CODE STORAGE AND
RETRIEVAL

The control in this 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 onlv be used bv a aualified 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.

FILTER PERFORMANCE

The airflow capacity data published in Table 17 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 16.

The filter pressure drop values in Table 16 are typical values for the
type of filter listed and should only be used as a guideline. Actual pres-
sure drop ratings for each filter type vary between filter manufacturers.

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

Airflow Range

CFM m3/min In W.C. kPA In W.C. kPA In W.C.

0- 750 0- 21.4 0.01 0.00249 0.01 0.00249 0.15

751 -1000 21.25- 28.32 0.05 0.01245 0.05 0.01245 0.20
1001 -1250 28.33- 35.40 0.10 0.02491 0.10 0.02491 0.20
1251 -1500 35.41 -42.48 0.10 0.02491 0.10 0.02491 0.25
1501-1750 42.49-49.55 0.15 0.03736 0.14 0.03487 0.30
1751-2000 49.56-56.63 0.19 0.04733 0.18 0.04484 0.30

2001 & Above 56.64- Above 0.19 0.04733 0.18 0.04484 0.30

Unitary Products Group 27

Minimum

Opening Size

in2 cm 2
230 1484
330 2129
330 2129
330 2129
380 2452
380 2542
463 2987

Disposable

Filter Type

Washable Fiber

Pleated

kPA

0.03736

0.04982

0.04982

0.06227

0.07473

0.07473

0.07473

288130-UIM-A-0407

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

sure drop.

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

4. Select a filter pressure drop from the table based upon the number
of return air openings or return air opening size and add to the

ESP from Step 3 to determine the total system static.

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

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

Speed row.

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

0.58 w.c. (144 Pa), 0.75 w.c. (187 Pa), etc.), the static pressure
may be rounded to the nearest value in the table determining the

airflow using Step 5 or calculate the airflow by using the following

Example: For a 75,000 BTUH (21.98 kW) furnace with 2 return open-
ings and operating on high-speed blower, it is found that total system
static is 0.38" w.c. To determine the system airflow, complete the follow-
ing steps:

Obtain the airflow values at 0.30 w.c. (75 Pa) & 0.40 w.c. (99.6 Pa) ESR
Airflow @ 0.30": 1408 CFM (39.8 m3/min)
Airflow @ 0.40": 1343 CFM (38.0 m3/min)

Subtract the airflow @ 0.30 w.c. (75 Pa) from the airflow @ 0.40 w.c.
(199.6 Pa) to obtain airflow difference.

1343 - 1408 = -65 CFM (1.89 m3/min)
Subtract the total system static from 0.30 w.c. (75 Pa) and divide this

difference by the difference in ESP values in the table, 0.40 w.c.
(99.6 Pa) - 0.30 w.c. (75 Pa), to obtain a percentage.

(0.38-0.30)/ (0.40-0.30)= 0.8

Multiply percentage by airflow difference to obtain airflow reduction.

(0.8)X(-65)= -52

Subtract airflow reduction value to airflow @ 0.30 w.c. (75 Pa) to obtain
actual airflow @ 0.38 inwc (94.6 Pa) ESR
1408 - 52 = 1356

example.

TABLE 17: Blower Performance- CFM

BTU/H (kW) Cabinet Speed

Input Size Tap 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

High 1535 1470 1408 1343 1275 1202 1115 1014 43.5 41.6 39.9 38.0 36.1 34.0 31.6 28.7

75 (22.01 B Med 1215 1199 1182 1151 1106 1039 976 887 34.4 34.0 33.5 32.6 31.3 29.4 27.6 25.1

Low 875 874 864 847 827 799 736 658 24.8 24.7 24.5 24.0 23.4 22.6 20.8 18.6

High 1792 1724 1630 1552 1462 1367 1264 1152 50.7 48.8 46.2 43.9 41.4 38.7 35.8 32.6

75(22.0) 1 C Med 1597 1555 1496 1444 1372 1287 1190 1086 45.2 44.0 42.4 40.9 38.9 36.4 33.7 30.8

Low 1115 1140 1167 1183 1149 1093 1023 939 31.6 32.3 33.0 33.5 32.5 31.0 29.0 26.6

High 1868 1781 1690 1600 1498 1396 1277 1156 52.9 50.4 47.9 45.3 42.4 39.5 36.2 32.7

100(29.3) 1 C Med 1602 1553 1503 1447 1376 1287 1181 1060 45.4 44.0 42.6 41.0 39.0 36.4 33.4 30.0

Low 1147 1147 1147 1147 1132 1078 1009 918 32.5 32.5 32.5 32.5 32.1 30.5 28.6 26.0

High 1634 1562 1484 1417 1340 1238 1154 1030 46.3 44.2 42.0 40.1 37.9 35.1 32.7 29.2

75(22.0) 1 B Med 1243 1228 1214 1184 1133 1079 999 912 35.2 34.8 34.4 33.5 32.1 30.6 28.3 25.8

Low 886 886 886 886 865 823 777 700 25.1 25.1 25.1 25.1 24.5 23.3 22.0 19.8

High 1978 1896 1803 1693 1589 1478 1366 1235 56.0 53.7 51.1 47.9 45.0 41.9 38.7 35.0

75(22.0) 1 C Med 1682 1657 1606 1530 1455 1366 1265 1137 47.6 46.9 45.5 43.3 41.2 38.7 35.8 32.2

Low 1235 1235 1235 1235 1198 1154 1083 987 35.0 35.0 35.0 35.0 33.9 32.7 30.7 27.9

High 2122 2027 1916 1821 1717 1590 1462 1312 60.1 57.4 54.3 51.6 48.6 45.0 41.4 37.2

100(29.3) 1 C Med 1667 1696 1656 1597 1523 1438 1330 1191 47.2 48.0 46.9 45.2 43.1 40.7 37.7 33.7

Low 1130 1145 1177 1194 1181 1146 1077 982 32.0 32.4 33.3 33.8 33.4 32.5 30.5 27.8

High 1552 1491 1420 1348 1271 1185 1080 970 43.9 42.2 40.2 38.2 36.0 33.6 30.6 27.5

75 (22.0) 1 B Med 1229 1237 1198 1164 1105 1039 956 861 34.8 35.0 33.9 33.0 31.3 29.4 27.1 24.4

Low 889 892 879 866 846 807 760 689 25.2 25.3 24.9 24.5 24.0 22.9 21.5 19.5

High 1946 1862 1775 1620 1518 1409 1291 1160 55.1 52.7 50.3 45.9 43.0 39.9 36.6 32.8

75(22.0) 1 C Med 1683 1611 1551 1484 1388 1300 1190 1080 47.7 45.6 43.9 42.0 39.3 36.8 33.7 30.6

Low 1110 1138 1175 1190 1175 1126 1041 937 31.4 32.2 33.3 33.7 33.3 31.9 29.5 26.5

High 1997 1920 1822 1723 1620 1500 1355 1211 56.5 54.4 51.6 48.8 45.9 42.5 38.4 34.3

100(29.3) 1 C Med 1728 1679 1635 1556 1465 1359 1249 1117 48.9 47.5 46.3 44.1 41.5 38.5 35.4 31.6

Low 1131 1156 1181 1190 1171 1126 1049 926 32.0 32.7 33.4 33.7 33.2 31.9 29.7 26.2

1. Return air is through side opposite motor (left side) for one side return (worst case).
Airflows expressed in standard cubic feet per minute (CFM) and in cubic meters per minute (m3/min).
Motor voltage is 115VAC.

External Static Pressure, Inches WC

CFM CFM CFM CFM CFM CFM CFM CFM

UPFLOW, SINGLE SIDE RETURN (WITHOUT FILTER)

DUAL RETURN (TWO SIDES OR ONE-SIDE & BOTTOM)

BOTTOM/END RETURN

(0.025) (0.050) (0.075) (0.099) (0.124) (0.149) (0.174) (0.199)
m3/min m3/min m3/min m3/min m3/min m3/mn m3/m n m3/min

External Static Pressure (kPa)

28 Unitary Products Group

-11

r-

m
c0

5"

co

_D

co

B

BLOWER SPEED CHART

LADDER DIAGRAM

80+ CLAM TUBE FURNACE CONNECTION DIAGRAM

(_c =ou_',,_sr _._ _ -- -- -- ALLo_er _O_eLSUS_ _W_Re MOTORS

,_ _ k_,Mr_E _ _,_CCOR_ _ _Y_L" _eRE ORLY PRESENT OR _ TON FURRAC£S

_es_re_B_O_ErSPEE_ BLU-_eO _ _LOWeRMOTOR
V_TCSSE_ _O_LEr_E YEL-_

_L _AU_ERRZ_Z_tSEULE_E_tS_RLES

_OUR_A_S_S_ tO_ZS _OUt AutreMODZLe

_Rn i

i

NOTES:

ALL Ft_L_ weel_G PER _a_ _AT_O_ALeUe¢ COOZ(_EC_ANVJOR/

2 W AHy O_ THZ OR_GINAL W_RZ AS SUPPL_E_ W_T_ T_Z FURNACE MUST 5Z

REPLAC_O _T _T BE REPLAC[D WiTH W_R_N6 _ATER_AL HAVinG A

_PeRA_UR_ RA_NG Or at L_AS__ _ _os c_

3 CONRZCTOR$ SU_TABLZ FOR COPPER CONDUCTORS OMLY

ALL REPLACZ_ZNT COMPONENTS _UST BE PROPERLY GROUROED

PROWDZ D_CONRZCTS FOR ALL PO_ER SUPPUZS

B _OTOR5 AR£ _NH_RE_?LY PROTZCTZO

NO rE 3 :

1 TOUT FILAGE[_CHANTIERS_LO_; (A) CODE [LZC NATIONAL(C[N}ETIOU/

2 S_ LE F_LAGZDOIT ETREREMPLACEER PATR_ O_ Z_ TOUT _L OO_T

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SEULEMZNTDeS MARZTTZSpOUR F_LDE CU]VRe

4 TOUTECOMPOSA_E OEREMPLACEM_ DOIT {ETRZB_N _SE ZN TERRE
5 FOURN_SS{ZLZ$ DISJONCTZURSPOURL'AL_E,TA]TON
6 LE$ _OTEUR$SONT PROTEGES OZ PAR LEURCONCZPT_OM

I_I CANADIANELEC COD_(CEC)ANp/ORI

LOCALOR City CO_S

()B CODE ELZCCANAO_£N(CEC}ETIOUI
{C} CO_ES L_AUX ZT MUN_C_PAUX

- CAUTION - ,G_

¢AUT IOF,

PrJs, _ P_ PLUG_ S_KE_ON_NeT,oN COntrOleO_R_

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(C_PT_UR_ _k FOURN_ISE_ ,'_i ' _¢ _ BL_

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288130-UIM-A-0407

NOTES

30 Unitary Products Group

NOTES

288130-UIM-A-0407

Unitary Products Group 31

NOTES

Subject to change without notice. Printed in U.S.A.
Copyright _> by York International Corp. 2007. All rights reserved.

Unitary
Products

Group

EO.

Box
19014

288130-UIM-A-0407

Supersedes: 269326-UIM-A-1106

Wichita

KS

67204-9014