Coleman UGAA075BUA, UGAA075BUH, UGAB100BUG, UGAB100BUA, UGAB075BUH Installation Guide

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HIGH EFFICIENCY CLAM TUBE HEAT EXCHANGER SERIES

MODELS: UGAA & UGAB (Single Stage Upflow/Horizontal)

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

TABLE OF CONTENTS

SAFETY ................................................ 1 TWINNING AND STAGING ................................ 12

DUCTWORK ............................................ 4 VENT/COMBUSTION AIR SYSTEM ......................... 14

FILTERS ............................................... 8 SAFETY CONTROLS .................................... 20

GAS PIPING ............................................ 9 START-UP AND ADJUSTMENTS ........................... 20

ELECTRICAL POWER ................................... 11 WIRING DIAGRAM ...................................... 26

LIST OF FIGURES

Dimensions ............................................. 6

Floor Installation .......................................... 6

Platform Installation ....................................... 7

Typical Attic Installation .................................... 7

Typical Suspended Furnace / Crawl Space Installation ............ 8

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

Horizontal Mount and Filter ................................. 8

Gas Valve ............................................... 9

Upflow Configuration ...................................... 9

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

Burner Assembly ........................................ 10

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

Heating and cooling Thermostat Connections .................. 12

Two-Stage Heating and Cooling Thermostat Connections ........ 12

Accessory Connections ................................... 12

Typical Twinned Furnace Application ........................ 13

Single Stage Twinning Wiring Diagram ....................... 13

Two-Stage Twinning Wiring Diagram ......................... !4

Vent Termination ........................................ !4

Alternate Air Intake, Air Outlet and Chimney Connections ......... 15

Air Inlet, Outlet and Chimney Connections ..................... 15

Typical Sidewall Vent Application ............................ !6

Typical Sidewall Vent and Termination Configuration ............ 16

Typical Chimney Connections .............................. !6

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

Home Layout ........................................... !7

Combustion Airflow Path Through The Furnace Casing

to the Burner Box ........................................ !8

Outside and Ambient Combustion Air ......................... 19

Pressure Switch Tubing Routing ............................ 20

Gas Valve .............................................. 23

Reading Gas Pressure .................................... 23

Typical Heat/Cool Speed Tap Connections .................... 24

Wiring Diagram .......................................... 26

LIST OF TABLES

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

Minimum Duct Sizing For Proper Airflow ....................... 5

External Static Pressure Range .............................. 5

Cabinet and Duct Dimensions ............................... 6

Filter Sizes - Upflow ....................................... 8

Inlet Gas Pressure Range .................................. 9

High Altitude Conversion .................................. 1!

Ratings & Physical / Electrical Data - Upflow Models ............ 11

Roof Pitch .............................................. 14

Horizontal Sidewall Venting Clearances ....................... 16

Estimated Free Area ...................................... !8

Free Area .............................................. 18

Unconfined Space Minimum Area in Square Feet ............... 18

Inlet Gas Pressure Range ................................. 23

Nominal Manifold Pressure ................................. 23

Filter Performance - Pressure Drop Inches W.C. and (kPa) ........ 24

Blower Performance - CFM ................................ 25

Field Installed Accessories - Non Electrical .................... 25

Field Installed Accessories - Electrical ........................ 25

SECTION h SAFETY

Q _ ]SO 9001

Certified Quality

Management System

_WARNING

[_ 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 injury.

CAUTION indicates a potentially hazardous situation, which, if not avoided may result in minor or moderate iniurv. It is also used to

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

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, instafler or service agency.

A 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.

66840/035-20003-001 Rev. B (1205)

66840/035-20003-001Rev.B(1205)

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 d

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 VI! of these instructions.

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

TION VII of these instructions.

FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in serious

injury, death or property damage. Never test for gas leaks with an open flame. Use a commercially

available soap solution made specifically for detection of leaks to check all connections. A fire or explosion may result causing prop-

erty damage, personal injury or loss of life.

6. Test for gas leaks as specified in SECTION IX 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 may also be handled by duct(s) sealed to the furnace casing and terminating outside the space containing the furnace.

The return air duct system is required by the furnace manufacturer provided the combustion air and vent system have been installed

and maintained as a Two Pipe Sealed Combustion Air System and provided a return air duct system and return air plenum are not

required by state, local, or regional codes.

9. It is permitted to be use the furnace for heating of buildings or structures under construction. Installation must comply with all

manufacturer'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.

The following requirements to be met:

a. Clean, outside combustion air is provided to the furnace to

minimize the impact of corrosive adhesives, sealants, and other construction materials. Drywall dust is a major concern during construction, which can be pulled into the combustion air path, leading to plugged gas valves, burners, and inducer

assemblies.

b. Filter must be installed in the furnace as specified in the

installation instructions, and must be replaced or thoroughly cleaned prior to occupancy of the home. Again, drywall dust is the key issue, as that dust can be pulled into the circulating blower motor, plugging the motor vents, coating the rotors and stators, etc. which can lead to a potential fire hazard.

c. The temperature of the return air to the furnace must not be

less than 55 degrees F (13 deg C), with no evening setback or furnace shutdown, to prevent condensation in the primary heat exchangers.

d. The air temperature rise must be within the stated rise range

as indicated on the furnace rating plate, and the firing input rate must be set to the unit nameplate value.

e. The external static pressure of the air distribution system

ductwork must at set for heating operation to be at least 0.!0 to 0.20 inches water column, based on the input rate of the furnace, with the lower value for input rates less than 55,000 btu/hr and the upper value for units with input rates above 100,000 btu/hr.

f. A return air duct must be used, sealed to the furnace cabinet,

and terminated outside the space where the furnace is installed. This prevents any recirculation of supply air, which can generate a negative pressure condition at the furnace for non-direct vent furnaces, leading to possible flame rolIout or combustion problems.

g. The furnace and ductwork should be thoroughly and com-

pletely cleaned prior to occupancy of the dwelling to insure the proper operation of the furnace and to avoid potential

health concerns.

10. When installed in a Manufactured (Mobile) Home, Modular Home, or building constructed on-site, combustion air must never be sup-

plied 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 terminate 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.

2 Unitary Products Group

66840/035-20003-001Rev.B(1205)

SAFETY REQUIREMENTS

• 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 CANICSA 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 1. The plenum must be installed according to the instructions.

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

• Provide clearances for servicing ensuring that service access is allowed for both the burners and blower.

• These models are CSA listed or approved for installation into a Modular Home or a Manufactured (Mobile) Home.

• Failure to carefully read and follow all instructions in this manual can result in furnace malfunction, death, personal

injury and/or property damage.

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

other than wood flooring.

• Check the rating plate and power supply to be sure that the elec-

trical characteristics match. All models use nominal !15 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 manufac-

tured (mobile) home and modular home construction practices. These instructions are required as a minimum for a safe installa-

tion.

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.

_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 following on, near or in contact with the fur-

Race.

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.

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 carrieCs 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 have 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 vent piping and elbows will be required.

2. As centralized with the air distribution as possible.

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

4. 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.

5. 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 temoeratures:

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 (!27 ° C) at

any point in the flue pipe. The flue products will condense in the vent pipe if the flue temperature fails below 260 ° F (127 ° C) caus-

ing the vent pipe to deteriorate rapidly.

2. Do not allow return air temperature to be below 55° F (13 ° C) for extended periods. To do so may cause condensation to occur in

the main heat exchanger, leading to premature heat exchanger failure.

Unitary Products Group 3

66840/035-20003-001Rev.B(1205)

Improper installation in an ambient below 32°t: (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:

TABLE 1: Unit Clearances to Combustibles

1. Twenty-four (24) inches (61 cm) between the front d 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.

Installation in a residential aaraoe:

3. A gas-fired furnace for installation in a residential garage must be installed so the burner(s) and the ignition source are located not

less than 18 inches (46 cm) above the floor, and the furnace must be located or protected to avoid physical damage by vehicles.

APPLICATION

TOP FRONT REAR SIDES SINGLE WALL VENT

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

UPFLOW 1 (254) 2 (5.08) 0 (0.0) 0 (00) 6 (1524)

UPFLOW B-VENT 1 (254) 1 (2.54) 0 (0.0) 0 (00) N/A

HORIZONTAL 1 (254) 2 (5.08) 0 (0.0) 1 (5.08) 6 (1524)

HORIZONTAL B-VENT 1 (2.54)) 1 (254) 0 (0.0) 0 (00) N/A

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

FLOOR/ LINE

BOTTOM CONTACT

COMBUSTIBLE YES YES YES NO COMBUSTIBLE YES YES YES NO

COMBUSTIBLE NO YES YES YES 1 COMBUSTIBLE NO YES YES YES 1

CLOSET ALCOVE ATTIC

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. In Canada refer to the National Gas

and Propane Installation Code B149.!-00, Provincial, Local Fire and Safety Codes.

3. 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.

4. Complete a path for heated or cooled air to circulate through the air conditioning and heating equipment. Air must circulate to and

from the conditioned space.

A 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.

The duct system must be properly sized to obtain the correct airflow for the furnace size that is being installed.

Refer to Table 8 and the furnace rating plate for the correct rise range and static pressures If the ducts are undersized, the result will be high duct static 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.

DUCTWORK INSTALLATION Upflow Instructions

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- trois 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.

kWARNING

Attach the supply plenum to the furnace outlet duct

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 connection flanges. This is typically through the use of

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.

4 Unitary Products Group

66840/035-20003-001 Rev. B (1205)

Example:Thefurnaceinputis80,000BTUH,1,200CFM.Therecom- mendedductareais280sq.in,therearetwo8x14rectangularducts attachedtotheplenumandtherearetwo7inchroundductsattachedto

thefurnace.

1. Take8x14,whichequals112sq.in.X2,whichequals224square

inchthengotoroundductsizelocatedinTable2.

2. Thesquareinchareafor7inchroundpipeis38.4,multiplyby2for

tworoundductswhichequals76.8squareinch.

3. Thentakethe224squareinchfromtherectangularductandaddit

tothe76.8sq.in,ofroundduct.Thetotalsquareinchofduct attachedtothefurnaceplenumis300.8squareinch.Thisexceeds

therecommended280squareinchofduct.

Inthisexample,theductsystemattachedtotheplenumhasasufficient areasothatthefurnaceoperatesatthespecifiedexternalstaticpres- sureandwithintheairtemperaturerisespecifiedonthenameplate.

Considerationshouldbegiventotheheatingcapacityrequiredandalso totheairquantity(CFM)required.Thesefactorscanbedeterminedby calculatingtheheatlossandheatgainofthehomeorstructure.Ifthese calculationsarenotperformedandthefurnaceisover-sized,thefollow- ingmayresult:

1. Shortcyclingofthefurnace.

2. Widetemperaturefluctuationsfromthethermostatsetting.

3. Reducedoveralloperatingefficiencyofthefurnace. Thesupplyandreturnductsystemmustbeofadequatesizeand

designedsuchthatthefurnacewilloperatewithinthedesignedairtem- peratureriserangeandnotexceedthemaximumdesignedstaticpres-

sure.Thesevaluesarelistedinthetablebelow. TABLE2:MinimumDuctSizingForProperAirflow

TABLE 3: External Static Pressure Range

Input Output

MBH kW MBH kW

75 22.0 60 17.6 75 22.0 60 17.6

100 29.3 80- 23.4

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). The furnace

will not operate properly on a shorter plenum height. The minimum rec-

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

IMPORTANT: The air temperature rise should be taken only after the

furnace has been operating for at least 15 minutes. Temperatures and

external static pressures should be taken 6" (15 cm) past the first bend

from the furnace in the supply duct and the return duct. If an external fil-

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

Nominal

Air Flow

CFM cmm 1200 34.0

1600 45.3 1600 45.3

Ext. Static Pressure

Minimum Maximum

In.W.C kPa In.W.C kPa

0.12 0.0299 0.50 0.!245

0.12 0.0299 0.50 0.1245

0.15 0.0374 0.50 0.!245

Input

BTU/H

(kW)

75000

(2198)

75000 (2198) 100000

(2931)

NOTE: This chart does not replace proper duct sizing calculations or take into account static pressure drop for run length and fittings. Watch out for the temper- ature rise and static pressures.

1 Maximum return air velocity in rigid duct @ 700 feet per minute (19.82 m3/

minute)

2 Example return main trunk duct minimum dimensions 3 Maximum supply air velocity in rigid duct @ 900 feet per minute (25.49 m3 /

minute)

Airflow Return I Rectangular 2 Round 2 Supply 3

CFM Ins in. x in in Ins

(m 3) (cm _) (cm x cm) (cm) dia. (cm _)

1,200 280 14 x 20 18 216

(3398) (711) (356 x 508) (457) (549)

1,600 360 18 x 20 22 280

(4531) (914) (457 x 508)) (558) (711)

1,600 360 18 x 20 22 280

(4531) (914) (45.7 x 50.8) (558) (711)

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.

Unitary Products Group 5

66840/035-20003-001Rev.B(1205)

29-3/4

,7 cm) (75,6 cm_.

31-1/2

(80.0 cm)

13-15/16

(85A cm)

(58A cm)

FIGURE 1: Dimensions

TABLE 4: Cabinet and Duct Dimensions

BTUH (kW) Cabinet Cabinet Dimension

Input/Output CFM (m3/min) Size A(in.) A(cm) B(in.)* B(cm)*

/b/6U (22.0/1/.6) 1200 (33.98) B 1 / 1/2 44.b 16 1/2 41.9 /bt6U (22.0/1/.6) !600 (46.31) C 21 53.3 20 50.8

100/80 (29.3/23A) 1600 (45.31) C 21 53.3 20 50.8

* Dimensions "B", "C', "D', and "E" arewith duct flangesturned up "F', "G","H", and "J" are with flanges flat

MOBILE HOME AND 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 return air ducts to the furnace must have a total cross sectional

area of not less than two square inches per 1000 BTU H of furnace input rating for heating operation. If air conditioning is to be installed with the

furnace, larger return air ducts may be required, depending on the

capacity of the air conditioner and the airflow required. The return air opening in the top of the furnace is large enough for the largest capacity

air conditioner for which the furnace blower is rated. The return air duct or plenum can be connected to the furnace by performing the following

steps:

1. Bend the 3/4" (1.905 cm) flanges that will be used to attach the return air plenum using the scribe marks in the furnace base.

Refer to Figure 1 for flange locations.

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

Attic installations must meet all minimum clearances to combustibles

and have floor support with required service accessibility.

INSTALLATION RECOMMENDATIONS FLOOR INSTALLATIONS

As shown below in Figure 2, the furnace may be installed directly on the floor of the home, using a side return air connection. A short duct

should be connected to the side cutout in the furnace casing. The other end of the return air duct should be connected to a minimum 25" x 16"

filter grille. If a Blend Air ventilation system is to be installed, the return

air duct must be long enough so that the Blend Air damper can be mounted in the top of the duct.

1 I I J ( fZZCOIL

[ [l rd CAO'NET

F--_ ( /. H_ BLENDAIR _I_ FLEX DUCT

_I I # [_ BLEND AIR

_-GRILLrT=._ E

FIGURE 2: Floor Installation

PLATFORM INSTALLATIONS

As shown below in Figure 3, the furnace may be installed on a raised platform. The platform must be a minimum of 20" in height and a filter

grille with a minimum area of 25" x 16" must be mounted in the front, back or side of the platform. If a Blend Air ventilation system is to be

installed, the platform must be wide enough so that the Blend Air damper can be mounted in the top of the platform

C(in.)* C(cm)* 20 3/8 t1.8 20 3/8 51 .U

20 3/8 51.8

PLENOM

/DAMPER

I _[ 25"x 18"

I H _ FILTER

6 Unitary Products Group

25" x 16"

FILTER

GRILLE

FIGURE 3: Platform Installation

HORIZONTAL MODELS

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. Fellow the ceiI instructions for installing the supply ple-

num. For details of the coiI 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 ceil can be properly seated on the furnace. Attach the supply plenum to the air conditioning coiI 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

66840/035-20003-001 Rev. B (1205)

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.

Mobile Home and Modular Home Upflow/Horizontal Return Plenum Connections

The return air duct and the return air plenum is required by the furnace manufacturer.

If a upflow return air duct system and return plenum are required by state, local, or regional codes then the return plenum may be connected to the furnace inlet and must terminate outside the space containing the

furnace. The external air filter accessory shown in Figure 7 is designed

and recommended for use inside the return plenum.

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

for installations where a return air duct system is utilized, the use of a

listed flexible duct connector is recommended. 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 cross- hatched 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 and in Table 8.

An upflow return air duct and plenum can be attached to the bottom,

side, both sides, or bottom and side of the furnace as shown in Figure

4. Attic and crawl space installations must meet all minimum clearances to

combustibles and have floor support with required service accessibility Refer to Figures 4 and 5. All attic and crawl space installations must have a return air duct system and return plenum. Horizontal installa- tions require a single return duct as shown in Figure 4. A side return is not required in a horizontal application.

IMPORTANT: When replacing an existing furnace, if a return air plenum is used and 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 a return duct mounted filter

rack or filter grille 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 BE A MI NIMUM DISTANCE

OF 18" (45.7 CM) F! THE FURNACE

SUPPLY

AIR

TRAP

SHEET METAL IN FRONT OF FURNACE COMBUSTION

AIR OPENINGS IS RECOMMENDED

FIGURE 4: 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.

PLYWOOD FLOOR

Unitary Products Group 7

66840/035-20003-001Rev.B(1205)

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 5

for typical crawl space installation.

ANGLE IRON

BRACKET

SUPPORT ROD

1"MAX, BETWEEN 6"MtN BETWEEN

ROD & FURNACE ROD & FURNACE

FIGURE 5: Typical Suspended Furnace / Crawl Space Installation

SECTION IIh FILTERS

FILTER INSTALLATION

All applications require the use of a filter. Models must have a field-sup-

plied filter and mounting hardware. Replacement filter size is shown in Table 5.

TABLE 5: Filter Sizes - Upflow

UPFLOW Side

Input Output Air Flow Size

MBH kW MBH kW CFM cmrn in. crn

75 220 60 17.6 1200 34.0 B 25x16 64x41 75 220 60 17.6 1600 45.3 C 25x16 64x41

100 293 80 23.4 1600 45.3 C 25x16 64x41

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 Figures

1 and 6.

I I _ CORNER

Iq FJ J_ MARKINGS

FIGURE 6: Side Return Cutout Markings

Cabinet Return

1"MAX, BETWEEN ROD & FURNACE

Bottom/End

in. cm 24x 15 61 x38 24x 18 61 x46

24x 18 61 x46

_ FRONT OF

Return

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 1.

EXTERNAL FILTER INSTALLATION FOR UPFLOW/HORIZONTAL CONFIGURATIONS

1. Select desired filter position for upfiow/horizontal (left/right side, bottom). Remove the corresponding cabinet cut-outs per instruc-

tions 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 fil-

ter 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, place the external filter box between the return air ple- num and the base of the furnace. The casing bottom is embossed

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

leaks.

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 cIeanable permanent filters. Use d 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 operation.

RETURN DUCT

AIR__ _F

FILTER

FIGURE 7: Horizontal Mount and Filter

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 airfow. 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 16 and the furnace accessories for accessory external filter kit options.

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.

[] []

[] FURNACE []

[] []

[] D

[] [] []

MN I

[] []

8 Unitary Products Group

SECTION IV: GAS PIPING GAS SAFETY

kDANGER

This furnace is designed to operate on NATURAL GAS or PRO-

PANE GAS ONLX Do not burn any other fuel in this furnace. Bum- 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.

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 exceed- ing 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 wil! result in property damage and loss of life.

OUTLET PRESSURE r! I_] I'_

PORT L_ I I

WRENCH _ _

BOSS __

INLET/ PRESSURE

PORT

ON/OFF SWITCH (Shown in OFF position)

FIGURE 8: Gas Valve

VENT PORT

OUTLET

N REGULATOR

ADJUSTMENT

66840/035-20003-001Rev.B(1205)

GAS _ PIPE SHUT-OFF

VALVE

VENT -- BLOWER

DRIP LEG --_

ROLL-OUT _

SWITCH

FIGURE 9: Upflow 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 10.

GAS

MAN UAL

SHUT-OFF VALVE

PRESSURE

GAS VALVE

HOT

IGNITOR

ROLL-OUT SWITCHES

BLOWER DOOR

SWITCH

FURNACE CONTROL

CHECKING THE GAS PRESSURES

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

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

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

4. Using a 3/32" (0.2 cm) Allen wrench, loosen the set screw by turning it 1 turn counter clockwise. DO NOT REMOVE THE

SET SCREW FROM THE PRESSURE PORT.

5. Push one end the 3/8" (0.9 cm) ID flexible tubing over the pres- sure port so that the body of the port is inside the tubing.

6. Use a reducer connector to connect the 3/8" (0.9 cm) ID flexible tube to a 1/4" (0.9 cm) ID flexible tube that is connected to a "U"

tube manometer or digital pressure measuring equipment.

TABLE 6: Inlet Gas Pressure Range

INLET GAS PRESSURE RANGE

Natural Gas Propane (LP)

Minimum 45" W.C (1 12 kPa) 80" W.C (1 99 kPa)

Maximum 105" W.C. (261 kPa) 130" (3.24 kPa) WC.

IMPORTANT: The inlet gas pressure operating range table specifies the minimum and maximum gas line pressures required for safe fur-

nace operation. The minimum inlet gas pressure required to obtain the BTU input

specified on the rating plate and in these instructions is shown below:

• 4.5" W.C. (1.12 kPA) for Natural Gas

• 11.0" W.C. (2.74 kPA) for Propane (LP) Gas

--GAS BURNERS

-- GAS VALVE

HI....................................................................3

DRIP MANLJAL LEG SHUT-OFF VALVE

FIGURE 10: Horizontal Gas Piping

IMPORTANT: An accessible manual shut-off valve must be installed upstream of the furnace gas controls and within 6 feet (! .8 m) of the fur-

nace. Refer to Figures 9 and 10. 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]

The gas valve body is a very thin casting that cannot take any

external pressure. Never apply a pipe wrench to the body of the gas valve when installing piping. A wrench must be placed on the octa-

gon hub located on the gas inlet side of the valve. Placing a wrench to the body of the gas valve wil! damage the valve causing improper

operation and/or the valve to leak.

Gas piping may be connected from either side of the furnace using any of the gas pipe entry knockouts on both sides of the furnace. Refer to

Figure ! dimensions.

Unitary Products Group 9

66840/035-20003-001Rev.B(1205)

GAS ORIFICE CONVERSION FOR PROPANE (LP)

Refer to Table 7 for the proper gas orifice size.

The conversion shall 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.

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 d 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 GAS VALVE

GAS ORIFICE GAS

FIGURE 11: Burner Assembly

CONVERSION PROCEDURE

MANIFOLD

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.

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 or the instructions in the

high altitude conversion kit for the proper gas orifice size. The unit may also be converted for altitudes up to !0,000 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.

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

10 Unitary Products Group

66840/035-20003-001Rev.B(1205)

AkDANGER

PROPANE AND HIGH ALTITUDE CONVERSION KITS

It is very important to choose the correct kit and/or gas orifices for the altitude and the type of gas for which the furnace is being

installed. Only use natural gas in furnaces designed for natural gas. Only use

propane (LP) gas for furnaces that have been properly converted to use propane (LP) gas. Do not use this furnace with butane gas.

Incorrect gas orifices or a furnace that has been improperly con- verted will create an extremely dangerous condition resulting in pre- mature 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 misallgnment of the burner flames, causing premature heat exchanger burnout,

high levels of carbon monoxide, excessive sooting, a fire hazard, personal injury, property damage and/or death.

TABLE 8: Ratings & Physical / Electrical Data - 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

Wire size and over current protection must comply with the National Electrical Code (NFPA-70-1atest edition) and all locaI codes. AFUE 80%.

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" (5.1 cm) x 4"

(10.2 cm) box and cover on the outside of the furnace. Route the

furnace leads into the box using a protective bushing where the wires pass through the furnace panel. After making the wiring con-

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

12.

3. The furnace's control system requires correct polarity of the power supply and a proper ground connection. Refer to Figure 12.

Output

MBH kW

60 17.6 60 17.6 80 23.4

Max. Outlet

Air Temp

°F °C

!65 73.9 160 7! .1 !70 76.7

Nominal

CFM cmm

1200 34.0 1600 45.3 1600 45.3

Blower

Hp Amps

!/3 6.2 1/2 6.2 !/2 7.0

Cabinet Width Air Temp. Rise

In. cm AFUE °F °C

16 7/8 44.45 80.0 35-65 19.4-36.1

20 53.34 80.0 30-60 16.7-33.3 20 53.34 80.0 40-70 22.2-38.9

Blower Total Max Over-current Min.

Size Unit Size (awg) @ 76 ft. Wire

In. cm amps protect one way

10x8 25.4 x 20.3 6.7 15 14 10x!0 25.4 x 25.4 8.5 15 14 10x!0 25.4 x 25.4 8.5 15 14

TABLE 7: High Altitude Conversion

Type Orifice at 2,000 ft. 3,000 ft. 4,000 ft. 5,000 ft.

Of Gas Sea Level (610 m) (914m) (1219 m) (1624 m)

Natural #42 #42 #43 #43 #43

Propane #54 #54 #55 #55 #55

Type 6,000 ft. 7,000 ft. 8,000 ft. 9,000 ft. 10,000 ft.

Of Gas (1829 m) (2134 m) (2438 m) (2743 m) (3048 m)

Natural #44 #44 #45 #46 #47

Propane #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 8 in

these instructions for specific furnace electrical data.

A. CAUTIONI

Use copper conductors only.

B ._ BL_O_]

_WHT (NEUTRAL) j, NOMINAL120VOLT

GRN _..GRN

FIGURE 12: Line Wiring Connections

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 13. Electronic thermo- stats may require the common wire to be connected as shown with the dashed line in Figure 13. 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 13.

Operation Operation

WGT. WGT.

LBS Kg

1!6 53.5 129 58.5 135 61.2

Unitary Products Group 11

66840/035-20003-001Rev.B(1205)

Room Furnace Condensing Thermostat Control Unit

Controls

_, ......................

ToAir Conditioner

Common Trstat Connection

FIGURE 13: Heating and Cooling Thermostat Connections

Room Furnace Condensing Thermostat Control Unit

....... !!!!!!!!!!!!!!!!!!!

FIGURE 14: Two-Stage Cooling and Single Stage Heating

IMPORTANT: Set the heat anticipator in the room thermostat to 0.45 amps. Setting it lower will cause short cycles. Setting it higher will cause

the room temperature to exceed the set points. IMPORTANT: Some electronic thermostats do not have adjustable heat

anticipators. They may have other type cycle rate adjustments. Follow the thermostat manufacturer's instructions.

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

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

ACCESSORY CONNECTIONS

The furnace control will allow power-switching control of various acces- sories. Refer to Figure !5 for connection details.

Thermostat Connections

HUM. HOT

115 VOLT HUMID F ER

EAC HOT

BLK

_. ......................

ConO,ti......

HE_MSWITCHED

CIRCUITS

ELECTRONIC AIR CLEANER CONNECTION

Two 1/4" (0.6 cm) spade terminals (EAC and EAC N) for electronic air cleaner connections are located on the control board. The terminals

provide 115 VAC (1.0 amp maximum) during circulating blower opera- tion.

HUMIDIFIER CONNECTION

Two 1/4" (0.6 cm) spade terminals (HUM and HUM N) for humidifier connections are located on the control board. The terminals provide 115

VAC (1.0 amp maximum) during heating system operation.

SECTION 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 mod- ule. You _ two furnaces that have different integrated control module part numbers. If the part numbers of the two inte- grated 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.

AWARNING

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

CAUTIONI

The relay must not be installed in any location where it could be exposed to water If the relay has been exposed to water in any way, it must not be used.

115 VOLT ELECTRONIC A R CLEANER

HUMI NEUTRALS

FIGURE 15: Accessory Connections

12 Unitary Products Group

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 16. 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 Wl 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.

VENT PIPE

ELECTRICAL SUPPLY

FIGURE 16: Typical Twinned Furnace Application

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.

GAS SUPPLY

1COILFOR EACH FURNACE

66840/035-20003-001 Rev. B (1205)

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.

CAUTION1

The relay must not be installed in any location where it could be exposed to water. If the relay has been exposed to water in any way, it must not be used.

Single-Wire Twinning Instructions Connect the control wiring as shown in the Figure !7.

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 #! to the TWIN terminal of Furnace #2.

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

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

Single-Wire Twinning Operation Heating - On a call for heat (W signal) from the wall thermostat, both

furnaces will start the ignition sequence and the burners on both 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.

FURNACEICONTROLBOARD FURNACE2CONTROLBOARD

IA CAUTION]

If a return duct is connected to only one furnace (with a connection between the two furnaces) an imbalance in the airflow wil! occur

and the furnace furthest from the return plenum will overheat.

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.

Unitary Products Group 13

TO A/C

WALL THERMOSTAT

FIGURE 17: Single Stage Twinning Wiring Diagram

66840/035-20003-001Rev.B(1205)

STAGING

In applications where more heating capacity or more airflow capacity is needed than what one furnace can deliver, twinning can be used to make two furnaces operate in tandem, using one duct system and one room thermostat. This control can also be used along with a two-stage

wall thermostat to stage two twinned furnaces, making them operate

like a single two-stage furnace. This allows only one furnace to supply heat during times when the heat output from one furnace is sufficient to satisfy the demand. When one duct system is used for two furnaces, it is necessary that the two blowers operate in unison. The twinning func-

tion of this board ensures that both blowers turn on and off simulta- 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 controI wiring as shown in the Figure 16.

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

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

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

stat, Furnace #1 wilI 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 wilI 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.

FURNACEICONTROLBOARD FURNACE2CONTROLBOARD

SECTION Vlh VENT/COMBUSTION AIR SYSTEM

VENT SAFETY

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

other restrictions are met.

3FT(09m) MIN

WALL OR PARAPET

THAN 10 FT (3 0 m) CHIMNEY

HEIGHTABOVE ANY ROOF SURFACE WITHIN

R_DGE

FIGURE 19: Vent Termination

LOWEST DISCHARGE OPENING

LISTED CAP _

LtSTED GAS -- VENT

FIGURE 20: Vent Termination

TABLE 9: Roof Pitch

ROOF PITCH H(min) ft m

Fiat to 6/12 1.0 0.30

6/!2 to 7/12 1.25 0.36 Over 7/!2 to 6/12 1.5 0.46 Over 6/12 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 1!/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 16/12 7.0 2.13 Over 16/12 to 20/12 7.5 2.27 Over 20/12 to 2!/12 8.0 2.44

10 FT (30 m) HORIZONTALLY

CHIMNEY

ROOF PITCH

IS X/12

H (rain) - M_NIMUM HEIGHT FROM ROOF TO LOWEST DISCHARGE OPENING

WALL THERMOSTAT

FIGURE 18: Two-Stage Twinning Wiring Diagram

14 Unitary Products Group

66840/035-20003-001 Rev. B (1205)

CATEGORY 1 - 450 F. MAX. VENT TEMR

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 products could condense causing damage to the appliance heat exchanger.

IMPORTANT: The "VENT SYSTEM" must be installed as specified in these instructions for Residential 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. Modular Homes must be vented with an approved roof jack and may

not be common vented with other appliances.

VENTING

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

or B-vent connectors. Type B-vent system extends in a general vertical direction and does not contain offsets exceeding 45 degrees. A vent system having not more than one 60 degree offset is permitted.

CHIMNEY OR GAS VENT

ALTERNATE

VENTILATION LOUVERS FOR UNHEATED CRAWL SPACE

VENTILATION LOUVERS (each end of attic)

OUTLET

AIR

FIGURE 21: Alternate Air Intake, Air Outlet and Chimney Connections

CH IMNEY OR GAS VENT

VENTILATION LOUVERS

each end of attic)

OUTLET

AIR

INLET AIR DUCT [ends 1 ft (30 cm)

above floor]

FIGURE 22: 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 nationa!ly 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 1CKO6O4 must be used. Refer to the instructions with the kit to properly apply these masonry chimney

kits.

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 TjernIund Model GPAK-JT. Follow all application and installation details

provided by the manufacturer of the power vent. Refer to Figures 23 and 24 for typical installation views.

Unitary Products Group 15

66840/035-20003-001Rev.B(1205)

FAN ASSISTED FURNACE

FAN ASSISTED

FIGURE 23: Typical Sidewall Vent Appiication

VENT PIPE

BURNER

WALL PANEL

ACCESS

VENT

FLUE

FIGURE 24: Typical Sidewall Vent and Termination Configuration

VENT PIPING ASSEMBLY

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

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

2. Deburr the piping inside and outside.

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

CHIMNEY OR GAS VENT

OPENING

FIGURE 25: Typical Chimney Connections

FIGURE 26: Horizontal Air Inlet, Outlet and Chimney Connections

VENT CLEARANCES

IMPORTANT: The vent must be installed with the following minimum clearances as shown in Figure 27 and must comply with state, regional,

and local codes and requirements.

TABLE 10: Horizontal Sidewall Venting Clearances

Horizontal Vent Length Ft. (m)with 4 Elbows

Heating

Input

BTU/H

75,000 75,000

100,000

Heating

Input

22.0

29.5

Heating

Output BTU/H

60,000 60,000 80,000

Heating

Output

17.6

23.9

Furnace

Airflow

CFM 1200 1600 1600

Furnace

Airflow

cm/m

33.98

45.31

Pipe Size

Inches cm

4 10.16 4 10.16 4 10.16

Min. Vent Length

Feet meters

4.5 1.37

Max. VentLength

Feet meters

34.5 10.82

16 Unitary Products Group

66840/035-20003-001 Rev. B (1205)

VENT CLEARANCES

[] VENT TERMINAL

(_) AIR SUPPLY

[] AREA WHERE TERMINAL IS NOT PERMITTED

FIXED CLOSED

OPERABLE

FIGURE 27: 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)

6 inches (15 cm) for applications, I0,000 Btuh (3kW), 8 inches (15 cm) for applications lg,000 Btuh (3kW),

B. Clearance to window or door that may be opened I2 inches (30 cm) for appfiances > 10,000 Btuh (3kW) 9 inches (23 cm) for appliances > 10,000 Btuh (3kW)

C. Clearance to permanently closed window D. Vertical clearance to ventilated soffit located

above the terminal within a horizontal distance of 2 feet (61 cm) from the center line of the terminal

E. Clearance to unventilated soffit F Clearance to outside corner G Clearance to inside corner

H. Clearance to each side of center line extended 3 feet (91 cm) within a height I5 feet (4.5 m) above the

above meter/regulator assembly meter/regulator assembly

I. Clearance to service regulator vent outlet 3 feet (91 cm)

J Clearance to nonmechanical air supply inlet to building I2 inches (30 cm) for appliances > 10,000 Btuh (3kW) 9 inches (23 cm) for appliances > 10,000 Btuh (3kW)

or the combustion air inlet to any other appliance and < 100,000 Btuh (30kW), 36 inches (91 cm) and < 50,000 Btuh (15kW), 12 inches (30 cm)

K. Clearance to a mechanical supply inlet 6 feet (I .83 m) 3 feet (9I cm) above if within 10 feet (3 cm) hodzontally L. Clearance above paved sidewalk or paved driveway located on public property 7 feet (2.13 m) t

M Clearance under veranda, porch, deck. or balcony I2 inches (30 cm) $ Dryer Vent 3 ft (91.44 cm) 3 ft. (91 44 cm)

Plumbing Vent Stack 3 ft (91.44 cm) 3 ft. (91 44 cm) Gas Appliance Vent Terminal 3 [t. (9I .44 cm) * 3 ft. (91 44 cm) * Vent Termination from any Building Surface 12" (30.4 cm) 12" (304 cm) Above Any Grade Level 12" (30.4 cm) 12" (304 cm) Above anticipated snow depth 12" (30.4 cm) 12" (304 cm) Any forced air inlet to the building 10 ft. (304.8 cm) 10 ft (3048 cm)

The vent shall extend above the highest point where it passes through the roof, 18" (48 cm) 18" (46 cm) not less than

Any obstruction within a horizontal distance Not less than 18" (46 cm) Not less than 18" (46 cm)

1 In accordance with the current CSA B149 1-00, Natural Gas and Propane Installation Code 2 In accordance with the current ANSI Z223.1 / NFPA 54, National Gas Code. 1- A vent shalI not terminate directty 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 tocal 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 instaIlation instructions for a special venting system * Does not apply to multipte installations of this furnace model Refer to "VENTING MULTIPLE UNITS" in this section of these instructions IMPORTANT: Consideration must be given for degradation of buiIding materials by flue gases. Sidewatt termination may require sealing or shielding of buitding surfaces

with a corrosion resistant materiai 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 buitding surfaces Ifa metal shieId is used it must be a stainless steet matedai at a minimum

dimension of 20 inches It is recommended that a retaining type collar be used that is attached to the buiIding surface to prevent movement of the vent pipe. Responsibility for the provision of proper adequate venting and air supply for application shaII 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

and _ 100,000 Btuh (30kW), 36 inches (91 cm) and 5g,000 Btuh (15kW), 12 inches (30 cm) for appliances > 100,000 Btuh (30kW) for appliances > 50,000 Btuh (30kW)

6 inches (15 cm) for applications < I0,000 Btuh (3kW), 6 inches (15 cm) for applications < 10,000 Btuh (3kW),

for appliances > 100,000 Btuh (30kW) for appliances > 50,000 Btuh (30kW)

Unitary Products Group 17

66840/035-20003-001Rev.B(1205)

HORIZONTAL VENT APPLICATIONS AND

TERMINATION

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

nation, the following should be considered:

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

2. Termination should be positioned where 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.

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

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

6. Horizontal portions of the vent system must slope upwards and be supported to prevent sagging. The vent system may be supported

by the use of clamps or hangers secured to a permanent part of the structure every 4 ft. (1.22 m).

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 CEMENTS

COMBUSTION

ABOVE TOP PANEL

-- INTO SOCKET JUST

An unconfined space is not Iess 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.

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 alI 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 11, to estimate free area. TABLE 11: Estimated Free Area

Wood or MetaI Wood 20-25%*

Louversor Grilles Metal60-70% *

Screens+

Do not useIess than 1/4" (0635 cm) mesh

+ Free area or Iouvers and gritle varies widely; the installer should follow Iou-

veror grilte manufacturer'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" (0.835 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 12: Free Area

Minimum Free Area Required for Each Opening

BTUH Input Vertical Duct or

Rating Horizontal Duct Opening to Outside Round Duct

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

75,000 37.5 in2 (193 cm2) 18.7 in2 (97 cm2) 5" (!3 cm)

100,000 50 in 2 (322 cm2) 25 in2 (!61 cm2) 6" (15 cm)

EXAMPLE: Determining Free Area. Appliance 1Appliance 2Total Input

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

Appliance 1Appliance 2Total Input

100,000 + 30,000 = (130,000 + 2,000) = 85 Sq. In. Horizontal

1/4" (0.635 cm)

mesh or larger 100%

TABLE 13: Unconfined Space Minimum Area in Square Feet

BTUH Input Rating Minimum Free Area Required for Each Opening

FIGURE 28: Combustion Airflow Path Through The Furnace Casing to

the Burner Box

AWARNING

This type of installation requires that the supply air to the appli- ance(s) be of a sufficient amount to support all of the appliance(s) in the area. Operation of a mechanical exhaust, such as an exhaust fan, kitchen ventilation system, clothes dryer or fireplace may cre- ate conditions requiring special attention to avoid unsatisfactory operation of gas appliances. A venting problem or a lack of supply air will result in a hazardous condition, which can cause the appli- ance to soot and generate dangerous levels of CARBON MONOX- IDE, which can lead to serious injury, property damage and / or

death.

18 Unitary Products Group

75,000 469 (43.57 m2)

100,000 625 (58.06 m2)

EXAMPLE: Square feet is based on 8 foot ceilings. 28,000 BTUH X 50 Cubic Ft. = 1,400 = !75 Sq. Ft.

1,000 8' Ceiling Height

66840/035-20003-001Rev.B(1205)

GABLE VENT

OPTIONAL TOPABOVE

SOFFIT OUTLET

_:_ VENTILATED E_

CRAWL SPACE

when the required free area of the supply opening is 2. 9 in2(58•06 cm2) or larger• When a square or rectangular

duct is used, its small dimenstanshall not be less than 3 in (7•6 cm).

5. A square or rectangular shaped duct shall only be used vSO_ _ a means to prevent the direct entry of rain and wind•

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

7. An air supply inlet opening from the outdoors shall 3. be located not less than 12" (30•5 cm) above the _As

6. An att tiger supply fr td hall be equipped with _.... ..... _ _!

outside gradelevel• INLET H_TER NLET 4.

GAS

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 shah be located within 12" (30.5 cm) horizontally from, the burner level of the appliance. Refer to "AIR SOURCE FROM OUTDOORS

AND VENT AND SUPPLY AIR SAFETY CHECK" in these instructions for

additional information and safety check procedure•

2. The duct shah be either metal, or a material meeting the class 1

requirements of CAN4-S110 Standard for Air Ducts•

3. The duct shah be ]east the same cross-sectional area as the free

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

4 The duct shah terminate within 12 in (30.5 cm) above, and

• within 24 in (61 cm) horizontally from, the burner ]eve] of the appliance having the largest input•

GABLE VENT

AR b AIR(a)

GAS

WATER

FIGURE 29: Outside and Ambient Combustion Air

Vent and Supply (Outside) Air Safety Check Procedure

kWARNING

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,

When a Category I fumace 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.

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. Multistery 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 !/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.

GAS VENT

AIR (b) AIR (a)

INLET

COMBUSTION AIR SOURCE FROM OUTDOORS

1. Two permanent openings, one within 12 in (30.5 ram) of the top and one within 12 in (30.5 ram) of bottom of the confined space, Two permanent openings, shall communicate directly or by means of ducts

with the outdoors, crawl spaces or attic spaces•

One permanent openings, commencing within 12 in (30.5 ram)of the

top of the enclosure shall be permitted where the equipment has

clearances of at least 1 in (2.54 cm) from the sides and back and 6 in (15.24 cm) from the front of the appliance. The opening shall communicate directly with the outdoors and shall have a minimum

free area of:

a. 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 act grille is not known•

WATER HEATER INLET

,R/a)

Unitary Products Group 19

66840/035-20003-001Rev.B(1205)

AWARNING

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 shaft 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 d - 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 CANICGA 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 electricaI 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.

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 oower 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 30 for tubing connections.

1. Blockage of combustion air piping or terminal.

2. Blockage d vent piping or terminal.

3. Failure of combustion air blower motor.

FIGURE 30: 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.

20 Unitary Products Group

TOOLS AND INFORMATION THAT WILL BE REQUIRED IN ORDER TO PROPERLY PERFORM THE

FURNACE STARTUP PROCEDURE.

1. Call the local gas supplier to obtain heating value of the natural gas. If you cannot obtain the heating valve of the gas from the gas

supplier, you may use a default value of 1030 BTU/SCF (38.8 MJ / m3) for natural gas.

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 !2" (30 cm) in length, 2 - pieces of 118" (0.3 cm) tubing that are 4"

(10.0 cm) in length, a 1/8" (0.3 cm) tee and a 1t8" (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 !, 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

• ! - 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:

!2" (30 cm) length x 1/8" (0.3 cm) diameter tubing 2 - pieces of 4" (10 cm) length x !/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

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

These items are required in order to properly perform the required star- tup procedure.

IGNITION SYSTEM SEQUENCE

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

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

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

speed. Shortly after inducer start-up, the hot surface igniter will glow for about 17 seconds.

b. After this warm up, the ignition module will energize (open)

the main gas valve.

c. After flame is established, the supply air blower will start in

about 30 seconds.

66840/035-20003-001Rev.B(1205)

_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 al! 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. If the heating value of your gas is significantly different, it may be necessary to replace the orifices.

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.

Unitary Products Group 21

66840/035-20003-001Rev.B(1205)

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 ! 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 ! cubic

ft. of gas from the gas meter.

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

BTU/f 3 x 2 cult x 0960 x 3600 BTUH/H

Seconds it took to measure the 2 cu.ft, of gas NATURAL GAS INPUT CALCULATION

EXAMPLE:

Natural Gas

1030 x 2 x 0960 x 3600

905

BTU/SCF 1030

79,997.38

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 MJim3 (or Default 93.14), times ! 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 ! 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 Cony) x 0960 x 3600 Seconds it took to measure the 2 cu ft of gas NATURAL GAS INPUT CALCULATION

EXAMPLE:

Natural Gas

PROPANE (LP) GAS INPUT CALCULATION EXAMPLE:

Propane Gas

392 x 2 x 0.960 x 3600

90.5

BTU/SCF 1030 = 39.2 MJ/m 3

9315 x 1 x 0960 x 3600

108

BTU/SCF 2500+93 15 MJ/m 3

= MJ/H

= 8476

= 8441

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

Seconds it took to measure the 2 cuft of gas PROPANE (LP) GAS INPUT CALCULATION EXAMPLE:

2500 x 1 x 0960 x 3600

108

Propane Gas

BTU/SCF 2500

02777 kW x 3412.14 BTUH/H

02777 2354 x 3412.14 80,31262

02777 2345 x 3412.14 80,00000

= BTUH/H

= 80,00000

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 3gas MJim (or Default 39.2), times 0.0566 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 0.0566 m3 of gas from the gas meter.

For Propane (LP) Gas multiply the Heat content of the gas MJim 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 Cony) x 0960 x 3600 Seconds it took to measure the 2 cu ft of gas

NATURAL GAS INPUT CALCULATION EXAMPLE:

Natural Gas

PROPANE (LP) GAS INPUT CALCULATION EXAMPLE:

Propane Gas

392 x 2 x 0.960 x 3600

90.5

BTU/SCF 1030 = 39.2 MJ/m 3

9315 x 1 x 0960 x 3600

108

BTU/SCF 2580+93 15 MJ/m 3

= MJ/H

= 8476

= 8441

02777 kW x 3412.14 BTUH/H

02777 2354 x 3412.14 80,31262

02777 2345 x 3412.14 80,00000

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.

For altitudes above 2,000 ft. (610 m) the furnace input MUST BE DERATED. Refer to the GAS CONVERSION FOR PROPANE (LP) AND HIGH

ALTITUDES IN SECTION IV for information on high altitude conversions.

22 Unitary Products Group

[A 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 45" WC (1 12 kPa) 80 _W.C (1 99 kPa)

Maximum 105 _W.C (261 kPa) 130" (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

• !1" 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 cock on gas supply line

before the gas valve. Find the pressure ports on the gas valve marked OUT P and IN P.

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

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

3. Using a 3/32" 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 manifold pressure

port. Refer to Figure 32 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 31 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" wc (2488 kPa)

OUTLET PRESSURE r_ _ Im

PORT _ I I

WRENCH J __

BOSS INLET_ _

PRESSURE PORT

ON/OFF SWITCH (Shown in OFF position)

ENT PORT

OUTLET

N REGULATOR

STMENT

66840/035-20003-001 Rev. B (1205)

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 wil! 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

_j_llr_F_ / PRESSURE TAP

GASVALVE7 -_ MANIFOLDPIPE

_. / 1/4"TUBING

\ I_j,c._c _ WATER FLAME U-TUBE I I_--_: COLUMN SENSOR MANOMETER I I_--_: GAS

FIGURE 32: Reading Gas Pressure

ADJUSTMENT OF TEMPERATURE RISE

OUTLET

I_-- _-- PRESSURE

SHOWN

ADANGER

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 fumace rating plate and within the application

limitations shown in Table 8 "ELECTRICAL AND PERFORMANCE DATA".

The supply air temperature cannot exceed the "Maximum Supply Air Temperature" specified in these instructions and on the 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 wil! cause premature heat exchanger failure, high levels of Carbon Monoxide, a fire hazard, personal inju04 property damage, and/or

death.

FIGURE 31: Gas Valve

Unitary Products Group 23

66840/035-20003-001Rev.B(1205) Thetemperaturerise,ortemperaturedifferencebetweenthereturnair

andtheheatedsupplyairfromthefurnace,mustbewithintherange shownonthefurnaceratingplateandwithintheapplicationlimitations

asshowninTable8.

Afterabout15minutesofoperation,determinethefurnacetemperature

rise.Takereadingsofboththereturnairandtheheatedairintheducts, aboutsixfeet(1.83m)fromthefurnacewheretheywillnotbeaffected byradiantheat.Increasetheblowerspeedtodecreasethetemperature rise;decreasetheblowerspeedtoincreasetherise.

Alldirect-driveblowershavemulti-speedmotors.Theblowermotor

speedtapsarelocatedinthecontrolboxintheblowercompartment. RefertoFigure33,andtheunitwiringlabeltochangetheblower speed.Tousethesamespeedtapforheatingandcooling,theheatter- minalandcoolterminalmustbeconnectedusingajumperwireand

connectedtothedesiredmotorlead.Placeallunusedmotorleadson Parkterminals.Twoareprovided.

CAUTION1

Do not energize more than one motor speed at a time or damage to the motor wil! 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 !80 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 33.

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

180

FIGURE 33: Typical Heat!Cool Speed Tap Connections

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.

Airflow Range Disposable Hogs Hair* Pleated

CFM Cm/m In3 m3 In3 I m3 inwc kPa inwc kPa inwc kPa inwc kPa inwc kPa

751 - 1000 21.27- 28.32 330 0.0054 0.05 0.0125 0.05 0.0125 0.2 0.0498

1001 - 1250 28.35- 35.40 330 0.0054 0.1 0.0249 0.1 0.0249 0.2 0.0498

0-750 0-21.24 230 0.0038 !li!_ 0.01 0.0025 i_lil_ 0.01 0.0025 i_Ii1_i_015 0.0374

1251 - 1500 35.42- 42.47 330 0.0054 0.1 0.0249 0.1 0.0249 0.25 0.0623

1501 - 1750 42.50- 49.55 380 0.0062 ............ 0.15 0.0374 0.14 0.0349 0.3 0.0747

1751-2000 49.58-56.63 380 0.0062 658 0.0108 0.19 0.0473 0.!1 0.0274 0.18 0.0448 0.! 0.0249 0.3 0.0747 0.!7 0.0423

2001 &Above 56.66&Above 463 0.0076 658 0.0108 0.!9 0.0473 0.11 0.0274 0.18 0.0448 0.1 0.0249 0.3 0.0747 0.17 0.0423

* Hogs Hair Filtersare the type supptied with furnace (if suppIied)

APPLYING FILTER PRESSURE DROP TO

DETERMINE SYSTEM AIRFLOW

To determine the approximate airflow of the unit with a filter in place, foI-

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.

Minimum Opening Size Filter Type

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

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. (99.6 Pa) to obtain airflow difference.

1343 - 1408 = -65 CFM (!.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- O.30) / (O.40- 0.3O) = O.8 Multiply percentage by airflow difference to obtain airflow reduction. (O.8) X (-65) = -52 Subtract airflow reduction value to airflow @ 0.30 w.c. (75 Pa) to obtain actual airflow @ 0.38 in wc (94.6 Pa) ESP.

1408 - 52 = 1356

24 Unitary Products Group

66840/035-20003-001Rev.B(1205)

TABLE 17: Blower Performance - CFM

UPFLOW, SINGLE SIDE RETURN (WITHOUT FILTER)

BTU/H (kW) Cabinet Speed

Input/Output Size Tap 0.1 (0025) 0.2 (0050) 0.3 (0075) 0.4 (0099) 0.5 (0124) 0.6 (0149) 07 (0174) 0.8 (0199)

75/60 (22.0/176) I B Medium 1215 34.4 1199 34.0 1182 33.5 1151 32.6 1106 31.3 1039 29.4 976 27.6 887 25.1

75/60 (22.0/17.6) 11 C Medium 1597 45.2 1555 44.0 1496 42.4 1444 40.9 1372 38.9 1287 36.4 1190 33.7 1086 30.8

100/80(293/234) 2 C Medium 1602 45.4 1553 44.0 1503 42.6 1447 41.0 1376 39.8 1287 38.4 1181 33.4 1060 30.0

BTU/H (kW) Cabinet Speed

Input/Output Size Tap 0.1 (0025) 0.2 (0050) 0.3 (0075) 0.4 (0099) 0.5 (0124) 0.8 (0149) 07 (0174) 0.8 (0199)

75/60 (22.0/176) I B Medium 1243 35.2 1228 34.8 1214 34.4 1184 33.5 1133 32.1 1079 30.6 999 28.3 912 25.8

75/60 (22.0/176) I C Medium 1682 47.6 1657 46.9 1606 45.3 1530 43.3 1455 41.2 1366 38.7 1265 32.2 1137 32.2

100/80 (293/234) 2 C Medium 1667 47.2 1696 48.0 1656 46.9 1597 45.2 1523 43.1 1438 40.7 1330 37.7 1191 33.7

BTU/H (kW) Cabinet Speed

Input / Output Size Tap

75/60 (22.0/176) I B Medium 1229 34.8 1237 35.0 1198 33.9 1164 33.0 1105 31.3 1039 29.4 956 27.1 861 24.4

75/60(22.0/17.6) 11 C Medium 1683 47.7 1611 45.6 1551 43.9 1484 42.0 1388 39.3 1300 36.8 1190 33.7 1080 30.6

100/80 (293/234) 2 C Medium 1728 48.9 1679 47.5 1635 46.3 1556 44.1 1465 41.5 1359 38.5 1249 35.4 1117 31.6

1 Return air is through side opposite motor (left side). 2 Motor voltage at 115 V

Airflow expressed in standard cubic feet per minute (CFM) and in cubic meters per minute (m3/min)

TABLE 18: Field Installed Accessories - Non Electrical

MODEL NO. DESCRIPTION USED WITH

1NPOSO5 PROPANE (LP) CONVERSION KIT 50, 7512 1NPOS06 PROPANE (LP) CONVERSION KIT 7516, 10016

1LNOS02 LOW NOX KiT ALL MODELS 1FFO110 FILTER FRAME KIT 50, 7512

1FF0112 FILTER FRAME KiT 7516, 10016

1HAOS02 HiGH ALTITUDE iNSTRUCTION PACKET (DOES NOT iNCLUDE ORIFICES) ALL MODELS

TABLE 19: Field Installed Accessories - Electrical

MODEL NO. DESCRIPTION USED WITH 2TH07700124 THERMOSTAT-One-stage Heat, One-Stage CooI, with subbase ALL MODELS 2TH13700424 THERMOSTAT-One-stage Heat, One-Stage Cool ALL MODELS

2TB17700424 THERMOSTAT Subbase for 2TH13700424 ALL MODELS 2ET07700324 THERMOSTAT - Programmable ALL MODELS

2ET07700224 THERMOSTAT- Deluxe Programmable, One-stage Heat, One-stage Cool with subbase ALL MODELS

cfm cm/m cfm cm/m cfm cm/m cfm cm/m cfm cm/m cfm cm/m cfm cm/m cfm cm/m

High 1535 43.5 1470 41.6 1408 399 1343 38.0 1275 36.1 1202 34.0 1115 31.6 1014 28.7

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

High 1792 50.7 1724 48.8 1630 462 1552 43.9 1462 41.4 1367 38.7 1264 35.8 1152 32.8

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

High 1888 52.9 1781 50.4 1690 479 1600 45.3 1498 42.4 1396 39.5 1277 36.2 1156 32.7

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

UPFLOW, DUEL RETURN, BOTTOM AND ONE SIDE OR TWO SIDE RETURN (WITHOUT FILTER)

HORIZONTAL APPLICATION BOTTOM RETURN (WITHOUT FILTER

cfm cm/m cfm cm/m cfm cm/m cfm cm/m cfm cm/m cfm cm/m cfm cm/m cfm cm/m

High 1634 48.3 1562 44.2 1484 420 1417 40.1 1340 37.9 1238 35.1 1154 32.7 1030 29.2

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

High 1978 56.0 1896 53.7 1803 511 1693 47.9 1589 45.0 1478 41.9 1366 38.7 1235 35.8

Low 1235 35.0 1235 35.0 1235 35.0 1235 35.8 1198 33.9 1154 32.7 1083 30.7 987 27.9

High 2122 60.1 2027 57.4 1916 543 1821 51.6 1717 48.6 1590 45.0 1462 41.4 1312 37.2

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

BLOWER PERFORMANCE CFM - BOTTOM RETURN (WITHOUT FILTER)

0.1 (0025) 0.2 (0050) 0.3 (0075) 0.4 (0099) 0.5 (0124) 0.6 (0149) 07 (0174) 0.8 (0199)

cfm cm/m cfm cm/m cfm cm/m cfm cm/m cfm cm/m cfm cm/m cfm cm/m cfm cm/m

High 1552 43.9 1491 42.2 1420 402 1348 38.2 1271 36.0 1185 33.6 1080 30.6 970 27.5

Low 889 25.2 892 27.8 879 24.9 866 24.5 846 24.0 807 22.9 760 21.5 689 19.5

High 1946 55.1 1862 52.7 1775 503 1628 45.9 1518 43.0 1409 39.9 1291 36.6 1160 32.8

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

High 1997 56.5 1920 54.4 1822 516 1723 48.8 1620 45.9 1500 42.5 1355 38.4 1211 34.3

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

EXTERNAL STATIC PRESSURE, INCHES WC (kPa)

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66840/035-20003-001 Rev. B (1205)

Unitary Products Group 27

NOTES

Unitary Product

Group

5OO5 York Drive

66840/035-20003-001 Rev. B (1205)

Supersedes: 035-20003-001 Rev. A (0704)

Norman

73069

Coleman UGAA075BUA, UGAA075BUH, UGAB100BUG, UGAB100BUA, UGAB075BUH Installation Guide

Specifications and Main Features

Frequently Asked Questions

User Manual