Coleman UGAB100BUJ, UGAB075BUJ, UGAA075BUJ Installation Guide
......................................... I-I ', H', ,'1.-¢" 'l.I
HIGH EFFICIENCY
CLAM TUBE HEAT EXCHANGER SERIES
MODELS: UGAA/UGAB
ISO 9001
(Single Stage Multi-Position)
75- 100 MBH INPUT
(21.98 - 29.31 KW) INPUT
!
LIST OF SECTIONS
SAFETY ................................................ 1 TWINNING AND STAGING ................................ 15
DUCTWORK ............................................ 4 VENT/COMBUSTION AIR SYSTEM ......................... 16
FILTERS .............................................. 10 SAFETY CONTROLS .................................... 22
GAS PIPING ........................................... 11 START-UP AND ADJUSTMENTS ........................... 22
ELECTRICAL POWER ................................... 13 WIRING DIAGRAM ...................................... 29
LIST OF FIGURES
Upflow/Horizontal Configuration .............................. 5
Downflow/Horizontal Configuration ........................... 5
Vent Blower ............................................. 6
Top Cap ................................................ 6
Dimensions ............................................. 7
Combustible Floor Base Accessory ........................... 8
Typical Attic Installation .................................... 9
Typical Suspended Furnace ! Crawl Space Installation ............ 9
Side Return Cutout Markings ............................... 10
Horizontal Mount and Filter ................................ 10
Downflow Filter .......................................... 10
Return Filter Grill and Return Duct Installation .................. 11
Gas Valve .............................................. 11
Upflow Configuration ..................................... 11
Downflow Configuration ................................... 12
Gas Piping ............................................. 12
Burner Assembly ........................................ 12
Electrical Wiring - Upflow Position ........................... 14
Single Stage Heat Thermostat Connections ................... 14
Accessory Connections ................................... 14
Typical Twinned Furnace Application ......................... 15
Single Stage Twinning Wiring Diagram ....................... 16
Two-Stage Twinning Wiring Diagram ......................... 16
Vent Termination ........................................ 16
Vent Termination ........................................ 17
Alternate Air Intake, Air Outlet and Chimney Connections ......... 17
Air Inlet, Outlet and Chimney Connections ..................... 17
Typical Sidewall Vent Application ............................ 18
Typical Sidewall Vent and Termination Configuration ............ 18
Typical Chimney Connections .............................. 18
Horizontal Air Inlet, Outlet and Chimney Connections ............ 18
Home Layout ........................................... 19
Combustion Airflow Path Through The Furnace
Casing to the Burner Box .................................. 20
Outside and Ambient Combustion Air ......................... 21
Pressure Switch Tubing Routing ............................ 22
Gas Valve .............................................. 25
Reading Gas Pressure .................................... 25
Furnace Control Board .................................... 26
Wiring Diagram .......................................... 29
Certified Quality
Management System
LIST
Unit Clearances to Combustibles ............................. 4
Minimum Duct Sizing For Proper Airflow ....................... 6
External Static Pressure Range .............................. 7
Cabinet and Duct Dimensions ............................... 7
Recommended Filter Sizes ................................ 10
High Altitude Conversion .................................. 13
Ratings & Physical ! Electrical Data - Upflow Models ............ 14
Roof Pitch .............................................. 17
Horizontal Sidewall Venting Clearances ...................... 18
SECTION h SAFETY
This is a safety alert symbol. When you see this symbol on
labels or in manuals, be alert to the potential for personal
injury.
Understand and pay particular attention to the signal words DANGER,
WARNING, or CAUTION.
DANGER indicates an imminently hazardous situation, which, if not
avoided, will result in death or serious iniurv.
WARNING indicates a potentially hazardous situation, which, if not
avoided, could result in death or serious iniurv.
CAUTION indicates a potentially hazardous situation, which, if not
avoided mav result in minor or moderate iniurv. It is also used to
alert against unsafe practices and hazards involving only property dam-
age.
OF TABLES
Estimated Free Area ...................................... 20
Free Area .............................................. 20
Unconfined Space Minimum Area in Square Inches ............. 20
Field Installed Accessories - Non Electrical .................... 23
Inlet Gas Pressure Range ................................. 25
Nominal Manifold Pressure ................................. 25
Filter Performance - Pressure Drop Inches W.C. and (kPa) ........ 27
Blower Performance - CFM ................................ 28
_WARNING
Improper installation may create a condition where the operation of
the product could cause personal injury or property damage.
Improper installation, adjustment, alteration, service or mainte-
nance can cause injury or property damage. Refer to this manual
for assistance or for additional information, consult a qualified con-
tractor, installer or service agency.
CAUTION
This product must be installed in strict compliance with the installa-
tion instructions and any applicable local, state, and national codes
including, but not limited to building, electrical, and mechanical
codes.
288130-UIM-A-0407
288130-UIM-A-0407
SPECIFIC SAFETY RULES AND PRECAUTIONS
1. Only Natural gas or Propane (LP) gas are approved for use with
this furnace. Refer to the furnace rating plate or Section IV of
these instructions.
2. Install this furnace only in a location and position as specified in
SECTION I of these instructions.
3. A gas-fired furnace for installation in a residential garage must be
installed as specified in SECTION I of these instructions.
4. Provide adequate combustion and ventilation air to the furnace
space as specified in SECTION VII of these instructions.
5. Combustion products must be discharged outdoors. Connect this
furnace to an approved vent system only, as specified in SEC-
TION VII of these instructions.
_WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warnings exactly could result in serious
injury, death or property damage.
Never test for gas leaks with an open flame. Use a commercially
available soap solution made specifically for detection of leaks to
check all connections. A fire or explosion may result causing prop-
erty damage, personal injury or loss of life.
6. Test for gas leaks as specified in SECTION Xl of these instruc-
tions.
7. Always install the furnace to operate within the furnace's intended
temperature rise range. Only connect the furnace to a duct system
which has an external static pressure within the allowable range,
as specified on the furnace rating plate.
8. When a furnace is installed so that supply ducts carry air circulated
by the furnace to areas outside the space containing the furnace,
the return air shall also be handled by duct(s) sealed to the fur-
nace casing and terminating outside the space containing the fur-
nace.
9. It is permitted to use the furnace for heating of buildings or struc-
tures under construction. Installation must comply with all manu-
facturer's installation instructions including:
Proper vent installation;
Furnace operating under thermostatic control;
Return air duct sealed to the furnace;
⢠Air filters in place;
Set furnace input rate and temperature rise per rating plate
marking;
Means for providing outdoor air required for combustion;
Return air temperature maintained between 55°F (13°C) and
80°F (27°C);
⢠The air filter must be replaced upon substantial completion of
the construction process;
Clean furnace, duct work and components upon substantial
completion of the construction process, and verify furnace-
operating conditions including ignition, input rate, temperature
rise and venting, according to the manufacturer's instructions.
10. When installed in a Non-HUD-Approved Modular Home or building
constructed on-site, combustion air shall not be supplied from
occupied spaces.
11. The size of the unit should be based on an acceptable heat loss
calculation for the structure. ACCA, Manual J or other approved
methods may be used.
12. Mobile Home Installations:
This appliance must be installed with a vent terminating in the
same atmospheric zone, external to the building.
13. Modular and Manufactured (Mobile) Home Installations:
This appliance must be installed so that the vent pipe from the
vent connection on the furnace can be easily connected to a B
type vent that terminates outdoors. This appliance cannot be con-
nected to a vent that is serving another appliance. This appliance
shall be installed in an area where there is an adequate supply of
combustion air available to assure proper combustion and ambient
air temperatures are maintained within safe operating limits.
If an adequate supply of combustion air is not available to assure
proper combustion and ventilation air, outside air shall be intro-
duced to the space in which the appliance is located. An outside
combustion air duct may be used to provide the outside air to the
space. Refer to ANSI Z223.1 National Fuel Gas Code or in Can-
ada B149-00 National Gas and Propane Installation Code for
proper duct sizing and installation.
NOTE: Air for combustion must never be taken from occupied spaces.
Appliance combustion air must be provided from outdoors.
14. Modular Home Definition:
Factory-built home constructed to the state, local, or regional code
where the house will be located. The home is transported in one or
more modules and joined at the home site.
15. Mobile Home Definition:
Factory-built home constructed, transported, and installed under
the federal building code administered by the U.S. Department of
Housing and Urban Development (HUD Code), rather than to
building codes at their destination. The house is built, transported,
and installed on a non-removable chassis.
16. This furnace is not approved for installation in trailers or recre-
ational vehicles.
SAFETY REQUIREMENTS
⢠This furnace should be installed in accordance with all national
and local building/safety codes and requirements, local plumbing
or wastewater codes, and other applicable codes. In the absence
of local codes, install in accordance with the National Fuel Gas
Code ANSI Z223.1/NFPA 54, National Fuel Gas Code, and!or
CAN/CGA B149.1 Natural Gas and Propane Installation Code
(latest editions). Furnaces have been certified to the latest edition
of standard ANSI Z21-47 ⢠CSA 2.3.
⢠A manufactured (mobile) home installation must conform with the
Manufactured Home Construction and Safety Standard, Title 24
CFR, Part 3280, or when such standard is not applicable, the
standard for Manufactured Home Installations (Manufactured
Home Sites, Communities, and Set-ups) ANSI/NCS A225.1, and/
or the Canadian Standard for CAN/CSA Z240 MH, Series M92
Mobile Homes. Furnaces have been certified to the latest edition
of standard ANSI Z21-47 ⢠CSA 2.3.
Refer to the unit rating plate for the furnace model number, and
then see the dimensions page of this instruction for return air ple-
num dimensions in Figure 5. The plenum must be installed
according to the instructions.
Provide clearances from combustible materials as listed under
Clearances to Combustibles.
Provide clearances for servicing ensuring that service access is
allowed for both the burners and blower.
⢠These models ARE NOT CSA listed or approved for installation
into a HUD APProved Modular Home or a Manufactured
(Mobile) Home.
⢠This furnace is not approved for installation in trailers or recre-
ational vehicles.
⢠Failure to carefully read and follow all instructions in this
manual can result in furnace malfunction, death, personal
injury and/or property damage.
2 Unitary Products Group
Furnaces for installation on combustible flooring shall not be
installed directly on carpeting, tile or other combustible material
other than wood flooring.
Check the rating plate and power supply to be sure that the elec-
trical characteristics match. All models use nominal 115 VAC, 1
Phase, 60-Hertz power supply. DO NOT CONNECT THIS APPLI-
ANCE TO A 50 HZ POWER SUPPLY OR A VOLTAGE ABOVE
130 VOLTS.
Furnace shall be installed so the electrical components are pro-
tected from water.
Installing and servicing heating equipment can be hazardous due
to the electrical components and the gas fired components. Only
trained and qualified personnel should install, repair, or service
gas heating equipment. Untrained service personnel can perform
basic maintenance functions such as cleaning and replacing the
air filters. When working on heating equipment, observe precau-
tions in the manuals and on the labels attached to the unit and
other safety precautions that may apply.
These instructions cover minimum requirements and conform to
existing national standards and safety codes. In some instances
these instructions exceed certain local codes and ordinances,
especially those who have not kept up with changing residential
and non-HUD modular home construction practices. These
instructions are required as a minimum for a safe installation.
COMBUSTION AIR QUALITY
(LIST OF CONTAMINANTS)
The furnace will require OUTDOOR AIR for combustion when the fur-
nace is located in any of the following environments.
Restricted Environments
Commercial buildings
Buildings with indoor pools
Furnaces installed in laundry rooms
Furnaces installed in hobby or craft rooms
Furnaces installed near chemical storage areas
Chemical exposure
The furnace will require OUTDOOR AIR for combustion when the fur-
nace is located in an area where the furnace is being exposed to the fol-
lowing substances and / or chemicals.
Permanent wave solutions
Chlorinated waxes and cleaners
Chlorine based swimming pool chemicals
Water softening chemicals
De-icing salts or chemicals
Carbon tetrachloride
Halogen type refrigerants
Cleaning solvents (such as perchloroethylene)
Printing inks, paint removers, varnishes, etc.
Hydrochloric acid
Cements and glues
Antistatic fabric softeners for clothes dryers
Masonry acid washing materials
If outdoor air is used for combustion, the combustion air intake duct sys-
tem termination must be located external to the building and in an area
where there will be no exposure to the substances listed above.
288130-UIM-A-0407
,&WARNING
The furnace area must not be used as a broom closet or for any
other storage purposes, as a fire hazard may be created. Never
store items such as the foflowing on, near or in contact with the fur-
nace.
1. Spray or aerosol cans, rags, brooms, dust mops, vacuum
cleaners or other cleaning tools.
2. Soap powders, bleaches, waxes or other cleaning com-
pounds; plastic items or containers; gasoline, kerosene, ciga-
rette lighter fluid, dry cleaning fluids or other volatile fluid.
3. Paint thinners and other painting compounds.
4. Paper bags, boxes or other paper products
Never operate the furnace with the blower door removed. To
do so could result in serious personal injury and/or equipment
damage.
FOR FURNACES INSTALLED IN THE COMMON-
WEALTH OF MASSACHUSETTS ONLY
For all side wall horizontally vented gas fueled equipment installed in
every dwelling, building or structure used in whole or in part for resi-
dential purposes, including those owned or operated by the Com-
monwealth and where the side wall exhaust vent termination is less
than seven (7) feet above finished grade in the area of the venting,
including but not limited to decks and porches, the following require-
ments shall be satisfied:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At
the time of installation of the side wall horizontal vented gas
fueled equipment, the installing plumber or gasfitter shall
observe that a hard wired carbon monoxide detector with an
alarm and battery back-up is installed on the floor level where
the gas equipment is to be installed. In addition, the installing
plumber or gasfitter shall observe that a battery operated or
hard wired carbon monoxide detector with an alarm is installed
on each additional level of the dwelling, building or structure
served by the side wall horizontal vented gas fueled equipment.
It shall be the responsibility of the property owner to secure the
services of qualified licensed professionals for the installation of
hard wired carbon monoxide detectors
a. In the event that the side wall horizontally vented gas
fueled equipment is installed in a crawl space or an attic,
the hard wired carbon monoxide detector with alarm and
battery back-up may be installed on the next adjacent floor
level.
b. In the event that the requirements of this subdivision can
not be met at the time of completion of installation, the
owner shall have a period of thirty (30) days to comply with
the above requirements; provided, however, that during
said thirty (30) day period, a battery operated carbon mon-
oxide detector with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS. Each car-
bon monoxide detector as required in accordance with the
above provisions shall comply with NFPA 720 and be ANSI/UL
2034 listed and IAS certified.
3. SIGNAGE. A metal or plastic identification plate shall be perma-
nently mounted to the exterior of the building at a minimum
height of eight (8) feet above grade directly in line with the
exhaust vent terminal for the horizontally vented gas fueled
heating appliance or equipment. The sign shall read, in print
size no less than one-half (1/2) inch in size, "GAS VENT
DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUC-
TIONS".
4. INSPECTION. The state or local gas inspector of the side wall
horizontally vented gas fueled equipment shall not approve the
installation unless, upon inspection, the inspector observes car-
bon monoxide detectors and signage installed in accordance
with the provisions of 248 CMR 5.08(2)(a)1 through 4.
Unitary Products Group 3
288130-UIM-A-0407
INSPECTION
As soon as a unit is received, it should be inspected for possible dam-
age during transit. If damage is evident, the extent of the damage
should be noted on the carrier's freight bill. A separate request for
inspection by the carrier's agent should be made in writing. Also, before
installation the unit should be checked for screws or bolts, which may
have loosened in transit, and any shipping or spacer brackets which
need to be removed.
FURNACE LOCATION AND CLEARANCES
The furnace shall be located usina the followina auidelines:
1. Where a minimum amount of air intake/vent piping and elbows will
be required.
2. As centralized with the air distribution as possible.
3. Where adequate combustion air will be available (particularly
when the appliance is not using outdoor combustion air).
4. Where it will not interfere with proper air circulation in the confined
space.
5. Where the outdoor vent terminal will not be blocked or restricted.
Refer to "VENT CLEARANCES" located in SECTION VII of these
instructions. These minimum clearances must be maintained in
the installation.
6. Where the unit will be installed in a level position with no more than
1/4" (0.64 cm) slope side-to-side and front-to-back to provide
proper condensate drainage.
Installation in freezina temperatures:
1. Furnace shall be installed in an area where ventilation facilities
provide for safe limits of ambient temperature under normal oper-
ating conditions. Ambient temperatures falling below 32° F (0° C)
may result in the flue temperature falling below 260 ° F (127 ° C) at
any point in the flue pipe between the furnace and the chimney or
a B-Vent. The flue products will condense in the vent pipe if the
flue temperature falls below 260 ° F (127 ° C) causing the vent pipe
to deteriorate rapidly.
2. Do not allow return air temperature to be below 550 F (13 ° C) for
extended periods. To do so may cause condensation to occur in
the main heat exchanger, leading to premature heat exchanger
failure.
TABLE 1: Unit Clearances to Combustibles
,&WARNING
Improper installation in an ambient below 32°F (0.0 ° C) could create
a hazard, resulting in damage, injury or death.
3. If this furnace is installed in an unconditioned space and an
extended power failure occurs, there will be potential damage to
the internal components. Following a power failure situation, do
not operate the unit until inspection and repairs are performed.
Clearances for access:
Ample clearances should be provided to permit easy access to the unit.
The following minimum clearances are recommended:
1. Twenty-four (24) inches (61 cm) between the front of the furnace
and an adjacent wall or another appliance, when access is
required for servicing and cleaning.
2. Eighteen (18) inches (46 cm) at the side where access is required
for passage to the front when servicing or for inspection or replace-
ment of flue/vent connections.
In all cases, accessibility clearances shall take precedence over clear-
ances for combustible materials where accessibility clearances are
greater.
,&WARNING
Downflow furnaces for installation on combustible flooring only
when installed on the accessory combustible floor base on wood
flooring only and shall not be installed directly on carpeting, tile or
other combustible material.
Check the rating plate and power supply to be sure that the electri-
cal characteristics match. All models use nominal 115 VAC, 1
Phase 60Hz power supply.
Furnace shall be installed so the electrical components are pro-
tected from water.
Installation in a residential aaraee:
A gas-fired furnace for installation in a residential garage must be
installed so the burner(s) and the ignition source are located not less
than (18) inches (46 cm) above the floor, and the furnace must be
located or protected to avoid physical damage by vehicles.
Application
Upflow 1 (2.5) 2 (5.1) 0 (0.0) 0 (0.0) 6(15.2)
Upflow B-Vent 1(2.5) 3 (7.6) 0 (0.0) 0 (0.0) 6 (15.2)
Horizontal 1 (2.5) 2 (5.1) 0 (0.0) 1 (5.08) 6 (15.2)
Horizontal B-Vent 1 (2.5) 3 (7.6) 0 (0.0) 0 (0.0) 6 (15.2)
Downflow 1 (2.5) 2 (5.1) 0 (0.0) 0 (0.0) 6(15.2)
Downflow B-Vent 1 (2.5) 3 (7.6) 0 (0.0) 0 (0.0) 6 (15.2)
1. Line contact only permitted between lines formed by the intersection of the rear panel and side panel (top in horizontal position) of the furnace jacket and building
joists, studs or framing.
SECTION Ih DUCTWORK
DUCTWORK GENERAL INFORMATION
The duct system's design and installation must:
1. Handle an air volume appropriate for the served space and within
the operating parameters of the furnace specifications.
2. Be installed in accordance with standards of NFPA (National Fire
Protection Association) as outlined in NFPA pamphlets 90A and
90B (latest editions) or applicable national, provincial, or state, and
local fire and safety codes or in Canada, refer to the Natural Gas
and Propane Installation Code B149.1-00.
Top Front Rear Sides Single Wall Vent
In, (cm) In, (cm) In, (cm) In, (cm) In, (cm)
3. Create a closed duct system. For residential and Non-HUD Modu-
lar Home installations, when a furnace is installed so that the sup-
ply ducts carry air circulated by the furnace to areas outside the
space containing the furnace, the return air shall also be handled
by a duct(s) sealed to the furnace casing and terminating outside
the space containing the furnace.
4. Complete a path for heated or cooled air to circulate through the
air conditioning and heating equipment and to and from the condi-
tioned space.
5. For manufactured (mobile) home and modular home return
duct system installation: The return air duct and the return air
plenum are required by the furnace manufacturer.
Floor/ Line
Bottom Contact
Combustible Yes Yes Yes No
Combustible Yes Yes Yes No
Combustible No Yes Yes Yes1
Combustible No Yes Yes Yes1
Non-Combustible Yes Yes Yes No
Non-Combustible Yes Yes Yes No
Closet Alcove Attic
4 Unitary Products Group
[,& CAUTION
The cooling coil must be installed in the supply air duct, down-
stream of the furnace. Cooled air may not be passed over the heat
exchanger.
When the furnace is used in conjunction with a cooling coil, the coil
must be installed parallel with, or in the supply air side of the furnace to
avoid condensation in the primary heat exchanger. When a parallel flow
arrangement is used, dampers or other means used to control airflow
must be adequate to prevent chilled air from entering the furnace. If
manually operated, the damper must be equipped with means to pre-
vent the furnace or the air conditioner from operating unless the damper
is in full heat or cool position.
AWARNING
The duct system must be properly sized to obtain the correct airflow
for the furnace size that is being installed.
Refer to Table 7 and the furnace rating plate for the correct rise
range and static pressures
If the ducts are undersized, the result will be high duct static pres-
sures and/or high temperature rises which can result in a heat
exchanger OVERHEATING CONDITION. This condition can result
in premature heat exchanger failure, which can result in personal
injury, property damage, or death.
288130-UIM-A-0407
14. Remove the rectangular knockout in the center of the top cap. See
Figure 4.
15. Install the top cap at the same end of the furnace as the vent
blower, using the sheet metal screws saved earlier. See Figure 1.
16. Install the bottom cap on the bottom of the furnace using the sheet
metal screws saved earlier. See Figure 1.
17. The conversion is now complete. The furnace may now be
installed in the upflow position or in the horizontal position on
either side.
TRANSITION
TOP j_ VENT
EXTRA PRESSURE
SCREWS
GASKET /
CAP
_i : ::::: PAN
' k J/ ,b; =- = e
J HOSE
/i
PRESSURE
SWITCH
VENT
BLOWER
i
INSTALLATION POSITION
This furnace may be installed in an upflow, downflow or horizontal posi-
tion. Depending on the configuration shipped from the factory, it may be
necessary to convert the furnace from downflow to upflow or from
upflow to downflow configuration. Use conversion instructions in this
document.
CONVERSION INFORMATION
This furnace may be shipped in either the upflow or the downflow con-
figuration. To convert from upflow to downflow or vice-versa it is neces-
sary only to exchange the top and bottom casing caps and to rotate the
vent blower 180 degrees. Use the step by step instructions to perform
the conversion.
TO CONVERT FROM DOWNFLOW TO UPFLOW
CONFIGURATION
1. Lay the furnace on its back.
2. Remove the front door.
3. Remove the seven sheet metal screws that are used to fasten the
top cap to the casing. Remove the top cap and save the screws.
4. Remove the four sheet metal screws that are used to fasten the
bottom cap to the casing. Remove the bottom cap and save the
screws.
5. Unplug the vent blower wires.
6. Disconnect the pressure hose from the vent blower.
7. Remove the four machine screws that fasten the vent blower to
the vent pan and save the screws. Leave the gasket in place on
the pan.
8. Remove the two extra machine screws in the vent pan front and
save the screws.
9. Rotate the vent blower and transition 180° so that its outlet points
to the outlet air end of the furnaces as shown in Figure 1.
10. Line up the vent blower mounting holes with the holes in the vent
pan and screw it into place. Use the same machine screws that
held the vent blower in place previously.
11. Install the two extra machine screws in the two open holes in the
front of the vent pan See Figure 1.
12. Plug in the vent motor wires.
13. Plug the pressure hose into the vent blower.
BOTTOM
j CAP
FIGURE 1: Upflow/Horizontal Configuration
TOP
CAP
TRANSITION
BOTTOM
CAP \_
/ /
PRESSURE VENT EXTRA VENT
HOSE PAN SCREWS BLOWER
/
_GASKET
FIGURE 2: Downflow/Horizontal Configuration
TO CONVERT FROM UPFLOW TO DOWNFLOW
CONFIGURATION
1. Lay the furnace on its back.
2. Remove the front door.
3. Remove the seven sheet metal screws that are used to fasten the
top cap to the casing.
4. Remove the four sheet metal screws that are used to fasten the
bottom cap to the casing. Remove the bottom cap and save the
screws.
Unitary Products Group 5
288130-UIM-A-0407
5. Unplug the vent blower wires.
6. Disconnect the pressure hose from the vent blower.
7. Remove the four machine screws that fasten the vent blower to
the vent pan and save the screws. Leave the gasket in place on
the vent pan.
8. Remove the two extra machine screws in the vent pan front and
save the screws.
9. Install the cast aluminum transition on the vent blower, using the
three screws supplied on the vent blower. See Figure 3.
TRANSITION-
FIGURE 3: Vent Blower
10. Rotate the vent blower 1800so that its outlet points toward the inlet
air end of the furnace. See Figure 2.
11. Line up the vent blower mounting holes with the holes in the vent
pan and screw it into place. Use the same machine screws that
held the vent blower in place previously.
12. Install the two extra machine screws in the two open holes in the
front of the vent pan. See Figure 2.
13. Plug in the vent motor wires.
14. Plug the pressure hose into the vent blower.
15. Remove the round knockout at the right side of the top cap. See
Figure 4.
UPFLOW _ VENT
VENT _ _ .......... _C:.. OPENING
OPENING ...... ........._ .........
FIGURE 4: Top Cap
16. Install the top cap at the opposite end of furnace from the vent
blower, using the seven sheet metal screws saved earlier. See
Figure 2.
17. Install the bottom cap on the bottom of the furnace using the sheet
metal screws saved earlier. See Figure 2,
18. The conversion is now complete. The furnace may now be
installed in the downflow position or in the horizontal position on
either side.
DOWNFLOW
FLOOR BASE AND DUCTWORK INSTALLATION
Upflow Instructions
Attach the supply plenum to the furnace outlet duct
connection flanges. This is typically through the use of
S cleat material when a metal plenum is used. The use
of an approved flexible duct connector is recom-
mended on all installations. This connection should be
sealed to prevent air leakage. The sheet metal should
be cross-hatched to eliminate any popping of the
sheet metal when the indoor fan is energized.
When replacing an existing furnace, if the existing plenum is not the
same size as the new furnace then the existing plenum must be
removed and a new plenum installed that is the proper size for the new
furnace. If the plenum is shorter than 12" (30.5 cm) the turbulent air flow
may cause the limit controls not to operate as designed, or the limit con-
trols may not operate at all.
The duct system is a very important part of the installation. If the duct
system is improperly sized the furnace will not operate properly.
The ducts attached to the furnace plenum, should be of sufficient size
so that the furnace operates at the specified external static pressure
and within the air temperature rise specified on the nameplate.
Table 2 is a guide for determining whether the rectangular duct system
that the furnace is being connected to be of sufficient size for proper fur-
nace operation.
Use the Example below to help you in calculating the duct area to deter-
mine whether the ducts have sufficient area so that the furnace oper-
ates at the specified external static pressure and within the air
temperature rise specified on the nameplate.
Example: The furnace input is 80,000 BTUH, 1,200 CFM. The recom-
mended duct area is 280 sq.in, there are two 8 x 14 rectangular ducts
attached to the plenum and there are two 7 inch round ducts attached to
the furnace.
1. Take 8 x 14, which equals 112 sq.in. X 2, which equals 224 square
inch then go to round duct size located in Table 2.
2. The square inch area for 7 inch round pipe is 38.4, multiply by 2 for
two round ducts which equals 76.8 square inch.
3. Then take the 224 square inch from the rectangular duct and add it
to the 76.8 sq.in, of round duct. The total square inch of duct
attached to the furnace plenum is 300.8 square inch. This exceeds
the recommended 280 square inch of duct.
In this example, the duct system attached to the plenum has a sufficient
area so that the furnace operates at the specified external static pres-
sure and within the air temperature rise specified on the nameplate.
Consideration should be given to the heating capacity required and also
to the air quantity (CFM) required. These factors can be determined by
calculating the heat loss and heat gain of the home or structure. If these
calculations are not performed and the furnace is over-sized, the follow-
ing may result:
1. Short cycling of the furnace.
2. Wide temperature fluctuations from the thermostat setting.
3. Reduced overall operating efficiency of the furnace.
The supply and return duct system must be of adequate size and
designed such that the furnace will operate within the designed air tem-
perature rise range and not exceed the maximum designed static pres-
sure. These values are listed Tables 2 and 3.
TABLE 2: Minimum Duct Sizing For Proper Airflow
Input Airflow Return I Rectangular 2 Round 2 Supply 3
BTU/H CFM In_ in. x in. in. In_
(kW) (m3) (cm 2) (cm x cm) (cm) dia. (cm2)
75,000 1,200 280 14 x 20 18 216
(21.98) (33.98) (1806) (35.6 x 50.8) (45.7) (1394)
75,000 1,600 360 18 x 20 22 280
(21.98) (45.31) (2322) (45.7 x 50.8) (55.8) (1806)
100,000 1,600 360 18 x 20 22 280
(29.31) (45.31) (2322) (45.7 x 50.8) (55.8) (1806)
NOTE: This chart does not replace properduct sizing calculationsor take into
account static pressure dropfor run length andfittings. Watch outfor thetemper-
ature rise and static pressures.
1. Maximum return air velocity in rigid duct @ 700 feet per minute (213 m/min).
2. Example return main trunk duct minimum dimensions.
3. Maximum supply air velocity in rigid duct @ 900 feet per minute (274 m/min)
6 Unitary Products Group
288130-UIM-A-0407
TABLE 3: External Static Pressure Range
Input
MBH kW
75 22.0
75 22.0
100 29.3
TABLES 2 and 3 are to be used as a guide only to help the installer
determine if the duct sizes are large enough to obtain the proper air flow
(CFM) through the furnace. TABLES 2 and 3 ARE NOT to be used to
design ductwork for the building where the furnace is being installed.
There are several variables associated with proper duct sizing that are
not included in the tables. To properly design the ductwork for the build-
ing, Refer to the ASHRAE Fundamentals Handbook, Chapter on
"DUCT DESIGN" or a company that specializes in Residential and Mod-
ular Home duct designs.
IMPORTANT: The minimum plenum height is 12" (30.5 cm). The fur-
nace will not operate properly on a shorter plenum height. The mini-
mum recommended rectangular duct height is 4 inches (10 cm)
attached to the plenum.
Nominal
AirFlow
CFM cmm
1200 34.0
1600 45.3
1600 45.3
DOWNFLOW
Ext. Static Pressure
Minimum Maximum
In,W,C kPa In,W,C kPa
0.12 0.0299 0.50 0.1245
0.12 0.0299 0.50 0.1245
0.15 0.0374 0.50 0.1245
IMPORTANT: The air temperature rise should be taken only after the
furnace has been operating for at least 15 minutes. Temperatures and
external static pressures should be taken 6" (15 cm) past the first bend
from the furnace in the supply duct and the return duct. If an external fil-
ter box or an electronic air cleaner is installed, take the return air read-
ings before the filter box or air cleaner.
kWARNING
The supply air temperature MUST NEVER exceed the Maximum
Supply Air Temperature, specified on the nameplate.
Operating the furnace above the maximum supply air temperature
will cause the heat exchanger to overheat, causing premature heat
exchanger failure. Improper duct sizing, dirty air filters, incorrect
manifold pressure, incorrect gas orifice and/or a faulty limit switch
can cause the furnace to operate above the maximum supply air
temperature. Refer to sections II, III and IX for additional informa-
tion on correcting the problem.
If a matching cooling coil is used, it may be place directly on the furnace
outlet and sealed to prevent leakage. Follow the coil instructions for
installing the supply plenum. On all installations without a coil, a remov-
able access panel is recommended in the outlet duct such that smoke
or reflected light would be observable inside the casing to indicate the
presence of leaks in the heat exchanger. This access cover shall be
attached in such a manner as to prevent leaks.
UPFLOW
i 3%1/2
BOTTOM VIEW
FIGURE 5: Dimensions
TABLE 4: Cabinet and Duct Dimensions
BTUH (kW)
Input
75 (22.0)
75 (22.0
100 (29.3)
BTUH (kW)
Input
75 (22.0)
75 (22.0)
100 (29.3)
1. All models are supplied with 3" (7.62 cm) vent connections. An installer supplied transition to 4" (10.16 cm) or 5" (12.7 cm) must be used where necessary.
* Dimensions "B", "C", "D", and "E" are with duct flanges turned up. "F", "G", "H", & "J" are with flanges flat.
Nominal Cabinet Cabinet Dimension
CFM (m3/min) Size A(in.) A(cm) B(in.) B(cm) C(in.) C(cm) D(in.) D(cm) E(in.) E(cm)
1200 (34.0) B 17 1/2 44.5 16 1/2 41.9 20 3/8 51.8 20.0 50.8 16 40.6
1600 (45.3) C 21 53.3 20 50.8 20 3/8 51.8 20.0 50.8 19 1/2 49.5
1600 (45.3) C 21 53.3 20 50.8 20 3/8 51.8 20.0 50.8 19 1/2 49.5
Nominal Cabinet K Vent K Vent
CFM (m3/min) Size F(in.) F(cm) G(in.) G(cm) H(in.) H(cm) J(in.) J(cm) (in.) (cm)
1200 (34.0) B 14 3/4 37.46 18 3/4 47.62 15 1/8 38.4 19.0 48.2 41 10.161
1600 (45.3) C 18 1/4 46.35 18 3/4 47.62 18 5!8 47.3 19.0 48.2 41 10.161
1600 (45.3) C 18 1/4 46.35 18 3/4 47.62 18 5!8 47.3 19.0 48.2 41 10.161
BOTTOM VIEW
Unitary Products Group 7
288130-UIM-A-0407
RESIDENTIAL AND NON HUD MODULAR HOME
UPFLOW RETURN PLENUM CONNECTION
Return air may enter the furnace through the side(s) or bottom depend-
ing on the type of application. Return air may not be connected into the
rear panel of the unit. For single return application, see data and notes
on blower performance data tables in this manual.
BOTTOM RETURN AND ATTIC INSTALLATIONS
Bottom return applications normally pull return air through a base plat-
form or return air plenum. Be sure the return platform structure or return
air plenum is suitable to support the weight of the furnace.
The furnace base is equipped with a rectangular blockoff panel that can
be removed by performing the following steps:
1. Lay the furnace on its back.
2. Remove the screws from the toe plate.
3. Remove the toe plate.
4. Pull the base plate out of the furnace base.
5. Reinstall the toe plate and secure with the screws that were
removed.
Attic installations must meet all minimum clearances to combustibles
and have floor support with required service accessibility.
IMPORTANT: If an external mounted filter rack is being used see the
instructions provided with that accessory for proper hole cut size.
FLOOR BASE AND DUCTWORK INSTALLATION
Downflow Combustible Floor Base
Installations on combustible material or floors must
use a combustible floor base shown in Figure 6. The
perforations in the wrapper flanges must be bent in
towards the heat exchanger to allow for the coil duct
flange to recess into the furnace Follow the instruc-
tions supplied with the combustible floor base acces-
sory. This combustible floor base can be replaced with
a matching cooling coil, properly sealed to prevent
leaks. Follow the instructions supplied with the cooling coil cabinet for
installing the cabinet to the duct connector. Refer to the installation
instructions for additional information.
Downflow Duct Connectors
DOWNFLOW
FURNACE
iI WARM AIR PLENUM
J WITH 1" FLANGES
__ FIBERGLASS
INSULATION
FIBERGLASS TAPE
_/ UNDER FLANGE
-- COMBUSTIBLEFLOOR
BASEACCESSORY
FIGURE 6: Combustible Floor Base Accessory
All downflow installations must use a suitable duct connector approved
by the furnace manufacturer for use with this furnace. The duct connec-
tors are designed to be connected to the rectangular duct under the
floor and sealed. Refer to the instructions supplied with the duct con-
nector for proper installation. Refer to the separate accessory parts list
at the end of these instructions for the approved accessory duct con-
nectors.
When replacing an existing furnace, if the existing plenum is not the
same size as the new furnace then the existing plenum must be
removed and a new plenum installed that is the proper size for the new
furnace.
IMPORTANT: If an external mounted filter rack is being used see the
instructions provided with that accessory for proper hole cut size.
Downflow Air Conditioning Coil Cabinet
The furnace should be installed with coil cabinet part number specifi-
cally intended for downflow application. If a matching cooling coil is
used, it may be placed directly on the furnace outlet and sealed to pre-
vent leakage. For details of the coil cabinet dimensions and installation
requirements, refer to the installation instructions supplied with the coil
cabinet.
The perforations in the wrapper flanges must be bent away from the
heat exchanger to create duct flanges so the air conditioning coil can be
properly seated on the furnace. Attach the air conditioning coil cabinet
to the duct connector, and then position the furnace on top of the coil
cabinet. The connection to the furnace, air conditioning coil cabinet,
duct connector, and supply air duct must be sealed to prevent air leak-
age.
IMPORTANT: On all installations without a coil, a removable access
panel is recommended in the outlet duct such that smoke or reflected
light would be observable inside the casing to indicate the presence of
leaks in the heat exchanger. This access cover shall be attached in
such a manner as to prevent leaks.
RESIDENTIAL AND NON HUD MODULAR HOME
DOWNFLOW RETURN PLENUM CONNECTION
The return duct system must be connected to the furnace inlet and the
return duct system must terminate outside the space containing the fur-
nace. When replacing an existing furnace, if the existing plenum is not
the same size as the new furnace then the existing plenum must be
removed and a new plenum installed that is the proper size for the new
furnace.
Attach the return plenum to the furnace inlet duct flanges. This is typi-
cally through the use of "S" cleat material when a metal plenum is used.
The use of an approved flexible duct connector is recommended on all
installations. The connection of the plenum to the furnace and all the
ducts connecting to the plenum must be sealed to prevent air leakage.
The sheet metal should be crosshatched to eliminate any popping of
the sheet metal when the indoor fan is energized.
The duct system is a very important part of the installation. If the duct
system is improperly sized the furnace will not operate properly. The
ducts attached to the furnace must be of sufficient size so that the fur-
nace operates at the specified external static pressure and within the air
temperature rise specified on the nameplate.
IMPORTANT: If an external mounted filter rack is being used see the
instructions provided with that accessory for proper hole cut size.
HORIZONTAL MODELS
//
Ls_f
IMPORTANT: This furnace may be installed in a horizontal position on
either side as shown above. It must not be installed on its back.
Horizontal Installations With a Cooling Coil Cabinet
The furnace should be installed with coil cabinet part number specifi-
cally intended for Horizontal application. If a matching cooling coil is
used, it may be placed directly on the furnace outlet and sealed to pre-
vent leakage. Follow the coil instructions for installing the supply ple-
num. For details of the coil cabinet dimensions and installation
requirements, refer to the installation instructions supplied with the coil
cabinet
The perforations in the wrapper flanges must be bent away from the
heat exchanger to create duct flanges so the air conditioning coil can be
properly seated on the furnace.
8 Unitary Products Group
288130-UIM-A-0407
Attach the supply plenum to the air conditioning coil cabinet outlet duct
flanges through the use of S cleat material when a metal plenum is
used. The use of an approved flexible duct connector is recommended
on all installations. The connection to the furnace, air conditioning coil
cabinet and the supply plenum should be sealed to prevent air leakage.
The sheet metal should be crosshatched to eliminate any popping of
the sheet metal when the indoor fan is energized.
The minimum plenum height is 12" (30.5 cm). If the plenum is shorter
than 12" (30.5 cm) the turbulent air flow may cause the limit controls not
to operate as designed, or the limit controls may not operate at all. Also
the plastic drain pan in the air conditioning coil can overheat and melt.
Refer to the installation instructions supplied with the air conditioning
coil for additional information.
Horizontal Installations Without a Cooling Coil Cabinet
When installing this appliance, the furnace must be installed so as to
create a closed duct system, the supply duct system must be con-
nected to the furnace outlet and the supply duct system must terminate
outside the space containing the furnace. When replacing an existing
furnace, if the existing plenum is not the same size as the new furnace
then the existing plenum must be removed and a new plenum installed
that is the proper size for the new furnace.
Attach the supply plenum to the furnace outlet duct flanges through the
use of S cleat material when a metal plenum is used. The use of an
approved flexible duct connector is recommended on all installations.
This connection should be sealed to prevent air leakage. The sheet
metal should be crosshatched to eliminate any popping of the sheet
metal when the indoor fan is energized. On all installations without a
coil, a removable access panel is recommended in the outlet duct such
that smoke or reflected light would be observable inside the casing to
indicate the presence of leaks in the heat exchanger. This access cover
shall be attached in such a manner as to prevent leaks.
Residential and Non Hud Modular Home Horizontal Return
Plenum Connections
The return duct system must be connected to the furnace inlet and the
return duct system must terminate outside the space containing the fur-
nace. When replacing an existing furnace, if the existing plenum is not
the same size as the new furnace then the existing plenum must be
removed and a new plenum installed that is the proper size for the new
furnace.
Attach the return plenum to the furnace inlet duct flanges. This is typi-
cally through the use of S cleat material when a metal plenum is used.
The use of an approved flexible duct connector is recommended on all
installations. The connection of the plenum to the furnace and all the
ducts connecting to the plenum must be sealed to prevent air leakage.
The sheet metal should be crosshatched to eliminate any popping of
the sheet metal when the indoor fan is energized.
The duct system is a very important part of the installation. If the duct
system is improperly sized the furnace will not operate properly. The
ducts attached to the furnace must be of sufficient size so that the fur-
nace operates at the specified external static pressure and within the air
temperature rise specified on the nameplate.
Attic installations must meet all minimum clearances to combustibles
and have floor support with required service accessibility.
IMPORTANT: if an external mounted filter rack is being used see the
instructions provided with that accessory for proper hole cut size.
ATTIC INSTALLATION
LINE CONNECT ONLY PERMISSIBLE BETWEEN
LINES FORMED BY THE INTERSECTION OF
FURNACE TOP AND TWO SIDES AND BUILDING
JOISTS, STUDS, OR FRAMING
FILTER RACK MUST f , /; --_
BEAMINIMUM DISTANCE J .... (_ /_ _']
OF 18" (45.7 CM) FROM / I I t_ /
T.EFURNAOE ,, IV/
TRAP / ___Z2/PLYWOOD
FIGURE 7: Typical Attic Installation
This appliance is design certified for line contact when the furnace is
installed in the horizontal left or right position. The line contact is only
permissible between lines that are formed by the intersection of the top
and two sides of the furnace and the building joists, studs or framing.
This line may be in contact with combustible material.
"_-_-_ FLOOR
SHEET METAL IN FRONT OFFURNACE COMBUSTION
AIR OPENINGS IS RECOMMENDED
_WARNING
When a furnace is installed in an attic or other insulated space,
keep all insulating materials at least 12 inches (30.5 Cm) away from
furnace and burner combustion air openings.
SUSPENDED FURNACE / CRAWL SPACE
INSTALLATION
The furnace can be hung from floor joists or installed on suitable blocks
or pad. Blocks or pad installations shall provide adequate height to
ensure the unit will not be subject to water damage. Units may also be
suspended from rafters or floor joists using rods, pipe angle supports or
straps. Angle supports should be placed at the supply air end and near
the blower deck. Do not support at return air end of unit. All four sus-
pension points must be level to ensure quiet furnace operation. When
suspending the furnace use a secure platform constructed of plywood
or other building material secured to the floor joists. Refer to Figure 8
for typical crawl space installation.
\
BRACKETX-- II I I
II RT
1" MAN. BETWEEN 6" MIN BETWEEN 1" MAX.BETWEEN
ROD & FURNACE ROD & FURNACE ROD & FURNACE
FIGURE 8: Typical Suspended Furnace / Crawl Space Installation
Unitary Products Group 9
288130-UIM-A-0407
SECTION IIh FILTERS
FILTER INSTALLATION
All applications require the use of a filter.
TABLE 5: Recommended Filter Sizes
UPFLOW
Input
MBH
75
75
100
DOWN FLOW
MBH kW
75 22.0 B
75 22.0 C
100 29.3 C
NOTES:
1.Air velocity through throwaway type filters may not exceed 300 feet per minute.
2.Air flows above 1800 CFM require either return from two sides or one side plus
kW
22.0
22.0
29.3
In _ut
Air Flow
CFM m3/min
1200 34.0
1600 45.3
1600 45.3
Air Flow
CFM m3/min
1200 34.0
1600 45.3
1600 45.3
Cabinet
Size
B
C
C
Cabinet Size
Side
Return
in,
25x 16
25x 16
25x 16
Top Return (Downflow)
Cleanable Air Filters
in. cm
14 x 20 (2) 36 x 51
16x20 (2)41 x51
16x20 (2)41 x51
All velocities over this require the use of high velocity filters.
bottom.
cm
64 x41
64 x41
64 x41
in.
25x 16
25 x 20
25 x 20
Top Return (Downflow)
Disposable Air Filters
in. cm
(2) 14 x 20 (2) 36 x 51
(2) 16x20 (2)41 x51
(2) 16 x 20 (2) 41 x 51
Bottom/End
Return
cm
64 x41
64 x 51
64 x 51
SIDE RETURN/BOTTOM EXTERNAL INSTALLATION
Locate and knock out the square corner Iocators. These indicate the
size of the cutout to be made in the furnace side panel. Refer to Figure 9.
FURNACE
ER
INGS
FIGURE 9: Side Return Cutout Markings
Install the side filter rack following the instructions provided with that
accessory. If a filter(s) is provided at another location in the return air
system, the ductwork may be directly attached to the furnace side
panel. An accessory filter rack is available for mounting the filter exter-
nal to the cabinet.
Some accessories such as electronic air cleaners and pleated media
may require a larger side opening. Follow the instructions supplied with
that accessory for side opening requirements. Do not cut the opening
larger than the dimensions shown in Figure 5.
EXTERNAL INSTALLATION FOR
UPFLOW/HORIZONTAL CONFIGURATIONS
1. Select desired filter position for upflow/horizontal (left/right side,
side and bottom). Remove the corresponding cabinet cutouts per
instructions provided.
2. Install the external filter box to the side of the cabinet and secure
to the cabinet as specified in the instructions provided with the air
filter kit. If a side return is to be used, cut out the side of the casing
14" high by 16 1/4" wide using the lances in the casing side as a
guide. DO NOT CUT THE OPENING LARGER THAN 14" X 16 1!
4". It is not permissible to cut out the back of the furnace. For bot-
tom returns you place the external filter box between the return air
plenum and the base of the furnace. The casing bottom is
embossed to indicate where to bend the flanges. Refer to Figure 5
for the maximum return air opening sizes. Seal this connection to
prevent leaks.
Do not cut the opening larger than the dimensions shown in Figure
5.
3. Install the return air duct to the air filter box and secure with
screws. Seal this connection to prevent leaks.
4. Install the field provided filter. Refer to Table 5 for the recom-
mended filter size for your furnace.
NOTE: Air velocity must not exceed 300 feet per minute through low
velocity disposable filters. Air velocity must not exceed 650 feet per
minute through high velocity cleanable permanent filters. Use of a filter
that is too small will cause static pressure in the duct system to be too
high, which will have an adverse effect on heating and cooling opera-
tion.
RETURN
DUCT
AIR _lJ
FILTER
FIGURE 10: Horizontal Mount and Filter
I% N-,t
[]
[]
[]
[]
[]
[]
[]
[]
/_ FILTER RACK
FURNACE
Di
[]
RACK AND FILTERS SECURED
...... SECT,ON
NOTE: FILTERACCESS THROUGH (
_ DUCTWORK MUST BE PROVIDED _ BRANCH
/ FOR REMOVALAND CLEANING _ DUCTS
(
',, FILTERS
DUCTWORK
CROSS SECTION A-A
(with Plenum and filters)
FIGURE 11: Downflow Filter
10 Unitary Products Group
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