INSTALLATION
HIGH EFFICIENCY
GAS-FIRED FURNACES
INSTRUCTION
CON TENTS
GENERA L IN FO R MA TI ON . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFIC UNIT INFORMATION . . . . . . . . . . . . . . . . . . 3
DUCTW ORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GA S PI P IN G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1
EL ECT RI CA L PO WER CONN ECTION . . . . . . . . . . . . 12
EL ECT RI CA L CON TROL CON NEC TI O NS . . . . . . . . . 1 3
COMBUSTION AIR AND VENT SYSTEM . . . . . . . . . . 14
COND E NSA TE PIP I NG . . . . . . . . . . . . . . . . . . . . . . . . 24
SA FET Y CO NT ROL S . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ST AR T- U P AND ADJ U STMENT S . . . . . . . . . . . . . . . . 26
FURNACE ACCESSORIES . . . . . . . . . . . . . . . . . . . . . 30
TUBULAR HEAT EXCHANGER SERIES
MODELS: P* UR / G9T-U P / FG 9- UP (Upfl ow)
40 - 140 MBH INPUT
MOD ELS: P*D H / G9T-DH / F G9 -DH (D own flo w / Hor izont al )
40 - 120 MBH INPUT
OPER AT IO N A ND M AI NT ENANCE . . . . . . . . . . . . . . . 33
TROU BL E SHO OTING . . . . . . . . . . . . . . . . . . . . . . . . . 36
EFFICIENCY
RATING
CERTIFIED
CAUTION: READ ALL SAFETY GUIDES BEFORE YOU
START TO INSTALL YOUR FURNACE.
SAVE THIS MANUAL
035-17477-002 Rev. D (1202)
IMPROPER INSTALLATION MAY CREATE A
CONDITION WHERE THE OPERATION OF T HE
PRODUCT COU L D CAU S E PER S ONA L IN JU RY
OR PROPERTY DAMAGE.
IMPROPER INSTALLATION, ADJUSTMENT,
ALTERATION, SERVICE OR MAINTENANCE
CAN CAUSE IN JU RY O R PR OPER TY DAM AGE.
REFER TO THIS MANUAL FOR ASSISTANCE
OR ADDITIONAL INFORMATION, CONSULT A
QUALIFIED INSTALLER, SERVICE AGENCY OR
THE GAS SUPPLIER.
THIS PRODUCT MUST BE INSTALLED IN
STRICT COMPLIANCE WITH THE ENCLOSED
INSTALLATION INSTRUCTIONS AND ANY
APPLICABLE LOCAL, STATE, AND NATIONAL
COD ES I NCLUDING BUT NOT LI MI TED TO ,
BUILDING, ELECTRICAL AND MECHANICAL
CODES.
The furnace area must not be used as a broom
closet or for any other storage purposes, as a fire
hazard bay be created. Never store items such as
the following on, near or in contact with the furnace.
1.Spray or aerosol cans, rags, brooms, dust mops,
vacuum cleaners or other cleaning tools.
2.Soap powders, bleaches, waxes or other cleaning compounds; plastic items or containers; gasoline, kerosene, cigarette lighter fluid, dry cleaning
fluids or other volatile fluid.
3.Paint thinners and other painting compounds.
4.Paper bags, boxes or other paper products
Never operate the furnace with the blower door
removed. To do so could result in serious personal
injury and/or equipment damage.
035-17477-002 Rev. D (1202)
GENERAL INFORMATION
DESCRIPTION
This Category IV, dual certified direct vent and 1-pipe vent
furnace is designed for residential or commercial application. It may be installed without modification to the condensate system in a basement, garage, equipment room, alcove,
attic or any other indoor location provided the space temperature is 32 °F or higher and where all required clearance to
combustibles and other restrictions are met. If the furnace is
being installed where the space temperature is below 32°F,
refer to “BELOW FREEZING LOCATIONS” on page 4.
This furnace is constructed at the factory for natural gas-fired
operation at 0 - 4,500 ft. above sea level, but may be converted to operate on propane (LP) gas and at altitudes up to
10,000 ft. For applications at altitudes between 2,000 - 4,500
ft., s ee “ COMBUSTION AIR AND VENT SYSTEM” on
page 14, for required vent length reductions. For applications
at altitudes greater than 4,500 feet, see high altitude instructions 035-14447-000.
High altitude and propane (LP) changes or conversions
required in order for the appliance to satisfactory meet the
application must be made by an authorized distributor or
dealer. In Canada, a certified conversion station or ot her
qualified agency, using factory specified and/or approv ed
parts, must perform the conversion.
INSPECTION
As soon as a unit is received, it should be inspected f or possible damage during transit. If damage is evident, the extent of
the damage should be noted on the carrier's freight bill.
A separate request for inspection by the carrier's agent
should be made in writing. Also, before installation the unit
should be checked for screws or bolts which may have loosened in transit. There are no s hipping or spacer brackets
which need to be removed.
NOTES, CAUTIONS & WARNINGS
The installer should pay particular attention to the words:
NOTE, CAUTION and WARNING. NOTES are intended to
clarify or make the installation easier. CAUTIONS are given
to prevent equipment damage. WARNINGS are given t o alert
the installer that personal injury and/or equipment or property
damage may occur if installation procedures are not handled
properly.
The cooling coil must be installed in the supply air
duct, downstream of the furnace. Cooled air may
not be passed over the heat exchanger.
2 Unitary Products Group
035-17477-002 Rev. D (1202)
VENT SAFETY C HEC K PR OC EDU RE
This furnace may not be common vented with any
other appliance, since it requires separate, properly-sized air intake and vent lines. The furnace
shall not be connected to any type of B, BW or L
vent or vent connector, and not connected to any
portion of a factory-built or masonry chimney.
If this furnace is replacing a common-vented furnace, it may be necessary to resize the existing
vent line and chimney to prevent oversizing problems for the new combination of units. Refer to the
National Gas Code (ANSI Z223.1) or CAN/CGA
B149.1 or .2 Installation Code (latest editions).
The following steps shall be followed with eac h appliance
connected to the venting system placed in operation, while
any other appliances connected to the venting system are not
in operation:
1. Seal any unused openings in the venting system.
2. Inspect the venting system for proper size and horizontal
pitch, as required in the National Fuel Gas Code, ANSI
Z223.1, or the CAN/CGA B149 Installation Codes and
these instructions. Determine that t here is no blockage
or restriction, leakage, corrosion or other deficiencies
which could cause an unsafe condition.
3. Insofar as is practical, close all building doors and windows and all doors between the space in which the appliance(s) is located and other spaces of the building. Turn
on clothes dryers. Turn on any exhaust f ans, such as
range hoods and bathroom exhausts, so they s hall operate at maximum speed. Do not operate a summer
exhaust fan. Close fireplace dampers.
4. Follow the lighting instructions. Place the appliance
being inspected in operation. Adjust thermostat so the
appliance shall operate continuously.
5. Test for draft hood equipped appliance spillage at the
draft hood relief opening after 5 minutes of main burner
operation. Use the flame of a match or candle.
6. After it has been determined that each appliance connected to the venting system properly vents w hen tested
as outlined above, return doors, windows, ex haust fans,
fireplace dampers and any other gas burning appliance
to their previous conditions of use.
7. If improper venting is observed during any of the above
tests, the venting system m ust be corrected.
8. Any corrections to the common venting system must be
in accordance with the National Fuel Gas Code Z 223.1
or CAN/CGA B149.1 or .2 Installation Code (lat est editions). If the common vent system must be res ized, it
should be resized to approach the minimum size as
determined using the appropriate tables in Appendix G
of the above codes.
SPECIFIC UNIT INFORMATION
LIMITATIONS & LOCAT ION
This furnace should be installed in accordance with all
national and local building/safety codes and requirements, or
in the absence of local codes, with the National Fuel Gas
Code ANSI Z223.1 or CAN/CGA B149.1 or.2 Installation
Code (latest editions), local plumbing or waste water codes,
and other applicable codes.
Downflow/horizontal models when installed in a downflow
configuration are AGA/CGA listed for application into a manufactured (mobile) home.
Upflow models or horizontal applications are not approved for
mobile homes.
CLEARAN CES FOR ACCE SS
Ample clearances should be provided to permit easy access
to the unit. The following minimum clearances are recommended:
1. Twenty-four (24) inches between t he front of the furnace
and an adjacent wall or another appliance, when ac cess
is required for servicing and cleaning.
2. Eighteen (18) inches at the side where access is
required for passage to the front when servicing or for
inspection or replacement of flue/vent connections.
In all cases, accessibility clearances shall take precedence
over clearances for combustible materials where accessibility
clearances are greater.
Do not install the furnace in an unconditioned
space or garage that could experience ambient
temperatures of 32° F (0° C) or lower. For application in below freezing locations, See “BELOW
FREEZING LOCATIONS” on page 4.
The furnace is not to be used for temporary heating of buildings or structures under construction.
This unit must be installed in a level (1/4”) position
side-to-side and front-to-back to provide proper
condensate drainage.
Do not allow return air temperature to be below
55°F for extended periods. To do s o may cause
condensation to occur in the main fired heat
exchanger.
Only use natural gas in furnaces designed for natural gas. Only use propane (LP) gas for furnaces
that have been properly converted to use propane
(LP) gas. Do not use this furnace with butane.
Using wrong gas could create a haz ard, resulting
in damage, injury or death.
Unitary Products Group 3
Furnaces shall not be installed directly on carpeting, tile or other combustible material other than
wood flooring. An accessory combustible floor
base is available to allow direc t ins tallation of
downflow models on combustible flooring.
Furnace shall be installed so the elec trical components are protected from water.
A manufactured (mobile) home installation must conform with
the Manufactured Home Construction and Safety Standard,
Title 24 CFR, Part 3280, or when t his standard is not applic able, the Standard for Manufactured Home Installations (Manufactured Home Sites, Communities and Set-Ups), ANSI
A225.1, and/or CAN/CSA-Z240 MH Series, Mobile H omes.
The size of the unit should be based on an acceptable heat
loss calculation for the structure. ACCA, M anual J or ot her
approved methods may be used.
Refer to furnace rating plate for the type of gas approved for
this furnace - only use those approved gases.
Check the rating plate and power supply to be sure t hat the
electrical characteristics match. All models use nominal 115
VAC, 1 Phase, 60 Hertz power supply.
For installations above 2,000 feet, reduce input 4% for each
1,000 feet above sea level.
For installation between 2000 and 4500 feet, it is not required
that the pressure switch be changed, provided the maximum
vent/intake pipe lengths are adjusted as shown in the Note
from Tables 4, 5 and 7 on Pages 16 & 20. For altitudes abov e
4,500 feet, refer to ins tructions 035-14447-000 for correct
pressure switch/orifice or other required conversion information.
The furnace shall not be connected to a chimney flue serving
a separate appliance designed to burn solid fuel.
A furnace installed in a residential garage shall be located so
that all burners and burner ignition devices are located not
less that 18" above the garage floor, and located or protected
to prevent damage by vehicles.
Allow clearances from combustible materials as listed under
Clearances to Combustibles, ensuring that service access is
allowed for both the burners and blower.
035-17477-002 Rev. D (1202)
The furnace shall be located using t hese guidelines:
1. Where a minimum amount of air intake/vent piping and
elbows will be required.
2. As centralized with the air distribution as possible.
3. Where adequate combustion air will be available (particularly when installing as 1-pipe system).
4. In an area where ventilation facilities provide for safe lim its of ambient temperature under normal operating conditions. Ambient temperatures must not fall below 32°F
(0°C) unles s the condensate system is protected from
freezing (refer to “BELOW FREEZING LOCATIONS” on
page 4).
5. Where it will not interfere with proper air circulation in the
confined space.
6. Where the outdoor combustion air/vent terminal will not
be blocked or restricted.
CLEARAN CES TO COMBUSTIBLES
Minimum clearances from combustible construction are
shown in Table 3, “UNIT CLEARANCES TO COMBUSTIBLES,” on page 7. These minimum clearances must be
maintained in the installation.
BELOW FREEZING LOCATIONS
If this furnace is installed in any area where the ambient temperature may drop below 32° F, a UL listed self regulated
heat tape must be installed on any condensate drain lines. It
is recommended that self regulating heat tape rated at 3
watts per foot be used. This must be ins talled around the condensate drain lines in the unconditioned space. Always install
the heat tape per the manufacturer's instructions. Cover the
self-regulating heat tape with fiberglass or other heat resistant, insulating material.
If this unit is installed in an unconditioned space
and an extended power failure occurs, there will
be potential damage to the condensate trap, drain
lines and internal unit components. Following a
power failure situation, Do Not Operate the U nit
Until Inspectio n and Repair Ar e P er for me d.
4 Unitary Products Group
035-17477-002 Rev. D (1202)
.
20
6-3/8
1-1/4
B
3-1/8
OPTIONAL SIDE RETURN
CUT-OUT (EITHER SIDE)
CONDENSATE
DRAIN
B
20
FRONT
TOP IMAGE
SUPPLY END
28-1/2
28-1/2
2-3/4
6-1/8
T’STAT
WIRING
7/8” K.O.
9-7/8
6-7/8
WITH K.O.
REMOVED
23
BOTTOM IMAGE
RETURN END
A
C
FRONT
A
3/4”
FLANGE
4-1/8
45
1-3/4
20-5/8
MODELS P*UR/
G9T-UP/ FG9-UP
40 / 37 / 1000 /”A”
60 / 55 / 1000 /”B”
80 / 75 / 1200 /”B”
80 / 75 / 1600 /”C”
100 / 95 / 1400 /”C”
100 / 95 / 2000 /”C”
120 / 112 / 2000 /”D”
140 / 130 / 2000 /”D”
8-7/8
1-3/4
6
22-3/4
14-1/2
B
A
14-1/2
16-1/4
17-1/2
19-3/4
17-1/2
19-3/4
21
23-1/4
21 23-1/4 20-1/8
21 23-1/4 20-1/8
24-1/2 23-1/4 20-1/8
24-1/2 23-1/4 20-1/8
3/4
C
13-1/8
16-5/8
16-5/8
20-1/8
FIGURE 1 :
Table 1:
MO DE L S P *UR / G9 T- UP /
INPUT
MBH
DIMENSIONS - UPFLOW MODELS: P*UR/G9T-UP/FG9-UP
RATINGS & PHYSICAL / ELECTRICAL DATA - UPFLOW MODELS
MAX .
FG9-UP
OUTPU T
MBH
NO M.
CFM
CABINET
WIDTH
AFUE
*
AIR
TEMP
RISE °F
OUTLET
AIR
TE MP .
°F
HP AMPS SIZE (IN.)
BLOWER
TOTAL
UNIT
AMPS
MAX
OVER-
CURRENT
PROTE CT
MIN WIRE
SIZE (AWG)
@ 75 FT.
†
ONE WAY
†
40 37 1000 14-1/2 92.4 35 - 65 165 1/3 6.2 10 x 6 9.0 20 14
60 55 1000 17-1/2 92.2 45 - 75 175 1/3 6.2 10 x 6 9.0 20 14
80 74 1 200 17 -1/2 9 2.0 35 - 65 1 65 1/ 2 7.0 11 x 8 12. 0 2 0 1 4
80 76 1 600 21 9 4.3 30 - 60 1 60 3/ 4 11.5 11 x 8 12. 0 2 0 1 4
100 93 1400 21 92.2 45 - 75 175 1/2 10.7 10 x 10 12.0 20 14
100 94 2000 21 93.0 30 - 60 160 1 12.2 11 x 10 14.0 20 12
120 111 2000 24-1/2 92.0 45 - 75 175 1 12.2 11 x 10 14.0 20 12
140 130 2000 24-1/2 92.0 45 - 75 175 1 12.2 11 x 10 14.0 20 12
*.
AFUE numbers are determined in accordance with DOE test procedures
†.
Wire size and overcurr ent protection must comply with the N atio nal Electr ical Co de (NFPA-70 -latest editio n).
For altitudes above 2,000 ft., reduce capacity 4% for each 1,000 ft. above sea level. Refer to instruction 035-14460-000.
Wire size based on copper conductors, 60°C, 3% voltage drop.
Continuous return air temperature must not be below 55°F.
Unitary Products Group 5
035-17477-002 Rev. D (1202)
20
1-7/8
B
3/4
45
A
FRONT RIGHT SIDE
B
POWER
WIRING
7/8 K.O.
5-3/8
D
TOP IMAGE
RETURN END
E
20
CONDENSATE
DRAIN ACCESS
3-1/4 x 3
GAS INLET
1-1/4 x 2-1/2
AIR INTAKE
3-5/8 x 3-5/8
28-1/2
LEFT SIDE
A
19-1/4
C
FRONTFRONT
BOTTOM IMAGE
SUPPLY END
T'STAT WIRING
7/8 K.O.
5-1/4
1-1/4
3-3/4
1-3/8
8
VENT CONNECTION
1-3/4
35
18-1/2
6-1/4
2-3/4
MODELSP*DH/
G9T-DH / FG9-DH
40/37/1000/A
60/55/1200/B
80/75/1200/B
80/75/1600/C
100/95/2000/C
120/112/2000/D
ALL DIMENSION ARE IN INCHES, AND ARE APPROXIMATE.
16-3/4
7-1/2
3-3/4
1-1/4
13-1/4
16-1/4
16-1/4
19-3/4
19-3/4
23-1/4
ALT. GAS INLET
1-1/4 x 2-1/2
11-3/4
14-3/4
14-3/4
18-1/4
18-1/4
21-3/4
4-1/8
ABCDE
14-1/2
17-1/2
17-1/2
21
21
24-1/2
CONDENSATE
DRAIN ACCESS
3-1/4 x 3
AIR INTAKE
3-5/8 x 3-5/8
5-1/8
2-1/2
6-5/8
2-1/4
6-5/8
2-1/4
8-3/8
2-1/4
8-3/8
2-1/4
10-1/8
2-1/4
FIGURE 2 :
Tabl e 2:
MODELS P* DH /
FG9-DH/G9T—DH
INPUT
MBH
DIMENSIONS - DOWNFLOW/HORIZONTAL MODELS: P*DH/G9T-DH/FG9-D H
RATINGS & PHYSICAL / ELECTRICAL DATA - DOWNFLOW/HORIZONTAL MODELS
BLOWER
HP AMPS SIZE (IN)
OUTPUT
MBH
NOM.
CFM
CABINET
WIDTH
AFUE
AIR
*
TEM P
RISE °F
MAX.
OUTLET
AIR
TEMP. °F
TOTAL
UNIT
AMPS
MAX
OVER-
CURRENT
PROTECT
MIN WIRE
SIZE
(AWG) @
75 FT. ON E
†
WAY
†
40 37 1000 14-1/2 91.0 25 - 55 155 1/3 6.2 10 x 6 9.0 20 14
60 55 1200 17-1/2 91.0 35 - 65 165 1/2 7.0 11 x 8 12.0 20 14
80 73 1200 17-1/2 91.0 35 - 65 165 1/2 7.0 11 x 8 12.0 20 14
80 7 5 16 00 21 9 1.0 30 - 60 1 60 3/4 11. 5 11 x 8 12.0 20 14
100 93 2000 21 91.0 40 - 70 170 1 12.2 11 x 10 14.0 20 12
12 0 111 2000 2 4-1/2 9 1.0 40 - 70 1 70 1 12.2 11 x 1 0 14 .0 2 0 12
*.
AFUE numbers are determined in accordance with DOE test procedures
†.
Wir e size an d over curren t p ro tec t ion must comply with the N a ti on al Electrica l Code (NFPA-70-la tes t ed ition).
For altitudes above 2 ,000 ft., r educe capacity 4% for each 1,00 0 ft. abo ve se a le vel. R efer to instr uction 035-14460-000.
Wire size based on co pper conductors, 60°C, 3% voltage drop.
Continuous return air temperature must not be below 55°F.
6 Unitary Products Group
035-17477-002 Rev. D (1202)
Tabl e 3:
APP LICATION TOP FRONT REAR
DOWNFLOW130000
HORIZONTAL 1 3 0
UNIT CLEARANCES TO COMBUSTIBLES
LEFT
SIDE
UPFLOW MODELS (P*UR / G9T-UP / FG9-UP)
UPF LOW 1 3 0 0 0 0 COMBU S TIBLE Y ES YES YE S N O
DOWNFLOW / HORIZONTAL MODELS (P*DH / G9T-DH / FG9-DH )
0
*.
Special floor base or air conditioning coil required for use on combustible floor.
†.
Minimum of 8” clearance required to install condensate removal system.
‡.
Line contact only permit ted be tween lines formed by the inter section of the rear pa nel and si de pan el (top in horizont al position) of
the furnace jacket and building joists, studs or framing.
RI GH T
SIDE
†
0
FLUE
†
0 1” NO YES YE S
FL OOR/
BO TTOM
*
1"
CLO SET A LCOVE ATTI C
Y ES YES YE S NO
LINE
CONTA CT
YES
‡
DUCTWORK
The duct system's design and installation must:
1. Handle an air volume appropriate for the served space
and within the operating parameters of the f urnace specifications.
2. Be installed in accordance with standards of N FPA
(National Fire Protection Association) as outlined in
NFPA pamphlets 90A and 90B (latest editions) or applicable national, provincial, local fire and safety codes.
3. Create a closed duct system. The s upply duct s ystem
must be connected to the furnace outlet and the return
duct system must be connected to the furnace inlet . Both
supply and return duct systems must terminate outside
the space containing the furnace.
4. Complete a path for heated or cooled air to circulate
through the air conditioning and heating equipment and
to and from the conditioned space.
The cooling coil must be installed in the supply air
duct downstream of the furnace. Cooled air must
not be passed over the heat exchanger.
When the furnace is used in conjunction with a cooling coil,
the coil must be installed parallel with, or in the supply air s ide
of the furnace to avoid condensation in the primary heat
exchanger.
When a parallel flow arrangement is used, the dampers or
other means used to control air flow must be adequate to prevent chilled air from entering the furnace, and if manually
operated, must be equipped with means to prevent operating
of either unit unless the damper is in the full heat or c ool position.
UPFLOW MODELS
SUPPLY PLENUM CONNECTION
Attach the supply plenum to the furnace outlet duct connection flanges.
This is typically through the use of S
cleat material when a m etal plenum is
used. The use of an approved flexible
duct connector is recommended on all
installations. This connection should be
sealed to prevent air leakage.
If a matching cooling coil is used, it
may be placed directly on the furnace
outlet and sealed to prevent leakage.
Follow the coil instructions for installing
the supply plenum.
On all installations without a coil, a removable access panel
is recommended in the outlet duct such that smoke or
reflected light would be observable inside the casing to indicate the presence of leaks in the heat exchanger. This
access cover shall be attached in such a manner as to prevent leaks.
RET UR N DU CT CO NN ECT IO N
Return air may enter the furnace through the side(s) or bottom depending on the type of application. Retu rn a ir ma y
not be connected into the rear panel of the unit. Refer to
the "Filter Installation" section of this instruction for t he type of
application desired for specific installation details.
NOT E: In order to achieve the airflow indicated in the table, it
is recommended those applications over 1800 CFM use
return air from two sides, one side and the bottom or bottom
only. For single return application, see data and notes on
blower performance data tables in this manual.
Unitary Products Group 7
035-17477-002 Rev. D (1202)
FILTER INSTALLATION - UPF LOW
All applications require the use of a filter. A high velocity filter
and retainer are provided for field installation on P*UR &
G9T-UP models. FG9-UP models must have a field-supplied
filter and mounting hardware.
Internal In s tal lat i on
1. Select desired filter position (left/right side, and/or bottom). Remove the corresponding cabinet cut-outs per
instructions provided.
2. Install snap-in retainer clips into the corresponding slots
from the outside rear of the cabinet (Refer to Figure 3. )
To prevent cabinet air leaks, install snap-in plugs (provided) into the unused slots at the outside rear of the
cabinet.
FURNACE
RIGHT
SIDE
SLOTS
(REAR CABINET)
LEFT
SIDE
SLOTS
4. Install the filter(s) if provided. Cut filter if necessary to
match air opening in cabinet. Filter should extend
beyond opening edge as much as possible to prevent air
from bypassing the filter. DO NOT remove stiffening rods
from inside the filter. Shorten the rods, if necessary, t o
match final filter size.
5. Position the filter between the wire retainer and the c abinet wall (or floor) so it completely covers the cabinet air
opening and secure the filter in place at t he front of the
cabinet by fastening the closed (looped) end of the
retainer wire under the flanged edge of the cabinet.
When properly installed the filter should fit flush with all
four sides of the cabinet wall.
NOT E: Air velocity through t hrow-away type filters may not
exceed 300 feet per minute. All velocities over this require the
use of high velocity filters.
Side Return - External Filter
Locate and knock out the square corner locators. T hese indicate the size of the cutout to be made in the furnace side
panel. Refer to Figure 5.
FIGURE 3 :
CLIPS
FIGURE 4 :
BOTTOM SLOTS
CABINET
SLOT
PLUG UNUSED
CABINET SLOTS
Furnace Filter Slot Locations
POSITION WIRE RETAINER
(IF PROVIDED) UNDER FLANGE
IF FILTER
PROVIDED
RIGHT SIDE
INSTALLATION
SHOWN
FURNACE
FRONT
Filter Retainer Placement
FRONT OF
FURNACE
FIGURE 5 :
CORNER
MARKINGS
Side Return Cutout Markings
Install the side filter rack following the instructions provided
with that accessory. If a filter(s) is provided at another loc ation in the return air system, the ductwork may be directly
attached to the furnace side panel.
An accessory filter rack (1SR0302BK) is available for mounting the filter external to the cabinet.
NOT E: 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.
3. Install the wire retainer inside the cabinet (if provided).
Insert the open ends of the wire retainer into the clip
loops at the rear of the blower compartment. The retainer
wire should pivot freely like a hinge, on the clips at the
rear of the cabinet. (Refer to Figure 4).
8 Unitary Products Group
All installations must have a filter installed.
035-17477-002 Rev. D (1202)
The return duct may be attached to the furnace by S-cleat,
bend tabs or other approved methods. Be sure to seal the
duct to the furnace to prevent air leakage.
Where the return duct system is not complete, the return connection must run full size to a loc ation outside t he utility room
or basement. For further details, consult Section 5.3 (Air for
Combustion and Ventilation) of the National Fuel Gas Code,
ANSI Z223.1, or CAN/CGA B149.1 or .2, Installation Code latest editions.
Bottom Return
Bottom return applications normally pull return air through a
base platform or return air plenum. Be s ure the ret urn platform structure is suitable to support the w eight of the f urnace.
Refer to Figure 1 on Page 5, for unit dimensions. Be sure to
seal the furnace to plenum connection to prevent air leakage.
The bottom panel is equipped with a perforated opening f or
easy removal. Tabs must be cut with sheet metal snips to
allow removing knock-out. Scribe marks are included f or
forming flanges for attachment of the return air ductwork.
NOT E: If an external mounted filter rack is being used, see
the instructions provided with that accessory for proper hole
cut size.
Upflow attic installations must meet all m inimum clearances
to combustibles and have floor support with required service
accessibility.
DOWNFLOW/HORIZONTAL MODELS
COOLING COIL TRANSITION
These furnace models are equipped with perforations in t he
supply air wrapper flanges that allow for easy application of
an air conditioning coil to the furnace without the use of sheet
metal transition pieces. These perforations can be bent in
either direction depending on the type of application - either
downflow or horizontal left and right. Refer to either the
"Downflow Application" or "Horizontal Application" section
below for specific instructions on how to install the coil.
Downflow In s tal lat i on s
For installation of an air conditioning coil in a downflow application, the perforations in the wrapper flanges must be bent
in towards the heat exchanger to allow f or the coil duct flange
to recess into the furnace. Refer to the installation instructions supplied with the air conditioning coil for additional information and completion of the coil installation.
NOT E: Duct pliers or other suitable tool can be used to bend
perforations. To help bend flanges in a straight line, scribe a
line between the perforations prior to bending.
Horizontal Installations
For installation of an air conditioning coil in a horizontal application, the perforations in the wrapper flanges must be bent
away from the heat exchanger to create duct flanges so the
air conditioning coil can be properly seated on the furnace.
Refer to the installation instructions supplied with the air conditioning coil for additional information and completion of the
coil installation.
NOT E: Duct pliers or other suitable tool can be used to bend
perforations. To help bend flanges in a straight line, scribe a
line between the perforations prior to bending.
DOWNFL OW APPLICATION
DOWNFLOW FILTERS
All applications require the use of a filter. A high velocity filter and rack are
provided for field installation on P*DH &
G9T-DH models. FG9-DH models m ust
have a field-supplied filter and filter
rack.
Downflow furnaces typically are
installed with the filters located above
the furnace, extending into the return
air duct.
Any branch duct must attach to the vertical ductwork above the filter height
(FH) and for proper installation refer to
Figure 6 .
The filter rack should be secured to the
center of the front and rear flanges at
the furnace top. Drill a hole through the
front and rear duct flange into the filter
rack and secure it with a sheet metal
screw.
NOT E: For easier filt er access in a downflow configuration, a
removable access panel is recommended in the vertical run
of the return air duct immediately above the f urnace.
Refer to the unit rating plate for furnace model then see the
dimensions page of this instruction for return air plenum
dimensions. Install the plenum following instructions under
“DUCTWORK” on page 7, in t his instruction.
SUPPLY AIR DUCTS
Installations on combustible material or floors must use a
combustible floor base (shown in Figure 7 - 1CB0314, 17, 21
& 24) as specified on the rating plate. Follow the instructions
supplied with the combustible floor base accessory.
This base can be replaced with a m atching cooling c oil, properly sealed to prevent leaks. Follow the c ooling coil ins tructions for installing the plenum.
All downflow application supply duct systems must be
designed and installed in accordance with the standards of
NFPA 90A and 90B, and/or all local codes.
Unitary Products Group 9
035-17477-002 Rev. D (1202)
A
DUCTWORK
FIGURE 6 :
FILTER RACK
(FACTORY SUPPLIED)
A
NOTE: FILTER ACCESS THRU DUCTWORK MUST BE PROVIDED FOR
REMOVALAND CLEANING
CROSS SECTION A-A
(WITH PLENUM AND FILTERS)
RACK AND FILTERS SECURED
INSIDE BLOWER SECTION
FOR SHIPMENT
CASING SIZE DIMENSION FH
16-1/4 12-3/4
FILTERS
FILTER
RACK
down fl ow filters
22-1/4 11
26-1/4 8-1/4
BRANCH
DUCTS
FH
W
O
L
F
N
W
O
D
F
A
W
I
W
E
C
A
N
R
U
E
L
P
R
I
A
M
R
H
T
G
N
A
L
F
"
1
DOWNFLOW/HORIZONTAL MODELS
HOR IZONTAL APPLI CAT ION
Downflow furnaces may be ins talled horizontally with the s upply airflow toward the left or right by laying the unit on the left
or right side panel.
Do not install the unit on the rear panel.
After determining the best orientation, lay the unit on top of
the shipping carton to protect the finish. The appropriate electrical knock-outs for power wiring, control wiring and gas piping should be removed at this time.
For horizontal application, return air must enter t hrough the
end only. Return air may not be co nnected into the r ear or
sid e pan els of the un it.
HOR IZONTAL FILTERS
All filters and mounting provision must be field s upplied. Filters(s) may be located in the duct system external to the furnace or in a return filter grille(s). Ref er to furnace accessories
M
U
N
S
E
on Page 31 for external filter kit options.
ATTIC INSTAL LATIO N
S
S
A
L
G
R
E
B
I
FIGURE 7 :
F
N
O
I
T
A
L
U
S
N
I
S
A
L
G
R
E
B
I
F
N
U
B
M
O
C
E
S
A
B
A
L
F
R
E
D
E
L
B
I
T
S
U
S
S
E
C
C
A
Combustible Floor Base Accessory
LINE CONTACT ONLY PERMISSIBLE
BETWEEN LINES FORMED BY THE
INTERSECTION OF FURNACE TOP
AND TWO SIDES AND BUILDING
JOISTS, STUDS OR FRAMING
E
P
A
T
S
E
G
N
R
O
O
L
F
Y
R
O
RETURN AIR
FIGURE 8 :
typica l attic installation
SEDIMENT
TRAP
GAS PIPING
12”
SUPPLY AIR
30” MIN.
WORK AREA
VENT (Maintain
required clearances
to combustibles)
SHEET METAL
IN FRONT OF
FURNACE
COMBUSTION AIR
OPENINGS IS
RECOMMENDED
10 Unitary Products Group
035-17477-002 Rev. D (1202)
This appliance is design certified for line contact for furnaces
installed horizontally. The intersection of the furnace top and
sides form a line. This line may be in c ontact with combustible
material. Refer to the "SPECIFIC UNIT INFORMATION" section of this manual for further information on installation loca-
tion and limitations.
If this furnace is installed over a finished space, a
condensate safety pan must be installed.
When a furnace is installed in an attic or other
insulated space, keep all insulating materials at
least 12" away from furnace and burner combustion air openings.
Secure a platform constructed of plywood or other building
material to the floor joists.
NOT E: In eit her a horizontal left or right installation, a minimum of 8" clearance is required beneath the furnace t o allow
for the installation of the condensate trap and drain pipe.
Refer to "CONDENSATE PIPING" section of this manual for
more information.
NOT E: See crawl space installation for suspending the furnace in attic installations.
ANGLE IRON
BRACKET
SUPPORT
ROD
When suspending the furnace from rafters or floor joists using
rod, pipe or straps, refer to the Physical and Rating Data
Table for downflow/horizontal furnace weights to determine
suitable means of suspension.
Angle supports should be placed at the supply air end and
near the blower deck (Refer to Figure 9 ). Do not support
at return air end of unit.
Units may also be suspended by using straps or other material at the same location. All four suspension points must be
level to ensure quiet furnace operation.
In any application where temperatures below
freezing are possible, see “BELOW FREEZING
LOCATIONS” on page 4
GAS PIPING
The gas supply should be a separate line and m ust be
installed in accordance with the National Fuel Gas Code,
ANSI Z223.1 (latest edition), or the CAN/CGA B149.1 or .2
Installation Codes (latest edition) and all applicable loc al and
utility requirements.
Some utility companies or local codes require pipe sizes
larger than the minimum s izes listed in these instructions and
in the codes. Properly sized wrought iron, approved flexible
or steel pipe must be used when making gas connections to
the unit. The installation of a drop leg and ground union is
required (refer to Figure 10).
Gas piping may be connected from either side of the furnace
using any of the gas pipe entry knockouts on both sides of
the furnace (refer to Figures 1 or 2 for locations and dimensions).
NOT E: Plan your combustion air piping bef ore determining
the correct gas pipe entry. Use 90 degree service elbow(s), or
short nipples and conventional 90 degree elbow(s) to enter
through the cabinet access holes.
1” MAX. BETWEEN
ROD & FURNACE
6” MIN BETWEEN
ROD & FURNACE
FIGURE 9 : Typical Furnace Installation Using
Suspension Materials
CRAWL SPACE INSTAL LAT ION
The furnace can be hung from floor hoists or installed on suitable blocks or pad. Blocks or pad ins tallations s hall provide
adequate height to ensure the unit will not be subject to water
damage.
Unitary Products Group 11
1” MAX. BETWEEN
ROD & FURNACE
An overpressure protection device, such as a
pressure regulator, which conforms to the National
Fuel Gas Code, ANSI Z223.1 (U.S.) or CANB149.1 or.2 (Canada) and acts to limit the downstream pressure to a value that does not exceed
0.5 PSI (14" w.c.), must be installed in the gas piping system upstream of the furnace. Failure to do
so may result in a fire or explosion or cause damage to the furnace or some of its c omponents.
INLET GAS PRESSURE RANGE
Natural Ga s Pr opa ne (LP)
Minimum 4 .5 In. W.C. 11 In. W.C.
Maxi mum 1 3.9 In . W.C. 13.9 In . W.C.
NOT E: An accessible manual shutoff valve mus t be installed
upstream of the furnace gas controls and within 6 feet of the
furnace.
EXTERNAL MANUAL
SHUTOFF VALVE
TO GAS
SUPPLY
DROP
LEG
GROUND JOINT UNION
MAY BE INSTALLED
INSIDE OR OUTSIDE UNIT.
TO GAS
SUPPLY
035-17477-002 Rev. D (1202)
Never apply a pipe wrench to the body of the combination automatic gas valve. A wrench must be
placed on the projection or wrench boss of the
valve when installing piping to it.
ELECTRICAL POW ER CO NN ECTION
Field wiring to the unit must conform t o and be grounded in
accordance with the provisions of the National Elec trical
Code ANSI/NFPA No. 70-latest edition, Canadian Electric
Code C22.1 Part 1 - (latest edition) and/or local codes. Electric wires which are field installed shall conform with the temperature limitation for 63°F/35°C rise wire when installed in
accordance with instructions. Refer the rating plate or Physical and Rating Data Tables in these instructions for specific
furnace electrical data.
Provide a power supply separate from all other circuits. Install
overcurrent protection and disconnect switch per local/
national electrical codes. The switch should be close to the
unit for convenience in servicing. With the disconnect switch
in the OFF position, check all w iring against the unit wiring
label. Also, see the wiring diagram in this ins truction.
NOT E: The furnace’s control system depends on correct
polarity of the power supply and a proper ground connection.
Ref er to the “FU RN A CE CO N TR OL DI AG NOST IC S” on
page 36 for symptoms of reversed power s upply polarity.
FIGURE 10 :
Ga s Pi ping
NOT E: A 1/8” NPT plug is included in the inlet side of the gas
valve for measuring incoming gas pressure.
The furnace must be isolated from the gas supply piping system by closing its individual external manual shutoff valve
during any pressure testing of the gas supply piping system
at pressures equal to or less than 1/2 psig (3.48 kPa).
The furnace and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2
psig (3.48 kPa)
.
Compounds used on threaded joints of gas piping
must be resistant to the action of liquefied petroleum gases. After connections are made, leak-test
all pipe connections.
After all gas piping connections are completed,
leak test all joints, fittings and furnace connections
with rich soap and water solution, commercially
available bubble type leak detection fluid, or other
approved means.
Do not use an open flame or other source of
ignition for leak testing.
Use copper conductors only.
Connect the power supply as shown on the unit wiring label
on the inside of the blower compartment door. The black furnace lead must be connected to the L1 (hot) wire from the
power supply. The white furnace lead must be connected to
neutral. Also, the green equipment ground wire must be connected to the power supply ground.
Remove the screws retaining the wiring box cover. Route the
power wiring through the opening in the unit into the junction
box with a conduit connector or other proper connection.
Make wiring connections and replace the wiring box cover
and screws. Refer to Figures 11or 12.
An alternate wiring method is to use a field provided 2 x 4 box
and cover on the outside of the furnace. Route the furnace
leads into the box using a protective bushing where the wires
pass through the furnace pane.
12 Unitary Products Group
035-17477-002 Rev. D (1202)
BLK/BLK
WHT/WHT
GRN/GRN
JUNCTION
BOX
L1
(HOT)
BLK
N
GND
WHT
GRN
BLOWER COMPARTMENT
DOOR SWITCH
TRANSFORMER
IGNITION MODULE
YWRGC
C
P
X
H
O
A
FMR
L1
U
R
OL
M
NEUTRALS
K
P
H
E
A
E
A
R
A
C
K
T
CLASS 2 SYSTEM
CONTROL WIRING
TO THERMOSTAT
BURNER COMPARTMENT
FIGURE 11 : Electrical Wiring - Upflow Models
NOT E: The power connection leads and wiring box on upflow
units may be relocated 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 fasten using holes provided.
ELECTRICAL CONTROL CONNECTIO NS
Install the field-supplied thermostat. The thermostat instructions for wiring are packed with the t hermostat. With t he thermostat set in the OFF position and the main electrical source
disconnected, complete the low-voltage wiring from the thermostat to the terminal board on the ignition module. Connect
Class 2 control wiring as shown in Figure 14. Electronic thermostats may require a c ommon connection as shown dashed
in Figure 14.
Apply strain relief to thermostat wires passing through c abinet.
Set the heat anticipator in the room thermostat to .45
amps. Setting it lower will cause short cycles. Setting
it higher will cause the room temperature to exceed
the setpoints
BLK
WHT
GRN
FIGURE 13 :
BLK (HOT)
WHT (NEUTRAL)
GRD
Power Wiring Connections
NOMINAL
120 VOLT
L1
HOT
JUNCTION
BOX
BLK
N
WHT
GRD
GRN
BLK/BLK
WHT/WHT
GRN/GRN
WIRING INSIDE
JUNCTION BOX
BLOWER COMPARTMENT
VENT PIPE
EAC
HEAT
PARK
NEUTRALS
L1
HUM
XFMR
PARK
IGNITION MODULE
TRANSFORMER
DOOR
SWITCH
COOL
YWRGC
BURNER COMPARTMENT
CLASS 2 SYSTEM
CONTROL WIRING
TO THERMOSTAT
FLUE CHASE
FIGURE 12 : Electrical Wiring - Downflow / Horizontal
Models
ROOM
THERMOSTAT
R
W
G
Y
C
FIGURE 14 :
FURNACE
CONTROL
CONDENSING
UNIT
R
W
G
TO AIR CONDITIONER
CONTROLS
Y
C
Typical Heating and Cooling
NOT E: Some electronic thermostats do not have adjustable
heat anticipators. They may have other type cycle rat e 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.
Unitary Products Group 13
035-17477-002 Rev. D (1202)
ACCESSORY CONNECTIONS
The furnace control will allow power switching control of various accessories. Refer to Figure 15, for connection details.
ELECTRONI C AI R CL E AN ER CO N NEC TI O N
Two 1/4" spade terminals (EAC and EAC N) for elect ronic air
cleaner connections are located on the control board. The
terminals provide 115 VAC (1.0 amp maximum) during circulating blower operation.
HUMIDIFIER CONNEC TI O N
Two 1/4" 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.
TWINNING
When two furnaces are installed using t he same duct system,
it is very important that the two furnace circulating air blowers
operate simultaneously. If one blower starts before the second blower, the duct system will become pressurized with air
and the second blower will be made to turn backwards. During heating operation, this will cause overheating of t he
second furnace, possibly causing an unsafe condition and
damage to the furnace. If twinning of two furnaces is desired,
it is necessary to use the accessory twinning kit that is
designed for use with these furnaces.
Be sure to follow the appropriate venting section details,
related information and limitations for your type of installation.
Furnace Intake / Vent Connection Size (All Models)
40 - 100 MBH 120 - 14 0 M BH
I ntak e 2” 3"
Ve nt 2”
*.
Vent must be i ncrea sed to 3" on this mod el.
2"
*
Note 1:Any vent pipe size change must be made out-
side furnace casin g in a vertical pipe section
to allow proper drainage of condensate.
Note 2: An offset using two 45 degree elbows will be
requir ed for p l enu m cl earance when th e ve nt
is increased to 3”.
METHOD ONE: TWO PIPE SEALED
COMBUSTION AIR & VENT SYSTEM
COM BU STION AI R IN TAKE / VE NT C ONNECT IONS
This type installation requires outdoor combustion air. Two
separate, properly-sized pipes must be used. One bringing
air from the outdoors to the furnace combustion air intake c ollar on the burner box, and a second pipe from the furnace
vent connection (top right of unit) back to the outdoors.Figure
16 or 17.
HUM. HOT
115 VOLT
HUMIDIFIER
115 VOLT
ELECTRONIC
AIR CLEANER
FIGURE 15 :
BLK
WHT
SWITCHED
EAC
CIRCUITS
HUM
EAC HOT
BLK
WHT
EAC
HUM
NEUTRALS
Accessory Connections
COMBUSTION AIR AND VENT SYSTEM
This furnace is certified to be installed with one of three
possible intake/vent configurations.
1. Two-pipe with a sealed combustion intake/vent system
using outdoor combustion air.
2. Single pipe vent system using combustion air from the
area surrounding the furnace.
3. Two-pipe intake/vent system using combustion air from a
ventilated attic space and a vent pipe to the outside.
COMBUSTION AIR
PIPE PASSES
THROUGH TOP PANEL
CONNECTS TO
COLLAR ON TOP
OF BURNER BOX
VENT PIPE
CEMENTS
INTO SOCKET
JUST UNDER
TOP PANEL
FIGURE 16 : Air Intake and Vent Locations - Upflow
14 Unitary Products Group
035-17477-002 Rev. D (1202)
VENT PIPE PASSES
THROUGH TOP PANEL
OPTIONAL
LEFT SIDE
COMBUSTION
AIR PIPE
ROUTING
COMBUSTION
AIR PIPE
CONNECTS TO
COLLAR ON
BOTTOM OF
BURNER BOX
FIGURE 17 : Air Intake and Vent Locations -
Downflow/Horizontal
The intake/vent should be located either through the wall
(horizontal or side vent) or through the roof (vertical vent).
Care should be taken to locate side vented systems where
trees or shrubs will not block or restrict supply air from entering or combustion products from leaving the t erminal.
Also, the terminal assembly should be located as far as possible from a swimming pool or a location where swimming
pool chemicals might be stored. Be sure the terminal as sembly follows the outdoor clearances listed in Table 3 for U .S.
installations. In Canada, refer to CAN/CGA-B149.1 or.2
Installation Code (latest edition-Venting Systems and Air
Supply).
COM BUSTION AIR/ VENT PIPE SI ZING
To select the propeTable 4 or Table 5. The size will be determined by a combination of furnace model, total length of run,
and the number of elbows required. The following rules must
also be observed.Long radius elbows are required for all
units.
1. Long radius elbows are required for all units.
2. Elbows are assumed to be 90 degrees. Two 45 degree
elbows count as one 90 degree elbow.
3. Elbow count refers to combustion air piping and vent piping separately. For example, if the table allows for 5
elbows, this will allow a maximum of 5 elbows in the
combustion air piping and a maximum of 5 elbow s in the
vent piping.
4. Three vent terminal elbows (two for vent pipe and one for
air intake pipe) are already accounted for and should not
be counted in the allowable total indicated in the t able
(see vent termination section). These parts are shown
shaded.
For downflow/horizontal models, the two additional
elbows required for the air intake pipe entry into the
burner box are also accounted for and should not be
counted. These parts are shown shaded.
For downflow/horizontal models only two additional
elbows are also accounted for and also should not be
counted. These parts are shown shaded.
5. Combustion air and vent piping must be of the same
diameter.
6. All combustion air/vent pipe and fittings must conform t o
American National Standards Institute (ANSI) standards
and American Society for Testing and Materials (ASTM)
standards D1785 (Schedule 40 PVC), D2665 (PVCDWV), F891 (PVC-DWV Cellular Core). D2241 (SDR-21
and SDR-26 PVC), D2261 (ABS-DWV), or F628 (Sc hedule 40 ABS. Pipe cement and primer must conf orm to
ASTM Standards D2564 (PVC) or D2235 (ABS).
7. The use of flexible connectors or no hub connectors in
the vent system is not allowed. This type connection is
allowed in the combustion air pipe near the f urnace for
air conditioning coil accessibility.
Table 4:
140 / 1 30 / 2000 / D
INTAKE/VENT PIPING - 2 PIPE SYSTEM
Models P*UR/
FG9-UP/G9T-UP
40 / 3 7 / 1000 / A
60 / 5 5 / 1000 / B
80 / 7 5 / 1200 / B
80 / 7 5 / 16 00 / C
100 / 95 / 1400 / C
100 / 95 / 2000 / C
40 / 3 7 / 1000 / A
60 / 5 5 / 1000 / B
80 / 7 5 / 1200 / B
80 / 7 5 / 16 00 / C
100 / 95 / 1400 / C
100 / 95 / 2000 / C
120 / 112 / 2000 / D
*.
E lbow co un t do es not inc lude t he elbows requ ire d for
th e ter m inatio n. S ee Step 4 un der Comb usti on Air/Vent
Pipe Sizing
Pipe
Size
3" Only 6 5 4 N/A
Max. Elbows vs. One Way Vent
Len gt h ( Ft.)
5 - 40 45 50 75
2” 6 5 4 N/A
3”8765
*
Unitary Products Group 15
035-17477-002 Rev. D (1202)
Tabl e 5:
INTAKE/VENT PIPING 2-PIPE SYSTEM
Models P*DH/
FG9-DH/G9T-DH
40 /37 / 1000 / A
60 /55 / 1200 / B
80 /75 / 1200 / B
80 /75 / 1600 / C
100 /95 / 2000 / C
40 /37 / 800 / A
60 /55 / 1200 / B
80 /75 / 1200 / B
80 /75 / 1600 / C
100 /95 / 2000 / C
1 20 /112 / 2000 / D 3" O nly 6 5 4 N/ A
*.
Elbow c ou nt doe s not in clude (2) 90 ° elbo ws re qu ired
to pipe i ntake into burner box or t hose r equired for th e
ter minat ion. See Ste p 4 u nd er Com bustion Air/ Vent
Pipe Sizing
Pipe Size
2” 654N/A
3” 8765
Max. Elbows vs. One Way
Vent Length (Ft.)
5-30 35 40 60
*
NOT E: If installing furnace at altitudes between 2000 - 4500
ft., intake and vent pipe length must be reduced by 10 ft. If t he
installation requires the maximum allowable intake and vent
pipe length, the furnace must be converted f or high altitude
operation. Refer to the proper high altitude application
instruction for details.
VENT TERMINATION (2-PIPE)
Side wall horizontal vent terminals and roof mounted vertical
terminals may be field fabricated. Standard PVC/SRD fittings
may be used. Terminal configuration must comply as detailed
in this section.
NOT E: Combustion air and vent pipes must terminate
together in the same atmospheric zone, eit her through a roof
or sidewall.
NOT E: Accessory concentric intake/vent terminations,
models 1CT0302 and 1CT0303 are available and
approved for use with these furnaces. Refer to Form
650.75-N2.4V for installation details.
When selecting the location for combustion air/vent termination the following should be considered:
1. Comply with all clearance requirements as listed below.
2. Termination should be positioned where vent vapors will
not damage 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 objectionable.
VENT CLEARANCES (2-PIPE) U.S. ONLY
Dryer Vent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ft.
Plumbing Vent Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ft.
Gas Appliance Vent Terminal . . . . . . . . . . . . . . . . . . . 3 ft.*
From any mechanical fresh air intake . . . . . . . . . . . . . . 1 ft.
From any door, window or non-mechanical fresh air or
combustion air intake . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ft.
Above grade and anticipated snow depth . . . . . . . . . . . 1 ft.
Above grade when adjacent to public walkway . . . . . . 7 ft.
From electric, gas meters, regulat ors and relief equipment -
min. horizontal distance . . . . . . . . . . . . . . . . . . . . . . . . 4 ft.
* Does not apply t o multip le insta llations of this f urnace
model. Refer to “V ENTING M ULTIP LE
UNITS " Se ction on page 18 .
In Canada, refer to CAN/CGA-B149.1 or .2 Installation
Code (latest edition - Venting Systems and Air Supply)
NOT E: Consideration m ust be given for degradat ion of building materials by flue gases.
NOT E: Shaded components of the combustion air/vent system shown in Figures 18 to Figure 23 are considered to be
part of the termination. These components should not be
counted when determining piping limitations. Sidewall termination may require sealing or shielding of building surfaces
with a corrosive resistance material t o protect agains t combustion product corrosion.
16 Unitary Products Group
035-17477-002 Rev. D (1202)
OVERHANG
12” MINIMUM
VENT
90°
COMBUSTION AIR
12 SEPARATION BETWEEN
BOTTOM OF COMBUSTION AIR
AND BOTTOM OF VENT
MAINTAIN 12” CLEARANCE ABOVE
HIGHEST ANTICIPATED SNOW LEVEL
OR GRADE WHICHEVER IS GREATER
FIGURE 18 : Horizontal Termination Configuration w ith 12”
Minimum Clearance
.
OVERHANG
12” MINIMUM
VENT
90°
12 SEPARATION BETWEEN
BOTTOM OF COMBUSTION AIR
AND BOTTOM OF VENT
MAINTAIN 12” CLEARANCE ABOVE
HIGHEST ANTICIPATED SNOW LEVEL
OR GRADE WHICHEVER IS GREATER
12” VERTICAL SEPARATION
BETWEEN COMBUSTION
AIR AND VENT
VENT
FIGURE 21 : Vertical Termination
VENT
COMBUSTION AIR
2”
COMBUSTION AIR
MAINTAIN 12” MINIMUM
CLEARANCEABOVE HIGHEST
ANTICIPATED SNOWLEVEL.
MAXIMUM OF 24” ABOVE ROOF.
COMBUSTION AIR
FIGURE 19 : Horizontal Termination Raised
Configuration for Additional Clearance
OVERHANG
12” MINIMUM
VENT
90°
18” MAX.
COMBUSTION AIR
12 SEPARATION BETWEEN
BOTTOM OF COMBUSTION AIR
AND BOTTOM OF VENT
MAINTAIN 12” CLEARANCE ABOVE
HIGHEST ANTICIPATED SNOW LEVEL
OR GRADE WHICHEVER IS GREATER
FIGURE 20 : Horizontal Termination Configuration w ith Hori-
zontal Extension
FIGURE 22 : Double Sidewall Termination
6”
FIGURE 23 : Double Rooftop Termination
Unitary Products Group 17
035-17477-002 Rev. D (1202)
VENTING M ULTIP LE UNIT S
Each unit must have its own intake/vent piping and termination. Do not use common pipes for combustion air or venting.
The vent terminals must be located as shown in Figure 22 or
Figure 23.
PIPING ASSEMBLY
The final assembly procedure for the vent/combustion air piping is as follows:
1. Cut piping to the proper length, beginning at the furnace.
2. Deburr the piping inside and outside.
3. Chamfer the outer edges of the piping.
4. Dry-fit the entire vent/combustion air piping assembly.
5. Disassemble the piping and apply cement primer and
cement per the cement m anufacturer's instructions.
Primer and cement must conform to AST M D2564 for
PVC, or ASTM D2235 for ABS piping.
Solvent cements are flammable and must be used
in well-ventilated areas only. Keep them away from
heat, sparks and open flames (including pilots). Do
not breathe vapors and avoid contact with skin and
eyes.
METHOD TWO: ONE PIPE SYSTEM
This type installation will use combustion air from within t he
space surrounding the furnace. This may be from w ithin the
space in a non-confined location or it m ay be brought into t he
furnace area from outdoors. It is not direc tly ducted into t he
furnace. A single, properly sized pipe from the f urnace vent
connector to the outdoors must be provided.
For upflow models combustion air is brought into the furnace
through the unit top panel opening. Do not install a pipe into
the intake collar on top of the burner box. F igure 24 .
For downflow/horizontal models, remove a minimum of two
gas piping knockouts for combustion air ac cess. Do not
install a pipe into the intake collar on bottom of the burner
box. For details, refer to Figure 25.
COMBUSTION AIR
VENT PIPE CEMENTS
INTO SOCKET JUST
UNDER TOP PANEL
6. All joints must be made to provide a permanent, air-t ight,
water-tight seal.
7. Support the combustion air and vent piping such that it is
angled 1/4” per linear foot so that condensate will flow
back toward the furnace. Piping should be supported
with pipe hangers to prevent sagging. Maximum spacing
between hangers is five (5) feet, except SDR-PVC piping, where maximum spacing is t hree (3) feet.
8. Seal around the openings where the combustion air and
vent piping pass through the roof of side wall.
Vent piping must be insulated with 1/2” Armaflex
insulation if it will be subjected to freezing temperatures such as routing through unheated areas or
through an unused chimney.
When combustion air pipe is installed above a suspended ceiling, the pipe must be insulated with 1/
2” Armaflex type insulation. The combustion air
pipe should also be insulated when it passes
through a warm, humid space.
NOT E: Vent pipe m ust be sloped 1/4” per foot to allow condensate to flow back to the furnace.
FIGURE 24 : Vent Pipe Connection - Upflow
VENT PIPE PASSES
THROUGH TOP PANEL
GAS PIPING
KNOCKOUTS
COMBUSTION AIR
FIGURE 25 : Vent Pipe Connection -
Downflow/Horizontal
18 Unitary Products Group
035-17477-002 Rev. D (1202)
COM BU STION AI R
All installations must comply with Section 5.3, Air for Combustion and Ventilation of the National Fuel Gas Code, ANSI
Z223.1 or Sections 7.2, 7.3 or 7.4 of CAN/CGA B149.1 or .2
Installation Code - latest editions.
An unconfined space is not less than 50 cubic f eet per 1000
Btu/hr input rating for all appliances installed in that area.
Rooms communicating directly with the space containing the
appliances are considered part of the unconfined space, if
openings are not furnished with doors.
A confined space is an area with less than 50 cubic feet per
1000 Btu/hr input rating for all appliances installed in that
area.
The following must be considered to obt ain proper air for
combustion and ventilation in confined spaces.
Air Sou rce from Ins i de t he Bu il di ng
Two permanent openings, one within 12 inches of the top of
the confined space and one within 12 inches of the bottom,
shall each have a free area of not less than one square inch
per 1,000 Btuh of total input rating of all appliances located in
the space. The openings shall communicate freely with interior areas having adequate infiltration from the outside.
NOT E: At least 100 square inches free area shall be us ed for
each opening.
Air Sou rce fro m Ou tdoo rs
1. Two permanent openings, one within 12 inches of the
top of the confined space and one within 12 inches of the
bottom, shall communicate directly, or by m eans of
ducts, with the outdoors or to such craw l or attic spaces
that freely communicate with t he outdoors.
a. Vertical Ducts - Each opening must have a free
area of not less than one square inch per 4,000 Btuh
of total input of all appliances located in the space.
EXAMPLE:
Total Input of All Appliances
= Square Inches Free Area
4000
b. Horizontal Ducts - Each opening must have a free
area of not less than one square inch per 2,000 Btuh
of total input of all appliances located in the space.
NOT E: Ducts must have the same cross-sectional area as
the free area in the opening to which they are connected. The
minimum dimension of rectangular ducts shall be three
inches.
2. One permanent opening, commencing within 12 inches
of the top of the enclosure shall be permitted where the
equipment has clearances of at least 1 inch f rom the
sides and back and 6 inches from the front of the appliance. The opening shall communicate t hrough a vertical
or horizontal duct to the outdoors, or spaces (crawl or
attic) that freely communicate with the outdoors and shall
have a minimum free area of:
a. 1 sq. in. per 3000 Btu per hr of the total input rating
of all equipment located in the enclosure.
b. Not less than the sum of the areas of all vent con-
nectors in the confined space.
3. Louvers, Grilles and Screens
a. In calculating free area, consideration must be given
to the blocking effects of louvers, grilles and
screens.
b. If the free area of a specific louver or grille is not
known, refer to Table 6, to estimate free area.
NOT E: If mechanically operated louvers are used, a means
to prevent main burner ignition and operation must be provided should louvers close during startup or operation.
Tabl e 6:
ESTIMATED FREE AREA
Wood or Metal
Lo uve rs or Gri lle s
†
Scr eens
*.
Do not use le ss th an 1/ 4 in. mesh
†.
Free area or louvers an grilles varies widely; installer should
follow louver or grille manufacturer’s instructions.
Wood 20-25%
Meta l 60-7 0%
1/4 in. mesh or larger 100%
*
*
Special Combustion and Ventilation Considerations
Operation of a mechanical exhaust, such as an exhaust fan,
kitchen ventilation system, clothes dryer or fireplace may create conditions requiring special attention to avoid unsatisfactory operation of gas appliances.
Specially Engineered Installations
The above requirements shall be permitted to be waived
where special engineering, approved by the authority having
jurisdiction, provides an adequate supply of air for c ombustion, ventilation and dilution of flue gases.
Combustion Air Quality
The recommended source of combustion air is to use the out door air supply. Excessive exposure to contaminated combustion air will result in safety and performance related
problems. However, the use of indoor air in most applications
is acceptable, except as follows:
1. If the furnace is installed in a confined space it is recommended that the necessary combustion air come from
the outdoors by way of attic, crawl space, air duct or
direct opening.
2. If indoor combustion air is used, t here must be no exposure to the installations or substances listed in 3 below.
Unitary Products Group 19
035-17477-002 Rev. D (1202)
3. The following types of installations m ay require OU TDOOR AIR for combustion, due to c hemical exposure.
a. Commercial buildings
b. Buildings with indoor pools
c. Furnaces installed in laundry rooms
d. Furnaces installed in hobby or craft rooms
e. Furnaces installed near chemical storage areas
f. Permanent w ave solutions
g. Chlorinated waxes and cleaners
h. Chlorine based swimming pool chemicals
i. Water softening chemicals
j. De-icing salts or chemicals
k. Carbon tetrachloride
l. Halogen type refrigerants
m. Cleaning solvents (such as perchloroethylene)
n. Printing inks, paint removers, varnishes, etc.
o. Hydrochloric acids
p. Cements and glues
q. Antistatic fabric softeners for clothes dryers
r. Masonry acid washing chemicals
VENT PIPE SIZING (1-PIPE SYSTEM)
Refer to Table 7 to select the proper size piping for venting.
The size will be determined by a combination of furnace
model, total length of run, and the number of elbows required.
The following rules must als o be observed.
NOT E: Furnace vent pipe connections are sized for 2-in.
pipe. Any pipe size change must be made outside the furnace casing in a vertical pipe section to allow proper drainage
of vent connections.
NOT E: An offset using two 45 degree elbows may be
required for plenum clearance when the vent is increased to
3".
1. Long radius elbows are required for all units.
2. Elbows are assumed to be 90 degrees. Two 45 degree
elbows count as one 90 degree elbow.
3. One Vent terminal elbow is already accounted f or and
should not be counted in the allowable total indicated in
the table. See “VENT TERMINAL LOCAT ION
CLEARANCES" Section on page 21 . This part is shown
shaded.
4. All vent pipe and fittings must conform to Am erican
National Standards Institute (ANSI) standards and American Society for Testing and Materials (ASTM) s tandards
D1785 (Schedule 40 PVC), D2665 (PVC-DWV), F891
(PVC-DWV Cellular Core), D2241 (SD R-21 and SDR-26
PVC), D2261 (ABS-DWV), or F628 (Schedule 40 ABS.
Pipe cement and primer must conform to ASTM Standards D2564 (PVC) or D2235 (ABS).
5. The use of flexible connectors or no hub connectors in
the vent system is not allowed.
Tabl e 7:
120 / 112 / 2000 / D
140 / 1 30 / 2000 / D
120 / 112 / 2000 / D
140 / 1 30 / 2000 / D
120 / 112 / 2000 / D
140 / 1 30 / 2000 / D
VENT PIPING / 1-PIPE SYSTEM (ALL MODELS)
Max. Elbow s vs. O ne W ay Vent
Model Pipe Size
5-40 45 50 75
All Models Except:
2” 6 5 4 N/A
All Models Except:
3” 8 7 6 5
3” Only 6 5 4 N/A
Lengt h (Ft.)
NOT E: If installing furnace at altitudes between 2000 - 4500
ft., intake and vent pipe length must be reduced by 10 ft. If t he
installation requires the maximum allowable intake and vent
pipe length, the furnace must be converted f or high altitude
operation. Refer to the proper high altitude application
instruction for details.
VENT TERMINATION (1-PIPE SYSTEM)
Side wall horizontal vent terminals and roof mounted vertical
terminals may be field fabricated. Standard PVC/SRD fittings
may be used. Terminal configuration must comply as detailed
in this section.
When selecting the locations for vent termination, the following should be considered:
1. Comply with all clearance requirements. Refer to Figure
26 on page 21.
2. Termination should be positioned where vent vapors will
not damage 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 objectionable.
20 Unitary Products Group
In Canada, refer to CAN/CGA-B149.1 or .2 Installation
Code (latest edition - Venting Systems and Air Supply).
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