Hamilton P*UR, G9T-UP, FG9-UP, P*DH, G9T-DH Installation Instruction

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

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

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

19-3/4

23-1/4

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

11-3/4

14-3/4

18-1/4

21-3/4

4-1/8

ABCDE

14-1/2

17-1/2

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

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

E

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

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).

035-17477-002 Rev. D (1202)





VENT TERM INAL LO CATI ON CLE AR AN CES

The vent must be installed with the following minimum clearances (refer to Figure 26), and complying with local codes or utility requirements or other authority having jurisdiction.

SOFFIT VENTS

(10’ RECOMMENDED)

FURNACE VENT

INSIDE CORNER

6’

ELECTRIC METER

4’

3’

1’ PLUS SNOW CLEARANCE

10’

FORCED AIR INTAKE



FIGURE 27 :



  

Hor izo nt al Term ination Co nf ig ur atio n with 12” Minimum Clearance

FIGURE 26 : Minimum Vent Terminal Clearanc es

(1-Pipe System) - U.S. Only

1. 1 foot above grade and above normal snow levels.

2. Not above any walkway.

3. 4 feet below, 4 feet horizontally from, or 1 foot above any door/window or gravity air inlet to the building, or from gas or electric meters.

4. 6 feet from any inside corner formed by two exterior walls. 10 feet is recommended where possible.

5. At least 4 feet horizontally from any s offit or undereav e vent.

6. 10 feet from any forced air inlet to the building. Any fresh air or make up inlet as for a dryer or furnace area is considered to be a forced air inlet.

7. Avoid areas where condensate drippage may cause problems such as above planters, patios, or adjacent to windows where steam may cause fogging.

NOT E: Consideration m ust be given for degradat ion of building materials by flue gases.

NOT E: Shaded components of the vent system shown in Figures 27 through 29 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 resistant material to protect against combustion product corrosion.



FIGURE 28 :

FIGURE 29 :





  

Horizontal Termination Raised Configuration for Additional Clearance



   

Rooftop Termination

Unitary Products Group 21

035-17477-002 Rev. D (1202)

PIPING ASSEMBLY

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

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

2. Deburr the piping inside and outside.

3. Chamfer the outer edges of the piping.

4. Dry-fit the entire vent piping system.

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.

6. All joints must be made to provide a permanent, air tight. water tight seal.

7. Support the vent piping such that it is angled 1/4” per linear foot so that condensate will flow back t owards the furnace. Piping should be supported with pipe hangers to prevent sagging. Maximum spacing between hangers is 5 feet, except SDR-PVC piping, where m aximum spacing is 3 feet.

8. Seal around the openings where the vent piping passes through the roof or side wall.

METHOD THREE: TWO PIPE SYSTEM USING COMBUSTION AIR FROM A VENTILATED ATTIC SPACE

This type installation requires two properly sized pipes. One brings combustion air from a properly ventilated attic space and a second pipe from the furnace vent connection (top right of unit) exits to the outdoors.

In Canada, refer to CAN/CGA-B149.1 or .2 Installation Code (latest edition - Venting Systems and Air Supply)

COM BU STION AI R IN TAKE

Table 4 on page 15, for intake pipe sizing, allowable length and elbow usage. Follow all notes, procedures and required materials in the Two-Pipe Sealed Combustion section (Method 1) when installing the combustion air pipe within the unit and into the ventilated attic space.

COM BU STION AI R TE R MI NATI ON

Refer to Figure 30 for required termination method and configuration for the intake pipe. For attic termination, us e two 90 elbows with the open end in a downward position. Be sure t o maintain 12" clearance above any insulation, flooring or other mat erial.

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.

NOT E: Vent pipe m ust be sloped 1/4” per foot to allow condensate to flow back to the furnace.

22 Unitary Products Group

FIGURE 30 : Attic Combustion Air Termination

Be sure to instruct the owner not to block this intake pipe.

035-17477-002 Rev. D (1202)

COM BU STION AI R RE QU IR E MEN TS

The ventilated attic space from which the combustion air is taken must comply with the requirements shown on page 19 in this instruction or in Section 5.3, Air for Combustion and Ventilation of the National Fuel Gas Code, ANSI Z223.1 (latest edition).

VENT PIPE

For vent pipe sizing, allowable length and elbow usage, see Table 7 on Page 20. Follow all notes, installation procedures and required materials in the “METHOD TWO ONE PI PE SYSTEM, on page 18” to install the vent pipe from the unit t o the outdoors.

VENT TERMINATION

The vent pipe termination must be installed within the allowable locations shown in Figure 26 and Section 7.8 in t he National Fuel Gas Code, ANSI Z223.1 (current edition). Follow all local agency and utility requirements if m ore restrictive than those shown. Vent termination must be as shown in Figures 27 through 29.

In Canada, refer to CAN/CGA-B149.1 or .2 Installation Code (latest edition - Venting Systems and Air Supply).

EAC

HEAT

PARK

NEUTRALS

L1

HUM

XFMR

PARK

COOL

3.00” MINIMUM

YWRGC

LOOP DIA.

ATTACH THIS END TO CONDENSATE DRAIN SYSTEM

HORIZONTAL VENT APPLICATIONS

If installing a horizontal venting system through any unconditioned space such as an attic or crawl space, it is recommended, that a vent drain be added to the vent pipe to prevent the accumulation of excess condensate in the inducer motor during operational cycles, refer to F igures 31 or 32.

3.00” MINIMUM LOOP DIA.

ATTACH THIS END TO CONDENSATE DRAIN SYSTEM

FIGURE 32 : Horizontal Vent Drain -

Downflow/Horizontal Models

To install the vent drain, complete the following steps:

1. Place a tee of the proper diameter for the vent system being installed (2" or 3") in the horizontal run closest to the furnace.

2. Place a reducer bushing of proper diameter in the stem portion of the tee. The recommended size for the reducer is 5/8”.

3. Place a piece of 5/8” diameter or other selected size pipe a minimum of 3" long into the reducer to serve as a nipple.

NOT E: Tee, reducer and nipple must be properly cemented together using the appropriate method and materials specified in the Combustion Air Intake/Vent Connections s ection of these instructions.

4. Connect a piece of flexible drain tubing such as EPDM rubber, Vinyl or PVC to the nipple.

5. Loop the drain tubing to provide a trap.

6. Connect the discharge end of the drain tube to the condensate disposal system externally to the furnace.

FIGURE 31 :

Horizontal Vent Drain - Upflow Models

Unitary Products Group 23

035-17477-002 Rev. D (1202)

CONDENSATE PIPING

The condensate drain connection is packed in the furnace f or field installation. It consists of a formed hose with a 1/2” NPT male connection. A 1/2” FM x 3/4” PVC slip coupling is provided.

This drain hose may be installed to allow left or right side c ondensate drain connection, refer to Figures 33 and 34. Cut the hose to allow for proper fit for left or right exit.

LH DRAIN

RH DRAIN

FIGURE 33 : Condensate Piping - Upflow Models

Refer to Figure 35 for hose locations and Table 8 for hose cut lengths. All hoses are identified as shown in Figure 35.

For horizontal left airflow (inducer and vent low) or horizontal right airflow (inducer and vent high), install condensate drain hoses as follows:

RIGHT AIRFLOW (Inducer High) - Three hoses are required. Hoses are supplied with furnace. Refer to Figure 35 and Table 8 for application.

LEFT AIRFLOW (Inducer Low) - Two hos es are required. Inducer outlet to trap is supplied. C ondensate pan to t rap must be field supplied using 5/8” I.D. hose material. Refer to Figure 35 and Table 8, for hose placement and sizing..

Tabl e 8:

HORI ZONTAL CONDENSATE DRAIN HOSE SIZES MODELS P*DH / FG9-DH / G9T- DH

CABINET SIZE (IN.)

DIMEN.

A 4-1/2 4-3/4 3-1/2 5-1/4

B 7-1/2 10-1 /2 14 1 7-1/2

C 1 3-1/ 2 16 -1 /2 2 0 23- 1/2

D 3-3/8 3-1/4 3-1/4 3-1/4

RIGHT AIRFLOW (INDUCER HIGH)

14-1/2 17-1/2 21 24-1/2

LEFT AI RFLOW (INDUCER LOW)

CONDENSATE TRAP TUBING

FIGURE 34 : Downflow/Horizontal Models

To install the drain hose assembly, remove the 7/8” knoc kout in the side panel. Remove the conduit nut from the 1/2” male fitting. Push the male fitting through the hole and reinstall the nut. The use of the 3/4” PVC coupling is optional.

CONVERSION FOR HORIZONTAL APPLICATIONS (DOWNFLOW MODELS ONLY)

Remove the condensate trap and its mounting bracket from the unit side panel. Remove all drain hoses.

Reinstall the trap/bracket on the side panel which will be on the bottom when the unit is located horizontally. Use the original mounting screws.

Plug all unused condensate trap, condensate pan and inducer drain connection points using plugs provided.

Drain Connection:

The following steps apply to all models. For horizontal application, also follow the procedure for relocating the trap assembly and installing drain hoses.

1. It is recommended that either 1/2” or 3/4” PVC or equiva-

lent pipe be field installed as drain pipe. The condensate piping may be tied together with t he air conditioning condensate drain if the air conditioning condensate drain line is trapped upstream of the t ie-in and the c ombined drains are constructed of the same material.

2. All pipe joints must be cleaned, de-burred and cemented

using PVC primer and cement.

3. The furnace contains an internal trap. Therefore, no

external trap should be used.

4. If a condensate pump is used, it must be suitable f or use

with acidic water.

5. Where required, a field-supplied neutralizer can be

installed in the drain line, external to the furnace.

NOT E: The c ondensate drain from the furnace may be connected in common with the drain from an air conditioning coil if allowed by local code. Follow the instructions with the coil for trapping the drain.

24 Unitary Products Group

035-17477-002 Rev. D (1202)

RIGHT AIRFLOW (INDUCER HIGH)

HOSE IDENTIFIER NUMBERS:

C

B

A

1

3

2

1. CONDENSATE PAN TO TRAP “A” DIMENSIONS.

2. INDUCER BOTTOM TO TRAP “B” DIMENSIONS.

3. INDUCER OUTLET TO TRAP “C” DIMENSIONS.

LEFT AIRFLOW (INDUCER HIGH)

D

4

5

HOSE IDENTIFIER NUMBERS:

1. INDUCER OUTLET TO TRAP USE AS PROVIDED.

5. CONDENSATE PAN TO TRAP “D” DIMENSIONS.

FIGURE 35 : Horizontal Application Condensate Drain Connection (Models P*DH / FG9-DH / G9T-DH)

SAFETY CONTROLS

Rollout Swi tch Controls:

These controls are mounted on

the burner box assembly. If the temperature in the burner

Contr ol C ircuit F use: A 3 amp. fuse is provided to protect the 24 volt transformer from overload caused by control c ircuit wiring errors. This is an ATO 3, automotive type fuse and is located on the ignition control module.

Blower Door Safety Switch:

This unit is equipped with an electrical interlock switch mounted in the blower compartment. This switch interrupts all power at the unit when the panel covering the blower compartment is removed.

compartment exceeds its set point, the igniter control and the gas valve are de-energized. The operation of this control indicates a malfunction in the combustion air blower, heat exchanger or a blocked vent pipe connection. Corrective action is required. This is a m anual reset control and must be reset before operation can continue.

Pressure Switches:

This furnace is supplied with pressure switches which monitor the flow through the combustion air/ vent piping system. These switches de-energize the ignit ion control module and the gas valve if any of the f ollowing conditions are present. Refer to Figure 36 for tubing connections.

Blower and burner must never be operated without the blower panel in place.

Electrical supply to this unit is dependent upon the panel that covers the blower compartment being in place and properly positioned.

1. Blockage of combustion air piping or terminal. (1LP)

2. Blockage of vent piping or terminal (1LP).

3. Failure of combustion air blower motor (1LP).

4. Blockage of condensate drain piping:

• Upflow units (1LP)

• Downflow/Horizontal Unit s

• Downflow (1LP)

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

• Horizontal Left (1LP)

• Horizontal Right (2LP).

Limit Contr ol s:

There is high temperature lim it control located on the furnace vestibule panel near the gas valve. This is a automatic reset c ontrol that provide over temperature protection due to reduced airflow, such as a dirty filter.

Unitary Products Group 25

1L P

UPFLOW

DOWNFLOW / HORIZONTAL

FIGURE 36 :

P ressure Switch Tub ing Routing

Auxiliary Limit Controls: Downflow/horizontal units have a single limit switch mounted on the blower assembly. This is a manual reset control and gives high temperature protection in the event of a blower motor failure.

START-UP AND ADJUSTMENTS

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

1. When the gas supply is initially connected to the furnace, the gas piping may be full of air. In order to purge this air, it is recommended that the ground union be loosened until the odor of gas is detected. When gas is detected, immediately retighten the union and check for leaks. Allow five minutes for any gas t o dissipate before continuing with the start-up procedure.

035-17477-002 Rev. D (1202)

Perform the following procedures only after the condensate trap has been properly piped to a drain connection using the procedure in this instruction.

2. The condensate trap must be filled with w ater before putting the furnace into operation. The recommended procedure is as follows:

a. Disconnect the condensate drain hose from the

induced draft blower discharge.

b. Elevate this hose and fill with water using a funnel.

c. Replace the condensate drain hose and clamps.

: If this procedure is not followed, the unit may not

NOT E

properly drain on initial start up.

3. All electrical connections made in the f ield and in the factory should be checked for proper tightness.

IGNITION SYSTEM SEQUENCE

1. Turn the gas supply ON at external v alve and m ain gas valve.

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

3. System start-up will occur as f ollows:

a. The induced draft blower motor will start and come

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

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

(open) the main gas valve for seven seconds.

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

start in about 30 seconds.

NOT E: Burner ignition may not be satisfactory on first startup due to residual air in the gas line or until gas manifold pressure is adjusted. The ignition control will make 3 attempts to light before locking out.

4. With furnace in operation, paint the pipe joints and valve gasket lines with a rich soap and water solution, Bubbles indicate a gas leak. Take appropriate steps to stop the leak. If the leak persists, replace the component.

Be sure proper ventilation is available to dilute and carry away any vented gas.

26 Unitary Products Group

DO NOT om it this test! N ever use a flame to c heck for gas leaks.

035-17477-002 Rev. D (1202)

OFF

ON

INLET

WRENCH

BOSS

ON/OFF SWITCH

F

O

N

O

OUTLET

MAIN REGULATOR ADJUST

FIGURE 37 : White Rodgers 36G Gas Valve

CHECKING GAS INPUT (N ATURAL GAS)

NOT E: Front door of burner box must be secured when

checking gas input.

1. Turn off all other gas applianc es connected to the gas met er.

2. With the furnace turned on, measure the time needed for one revolution of the hand on the smallest dial on the meter. A typical domestic gas meter us ually has a 1/2 or 1 cubic foot test dial.

3. Using the number of seconds for each revolution and the size of the test dial increment, find the c ubic feet of gas consumed per hour, (Table 9 on Page 27).

NOT E: To f ind the Btuh input, multiply the number of cubic feet of gas consumed per hour by the BTU c ontent of t he gas in your particular locality. Contract your gas company for this information, as it varies widely from city to city.

EXAMPLE:

onds for the hand to turn on the 1 cubic foot dial to make a revolution with only a 120,000 Btuh furnace running. Using this information, locate 26 seconds in t he first c olumn of.

Read across to the column headed 1 Cubic Foot where you will see that 138 cubic feet of gas per hour are consumed by the furnace at that rate. Multiply 138 by 850 (the BTU rating of the gas obtained from the local gas company). T he result is 117,300 Btuh, which is close to the 120,000 Btuh rating of the furnace.

If the actual input is not within + allowance being made for the permissible range of the regulator setting (0.3 inches W.C.), replace the orifice spuds with spuds of the proper size.

It is found by measurement that it takes 26 sec-

2% of the furnace rating, with

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

Table 9:

GAS RATE (CUBI C FEET PER H OU R)

SIZE OF TEST DIAL

SECONDS FOR

ONE REVOLUTION

10 180 360

12 150 300

14 129 257

16 113 225

18 100 200

20 90 180

22 82 164

24 75 150

26 69 138

28 64 129

30 60 120

32 56 113

34 53 106

36 50 100

38 47 95

40 45 90

42 43 86

44 41 82

46 39 78

48 37 75

50 36 72

52 35 69

54 34 67

56 32 64

58 31 62

60 30 60

1/2 CUBIC

FOOT

1 CUBIC FOOT

Unitary Products Group 27

035-17477-002 Rev. D (1202)

ADJUSTMENT OF MANIFOLD GAS PRESSURE

Manifold gas pressure may be measured by two different procedures. It may be measured with the burner box cover in place or it may be measured with the burner box cover removed. Follow the appropriate section, 2a or 2b in the instructions below.

1. Turn gas off at main gas valve. Remove 1/8" N PT plug from the outlet pressure tap in the main gas v alve body and install a proper manometer tube adapter fitting (refer to Figure 37). Connect line from gas valve tap to a manometer.

2. Read the inlet gas pressure using either of the two methods below.

a. Reading the gas pressure with the burner box

cover in place - Disconnect the pressure reference hose from the right side of the burner box. Using a tee fitting and a short piece of hose, connect the negative side of the manometer to the burner box pressure reference port. Connect the positive side of the manometer to the adapter previously installed in the gas valve Refer to F igures 38 and 39 on page 29 for connection details.

b. Reading the gas pressure with the burner box

cover removed - Rem o ve t h e sc r ews s e cur in g the burner box front cover plate. Remove the c over. It is gasketed and may stick in place. Connect the positive side of the manometer to t he adapter prev iously installed in the gas valve. There will be no second connection to the manometer as it will reference atmospheric pressure.

NOT E: The screw-off cap for the pressure regulator must be removed entirely to gain access to the adjustment screw. Loosening or tightening the cap does not adjust the flow of gas.

3. Refer to Figure 37 on page 27, for location of pressure regulator adjustment cap and screw on m ain gas v alve.

4. Turn gas and electrical supplies ON . Start furnace and observe manifold pressure on manometer.

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

Nomi na l Mani fo ld P re ss ure

Natural Gas 3.5” w.c.

Propane (LP) Gas 10.0” w.c.

If gas valve regulator is turned in, or clockwise, m anifold pressure is increased. If screw is turned out, or counterclockwise, manifold pressure will dec rease.

6. Once the correct gas pressure to the burners has been established, turn the gas valve to OFF and turn t he electrical supply switch to OFF; then rem ove t h pressure tap at the gas valve and reinstall the plug, using a compound (on the threads) resistant to teh action of LP gases. Replace the burner box front cover or the pressure reference hose.

7. Turn the electrical and gas supplies back on, and w ith the burners in operation, check for gas leakage around the plug with a soap and water solution.

The manifold pressure must be checked with the screw-off cap for the gas valve pressure regulator in place. If not, the nominal manifold pressure setting will result in an over-fire condition.

If manifold pressure is too high, an over-fire condition exists which could cause heat exchanger failure. If the manifold pressure is too low, sooting and eventual clogging of the heat exchanger could occur.

Be sure that gas valve regulator cap is replaced and burner box to gas valve pressure reference hose is reconnected.

28 Unitary Products Group

035-17477-002 Rev. D (1202)

WITH BURNER BOX COVER IN PLACE WITH BURNER BOX COVER REMOVED

OUTLET PRESSURE TAP

BURNER BOX PRESSURE REFERENCE HOSE

BURNER BOX WITH COVER

U-TUBE MANOMETER

FIGURE 38 :

WITH BURNER BOX COVER IN PLACE WITH BURNER BOX COVER REMOVED

GAS VALVE

OUTLET PRESSURE TAP

TEE FITTING

BURNER BOX

6 5 4 3 2 1 0 1 2 3 4 5 6

3.5 IN WATER COLUMN GAS PRESSURE SHOWN

WITH COVER REMOVED

U-TUBE MANOMETER

Upflow Models (P*UR/ FG9-UP / G9T-UP) - Reading Gas Pressure

GAS VALVE

BURNER BOX PRESSURE REFERENCE HOSE (NOT USED)

6 5 4 3 2 1 0 1 2 3 4 5 6

3.5 IN WATER COLUMN GAS PRESSURE SHOWN

BURNER BOX PRESSURE REFERENCE HOSE

TEE FITTING

FIGURE 39 :

BURNER BOX WITH COVER

GAS VALVE

U-TUBE MANOMETER

OUTLET PRESSURE TAP

BURNER BOX PRESSURE REFERENCE HOSE

6 5 4 3 2 1 0 1 2 3 4 5 6

3.5 IN WATER COLUMN GAS PRESSURE SHOWN

BURNER BOX WITH COVER REMOVED

OUTLET PRESSURE TAP

GAS VALVE

U-TUBE MANOMETER

6 5 4 3 2 1 0 1 2 3 4 5 6

down flow/Ho rizontal Mo de ls (P*DH/ FG9-D H / G9T-D H) - Re ad in g G as P ressur e

3.5 IN WATER COLUMN GAS PRESSURE SHOWN

Unitary Products Group 29

035-17477-002 Rev. D (1202)

ADJUS TMENT OF TEMPERATURE RISE

The temperature rise, or temperature difference between the return air and the heated air f rom the furnace, must be within the range shown on the furnace rating plate and within the application limitations are shown in Tables 1 or 2. After t he temperature rise has been determined, the airflow (cfm) can be calculated.

After about 20 minutes of operation, determine the furnace temperature rise. Take readings of both the return air and the heated air in the ducts, about six feet from the furnace where they will not be affected by radiant heat.

Increase the blower speed to decrease the temperature rise; decrease the blower speed to increase the rise.

All direct-drive blowers have multi-speed motors. The blower motor speed taps are located in the control box in the blower compartment. Refer to Figure 40, and the unit wiring label to change the blower speed.

You may select a heating speed and a cooling speed. They may be the same s peed or a different speed.

To use the same speed tap for heating and cooling, the heat terminal and cool terminal must be connected using a jumper wire and connected to the desired motor lead. Place all unused motor leads on Park terminals. Two are provided.

ADJUS TMENT OF FAN-OFF CONTROL SETTINGS

This furnace is equipped with a time-on/time-off heating f an control. The fan on delay is fixed at 30 seconds. The fan off delay is field adjustable from 60 to 180 seconds. The fan off delay is factory set to 120 seconds.

The fan-off setting must be long enough to adequately cool the furnace, but not so long that cold air is blown into the heated space.

The fan-off timing may be adjusted by positioning the jumper located on the control board. Refer to Figure 40.

RED - LOW SPEED BLU - MEDIUM SPEED

BLK - HIGH SPEED

BLK

BLU RED

60

0

2

9

1

180

COOL

HEAT

PARK

LINE

XM

MOTOR LEADS

FAN OFF ADJUSTMENT SWITCHES

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

FIGURE 40 :

Typical Hea t/Coo l Sp ee d Tap Connections

FURNACE ACCESSORIES

ELECTRICAL

*ET03700324 Single Stage Thermostat, One-Stage Heat/One-Stage Cool, Non-Programmable *ET03700124 Deluxe Single Stage Theromstat, One Stage Heat /One Stage Cool, Programmable

2TH13700424 Single Stage Thermostat, One Stage Heat, Round - 2TB17700424 Heat/Cool Subbase 6TH13701024 Single Stage Thermostat, One Stage Heat, Round - 2TB17700424 Heat/Cool Subbase

2 TC 037 00 12 4 Twinning Co ntr o l

NON-ELECTRICAL

1NP0347 Propane (LP) Conversion Kit 1NP0349 Propane (LP) Conversion Kit

1PS0306 1PS0307

1PS0308 1PS0309

1PS0310

1SR0302BK External Side Filter Rack (6-Pack)

1BR0314 External Bottom or Horizontal Filter Rack - Cabinet “A” 1BR0317 External Bottom or Horizontal Filter Rack - Cabinet “B”

1BR0321 External Bottom or Horizontal Filter Rack - Cabinet “C” 1BR0324 External Bottom or Horizontal Filter Rack - Cabinet “D”

1 CT0 30 2 C once ntric Vent Ter mination - 2” Ve nt Pipe 1 CT0 30 3 C once ntric Vent Ter mination - 3” Ve nt Pipe

1CB0314 Combustible Floor Base - Cabinet “A” 1CB0317 Combustible Floor Base - Cabinet “B”

1CB0321 Combustible Floor Base - Cabinet “C” 1CB0324 Combustible Floor Base - Cabinet “D”

* Su bst it ute 2 for Yor k bra nds an d 6 fo r n on York br an ds.

High Altitude Pressure Switch (See instruction 035-14447-000 for proper application)

30 Unitary Products Group

035-17477-002 Rev. D (1202)

BLOWER PERFORMANCE CFM- UPFLOW (WITHOUT FILTER)

MO DE LS

I nput/O utput/ Airflow /

cabinet

4 0 / 37 / 1000 / "A"

6 0 / 55 / 1000 / "B"

80 / 75 / 1200 / "B”

80 / 75 / 1600 / "C”

10 0 / 95 / 1 400 / "C ”

10 0 / 9 5 / 20 00 / "C "

12 0 / 112 / 2 000 / "D”

14 0 / 13 0 / 20 00 / " D”

NOTE: Da ta below reflects airflows with two return openings - two sides or one side and bottom.

10 0 / 9 5 / 20 00 / "C "

12 0 / 112 / 2 000 / "D”

14 0 / 13 0 / 20 00 / " D”

Airflow expressed in standard cubic feet per minute. Note s: 1. Ret urn air is t hrough side opposite motor (left side ).

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

3. M oto r vol ta ge at 11 5 V.

SP EED T AP

HIGH 13 30 1 260 12 10 11 50 10 90 1 025 95 5 8 80 77 5 6 45

MED-H IGH 9 85 970 96 5 9 35 90 0 8 60 80 0 7 40 66 5 5 35

MED-LOW 790 780 760 740 715 685 635 575 485 365

LOW 635 625 610 590 565 535 490 435 360 250

HIGH 13 60 1 330 12 90 125 0 119 0 1130 105 5 970 86 5 7 35

MED-H IGH 9 80 970 96 0 9 45 92 0 8 70 83 0 7 75 68 5 5 75

MED-LOW 765 755 740 725 710 680 645 590 510 405

LOW 635 625 610 590 565 540 500 440 375 290

HIGH 14 65 1 440 13 90 1 365 13 15 1 255 1190 11 25 1 055 9 40

MED 10 85 1 075 10 60 104 5 10 30 1 000 96 0 910 830 755

LOW 805 795 785 770 755 730 700 655 615 565

HIGH 19 40 1 905 18 70 1 815 17 60 1 700 1620 15 55 1460 13 05

MED 14 00 1 390 13 80 1370 13 55 1 320 1285 12 55 1210 1135

LOW 1245 1225 1205 1185 1165 1145 1125 1095 1050 970

HIGH 17 85 1 720 16 50 1 575 14 95 1 405 1315 11 90 1 050 8 80

MED 1430 1405 1375 1340 1290 1220 1130 1025 885 730

LO W 115 0 11 35 112 0 1 080 10 45 1 000 92 5 8 25 70 0 5 75

HIGH 23 55 2 285 22 05 2 145 20 80 1 995 1905 18 20 1715 16 10

MED 19 50 1 915 18 70 1830 17 80 1 710 1640 15 60 1475 1375

LO W 15 75 1555 1540 1505 14 70 1 430 138 0 13 15 1245 115 0

HIGH 23 75 2 315 22 45 2 175 21 00 2 020 1935 18 40 1755 16 50

MED 19 90 1 955 19 20 1875 18 35 1 775 1715 16 30 1550 1450

LO W 15 65 1550 1530 1505 14 80 1 445 140 5 13 50 1280 12 00

HIGH 24 10 2 340 22 65 2 200 21 25 2 035 1960 18 60 1775 16 70

MED 20 20 1 975 19 40 1895 18 55 1 790 1725 16 55 1570 1470

LO W 15 80 1565 1550 1520 14 95 1 460 142 0 13 60 1295 12 10

HIGH 23 65 2 295 22 15 2 155 20 90 2 005 1915 18 30 1725 16 20

MED 19 65 1 930 18 85 1845 17 95 1 725 1655 15 75 1490 1390

LO W 15 95 1575 1560 1525 14 90 1 450 140 0 13 35 1265 117 0

HIGH 2385 2325 2255 2185 2110 2030 1945 1850 1765 1660

MED 20 05 1 970 19 35 1890 18 50 1 790 1730 16 45 1565 1465

LO W 15 85 1570 1550 1525 15 00 1 465 142 5 13 70 1300 12 20

HIGH 24 20 2 350 22 75 2 210 21 35 2 045 1970 18 70 1785 16 80

MED 20 35 1 990 19 55 1910 18 70 1 805 1740 16 70 1585 1485

LO W 16 00 1585 1570 1540 15 15 1 480 144 0 13 80 1315 12 30

0.10.20.30.40.50.60.70.80.91.0

E XTER NAL STATIC PRE SSU RE, INCHES W C

Unitary Products Group 31

AIRFLOW DATA - DOW NF LO W /H ORI ZON TAL MODELS: P*D H/ G9 T-DH /F G 9- DH

MODELS

Input /Out put/Airfl ow/

ca bine t

40 / 3 7 / 1000 / "A ”

60 / 55 / 1 200 / "B" 80 / 7 5 / 1200 / "B ”

80 / 7 5 / 1600 / "C ”

100 / 9 5 / 2000 / "C”

1 20 / 11 2 / 2000 / "D ”

Airflow expressed in standard cubic feet per minute. Notes: 1. Air filter inst alled. All filters must be high velocity, cleanable type.

2. M oto r vol tag e at 11 5 V.

S PEE D TAP

HIG H 14 00 1 350 13 00 1250 1 20 0 11 35 10 60 97 0 880 7 65

MED- HI GH 970 955 9 45 935 91 5 8 85 8 40 78 0 705 6 00

MED- LOW 770 760 7 50 735 71 0 6 80 6 40 59 5 535 4 50

LOW 595 585 575 560 540 520 485 455 400 270

HIGH 1605 1590 1570 1545 1510 1470 1415 1360 1285 1205

MED 12601245122512051180 1150111010651005930

LOW 930 915 895 880 860 835 810 770 695 620

HIGH 2030 1980 1925 1870 1830 1755 1675 1600 1515 1435

MED 1505149014751460144014201380134012801215

LOW 1295 1285 1260 1240 1215 1190 1160 1130 1080 1000

HIGH 2330 2270 2200 2130 2060 1985 1890 1810 1710 1625

MED 2005196519201870182017501680160015001395

LOW 1580 1560 1535 1510 1480 1440 1390 1325 1255 1175

HIGH 2335 2280 2215 2145 2065 2000 1905 1820 1720 1620

MED 1975193018851830177517201655158015001400

LOW 1515 1495 1475 1450 1415 1380 1330 1275 1210 1135

0.1 0.2 0.3 0 .4 0.5 0.6 0.7 0. 8 0.9 1 .0

EX TER NAL STAT IC PRE SSURE, I NCHES WC

035-17477-002 Rev. D (1202)

FILTER PERFORMANCE

The airflow capacity data published in Tables 8 & 9 represents blower performance WITHOUT filters. To determine the approximate blower performance of the system, apply the fil-

NOT E: The filter pres sure drop values in Table 10 are typical values for the type of filter listed and should only be us ed as a guideline. Actual pressure drop ratings for each filter type vary between filter manufacturer.

ter drop value for the filter being used or select an appropriate value from the Table 10.

Table 10:

Airflow Range

2001 & Above 46 3 658 0.17 0.09 0.15 0.07 0.30 0.17

FILTER PERFORMANCE - PRESSURE DROP INCHES W.C.

Mini mum Opening Size

(in.2)

1 Opening 2 O penings 1 Opening 2 O p enings 1 Opening 2 O penings 1 Opening 2 Openings

0 - 750 230 0.0 1 0.0 1 0.1 5

751 - 1000 33 0 0.0 4 0.0 3 0.2 0

1001 - 1250 330 0.0 8 0.0 7 0.2 0

1251 - 1500 330 0.0 8 0.0 7 0.2 5

1501 - 1750 380 658 0.14 0.08 0.13 0.06 0.30 0.17

1751 - 2000 380 658 0.17 0.09 0.15 0.07 0.30 0.17

*.

Hogs Hair Filters are the type supplied with furnace (if supplied).

Disposable

Filter Type

Hogs Hair

*

Pleated

32 Unitary Products Group

035-17477-002 Rev. D (1202)

APPLYING FILTER PRESSURE DROP TO DETERMINE SYSTEM AIRFLOW

To determine the approximate airflow of the unit wit h a filter in place, follow the steps below:

1. Select the filter type.

2. Select the number of return air openings or calculate the return opening size in square inches to determine the proper filter pressure drop.

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

4. Select a filter pressure drop from the table based upon the number of return air openings or return air opening size and add to the ESP from Step 3 t o determine the total system static.

5. If total system static matches a ESP value in the airflow table (i.e. 0.20, 0.60, etc,) the system airflow corresponds to the intersection of the ESP column and Model/ Blower Speed row.

6. If the total system static falls between ESP values in the table (i.e. 0.58, 0.75, etc.), the static pressure may be rounded to the nearest value in the table determining the airflow using Step 5 or calculate the airflow by us ing the following example.

Example: For a 130,000 Btuh furnace with 2 return openings and operating on high speed blower, it is found that total system static is 0.58" w.c. To determine the system airflow, complete the following steps:

1. Obtain the airflow values at 0.50" & 0.60" ESP.

Airflow @ 0.50": 2125 CFM Airflow @ 0.60": 2035 CFM

2. Subtract the airflow @ 0.50" from the airflow @ 0.60" to obtain airflow difference.

2035 - 2125 = -90 CFM

3. Subtract the total system static from 0.50" and divide this difference by the difference in ESP values in the table,

0.60" - 0.50", to obtain a percentage.

(0.58 - 0.50) / (0.60 - 0.50) = 0.8

4. Multiply percentage by airflow difference to obtain airflow reduction.

(0.8) x (-90) = -72

5. Subract airflow reduction value to airflow @ 0.50" to obtain actual airflow @ 0.58" ESP.

2125 - 72 = 2053

OPERATION AND MAINTENANCE

SEQUENCE OF OPERATION

The following describes the sequence of operation of the furnace. Refer to the schematic wiring diagrams in the bac k of this manual for component loc ation.

CONTINUOUS BLOWER

On cooling/heating thermostats with fan switch, when the fan switch is set in the ON position, a circuit is completed between terminals R and G of the thermostat. The blower motor is energized through the cool terminal and runs on the selected speed. This allows constant air c irculation at low er flow rat e.

INTERMITTENT BLOWER - COOLING

On cooling/heating thermostats with fan switch, when the fan switch is set in the auto position and the thermostat calls for cooling, a circuit is completed between the R, Y and G terminals.

The motor is energized through the cool fan terminal and runs on the selected speed. The fan off setting is fixed at 60 seconds for SEER enhancement.

HEATING CYCLE

Label all wires prior to disconnecting when servicing controls. Wiring errors can c ause improper and dangerous operation. Verify proper operation after servicing.

When the system switch is set on HEAT and the f an is set on AUTO, and the room thermostat calls for heat, a circuit is completed between terminals R and W of the thermostat. When the proper amount of combustion air is being provided, a pressure switch activates t he ignition c ontrol.

The ignition control provides a 17-second warm-up period. The gas valve then opens for 10 seconds.

As the gas starts to flow and ignition occurs, the flame sensor begins its sensing function. If a flame is detected during t he 10 second flame stabilization period the circulating blower will energize 30 seconds after the gas valve opens (20 seconds after the flame stabilization period ends). Normal furnace operation will continue until the thermostat circuit between R and W is opened. When the thermostat circuit opens, the ignition control is de-energized. When the ignition control is de-energized, the gas flow stops, and the burner flames are extinguished. The ventor continues to operate for 15 s econds after the gas flow stops.

Unitary Products Group 33

035-17477-002 Rev. D (1202)

The blower motor continues to operate for the amount of time set by the fan-off delay "Jumper" located on the ignition control board (Figure 16). The heating cycle is complete, and t he furnace is ready for the start of the next heating cycle.

If the flame is not detected within 2 seconds of the gas valve opening, the gas valve is shut off and a retry operation begins. If the flame is lost for 2 s econds during the 10 second stabilization period, the gas valve is shut off and a retry operation begins. During a retry operation the ventor starts a 15 second inter-purge and the ignitor warm-up time is extended to 27 seconds. If the flame is es tablished for more than 10 seconds after ignition, during a retry, the control will clear the ignition attempt (retry) counter. If three retries occur during a call for heat, the furnace will shut down for one hour. If at the end of the one hour shut down there is a call for heat, the furnace will initiate a normal start cycle. If the problem has not been corrected the furnace will again lockout after three retries.

A momentary loss of gas supply, f lame blowout, or a faulty flame probe circuit will result in a disruption in the flame and be sensed within 0.8 seconds. The gas v alve will de-energize and the control will begin a recycle operation. A normal ignition sequence will begin after a 15 second inter-purge. If during the five recycles the gas supply does not return, or the fault condition is not corrected the ignition control w ill lock-out for 60 minutes.

During burner operation, a momentary loss of power for 50 milliseconds or longer will de-energize the gas valve. When the power is restored, the gas valve will rem ain de-energized and the ignition sequence will immediately res tart.

HOT SURFACE IGNITION SYSTEM

All filters used with the furnace are the high-velocity, c leanable type. Clean these filters by washing in warm water. Make sure to shake all the water out of the filter and have it reasonably dry before installing it in the furnace. When replacing filters, be sure to use the same size and type as originally supplied.

FILTER REMOVAL - U PFLOW MODELS

To remove a filter from the side or bottom location, push the closed end of the filter retainer to the left until it clears the lip on the front of the furnace base, which ac ts as a c atch for t he retainer. When the retainer is clear of the flange, it will pivot in the loops.

Swing the retainer toward the center of the furnace. This will expose the filter to allow removal. To reinstall the filter, s imply reverse this procedure.

SIDE APPLICATION

FRONT

METAL LOOPS

RETAINER

FRONT

BOTTOM APPLICATION

Do not attempt to light this furnace by hand (with a match or any other means). There may be a potential shock hazard from the c omponents of the hot surface ignition system. The furnace can only be lit automatically by its hot surface ignition system.

MAINTENANCE

AIR FILTER S

The filters must be checked periodically for dirt accumulation. Dirty filters greatly restrict the flow of air and may cause damage to the system.

Clean the filters at least every three months. On new construction, check the filters every week for the first four weeks. Inspect the filters every three w eeks after that, es pecially if the system is running constantly.

34 Unitary Products Group

FIGURE 41 :

FILTER REMOVAL - D OWNFLOW MODELS

1. Turn off electrical power supply to the f urnace at disconnect switch. Remove access doors.

2. Filters are installed in the plenum area above the blower assembly. Filters rest against the side of the plenum wall and are supported in the middle by a frame. Lift filter slightly to dislodge and remove for service.

3. Remove the filter and follow the c leaning instructions above. DO NOT remove t he filter stiffener rods, if provided. When reinstalling the filter(s) be sure it completely covers the plenum opening.

To reinstall the filters, simply reverse this procedure.

Upflow Filter Re tain er

035-17477-002 Rev. D (1202)

HOR IZONTAL APPLI CAT ION S

In most horizontal applications the filter is located in the return air duct near the furnace or in a filter grille.

When replacing filters, DO NOT use a type with excessively high pressure drop. Som e high efficiency filters available will cause the furnace to operate improperly and could result in a safety hazard.

LUBRICATION

Blower motors in these furnaces are permanently lubricated and do not require periodic oiling.

FIGURE 42 :

BLOWER CARE

Even with good filters properly in place, blower wheels and motors will become dust laden after long months of operation. The entire blower assembly should be inspected annually. If the motor and wheel are heavily coated with dust, they c an be brushed and cleaned with a vacuum cleaner.

The procedure for removing the direct drive blower assembly for cleaning is as follows:

1. Disconnect the electrical supply to the furnace and remove remove the access doors.

2. On downflow/horizontal models only, remove the two wires leading to the auxiliary limit mounted on the blow er housing.

3. On downflow/horizontal models only, remove four top panel screws and lift the top panel enough to dis engage and remove the flue chase assembly.

Unitary Products Group 35

Fur nace C o ntrol Event S chedul e

4. Remove blower assembly mounting screws and slide the blower assembly out of the slots in t he deck. I f the two shipping screws were not prev iously removed, als o remove and discard these two screws located on each front corner of the blower assembly.

5. On downflow models only, note the wire/terminal location and then remove the blower wiring from the furnace c ontrol. Remove the protective boot and dis connect run capacitor wires. Remove the screws securing the electrical panel to the blower housing. Pull blower assembly out of the unit. When cleaning or servicing the blower assembly, DO NOT remove or change t he balance c lips on the blower wheel.

6. To reassemble, reverse the procedure, restore power to the furnace and verify operation.

035-17477-002 Rev. D (1202)

BURNER REMOVAL /C LEA NI NG

The main burners should be checked periodically for dirt accumulation.

If cleaning is required, follow this proc edure:

1. Turn off the electrical power to the unit.

2. Turn off the gas supply at the ex ternal manual shutoff valve and loosen the ground union joint.

3. Remove the upper access panel and remove the burner box cover.

4. Remove the screws that hold the burner box assembly to the vest panel and remove the assembly.

5. Remove burners from the burner assembly.

6. Burners may be cleaned by rinsing in hot water.

7. Reassemble the burners in the reverse order.

CLEANING THE HEAT EXCHANGER

1. Turn off the main manual gas valve external to the furnace.

2. Turn off electrical power to the furnace.

3. Remove the upper access panel and remove the burner box cover.

4. Disconnect wires from flame sensor, rollout switch and HSI igniter. Remove igniter carefully, as it is easily broken.

Label all wires prior to disconnection when servicing controls. Wiring errors can c ause improper and dangerous operation. Verify proper operation after servicing.

5. Remove the screws that hold the burner box assembly to the vestibule panel and remove the assembly. The upper portion of the heat exchanger will now be exposed.

6. Remove the upper cover plate at the top of the furnace. Remove the internal baffle.

7. The upper portion of the heat exchanger is now exposed.

8. With a long flexible wire brush, clean inside eac h tube at both the top and bottom. The brush must pass around the rear heat exchanger tubes. Vacuum loos e scale and dirt from each tube.

9. Clean - vacuum all burners.

10. Replace all components in reverse order. Reconnect all wiring.

11. Restore electrical power and gas supply to the furnace.

12. Check furnace operation.

CLEAN ING THE SECON DA RY H EAT EX CH ANGE R

1. Follow steps 1 thru 10 under Cleaning the Primary Heat Exchanger.

2. Remove the vent piping from the venter hous ing. Disconnect the drain lines from the venter and f rom the condensate drain pan. Remove the venter blower and the condensate pan. The turbulators can then be gently removed from the secondary heat exchanger.

3. With a stiff wire brush, brush out loos e scale or soot.

4. Vacuum the secondary heat exchanger.

5. Finish the cleaning procedure by following steps 10 thru 12 under Cleaning the Primary Heat Exchanger.

VENT/AIR INTAKE

Should it be necessary to service the vent/air intake system, the manufacturer recommends this service be conducted by a qualified service agency.

The operation of this appliance requires the reassembly and resealing of the vent/air intake system as specified on Page 11 .

TROUBLESHOOTING

The following visual checks should be made before troubleshooting:

1. Check to see that the power t o the f urnace and t he ignition control module is ON.

2. The manual shutoff valves in the gas line to the furnace must be open.

3. Make sure all wiring connections are secure.

4. Review the sequence of operation.

Start the system by setting the thermostat above the room temperature. Observe the system's response. Then use the troubleshooting section in this manual to check the system's operation.

FURNACE CONTROL DIAGNOSTICS

The furnace has built-in, self diagnostic capability. I f a s ystem problem occurs, a fault code is shown by a blinking red LED. It is located behind a clear view port in the blower compartment door. DO NOT remove the f urnace blower compartment panel OR turn off furnace power as either action w ill clear t he control's memory of the fault.

The control continuously monitors its own operation and the operation of the system. If a failure occurs, the LED will indicate the failure code. If the failure is internal to the control, t he light will stay on continuously. In this case, the entire control should be replaced as t he control is not field repairable.

Flash sequence codes 1 through 11 are as follows: LED will turn “on” for one second and “off” for one second. This pattern will be repeated the number of times equal to the code. For example, six “on” flashes equals a number 6 fault code.

36 Unitary Products Group

All flash code sequences are broken by a 2 second “off” period.

035-17477-002 Rev. D (1202)

IGNITION CONTROL (P/N 031-01267-001)

Normal flame sense current is approx imately

3.7 microamps DC (υa)

Low flame signal control lockout point is

0.9 microamps DC (υa)

CON TI NU OUS FL AS H : This indicates that flame was sensed when there was not a call for heat. With this fault code the control will turn on both the inducer motor and supply air blower. This fault would typically be caused by a gas valve that leaks through or is slow closing.

2 FLASH:

This indicates that the normally open pressure switch contacts are stuck in the closed position. T he control confirms these contacts are open at the beginning of each heat cycle. This would indicate a faulty pressure switch or mis-wiring.

3 FLASH:

This indicates the normally open pressure switch contact did not close at the beginning of the heat cycle. This could be caused by a number of problems; faulty inducer, blocked vent pipe, broken pressure switch hose or faulty pressure switch.

4 FLASH:

This indicates that a primary or auxiliary limit switch has opened its normally c losed contacts. W ith this fault code the control will operate the supply air blower and inducer. This condition may be caused by: dirty filter, improperly sized duct system, incorrect blower speed setting, incorrect firing rate or faulty blower motor.

5 FLASH:

This fault is indicated if the normally c losed contacts in the rollout switch opens. The rollout control is manually reset. If it has opened, check for proper combustion air, proper inducer operation, primary heat exchanger failure or burner problem. Be sure to reset the switch after c orrecting the failure condition.

6 FLASH:

This indicates that after the unit was operating, the pressure switch opened 4 times during the c all for heat . If the main blower is in a "Delay on" mode it will complete it, and any subsequent delay off period. The ventor c ontinues to operate until the pressure switch re-closes or a call for heat is removed.

7 FLASH:

This fault code indicates that the flame could not be established. This no-light condition occured 3 times (2 retries) during the call for heat before locking out . This may be caused by low gas pressure, faulty gas valve, faulty hot surface ignitor or burner problem.

8 FLASH:

This fault is indicated if the flame is lost 5 times (4 recycles) during the heating cycle. This could be caused by low gas pressure or faulty gas valve.

9 FLASH:

Indicates reversed line voltage polarity. Both heating and cooling operations will be affected. Check polarity at furnace and branch.

11 FLASH :

This fault will be indic ated if the rollout jumper wire connection soldered into the board, is broken. I f this fault occurs the control will have to be replaced. This fault may also occur in installations where an improper ground is present. Prior to replacing control, verify that unit is properly grounded.

STEADY ON:

This fault occurs if the gas valve is energiz ed when there is no call for heat. If this happens the ventor is energized and will remain energized for 5 seconds or until t he fault clears itself at which point the ventor de-energizes. This failure is counted as a recycle. Check the gas valve and control for proper operation.

60 MINUTE AUTOMATIC RESET F ROM LOCKOUT:

This control includes a "watchdog" type circuit that will reset from a lockout condition after 60 minutes. Operational faults 1,6,7,8 and Steady On will be reset. This prov ides protection to an unoccupied structure if a temporary c ondition exists causing a furnace malfunction. An example w ould be a low incoming gas supply pressure preventing unit operation. When the gas pressure is restored , at some point t he "watchdog" would restart the unit and provide heat for the house.

NOT E: If a flame is detected the control flashes the LED for 1/8 of a second and then enters a flame stabilization period.

Never jump pressure switch to allow furnace operation. To do so will allow furnace to operat e under potentially hazardous conditions.

Do not try to repair controls. Replace defective controls with UPG Source 1 Parts.

Never adjust pressure switch to allow furnace operation.

Unitary Products Group 37

035-17477-002 Rev. D (1202)

WIRING DIAGRAM - U PFLOW MODELS: P*UR / FG9-UP / G9T-UP

NOT E: THE FURNACE’S CONTROL SYSTEM REQUIRES CORRECT POLARITY OF THE POWER SUPPLY.

BLK

GRN

GND

VENTOR

BLK

2

IGNITER

P3/S3

BLK

YEL

WHT

3

2

4

1

P2/S2

FURNACE CONTROL

MOTOR

1

P4/S4

BLU

WHT

24V SEC

BLK

3

6

987

12

GRN

2

5

11

PRI

BRN

COM

115V

GRN

GND

1

4

P1/S1

10

LEGEND

IDENTIFIED RUN CAPACITOR

24V CONNECTION ROOM THERMOSTAT

FACTORY WIRING AND DEVICES

FUSE

1RC RUN CAPACITOR

1LP PRESSURE SW, BURNER BOX/VENTOR

FIELD CONNECTION

RELAY CONTACTS ON IGNITION

1T TRANSFORMER, 40VA

----- FIELD WIRING AND DEVICES

CONTROL BOARD

- CAUTION -

SERVICING THIS UNIT

OPEN ALL DISCONNECTS BEFORE

YWRGC

3. CONNECTORS SUITABLE FOR COPPER CONDUCTORS ONLY.

TEMPERATURE RATING OF AT LEAST 221ßF (105ßC).

REPLACED, IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A

2. IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE FURNACE MUST BE

(C) LOCAL OR CITY CODES.

(B) CANADIAN ELEC. CODE (CEC) AND/OR

1. ALL FIELD WIRING PER: (A) NATIONAL ELEC. CODE (NEC) AND/OR

NOTES:

GRN

BRN

MOTOR

BLOWER

RED (LOW)

YEL (MED LOW)

BLU (MED/MED HI)

BLK (HI)

BLOWER SPEED

FOR DESIRED

SEE CHART

GND

1RC

DOOR

WHT (NEUT)

EAC

115VAC

BLK

C

N.O.SW

NO

BRN

HUM

LINE

NEUT.

115VAC

WHT

EAC

PARK

HEAT

NEUTRALS

HUM

XFMR

L1

PARK

COOL

HOT SURFACE

WHT

12

035-17474-000A

6. MOTORS ARE INHERENTLY PROTECTED.

5. PROVIDE DISCONNECTS FOR ALL POWER SUPPLIES.

4. ALL REPLACEMENT COMPONENTS MUST BE PROPERLY GROUNDED.

BLK

YEL

2

REDBLUBLKBLK*

1600

080

BLK

---

REDBLUBLK1400

100

REDBLUBLKBLK*

2000

100

1

REDBLUBLKBLK*

2000

120

GAS

REDBLUBLKBLK*

2000

140

ROS1

PARKPARKHEATCOOL

CFM

INPUT

REDYELBLUBLK

1000

040

REDYELBLUBLK

1000

060

BRN

RED

BLU

BLKBLK*

1200

080

CONNECTION DIAGRAM

BLOWER SPEED CHART

VALVE

PRP

FLAME

SENSOR

C

1LP

NO

BLU

JUMPERED.

AND COOL TERMINALS

* UNITS SHIPPED WITH HEAT

WHT

GND

WHT

LS1

RED

SEE NOTE 1

POWER SUPPLY 115-1-60

ELEMENTARY DIAGRAM

DS

C

NO

DOOR SWITCH

N.O.SW

P1/S1 12 PIN PLUG & SOCKET ON IGNITION

IGN HOT SURFACE IGNITOR

GV GAS VALVE

DS DISCONNECT SWITCH

GND

1RC

MOTOR

BLOWER

HEAT

COOL

RELAY

HEAT/COOL

IGNITOR

P3/S3 2 PIN PLUG & SOCKET AT HOT SURFACE

CONTROL BOARD

P2/S2 4 PIN PLUG & SOCKET ON IGNITION

CONTROL BOARD

EAC

HUM

EAC

HUMIDIFIER

HUM

EAC

HUMIDIFIER

ROS1 ROLL OUT SWITCH

LS1 PRIMARY LIMIT SWITCH

MOTOR

P4/S4 2 PIN PLUG & SOCKET AT INDUCER

GND

GV

RELAYS

GAS VALVE

1T (40VA)

COM120V

IGN

PRI

24V SEC

RELAY

MOTOR

VENTOR

RELAY

VENTOR

RELAY

IGNITER

3A

R

G

R

G

ON

AUTO

C

Y

COOL

ROS1

OFF

LS1

1LP

HEAT

90+ UPFLOW FURNACE

C

NO

W

HEAT/COOL THERMOSTAT

38 Unitary Products Group

035-17477-002 Rev. D (1202)

WIRING DIAGRAM - D OWNFLOW/HORIZONTAL MODELS: P*DH / FG9-DH / G9T-DH

NOT E: THE FURNACE’S CONTROL SYSTEM REQUIRES CORRECT POLARITY OF THE POWER SUPPLY.

Unitary Products Group 39

Su bject to chan ge without not ice . Prin ted in U.S .A. 035 -17477-002 Rev. D (120 2) Copyrigh t © b y Yo rk Inte r nat io na l Cor p. 2002. All rights re ser ved. S up ersed es: 035 -17477-002 Rev. C (100 2)

Unitary 5005 Norman Product York OK Group Drive 73069

USER’S INFORMATION, MAINTENANCE AND

EFFICIENCY RATING CERTIFIED

SERVICE MANUAL

MODELS: P*UR / G9T-UP / FG9-UP (Upflow)

CONTACT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

TABLE OF CONTENTS

USER’S INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

INSTRUCTIONS FOR EXAMINING THE FURNACE

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

HOW YOUR GAS FURNACE WORKS . . . . . . . . . . . . . . . . . . . . . .3

START-UP AND SHUTDOWN INSTRUCTIONS . . . . . . . . . . . . . . . 3

Read the Instructions Below Before Trying to Start the Furnace . . 3

Operating Instructions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

To Turn Off the Appliance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FURNACE USER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . .4

SERVICE AND MAINTENANCE MANUAL . . . . . . . . . . . . . . . . . . . . . 4

SAFETY SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FURNACE MAINTENANCE SECTION . . . . . . . . . . . . . . . . . . . . . . .4

Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Removing Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Blower Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

CONTACT INFORMATION

• Go to website at www.york.com click on “contact”, then click on “contact form” and follow the instructions.

• Contact us by mail:

York International

Consumer Relations

5005 York Drive

Norman, OK 73069

Motor Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Continuous Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Intermittent Blower - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Heating Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Hot Surface Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

FURNACE CLEANING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Burner Removal/Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Cleaning the Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Cleaning the Secondary Heat Exchanger . . . . . . . . . . . . . . . . . . .6

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

FURNACE CONTROL DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . .7

REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

FIELD INSTALLED ACCESSORIES - NON-ELECTRICAL . . . . . .10

FIELD INSTALLED ACCESSORIES - ELECTRICAL . . . . . . . . . . .10

REPLACEMENT PART CONTACT INFORMATION . . . . . . . . . . . . .10

LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

This product was manufactured in a plant whose quality system is certified/registered as being in conformity with ISO 9001.

The manufacturer recommends that the user read all sections of this manual and keep the manual for future reference.

FIRE OR EXPLOSION HAZARD - Failure to follow safety

warnings exactly could result in serious injury, death, or property damage.

— Do not store or use gasoline or other flammable

vapors and liquids in the vicinity of this or any other appliance.

— WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone (including cell phone) in your building.

• Leave the building immediately.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

— Installation and service must be performed by a quali-

fied installer, service agency or the gas supplier.

SECTION I: USER’S INFORMATION

SAFETY

1. The furnace area must be kept clear and free of combustible materials, gasoline and other flammable vapors and liquids.

2. Insulating materials may be combustible. The furnace must be kept free and clear of insulating materials. The furnace area must be examined when installed in an attic or other insulated space or when insulation is added to be sure that the insulation material has been kept away from the furnace.

3. The furnace needs air for combustion in order to operate properly and safely. Do not block or obstruct air openings on the furnace, air openings to the area where the furnace is installed, or spaces around the furnace.

4. Follow the instructions exactly as shown on the OPERATING INSTRUCTION LABEL or the Start-up and Shutdown Instructions on Page 3 of this manual when lighting the furnace or turning the furnace off.

5. Should the gas supply fail to shut off or if overheating occurs, shut off the gas valve to the furnace before shutting off the electrical supply.

6. Do not use this furnace if any part has been under water. A flooddamaged furnace is extremely dangerous. Attempts to use the furnace can result in fire or explosion. A qualified service agency should be contacted to inspect the furnace and replace all gas controls, control system parts, electrical parts that have been wet or the furnace if deemed necessary.

035-19592-001 Rev. C (0204)

BURNER BOX

PRESSURE SWITCH

BLOWER

GAS VALVE

VENT PIPE

CONDENSATE DRAIN SYSTEM

INDUCER ASSEMBLY

INDUCER MOTOR

CONTROL BOARD

FIGURE 1: Component Locations

7. NEVER . . .Store flammable materials of any kind near your furnace. Gasoline, solvents, and other volatile liquids should be stored only in approved containers outside your home. These materials vaporize easily and are extremely dangerous.

8. NEVER . . .Store cleaning materials near your furnace. Materials such as bleaches, detergents, powdered cleansers, etc., can cause corrosion of the heat exchangers.

9. NEVER . . . Use the area around your furnace as a storage area for items which could block the normal flow of air. This flow of air is required for ventilation of the various furnace components.

INSTRUCTIONS FOR EXAMINING THE FURNACE INSTALLATION

It is the owner’s responsibility to ensure that an annual inspection of the entire heating portion of the unit is made by a qualified service agency.

1. Examine the heating exchanger, vent/combustion air piping, vent connectors and chimney to be sure they are clear and free of obstructions.

2. Examine the vent pipe making sure it is in firmly place, that it slopes slightly upward and is physically sound without holes and all of the connections are secure.

3. Examine the return-air duct connections to make sure they are physically sound, sealed to the furnace casing, and the ducts terminate outside the space containing the furnace.

4. Examine the furnace casing making sure the physical support is sound without sagging, cracks or gaps. Examine the furnace base making sure it is physically sound without cracks, gaps or sagging and has a good seal.

5. Examine the furnace casing for obvious signs of deterioration.

6. Examine the burner flames to make sure they are in good adjustment. Refer to the pictorial sketch shown in Figure 2 as a comparison to the actual flame.

7. Examine the furnace as outlined above in steps “1 - 6” before each heating season. Use Figure 3 for visual reference.

COMBUSTION AIR INTAKE

BURNER FLAME

FIRE OR EXPLOSION HAZARD This furnace is designed and approved for use with Nat-

ural Gas and (LP) Propane Gas ONLY. DO NOT BURN ANY LIQUID FUEL OR SOLID FUEL IN THIS FURNACE.

Burning any unapproved fuel will result in damage to the furnace heat exchanger, which could result in Fire, Personal Injury, and/or Property Damage.

EXAMINE HEA T EX CHANGER INTERNAL VENT COMBUSTION AIR PIPE. MUST REMOVE PANEL

5

EXAMINE ENTIRE FURNACE CASING SHOWN IN ALL DRAWINGS

3

EXAMINE RETURN-AIR DUCT CONNECTION

4

EXAMINE FURNACE CASING

TO EXAMINE.

FIGURE 2: Burner Flame Drawing

6

REMOVE PANEL TO EXAMINE BURNER FLAMES

MANIFOLD

2

EXAMINE EXTERNAL VENT PIPE

MAIN BURNER

4

EXAMINE FURNACE

CASING

INNER FLAME CONES

3

EXAMINE RETURN-AIR DUCT CONNECTION

(SIDE OR BOTTOM)

FIGURE 3: Furnace Examination Checkpoints

2 Unitary Products Group

035-19592-001 Rev. C (0204)

HOW YOUR GAS FURNACE WORKS

Your furnace is a very easy appliance to take for granted. Season after season, it sits there in your home, keeping you warm and comfortable. For this reason, you may never have given much thought to the way your furnace operates. In order to get the safest and most efficient operation from your furnace, you should understand how your furnace does its job.

When you set your thermostat to provide more heat in your home, you are starting the heating cycle of the furnace. First, the inducer motor starts to purge the heat exchanger of any remaining gases. Next, the hot surface ignitor glows and after a warm-up period the gas valve opens and ignition occurs. A short time later, the blower starts and distributes the warm air throughout the home. When the temperature setting on your thermostat is reached, the gas valve closes, the main burners are turned off, and the blower continues to run until the remaining warm air in the system is distributed. When the blower stops, the heating cycle has ended.

START-UP AND SHUTDOWN INSTRUCTIONS

Read the Instructions Below Before Trying to Start the Furnace

If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury, and/or loss of life.

A. This appliance does not have a pilot. It is equipped with an ignition

device which automatically lights the burner. Do not try to light the burner by hand.

B. BEFORE OPERATING; smell all around the appliance area for

gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

C. Use only your hand to push the gas control switch to the “on” posi-

tion. Never use tools. If the switch will not operate by hand, don’t try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

D. Do not use this appliance if any part has been under water. Imme-

diately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control, which has been under water.

Operating Instructions:

1. STOP! Read the safety information above.

2. Set the thermostat to the lowest setting.

3. Turn off all electric power to the appliance.

4. Remove burner access panel.

5. Move gas control switch to the “OFF” position. Do not force.

6. Wait five (5) minutes to clear out any gas. If you then smell gas, STOP! Follow “B” in the safety information above. If you don’t smell gas, go to next step.

7. Move gas control switch to the “ON” position. Do not force.

8. Replace burner access panel.

9. Turn on all electric power to the appliance.

10. Set thermostat to the desired setting. Burner will light, which may take 30-60 seconds.

11. After three (3) trials for ignition, if the appliance will not operate follow the instructions, “TO TURN OFF THE APPLIANCE” and call your service technician or gas supplier.

To Turn Off the Appliance:

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

3. Remove burner access panel.

4. Move gas control switch to the “OFF” position.

5. Replace burner access panel.

Should overheating occur, or the gas valve fail to shut off, turn the external manual gas valve in the gas supply line to the furnace to the “off” position and let the furnace cool off before shutting off the electrical power supply. Refer to Figure 5.

OUTLET PRESSURE PORT

INLET

WRENCH BOSS

INLET PRESSURE PORT

ON/OFF

SWITCH

FIGURE 4: Gas Valve - White Rodgers

EXTERNAL MANUAL SHUTOFF VALVE

TO GAS SUPPLY

GROUND JOINT UNION MAY BE INSTALLED

DROP

INSIDE OR OUTSIDE UNIT.

LEG

FIGURE 5: Gas Piping NOTE: The spring-loaded safety cut-off switch, mounted under the

blower deck will automatically cut off the electrical power supply to the furnace when the blower panel is removed. As a safety precaution, all electrical power and the gas supply to the furnace should be turned off before servicing.

OUTLET

MAIN REGULATOR ADJUSTMENT

TO GAS SUPPLY

Unitary Products Group 3

035-19592-001 Rev. C (0204)

FURNACE USER MAINTENANCE

Before proceeding, be sure the area is well ventilated. Turn the thermostat OFF. If the blower is running, wait until it stops automatically. Turn OFF the gas and electrical power supplies to the furnace. Check all metal parts and surfaces to be sure they have cooled to room temperature before you begin.

Every time the filters are changed the following items should be visually inspected:

• Check combustion air and vent pipe for blockage or leakage.

• Check all components to be sure they are in good condition and that there are no obvious signs of deterioration.

• Check the drain lines to make sure there are no cracks or leaks.

• Check for dirt or lint on any surfaces or on components. Do not try to clean any of the surfaces or components. Cleaning of the furnace and its components must be done by a qualified service professional.

If, during the inspection of your furnace, you find any of the following conditions:

• Excessive amounts of dust and lint on components.

• Damaged or deteriorated components or surfaces.

• Leaks or blockage in the vent pipe passages.

• Water on any surface inside or outside of the furnace.

Do not operate the furnace, call a certified dealer / servicing contractor to check and / or clean your furnace, or for more information if you have questions about the operation of your furnace.

If all components appear to be in good operating condition, replace the front panels. Turn ON the gas and electrical power supplies to the furnace, and set thermostat to the desired temperature.

SECTION II: SERVICE AND MAINTENANCE MANUAL

2. The furnace vent and combustion air intake passageways. Should it be necessary to service the vent/air intake system, the manufacturer recommends this service be conducted by a qualified service agency. The operation of this appliance requires the reassembly and resealing of the vent/air intake system.

3. The furnace burners, ignitor and flame sensor.

4. The condensate collection and disposal system. If any disassembly of components containing flue or vent gases is required, a qualified service agency must perform the service.

Air Filters

The filters should be checked every 3 months. On new construction, check the filters every week for the first four weeks and every three weeks after that, especially if the indoor fan is running continuously. When replacing the filter(s), refer to Table 1 to be sure you install the right size filter for your furnace. Dirty filters greatly restrict the flow of air and may cause damage to the moving parts of the furnace. If the filters become clogged the heat exchangers and blower motor could overheat resulting in a potentially dangerous situation.

Never operate your furnace without a suitable air filter.

Removing Filters

Internally Mounted Air Filters

Most upflow furnaces have their filters located on the side or bottom of the furnace in a filter wire retainer located inside the blower compartment. To check filters located in the blower compartment:

1. Remove the upper furnace door by lifting up. Pull out bottom of door and lower from furnace.

2. Remove the blower compartment panel by lifting up.

3. The filters will be located on the bottom or the one of the sides. To remove bottom-mounted or side mounted filter (s) on all furnaces, push the looped end of the filter retainer rod in, and then move away from the filter.

4. Reverse the procedure to reinstall filters.

POSITION WIRE RETAI N ER (IF PROVIDED) UNDER FLANGE

SAFETY SECTION

The following safety rules must be followed when servicing the furnace.

ELECTRIC SHOCK, FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in

dangerous operation, serious injury, death or property damage.

Improper servicing could result in dangerous operation, serious injury, and death or property damage.

• Before servicing, disconnect all electrical power to the furnace.

• When servicing controls, label all wires prior to disconnecting. Reconnect wires correctly.

• Verify proper operation after servicing.

FURNACE MAINTENANCE SECTION

The furnace should be cleaned and adjusted by a certified dealer or qualified service contractor once a year or before the start of every heating season. The following items must be cleaned and serviced or replaced if there are signs of deterioration.

1. The vent terminal screen (if applicable).

CLIPS

RIGHT SIDE INSTALLATION SHOWN

FIGURE 6: Upflow Internal Filter Retainer Externally Mounted Air Filters

Some installations may have the air filter in a rack attached to the casing of the furnace or placed in the return air duct. You can gain access to the filter by pulling on the door or unscrewing the retaining screw, then slide the filter(s) out of its channel. Replace throw away filter(s) with the same size new filter(s). Throw away filter(s) may be replaced with cleanable filter(s) at this time. Cleanable filter(s) may be cleaned as described in the manufacturer instructions or as described below and then re-installed.

To replace the filter after cleaning you must do the following:

1. Slide filter into place.

2. Snap the door on or place the door in position and tighten the retaining screws, if provided.

3. Make sure the door is secure to the end of the filter rack.

IF FILTER PROVIDED

FURNACE FRONT

4 Unitary Products Group

035-19592-001 Rev. C (0204)

TABLE 1:

Filter Sizes

Input / Output

BTU/H (kW)

CFM (cm/m)

Cabinet

Size

Side (in) Side (mm) Bottom (in) Bottom (mm)

40/37 (11.71/10.84) 1000 (28.32) 14-1/2” (A) 16 x 25 406 x 635 14 x 25 356 x 635 60/55/ (17.57/16.10) 1000 (28.32) 17-1/2” (B) 16 x 25 406 x 635 16 x 25 406 x 635 80/75/ (23.42/21.96) 1200 (33.98) 17-1/2” (B) 16 x 25 406 x 635 16 x 25 406 x 635 80/75/ (23.42/21.96) 1600 (45.31) 21” (C) 16 x 25 406 x 635 20 x 25 508 x 635

100/95 (29.28/27.82) 1400 (39.64) 21” (C) 16 x 25 406 x 635 20 x 25 508 x 635

100/95 (29.28/27.82) 2000 (56.63) 21” (C) (2) 16 x 25 (2) 406 x 635 20 x 25 508 x 635 120/112/ (35.14/32.80) 2000 (56.63) 24-1/2” (D) (2) 16 x 25 (2) 406 x 635 22 x 25 559 x 635 140/130/ (40.99/38.06) 2000 (56.63) 24-1/2” (D) (2) 16 x 25 (2) 406 x 635 22 x 25 559 x 635

How to Clean your Filter

High-velocity filters may be cleaned with a vacuum cleaner or washed with a garden hose. Be sure to shake off excess water and allow filter to completely dry before re-installing the filter.

Blower Care

Even with good filters properly in place, blower wheels and motors will become dust laden after long months of operation. The entire blower assembly should be inspected annually. If the motor and wheel are heavily coated with dust, they can be brushed and cleaned with a vacuum cleaner. If the blower cannot be properly cleaned without removing it from the furnace, then this service must be performed by a qualified service agency.

Intermittent Blower - Cooling

Cooling/heating thermostats have a fan switch that has an ON and AUTO position. In the AUTO position the thermostat circuit is completed between terminals R and G when there is a call for cooling. The motor will operate on the speed tap wire that is connected to the cooling terminal on the control board. The fan off setting is fixed at 60 seconds for SEER enhancement.

Heating Cycle

When the thermostat switch is set on HEAT and the fan is set on AUTO, and there is a call for heat, a circuit is completed between terminals R and W of the thermostat. When the proper amount of combustion air is being provided, the pressure switch will close, the ignition control provides a 17-second warm-up period, the gas valve then opens, the gas starts to flow, ignition occurs and the flame sensor begins its sensing function. The blower motor will energize 30 seconds after the gas valve

Make sure you DO NOT move the clip on weight on the indoor fan wheel when cleaning the wheel. This weight is used to balance the wheel. Moving the weight will cause the fan wheel to vibrate.

Motor Lubrication

The motors in these furnaces are permanently lubricated, and do not require periodic oiling.

SEQUENCE OF OPERATION

The following describes the sequence of operation of the furnace. Refer

opens, if a flame is detected. Normal furnace operation will continue until the thermostat circuit between R and W is opened, which causes the ignition system and gas valve to de-energize and the burner flames to be extinguished. The vent motor will operate for 15 seconds and the blower motor will operate for the amount of time set by the fan-off delay jumper located on the control board. See Figure 7. The heating cycle is complete, and ready for the start of the next heating cycle.

RED-LOW SPEED BLU-MEDIUM SPEED BLK-HIGH SPEED

MOTOR LEADS

to Figure 1 for component location.

120

180

BLK

BLU

RED

60

COOL

HEAT PARK PARK

LINE XM

90

FAN OFF ADJUSTMENT

SWITCHES

Continuous Blower

Cooling/heating thermostats have a fan switch that has an ON and AUTO position. In the ON position the thermostat circuit is completed between terminals R and G. The motor will operate on the speed tap wire that is connected to the cooling terminal on the control board. To obtain a constant air circulation at lower flow rate, change the highspeed wire to either the medium speed wire or the low speed wire.

Unitary Products Group 5

FIGURE 7: Typical Heat/Cool Speed Tap Connections

035-19592-001 Rev. C (0204)

If the flame is not detected within 2 seconds of the gas valve opening, the gas valve is shut off and a retry operation begins. If the flame is lost for 2 seconds during the 10-second stabilization period, the gas valve is shut off and a retry operation begins. During a retry operation, the vent motor starts a 15 second inter-purge and the ignitor warm-up time is extended to 27 seconds. If the flame is established for more than 10 seconds after ignition during a retry, the control will clear the ignition attempt (retry) counter. If three retries occur during a call for heat, the furnace will shut down for one hour. If at the end of the one hour shut down there is a call for heat, the furnace will initiate a normal start cycle. If the problem has not been corrected the furnace will again lockout after three retries.

A momentary loss of gas supply, flame blowout, or a faulty flame probe circuit will result in a disruption in the flame and be sensed within 1.0 seconds. The gas valve will de-energize and the control will begin a recycle operation. A normal ignition sequence will begin after a 15 second inter-purge. If during the five recycles the gas supply does not return, or the fault condition is not corrected the ignition control will lockout for 60 minutes.

During burner operation, a momentary loss of power for 50 milliseconds or longer will de-energize the gas valve. When the power is restored, the gas valve will remain de-energized and the ignition sequence will immediately restart.

Hot Surface Ignition System

HOT SURFACE IGNITION SYSTEM Do not attempt to light this furnace by hand (with a match or any other means). There may be a potential shock hazard from the components of the hot surface ignition system. The furnace can only be lit automatically by its hot surface ignition system.

FURNACE CLEANING SECTION

NOTE: The cleaning operations listed below must be performed only by

a qualified service agency.

Burner Removal/Cleaning

The main burners should be checked periodically for dirt accumulation. If cleaning is required, follow this procedure:

1. Turn off the electrical power to the unit.

2. Turn off the gas supply at the external manual shut-off valve and loosen the ground union joint.

3. Remove the upper access panel and remove the burner box cover .

4. Disconnect wires from flame sensor, rollout switch and HSI igniter. Remove igniter carefully, as it is easily broken.

5. Remove the screws that hold the burner box assembly to the vest panel and remove the assembly.

6. Remove burners from the burner assembly.

7. Burners may be cleaned by rinsing in hot water.

8. Reassemble the burners in the reverse order.

Cleaning the Heat Exchanger

1. Turn off the electrical power to the unit.

2. Turn off the gas supply at the external manual shut-off valve and loosen the ground union joint.

3. Remove the upper access panel and remove the burner box cover .

4. Disconnect wires from flame sensor, rollout switch and HSI igniter. Remove igniter carefully, as it is easily broken.

5. Remove the screws that hold the burner box assembly to the vest panel and remove the assembly.

6. Remove burners from the burner assembly.

7. Remove the upper cover plate at the top of the furnace. Remove the internal baffle.

8. The upper portion of the heat exchanger is now exposed.

9. With a long flexible wire brush, clean inside each tube at both the top and bottom. The brush must pass around the rear heat exchanger tubes and then vacuum loose the scale and dirt from each tube.

10. Clean - vacuum all burners.

11. Replace all components in reverse order. Reconnect all wiring.

12. Restore electrical power and gas supply to the furnace.

13. Check furnace operation.

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

Cleaning the Secondary Heat Exchanger

1. Follow steps 1 - 8 under cleaning the Heat Exchanger.

2. Remove the vent piping from the vent blower housing. Disconnect the drain lines from the vent blower housing and from the condensate drain pan. Remove the vent blower housing blower and the condensate pan. The turbulators can then be gently removed from the secondary heat exchanger.

3. Using a stiff wire brush, remove the loose scale or soot from each tube.

4. Vacuum the secondary heat exchanger.

5. Finish the cleaning procedure by following steps 11 thru 13 under cleaning the Heat Exchanger.

TROUBLESHOOTING

The following visual checks should be made before troubleshooting:

1. Check to see that the power to the furnace and the ignition control module is ON.

2. The manual shut-off valves in the gas line to the furnace must be open.

3. Make sure all wiring connections are secure.

4. Review the sequence of operation. Start the system by setting the thermostat above the room temperature. Observe the system’s response. Then use the troubleshooting section in this manual to check the system’s operation.

FURNACE CONTROL DIAGNOSTICS

The furnace has built-in, self-diagnostic capability. If a system problem occurs, a blinking red LED shows a fault code. It is located behind a clear view port in the blower compartment door. DO NOT remove the furnace blower compartment panel OR turn off furnace power, as either action will clear the control’s memory of the fault.

The control continuously monitors its own operation and the operation of the system. If a failure occurs, the LED will indicate the failure code. If the failure is internal to the control, the light will stay on continuously. In this case, the entire control should be replaced, as the control is not field repairable.

Flash sequence codes 1 through 11 are as follows: LED will turn “on” for one second and “off” for one second. This pattern will be repeated the number of times equal to the code. For example, six “on” flashes equals a number 6 fault code. All flash code sequences are broken by a 2 second “off” period.

6 Unitary Products Group

035-19592-001 Rev. C (0204)

Never bypass pressure switch to allow furnace operation. To do so will allow furnace to operate under potentially hazardous conditions.

Do not try to repair controls. Replace defective controls with UPG Source 1 Parts.

Never adjust pressure switch to allow furnace operation.

CONTINUOUS FLASH: This indicates that flame was sensed when there was not a call for heat. With this fault code the control will turn on both the inducer motor and supply air blower. A gas valve that leaks through or is slow closing would typically cause this fault.

2 FLASHES: This indicates that the normally open pressure switch contacts are stuck in the closed position. The control confirms these contacts are open at the beginning of each heat cycle. This would indicate a faulty pressure switch or miswiring.

3 FLASHES: This indicates the normally open pressure switch contact did not close at the beginning of the heat cycle. This could be caused by a number of problems faulty inducer, blocked vent pipe, broken pressure switch hose or faulty pressure switch.

4 FLASHES: This indicates that a primary or auxiliary limit switch has opened its normally closed contacts. With this fault code the control will operate the supply air blower and inducer. This condition may be caused by: dirty filter, improperly sized duct system, incorrect blower speed setting, incorrect firing rate or faulty blower motor.

5 FLASHES: This fault is indicated if the normally closed contacts in the rollout switch opens. The rollout control is manually reset. If it has opened, check for proper combustion air, proper inducer operation, and primary heat exchanger failure or burner problem. Be sure to reset the switch after correcting the failure condition.

6 FLASHES: This indicates that after the unit was operating, the pressure switch opened 4 times during the call for heat. If the main blower is in a “Delay on” mode it will complete it, and any subsequent delay off period. The vent motor continues to operate until the pressure switch re-closes or a call for heat is removed.

7 FLASHES: This fault code indicates that the flame could not be established. This no-light condition occurred 3 times (2 retries) during the call for heat before locking out. Low gas pressure, faulty gas valve, faulty hot surface ignitor or burner problem may cause this.

8 FLASHES: This fault is indicated if the flame is lost 5 times (4 recycles) during the heating cycle. This could be caused by low gas pressure or faulty gas valve.

9 FLASHES: Indicates reversed line voltage polarity. Both heating and cooling operations will be affected. Check polarity at furnace and branch.

11 FLASHES: This fault will be indicated if the rollout jumper wire connection soldered into the board is broken. If this fault occurs the control will have to be replaced. This fault may also occur in installations where an improper ground is present. Prior to replacing control, verify that unit is properly grounded.

STEADY ON: This fault occurs if the gas valve is energized when there is no call for heat. If this happens the vent motor is energized and will remain energized for 5 seconds or until the fault clears itself at which point the vent motor de-energizes. This failure is counted as a recycle. Check the gas valve and control for proper operation.

60-MINUTE AUTOMATIC RESET FROM LOCKOUT: This control includes a “watchdog” type circuit that will reset from a lockout condition after 60 minutes. Operational faults 1,6,7,8 and Steady On will be reset. This provides protection to an unoccupied structure if a temporary condition exists causing a furnace malfunction. An example would be a low incoming gas supply pressure preventing unit operation. When the gas pressure is restored, at some point the “watchdog” would restart the unit and provide heat for the house.

NOTE: If a flame is detected the control flashes the LED for 1/8 of a

second and then enters a flame stabilization period.

IGNITION CONTROL (P/N 031-01972-001)

Normal flame sense current is approximately

3.7 microamps DC (µa)

Low flame signal control lockout point is

0.9 microamps DC (µa)

Thermostat Satisfied

0

OFF

15 Sec. Post Purge

OFF

60, 90, 120, 180 SEC. Selectable Fan Off Delay

OFF

(Seconds)

THERMOSTAT

INDUCER

IGNITOR

MAIN VALVE

HUMIDIFIER

ELECTRONIC AIR CLEANER

CIRCULATING BLOWER

OFF

Thermostat Calling for Heat

0

2

ON

17 22

ON

Fan on Delay 30 Seconds

OFF

52

ON

OFF

ON

OFF

ON

OFF

FIGURE 8: Furnace Control Event Schedule

Unitary Products Group 7

035-19592-001 Rev. C (0204)

SECTION III: REPLACEMENT PARTS LIST

47

34

31

48

29

33

8

32

27

10

36

38

37

26 44

CGRWY

30

HUM

EAC

XFMR

LINE

CIR

HUM

EAC

XFMR

LINE

PARK

HEAT

COOL

63

13

45

23

5

24

9

6

20

28

58

43

62

4

2

59

14

17 18

12

11

56 60

22

21

1

16

49

50

7

3

25

52

51

15

8, 61

19

29

53

35

40, 42

27

24

46

9

13

9

OFF

ON

6

8 Unitary Products Group

035-19592-001 Rev. C (0204)

ITEM DESCRIPTION

MOTOR

1MOTOR,DIRECT DRIVE BLOWER 2 MOTOR,VENTOR ASS’Y

ELECTRICAL

CAPACITOR (7.5MFD/370V)

3

CAPACITOR (10 MFD/370V) 4 CAPACITOR, VENTOR (4MFD/370V) 5 CONTROL, HIGH LIMIT 6CONTROL,FLAME ROLL OUT 7 CONTROL,FURNACE

7A FUSE

8IGNITER 9 SENSOR, FLAME

10 SWITCH, AIR PRESSURE [LP] 11 SWITCH, DOOR 12 TRANSFORMER 13 VALVE, GAS

AIR MOVING

14 CUTOFF,BLOWER 15 HOUSING, BLOWER 16 WHEEL, BLOWER

FABRICATED PARTS

17 BAFFLE, AIR (LH Recoup.Coil) 18 BAFFLE, AIR (RH Recoup.Coil) 19 BURNER, MAIN GAS 20 COIL,

SECONDARY HEAT EXCHANGER

21 DECK, BLOWER (Rear) 22 DECK, FRONT 23 HEAT EXCHANGER ASS’Y 24 MANIFOLD, GAS 25 PAN, BASE 26 PAN, CONDENSATE 27 PANEL, BURNER BOX (Bottom) 28 PANEL, BURNER BOX (Front) 29 WRAPPER, BURNER BOX 30 CHANNEL, TOE PLATE

(Primary)

ITEM DESCRIPTION

31 COVER, HEAT EXCHANGER 32 PANEL, FRONT (Blower) 33 PANEL, FRONT (Burner) 34 PANEL, TOP 35 SUPPORT, BURNER 36 WRAPPER, CABINET 37 PANEL, VESTIBULE (Lower) 38 PLUG, WINDOW, CLEAR - .875”

MISCELLANEOUS

39*

CLIP, FILTER RETAINER(2Req’d)P3U,G9T

40 COLLAR, AIR INTAKE (Bur ne r Box ) 41 FILTER, AIR

FILTER SIZE - Refer to Table 1 42 GASKET, AIR INTAKE 43 GASKET,

COMBUSTION BLOWER

44 GASKET, CONDENSATE PAN 45 GASKET,

BURN BOX TO VEST PANEL

46 GROMMET, MANIFOLD SEAL 47 PLUG, WINDOW,CLEAR - 1.5” 48 HANDLE, DOOR 49 ISOLATOR, TUBE (3 Req’d.) 50 ISOLATOR, WASHER (3 Req’d.) 51 ISOLATOR,SLEEVE (3 Req’d.) 52 MOUNT, MOTOR 53 ORIFICE, BURNER

(Natural #45)

54

55* RETAINER, FILTER

56 TRAP, CONDENSATE

57* WIRING DIAGRAM

58 TUBE, DRAIN RAIN GUTTER 59 TUBE,

CONDENSATE DRAIN

60 TUBE, DRAIN CONDENSATE TRAP 61 BRACKET, IGNITOR 62 TUBE, DRAIN

CONDENSATE PAN

63 PIPE EXHAUST VENT

NOTE: *Not Shown

New replacement parts shown in bold face type at the first printing of parts list dated 11/02. Major components and suggested stocking items are shown with shaded item number.

Unitary Products Group 9

035-19592-001 Rev. C (0204)

FIELD INSTALLED ACCESSORIES NON-ELECTRICAL

MODEL NO. DESCRIPTION USED WITH

1NP0347 1NP0349 PROPANE (LP) 140 MBH

1CT0302 CONCENTRIC INTAKE/VENT 2” 1CT0303 CONCENTRIC INTAKE/VENT 3”

1PS0306

1PS0307

1PS0308

1PS0309

1PS0310

1BR0314 1BR0317 17-1/2” CABINETS

1BR0321 21” CABINETS 1BR0324 24-1/2” CABINETS

1NK0301

PROPANE (LP) CONVERSION

KIT ALL MODELS EXCEPT 140 MBH

HIGH ALTITUDE PRESSURE SWITCH KIT

(Does Not Include Orifices)

HIGH ALTITUDE PRESSURE SWITCH KIT

(Does Not Include Orifices)

HIGH ALTITUDE PRESSURE SWITCH KIT

(Does Not Include Orifices)

HIGH ALTITUDE PRESSURE SWITCH KIT

(Does Not Include Orifices)

HIGH ALTITUDE PRESSURE SWITCH KIT

(Does Not Include Orifices)

EXTERNAL BOTTOM FILTER

RACK 14-1/2” CABINETS

CONDENSATE NEUTRALIZER

KIT ALL MODELS

FIELD INSTALLED ACCESSORIES ELECTRICAL

MODEL NO. DESCRIPTION USED WITH

THERMOSTAT- One-stage heat/cool.

2TH07700124-

2TH13700424

2TB17700424

2ET07700224

6TH13701024

6TH07700124

2CT03700124 TWINNING CONTROL ALL MODELS

Manual changeover, integral sub-base.

System Switch: Cool-Off-Heat.

Fan Switch: Auto-On.

ALL P3U MODELS

THERMOSTAT- One-stage heat.

Deluxe 24V with heat only sub-base

does not include fan switch.

NOTE: For one-stage cool or

one-stage heat/cool, must be used

with sub-base 2TB17700424.

SUBBASE (24V) - One-stage heat/cool. Man-

ual changeover, integral sub-base.

System Switch: Cool-Off-Heat.

Fan Switch: Auto-On.

THERMOSTAT- One-stage heat/cool.

Programmable changeover, with sub-base.

System Switch: Cool-Off-Heat.

Fan Switch: Auto-On.

THERMOSTAT- Heating, One-stage heat, No

Fan Switch.

ALL G9T, FG9 MODELS

THERMOSTAT- Heating/Cooling,

One-stage heat/cool. Manual changeover.

REPLACEMENT PART CONTACT INFORMATION

This is a generic parts list. To request a complete parts list, refer to the contact information below:

• Visit our website at www.source1parts.com for the following information:

1. Search for a part or browse the catalog.

2. Find a dealer or distributor.

3. Customer Service contact information. a. Click on the “Brand Links” button

b. Click on the “Customer Service” button

• You can contact us by mail. Just send a written request to:

York International

Consumer Relations

5005 York Drive

Norman, OK 73069

10 Unitary Products Group

035-19592-001 Rev. C (0204)

SECTION IV: WIRING DIAGRAM

FIGURE 9: Wiring Diagram

Unitary Products Group 11

Limited Warranty

UPG warrants this product to be free from defects in factory workmanship and material under normal use and service and will, at its option, repair or replace any parts that prove to have such d efects according to the terms outlined on t he reverse side of this warranty. This warranty covers onl y the equipment described by the Product Model Number and Serial Number listed on the Warranty Registration Card. UPG warrants the primary heat exchangers in the product to be free from defects in factory workmanship and material under normal use and service and will at its option, repair or furnish a replaceme nt heat exchanger, either new or reconditioned, that meets the intended fit, use and function of the original heat exchanger for any heat exchanger furnished by UPG which proves to have such defects within the duration of warranty coverage. Alternatively, UPG may, at it s option, extend a replacement all owance to be applied toward th e purchase of a new furnace or packag ed unit marketed by UPG. The exact amount of the allowance will be determined at the discretion of UPG, based upon current market conditions, but in no case shall this allowance exceed thirty (30) percent of the original consumer pu rchase pr ice o f the fu rnace, exclu ding suc h items as du ctwork, w iring, piping and ins tallation costs. U PG shall have no responsibility hereunder for installation, shipping, handling or other charges except as specifically provided herein. For your benefit and protection, return the Warranty Registration Card to UPG promptly after installation. This will initiate the warranty period and all ow us to contact you, should it beco me necessary. In the abse n ce of a rec or ded Warranty Registration Card, the warranty period will begin upon product shipment from UPG. This warranty extends only to the original consumer purchaser and is non-transferable. For this warranty to apply, the product must be installed accord ing to UPG recommendations and specifica tions , and in acc ordance with all l ocal, state, an d natio nal codes; and the pr oduct mus t not be removed f rom its plac e of original installation. The warranty period for repair or repla cement parts provided hereunder shall not extend beyond the warranty period stated on the re ve rs e

side of this warranty.

HEAT EXCHANGER

FURNACE TYPE

Original Owner Subsequent Owner

P*UR / G9T-UP

90%

FG9-UP

UPG strongly recommends regular periodic preventative maintenance on this equipment. The person most familiar with the equipment in your HVAC system is a UPG dealer. The UPG dealer can ensure your maintenance program meets the conditions of the "UPG Warranty", maximize the efficiency of the equipment, and service your unit within the mandated guidelines with regard to unlawful discharge of refrigerants into the atmosphere. This warranty applies only to products installed in the United States and Canada.

Lifetime 20 10 5

15 N/A 10 1

Non-Residential

Applications

EXCLUSIONS

This warranty does not cover any:

1. Shipping, labor, or material charges.

2. Damages resulting from transportation, installation, or servicing.

3. Damages resulting from acci dent, abuse, fire, flood, alterat ion, or acts of God (tampe ring, altering, d efacing or removin g the produc t serial number will serve to void this warranty).

4. Damages resulting from use of the product in a corrosive atmosphere.

5. Damages resulting from inade quacy or interruption of electrical servi c e or fuel supply, improper voltage conditions, blown fuses, or other like damages.

6. Cleaning or replacement of filters.

7. Damages resulting from failure to properly and regularly clean air and/or water side of condenser and evaporator.

8. Damages resulting from: (I) freezing of condenser water or condensate; (II) inadequate or interrupted water supply; (III) use of corrosive water; (IV) fouling or restriction of the water circuit by foreign material or like causes.

9. Damages resulting from operation with inadequate supply of air or water.

10. Damages re su lting from use of components or accessories not approved by U PG (ve n t damp er s, etc.).

11. Increase in fuel or electric cost.

THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

SOME STATES DO NOT ALLOW THE DISCLAIMER OF IMPLIED WARRANTY, SO THAT THE ABOVE DISCLAIMER MAY NOT APPLY TO YOU. SOME STATES ALLOW ONLY A PARTIAL LIMITATION ON IMPLIED WARRANTIES T O LIMIT THE DURATION OF IMPLIED WARRANTIES TO THE DURA-

TION OF THE EXPRESS WARRANTY. IN SUCH STATES, THE DURATION OF IMPLIED WARRANTIES IS HEREBY EXPRESSLY LIMITED TO THE DURATION OF THE EXPRESS WARRANTY ON THE FACE HEREOF.

IN NO EVENT, WHETHER AS A RESULT OF BREACH OF WARRANTY OR CONTRACT, TORT (INCLUDING NEGLIGENCE) STRICT LIABILITY OR OTHERWISE, SHALL UPG BE LIABLE FOR SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES, INCLUDING BUT NOT LIMITED TO LOSS OF USE OF THE EQUIPMENT OR ASSOCIATED EQUIPMENT, LOST REVENUES OR PROFITS, COST OF SUBSTITUTE EQUIPMENT OR COST OF FUEL OR ELECTRICITY. THE ABOVE LIMITATIONS SHALL INURE TO THE BENEFIT OF UPG'S SUPPLIERS AND SUBCONTRACTORS. THE ABOVE LIMITATION ON CONSEQUENTIAL DAMAGES SHALL NOT APPLY TO INJURIES TO PERSONS IN THE CASE OF CONSUMER GOODS.

SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF LIABILITY FOR CONSEQUENTIAL OR INCIDENTAL DAMAGES, OR FOR STRICT LIABILITY IN TORT, SO THAT THE ABOVE EXCLUSIONS AND LIMITATIONS MAY NOT APPLY TO YOU.

UPG DOES NOT ASSUME, OR AUTHORIZE ANY OTHER PERSON TO ASSUME FOR UPG, ANY OTHER LIABILITY FOR THE SALE OF THIS PRODUCT . THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS. YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE. For Owner's Information:

PARTSResidential Applications

PRODUCT MODEL. NO. ____________________ INSTALLATION DATE ______________________________ UNIT SERIAL NO. _________________________ INSTALLING DEALER ______________________________

Unitary 5005 Norman Products York OK Group Drive 73069

USER’S INFORMATION, MAINTENANCE AND

EFFICIENCY RATING CERTIFIED

SERVICE MANUAL

MODELS: 90% P*DH / G9T-DH / FG9-DH (Downflow)

CONTACT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

TABLE OF CONTENTS

USER’S INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

INSTRUCTIONS FOR EXAMINING THE FURNACE

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

HOW YOUR GAS FURNACE WORKS . . . . . . . . . . . . . . . . . . . . . .3

START-UP AND SHUTDOWN INSTRUCTIONS . . . . . . . . . . . . . . . 3

Read the Instructions Below Before Trying to Start the

Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Operating Instructions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

To Turn Off the Appliance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FURNACE USER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . .4

Blower Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Removing Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Motor Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE AND MAINTENANCE MANUAL . . . . . . . . . . . . . . . . . . . . . 5

SAFETY SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

CONTACT INFORMATION

• Go to website at www.york.com click on “contact”, then click on “contact form” and follow the instructions.

• Contact us by mail:

York International Corperation

Consumer Relations

Norman, OK 73069

FURNACE MAINTENANCE SECTION . . . . . . . . . . . . . . . . . . . . . . .5