Johnson P4HUE30N13006 Installation Instructions Manual

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Page 1

INSTALLATION INSTRUCTIONS

CONTENTS

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

UNIT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

UPFLOW APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

HORIZONTAL APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . .9

GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

ELECTRICAL POWER CONNECTION . . . . . . . . . . . . . . . . . . .11

ELECTRICAL CONTROL CONNECTIONS . . . . . . . . . . . . . . .12

SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

TSTART-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . .14

ACCESSORY CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . .16

OPERATION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . .18

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

HORIZONTAL (WITHOUT FILTER) . . . . . . . . . . . . . . . . . . . . .22

FILTER PERFORMANCE-PRESSURE DROP

INCHES W.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

MULTI-POSITION

GAS-FIRED FURNACES

COMMERCIAL BELT DRIVE

UPFLOW / HORIZONTAL MODELS: P4HUE30N13006

130 MBH OUTPUT

CAUTION: READ ALL SAFETY GUIDES BEFORE YOU

START TO INSTALL YOUR FURNACE.

SAVE THIS MANUAL

035-17443-000 Rev. A (800)

Page 2

IMPROPER INSTALLATION MAY CREATE A CONDITION WHERE THE OPERATION OF THE PRODUCT COULD CAUSE PERSONAL INJURY OR PROPERTY DAMAGE.

IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE CAN CAUSE INJURY OR PROPERTY DAMAGE. REFER TO THIS MANUAL FOR ASSISTANCE OR ADDITIONAL INFORMATION, CONSULT A QUALIFIED INST ALLER, SER VICE 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 CODES INCLUDING BUT NOT LIMITED TO, BUILDING, ELECTRICAL AND MECHANICAL CODES.

The furnace area must not be used as a broom closet or f or any ot her sto rage pu rposes , as a fir e hazard bay be cr eat ed. N ever stor e it ems s uch 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 thin ners 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.

035-17443-000 Rev. A (800)

CONTENTS

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

NOTES, CAUTIONS & WARNINGS . . . . . . . . . . . . . . . . . . . . 3

LIMITATIONS AND LOCATION . . . . . . . . . . . . . . . . . . . . . . . 3

UNIT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

COMBUSTION AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Air Source from Outdoors . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Special Combustion and Ventilation Considerations . . . . . . 5

Specially Engineered Installations . . . . . . . . . . . . . . . . . . . . 5

Combustion Air Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

CATEGORY 1 - VERTICAL VENTING . . . . . . . . . . . . . . . . . . 7

CATEGORY 1 - 450 F. MAX. VENT TEMP. . . . . . . . . . . . . . 7

HORIZONTAL SIDEWALL VENTING . . . . . . . . . . . . . . . . . . 7

VENT SAFETY CHECK PROCEDURE . . . . . . . . . . . . . . . . . 7

DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

UPFLOW APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SUPPLY PLENU M CONNECTION . . . . . . . . . . . . . . . . . . . . 8

Return Duct Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

FILTER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Bottom Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

HORIZONTAL APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SUPPLY PLENU M CONNECTION . . . . . . . . . . . . . . . . . . . . 9

ATTIC INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

CRAWL SPACE INSTALLATION . . . . . . . . . . . . . . . . . . . . 10

GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

ELECTRICAL POWER CONNECTION . . . . . . . . . . . . . . . . . . . . 11

FURNACE CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . 11

BLOWER MOTOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . 11

ELECTRICAL CONTROL CONNECTIONS . . . . . . . . . . . . . . . . . 12

SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

TSTART-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . 14

IGNITION SYSTEM CHECKOUT / ADJUSTMENT . . . . . . . 14

CHECKING GAS INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Example - Checking Gas Input . . . . . . . . . . . . . . . . . . . . . . 14

ADJUSTMENT OF MANIFOLD GAS PRESSURE . . . . . . . . 15

ADJUSTMENT OF TEMPERATURE RISE . . . . . . . . . . . . . 16

ADJUSTMENT OF FAN-OFF CONTROL SETTINGS . . . . . 16

ACCESSORY CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 16

OPERATION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . 18

SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . 18

CONTINUOUS BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

INTERMITTENT BLOWER - COOLING . . . . . . . . . . . . . . . . 18

HEATING CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

HOT SURFACE IG N ITION SYSTEM . . . . . . . . . . . . . . . . . . 18

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

AIR FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

BLOWER CARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

BURNER REMOVAL / CLEANING . . . . . . . . . . . . . . . . . . . . 19

CLEANING THE HEAT EXCHANGER . . . . . . . . . . . . . . . . . 19

Lower Heat Exchanger Access . . . . . . . . . . . . . . . . . . . . . . 19

Upper Heat Exchanger Access . . . . . . . . . . . . . . . . . . . . . . 20

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

FURNACE CONTROL DIAGNOSTICS . . . . . . . . . . . . . . . . 20

BLOWER PERFORMANCE CFM -UPFLOW/

HORIZONTAL (WITHOUT FILTER) . . . . . . . . . . . . . . . . . . . . . . . 22

FILTER PERFORMANCE-PRESSURE DROP

INCHES W.C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2 Unitar

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035-17443-000 Rev. A (800)

gory

GENERAL INFORMATION

DESCRIPTION

This Category I furnace is designed for installation in a residential or commercial application. A Cate a fan assist ed combustion s mechanical means to draw products of combustion throu the combustion chamber and heat exchan installed in a basement, attic or an ances to combustibles and other restrictions are met. It is designed for natural gas-fired operation, but may be converted to propane (LP) usin

other indoor location where all required clear-

stem equi pped with an i ntegral

arage, equipment room, alcove,

the INP0349 kit.

1 furnace has

er. It may be

Each furnace in this series is a Categ ory I furnace , suitable for common venting with other gas-fired appliances as allowed by the National Fuel Gas Code, NFPA 54/ANSI Z223.1-latest edition.

This appliance is not to be used for temporary heating of buildings or structures under construction.

Do not install this furnace in a corrosive or contaminated atmosphere.

High altitude and propane (LP) changes or conversions required in order for the appliance to satisfactoril application must be made b Canada, a certified conversion station or other qualified

ency, using factory specified and/or approved parts.

a This furnace may be used only as a Category 1 unit. The furnace must be installed so that all electrical compo-

nents are protected from water.

an authorized distributor: in

meet the

INSPECTION

As soon as a unit is receiv ed, it s hould be ins pecte d for po ssible dama extent of t he dam a bill.

A separate request for inspection b should be made in writin should be checked for belt, screws or bolts which ma loosened in transit.

e during transit. If the damage is evident, the

e should be noted on t he c arri er’s freight

the carrier's agent

. Also, before installation, the unit

have

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 dama the installer that personal injur damage may occur if installation procedures are not handled properl

e. WARNINGS are given to alert

and/or equipment or propert

LIMITATIONS AND LOCATION

Do not install this furnace in a mobile home or recreational vehicle.

Furnaces shall not be installed directly on carpeting, tile or other combustible material other than wood flooring.

Continuous return air temperature must not be below 55 °F (13 °C).

Use onl the furnace ratin

the type of gas approved for this furnace; refer to

plate.

Only use natural gas in furnaces designed for natural gas. Only use propane (LP) gas for furnaces that have bee n pr ope rly co nver te d to us e pr opa ne (LP) gas. Do not use this furnace with butane. Using wrong gas could create a hazard, resulting in damage, injury or death.

For install ations ab ove 2,00 0 feet, re duce inpu t 4% for ea ch 1,000 feet above sea level. Canadian installations must be derated 10% for elevations from 2,000 ft. to 4,500 ft. Use 1PS0301 kit to properl

The furnace shall not be connected to a chimney flue servin a separate appliance designed to burn solid fuel.

Check the rating plate and power supply to be sure that electrical cha racteristics matc h. All models are factor 208 / 230 VAC, 1 phase, 60 Hertz power suppl

derate this furnace.

wired for

This furnace should be installed in accordance with all national / local buildin the absence of local codes, with the National Fuel Gas Code, ANSI Z223.1 - (latest edition) or, in Canada, CAN/CGA B149.1 or.2 - (latest edition), and other applicable codes.

Unitar

Products Group 3

/ safety codes and requirements, or in

A furnace installed in a residential that all burners and burner i less than 18" above the tected to prevent dama

arage floor, and located or pro-

e by vehicles.

arage must be located so

nition devices are located no

Page 4

035-17443-000 Rev. A (800)

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

The furnace should be located usin

1. Where a minimum amount of vent pipin be required.

2. As centralized with the air distribution as possible.

3. Where adequate combustion air will be available.

4. In an area where ventila tio n fa ci lities provide for sa fe lim its of ambient temperature under normal operatin ditions.

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

6. Where the vent will not be blocked or restricted.

7. Where sufficient space is provided to allow proper service access. Mi nimum re commen ded servi ce clearanc es are as follows:

-four (24) inches between the fron t of th e furnace

Twent and an adjacent wall or an oth er ap pliance, when access is required for servicing and cleaning.

Eighteen (18) inches at the side where access is required for passa or replacement of flue / vent connections.

8. Where it will not interfere with the cleanin removal of other appliances.

be used. (See Table 3 on page 6).

these guidelines:

and elbows wi ll

con-

e to the front for servicing, inspection

, servicing or

Rooms communicati n appliances are considered part of the unconfined space, if openin

A confined space

1000 Btu/hr input ratin area.

The followin combustion and ventilation in confined spaces.

Air Source from Inside the Building

Two permanent openin 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 ratin the space. The openin rior areas havin

NOTE:

s are not furnished with doors.

must be considered to obtain proper air for

At least 100 square inch es free area sh all be used f or

directly with the space containing the

is an area with less than 50 cubic feet per

for all appliances installed in that

s, one within 12 inches of the top of

of all appliances located in

s shall communicate freely with inte-

adequate infiltration from the outside.

each opening.

Air Source from Outdoors

1. Two permanent openin top of the confine d space and one with in 12 inc hes of th e bottom, shall commun ica te dire ctl ducts, with the outdoors or to such cr a wl or atti c spa ce s that freel

communicate with the outdoors.

Vertical Ducts

area of not less th an one square inch per 4,00 0 Btuh of total input of all appliances located in the space.

s, one within 12 inches of the

, or by means of

- Each openin

must have a free

9. Wh ere the follow in combustibles can be maintained: Table 1 on pa

minimum clearances (in inches) to

e5.

UNIT INSTALLATION.

Remove blower shipping support, located under blower assembly, only after unit has been positioned for installation or damage may occur.

COMBUSTION AIR

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

Btu/hr input ratin

is not less than 50 cubic feet per 100 0

for all appliances install ed in that area.

EXAMPLE:

Total Input of All Appliances

4000

Horizontal Ducts

area of not less th an one square inch per 2,00 0 Btuh of total input of all appliances located in the space.

Ducts must have the same cross-sectional area as

NOTE:

- Each openin

= Square Inches Free Area

must have a f ree

the free area in the opening to whic h they are conn ected. 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 from the sides and back and 6 inches from the front of the appliance. The openin or horizontal duct to the outdoors, or spaces (crawl or attic) that freely communicate with th e outdoors and shall have a minimum free area of:

a. 1 sq. in. per 3000 Btu per hr of the total input ratin

of all equipment located in the enclosure.

shall communicate through a vertical

4 Unitar

Products Group

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035-17443-000 Rev. A (800)

g ty

TABLE 1: UNIT CLEARANCES TO COMBUSTIBLES (ALL DIMENSIONS ARE IN INCHES)

ALL SURFACES IDENTIFIED WITH THE UNIT IN AN UPRIGHT CONFIGURATION

APPLICATION TOP FRONT REAR

UPFLOW / HORIZONT AL MODELS - UPFLOW APPLICATION

UPFLOW 1 6 0 0 3 6 COMBUSTIBLE YES YES YES NO

UPFLOW B-VENT 1 3 0 0 0 1 COMB USTIBLE YES YES YES NO

UPFLOW / HORIZONT AL MODELS - HORIZONTAL APPLICATION

HORIZONTAL 1 6 0 0 3 6 COMBUSTIBLE NO YES YES HORIZONTAL

B-VENT

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

1 3 0 0 0 1 COMBUSTIBLE NO YES YES YES1

LEFT SIDE

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 calculatin

to the blockin

free area, conside r ati on m ust b e given

effects of louvers, grilles and

screens.

If the free area of a specific louver or grille is not known, refer to Table 2 to estimate free area.

TABLE 2: ESTIMATED FREE AREA

Wood or Metal

Louvers or Grilles

Screens

Do not use less than 1/4 in. mesh

Free area of louvers and grilles varies widely; installer should follow louver or grille manufacturer’s instructions.

Wood 20-25%

Metal 60% - 70%

1/4 in. mesh or larger 100%

RIGHT

SIDE

FLUE

FLOOR /

BOTTOM

CLOSET ALCOVE ATTIC

CONTACT

Combustion Air Quality

The recommended sourc e of comb ustion air is to us e the outdoor air suppl bustion air will result in safet

. Excessive exposure to contaminated com-

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 recom-

mended that the necessar the outdoors b direct openin

way of attic, crawl space, air duct or

combustion air come from

2. If outdoor combustion ai r is used, ther e mus t be no e xpo-

sure to the installations or substances listed in #3 below.

3. The followin

pes of installations may require OUT-

DOOR AIR for combustion, due to chemical exposure. a. Commercial buildings

b. Buildin

s with indo or pools c. Furnaces installed in laundry rooms d. Furnaces installed in hobby or craft rooms

If mechanically operated louvers are used, a means

NOTE:

to prevent main burner ignition and operation must be provided should louvers close during startup or operation.

Special Combustion and Ventilation Considerations

Operation of a mechanical exhaust, such as an exhaust fan, kitchen ventilation s ate conditions requirin tor

operation of gas appliances.

stem, clothes dryer or fireplace may cre-

special att ention to av oid un satisf ac-

Specially Engineered Installations

The above requirements shall be permitted to be waived where special engineering, approved by the authority havin jurisdiction, provides an adequate supply of air for combustion, ventilation and dilution of flue

ases.

e. Furnaces installed near chemical stora f. Permanent wave solutions

. Chlorinated waxes and cleaners

h. Chlorine based swimmin

pool chemicals i. Water softening chemicals j. De-icing salts or chemicals k. Carbon tetrachloride l. Halo

en type refrigerants m. Cleaning solvents (such as perchloroethylene) n. Printin

inks, paint removers, varnishe s, etc . o. Hydrochloric acids p. Cements and glues q. Antistatic fabric softeners for clothes dr r. Masonry acid washing chemicals

e areas

ers

LINE

YES

Unitar

Products Group 5

Page 6

FIGURE 1: DIMENSIONS

(

035-17443-000 Rev. A (800)

Note: Vent must be increased to 5” using adaptor provided (7” tall).

All dimensions are in inches and are approximate.

TABLE 3: RATINGS & PHYSICAL/ELECTRICAL DATA

LOWER

MAX.

OVERCURRENT PROTECT

MODEL

INPUT

MBH

OUTPUT

MBH

AFUE

AIR T

EMP

RISE °F

OUTLET

TEMP. °F

MOTOR

OMINAL

OTOR

MPS

SIZE

OTAL

UNIT

AMPS

@230V

P4HUE30N13006 160 130 78 25 - 55 150 1-1/2 10 12 x 15 250

208/230 VAC (ONLY ) 15 20 12

115 and 208/230 VAC (SPLIT) 6 & 11 15 12

115 VAC (ONLY)

AFUE numbers are determined in accordance with DOE test procedures.

Wire size and overcurrent protection must comply with the National Electrical Code (ANSI / NFPA-70-latest edition)

Motor must be converted for 115 VAC operation.

• For altitudes above 2,000 ft., reduce capacity 4% for each 1,000 ft. above sea level. Refer to Form 650.74-N1.1V.

• Wire size based on copper conductors, 60° C, 3% voltage drop.

• See Replacem ent Parts list for LP gas and High Altitude conversion kits. External filter kits (bottom & side) are also available for

models above.

• Continuous return air temperatures must not be below 55

F (13° C)

27 30 10

IRE

W SIZE AWG)

@ 75 FT.

ONE

WAY

OPER

WGT. (LBS)

6 Unitar

Products Group

Page 7

035-17443-000 Rev. A (800)

g sy

VENTING

It is the responsibility of the installer to verify proper vent system operation.

CATEGORY 1 - VERTICAL VENTING

Category 1 venting consists of vertically venting one or more appliances in B-vent or masonr single wall metal pi p e or B -ve nt co nn ec to r s. Type B vent system extends in a tain offsets exceedin

not more than one 60-degree offset is permitted.

havin

This appliance may be common vented with another

NOTE:

eneral vertical direction and does not con-

45 degrees, except that a vent system

gas appliance as allowed by the following codes and standards.

The furnace rating plate lists t he ma xi mum v ent gas temperature. This temperature must be used to select appropriate

materials and cle ara nce s. A typical example is show n

ventin below.

CATEGORY 1 - 450 F. MAX. VENT TEMP.

All installations must be vented in accordance with the National Fuel Gas Code, NFPA 54 / ANSI Z223.1 - latest edition. For reference, the National Fuel Gas Code Handbook, available from NFPA (item JP-54HB96) is recommended. The appliance must also be vented in compliance with all local utilit must be vented in accordance with the National Standard of Canada, CAN / CGA-B149.1 and.2 - latest editions.

and code requirements. In Canada, the furnace

A furnace shall not be connected to a chimney flu e serving a separate appliance designed to burn solid fuel.

This furnace requires the use of a special 4" to 5" vent adapter. It is provided with the furnace and must be installed.

HORIZONTAL SIDEWALL VENTING

For applications where vertical venting is not possible, the onl

approved method of horizontal venting is through the use of an auxiliar Fields Controls Mod el SW G-4 Y or Tjernlund Model GPAK-JT. Follow all application and installation details provided by the manufacturer of the power venter.

power venter. Approved p ow er ve nters a re

chimney (as allowed), usin

VENT SAFETY CHECK PROCEDURE

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 Fuel Gas Code, ANSI Z223.1 or CAN/ CGA B149.1 or .2 Installation Code - latest editions.

The following steps shall be followed with each appliance connected to the ventin

other applia nces con nected to the comm on venti ng sys-

an tem are not in operation.

1. Seal an tem.

2. Inspect ventin pitch, as required in the National Fuel Gas Code ANSI Z223.1 or the CAN / CGA B149 Installation Codes and these instructions. Determine that there is no blocka or restriction, leaka which could cause an unsafe condition.

3. Insofar as is practical, close all buildin dows and all doors betwe en the s pace in whic h the a ppliance(s) connecte d to the v entin other spaces of the buildin an in

Turn on an bathroom exhausts so the speed. Do not operate a summer exh aust fan. Close fireplace dampers.

4. Follow the lighting instructions. Place the appliance bein ance will operate continuousl

5. Test for draft hood equipped appliance spillage at the draft hood relief openin 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 when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-burning appliance to its previous condition of use.

7. If improper ventin tests, the ventin

8. Any corrections or resizing of the common venting system must be in accordance with the National Fuel Gas Code, ANSI Z223.1 or Section 7, Venting Systems and Air Suppl lation Code - latest editions. If the common vent s must be resized, it should be resized to approach the minimum size as determ ine d usi n tables in Appendix G of the above codes.

unused openings in the common venting sys-

other appliances not conne cted to the commo n vent-

stem.

exhaust fans, such as range hoods and

operated in operation. Adjust thermostat so appli-

for Appliances, CAN/CGA B149.1 or.2 Instal-

stem placed in operation, while

stem for proper size and horizontal

e, corrosion or other deficiencies

doors and win-

stem are located and

. Turn on clothes dryers and

will operate at maximum

at full input rate.

after 5 minutes of main burner

is observed during any of the above

stem must be corrected.

stem

the appropriate

Unitar

Products Group 7

Page 8

035-17443-000 Rev. A (800)

DUCTWORK

The duct system design and installation must:

1. Handle an air volume appropriate for the served sp ace and within the operatin ifications.

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

3. Create a closed duct s be connected to the furnace outlet and the return duct system must be conn ected to the furna ce inle t. Both su p-

and return duct systems must terminate outside the

pl space containin

4. Generall culate throu ment and to and from the conditioned space.

complete a path for heated or cooled air to cir-

h the air conditioning and heating equip-

The cooling coil must be installed in the supply air duct downstream of the furnace.

parameters of the furnace spec-

stem. The supply system must

the furnace.

On all installations without a coil, a removable access panel is recommended in the outlet duct such that smoke or reflected li cate the presence of leaks in the heat exchan access cover shall be attached in such a manner as to prevent leaks.

Return Duct Connection

Return air must enter the cabinet throu a bottom and one side. Single or Dual side return only is not allowed.

panel of the unit.

tion for details. Be sure to see the “Filters” section of this instruction and side-return detail (See Fi

FILTER INSTALLATION

All applications require the use of a filter. All filters must be field supplied and located outside the furnace cabinet in either a filter rack, duct s

NOTE:

ht would be observable inside the casing to indi-

er. This

h the bottom only, or

Return air may not be connected into the rear

See the sp ecific t

stem or filter grille.

pe application installa-

ure 2 ).

All air velocities over 300 feet per mi nute, requ ire the

use of high velocity filters.

The return air return requirements for this furnace consist of:

1. Bottom Onl

Return = 536 Ft./Min.

When the furnace is used in conjunction with a coolin the coil must be installed parallel with, or in the suppl side of the furnace to avoid condensation in the primar exchan

When a parallel flow arran other means used to control air flow must be a dequat e to p revent chilled air from entering the furnace, and if manuall operated, must be equipped with means to prevent operatin of either unit unl es s the dam pe r is i n the full heat or coo l p os ition.

er.

ement is used, the dampers or

coil,

air

heat

UPFLOW APPLICATIONS

SUPPLY PLENUM CONNECTION

Attach the supply plenum to the furnace outlet duct connection flan t

pically through the use of S cleat material when a metal plenum is used. The use of an approved flexible duct connector is recommended on all installations. This connec tion sh ould be sealed to prevent air leaka

If a matching cooling coil is used, it ma be placed directly on the furnace outlet and sealed to prev ent lea ka coil instructions for installin plenum.

es. This is

e. Follow the

the suppl

2. Bottom & Sin

3. Bottom & Two-Sides = 300 Ft./Min.

le Side = 390 Ft./Min.

All installations must have a filter installed.

The return duct ma bend tabs or other approved methods. Be sure to seal the duct to the furnace to prevent air leaka

Where the return duct system is not complete , th e re turn co nnection must ru n ful l s ize to a location o uts ide th e utilit basement or space where furnace is installed. 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.

An external mounted (1SR0302) upflow side-return

NOTE:

be attached to the furnace by “S-cleat,”

room,

accessory kit , which includes an aluminized mesh filter, is available and is size d to fit the si de kno ckou ts on th e cab ine t.

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FIGURE 2:SIDE RETURN CUTOUT MARKINGS

Bottom Return

Bottom return applications normall base platform or return air plenum. Be sure the return platform structure is suitab le to support the wei Refer to Fi wei num connection to prevent air leaka

NOTE

ure 1 on page 6, and Table 3 on page6 for unit

hts and dimensions. Be sure to seal the furnace to ple-

:A bottom filter frame accessory kit (1BR0332) is avail-

pull return air through a

ht of the furnace.

able (less filters) for this model. If the external mounted filter rack is being used, see the instructions provided with that accessory for installation.

Upflow attic in stallations must meet all minimum clearanc es to combustibles and have floor support with required service accessibility.

HORIZONTAL APPLICATION

The appropriate electrical knock-outs for power wirin trol wirin

Return air may enter the furnace through either one side and a bottom or throu application. Return air may not be connected into the rear panel of the unit. See the specifi c t tion for details. Be sure to see the Filters section of this instruction.

ATTIC INSTALLATION

This appliance is desi installed horizontall sides form a line.

This line ma ever, refer to the “VENTING, and “CLEARANCES” sections in this manual for additional information.

Secure a platform constructed of pl material to the floor joists. Sheet metal, 12" in front of the furnace combustion air openi n ure 3 on pa

and gas piping should be removed at this time.

h bottom on ly, depending on the type of

pe application installa-

n certified f or lin e cont act for f urn aces

. The intersection of the furnace top and

be in contact with combustible material. How-

wood or other buildin

s is recommended. Refer to Fig-

e 9 for details.

, con-

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.

NOTE:

See crawl s pace inst allation f or suspendi ng the fur-

nace in attic installations.

SUPPLY PLENUM CONNECTION

The furnace may be installe d ho riz onta lly with the supply airflow toward the left or ri

ht side panel.

Do not install the unit on the rear panel.

After determinin the shippin

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the best orientation, lay the unit on top of

carton to protect the finish.

ht by laying the unit on the left or

FIGURE 3: TYPICAL ATTIC INSTALLATION

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035-17443-000 Rev. A (800)

CRAWL SPACE INSTALLATION

The furnace can be hu n able blocks or pad. Blocks or pad installations shall provide adequate hei dama

When suspending the furnace from rafters or floor joists

rod, pipe or straps, refer to Figure 1 on page6 and

usin Table 3 on pa determine suitable means of suspension.

le supports should be located as shown in Figure 5 to

An permit service of blower and burner compartments. All six suspension points must be level to ensure proper door fit-up and quiet furnace operation. Isolators shoul d be use d to m in imize noise bein be securel vent movement and vibration.

ht to ensure the unit will not be subject to wa ter

e 6, for furnace weight and dimensions to

transferred to the structure. Furnace should

fastened to the bottom angle iron bracket to pre-

from floor hoists or i ns tal led on su it-

GAS PIPING

An overpressure protection device, such as a pressure regulator, which conforms to the National Fuel Gas Code, ANSI Z22 3.1 (U S) or CAN -B1 49. 1 or .2 (Canada) and acts to limit the downstream pressure to 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 ex plo si on or c au se dam ag e t o th e furnace or some of its components.

An accessible manual shutoff valve must be installed

NOTE:

upstream of the furnace gas controls and within 6 feet of the furnace.

The furnace and its individual shutoff valve must be disconnected fr om the sure testin

(3.48 kPa).

psi The furnace must be isolated from the

closing its individual external manual shutoff valve

tem b

any pressure te sting of the gas supply piping system

durin at test pressures equal to or less than 1/2 psi

as supply piping system duri ng any pres-

of that system at test pressures in excess of 1/2

as supply piping sys-

(3.48 kPa).

FIGURE 4 : TYPICAL FURNACE INSTALLATION

USING SUSPENSION MATERIALS

FIGURE 5 : TYPICAL FURNACE INSTALLATION

USING SUSPENSION MATERIALS

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 pip ing to it.

Gas pipin Sizin with the local utility requirements.

The gas supply should be a separate line, installed in accordance with the National Fuel Gas Code, ANSI Z223.1, or CAN / CGA B149.1 or.2 Installation Codes - (latest editions).

Some utilit lar wrou connections to the unit. Installation of a drop le union is required (refer to Fi

may be connected from either side of the furnace.

and installation of the supply gas line should compl

companies, or local codes, require pipe sizes

er than the minimum sizes listed. Use properly sized

ht iron, approved flexible or steel pipe, to make gas

and ground

ure 6 )

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Drop Leg

FIGURE 6 : GAS PIPING

Compounds used on t hreaded joints of gas pip ing must be resistant to the action of liquefied petroleum gases.

Provide a power suppl

(s) separate from all other circuits. Install overcurrent protection and disconnect switch per local / national el ec tric al codes. The switc h s hou ld be reason-

close to the unit for convenience in servicing. With the

abl disconnect switch(s) in the OFF position, check all wirin against the unit wiring label. Also, see the wiring diagram in this instruction. .

Use copper conductors only.

NOTE:

The furnace control system depends on correct polarity of the power supply and a proper ground connection. Refer to the Furnace Control Diagnostics section for symptoms of reversed power supply polarity.

Connect th e power supply as shown on the unit wiring label on the inside of the blow er compartment door and as deta ile d in (Refer to Fi

ure 7 on page12).

FURNACE CONTROL CIRCUIT

The control circuit requires 115 volt power suppl

. The black and blue leads must be c onn ec ted to the hot conductor of the power suppl

. Refer to Figure 7 on page 12.

After all gas piping connections are completed, leak test all joints, fittings and furnace connections with rich soap and water solution, commercial available bubble type leak detection fluid, or other approved means.

Do not use an open flame or other source of ignition for leak testing.

NOTE

A 1/8” NPT plug is includ ed in the in let s ide of the gas valve for measuring incoming gas pressure. Refer to Table 4 for inlet pressure information.

TABLE 4: INLET GAS PRESSURE RANGE

INLET GAS PRESSURE RANGE

Natural Gas Propane (LP)

Minimum 4.5 In. W.C. 11 In. W.C.

Maximum 13.9 In W.C. 13.9 In. W.C.

ELECTRICAL POWER CONNECTION

Field wiring to the unit must conform to and be grounded in accordance with the provisions of the National Electrical Code ANSI/NFPA No. 70 -latest edition, Canadian Electric Code C22.2 Part 2 - (latest edition) and / or local codes. Electrical wires which are field instal led sh all con form with th e temperature limitatio n fo r 63°F / 35°C rise wire when installed in accordance with instructions. Specific electrical data is

iven on the furnace rating plate.

BLOWER MOTOR CIRCUIT

The motor circuit requires 230 volt power suppl This circuit ma motor onl to wirin

diagram on the motor.

be changed to 115 volts (standard 1-1/2 HP

) by revising the internal motor connections. Refer

as shipped.

All field power wiring connections are shown in Figure 7 A, B, & C on pa

e 12.

Remove the 4 x 4 junction box cover plate. Route the power

through the unit side panel with a conduit connector or

wirin other proper connection. Make wirin in Fi

ures 7 A, B, or C. Replace the wiring box cover pl ate

connections as shown

and secure with screws.

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035-17443-000 Rev. A (800)

FIGURE 7A

FIGURE 7B

ELECTRICAL CONTROL CONNECTIONS

Install th e field-supplie d thermostat. Th e thermostat inst ructions for wirin mostat set in the OFF position and the main electrical source disconnected, complete the low-volta mostat to the terminal board on the low-volta Connect Class 2 control wirin “WIRING DIAGRAM”.

strain relief to the therm os tat wi res pas sing through the

Appl cabinet.

FIGURE 8 : TYPICAL HEATING AND COOLING

Set the heat ant icip at or in the ro om t herm ost at to .45 amps. Setting it lower will cause short cy cle s. Setti ng it higher will cause the room temperature to exceed the setpoint.

are packed with the thermostat. With the ther-

e wiring from the ther-

e transformer.

as shown in F igures 8 and 14

CONTROL CONNECTIONS

FIGURE 7C

FIGURE 7 : ELECTRICAL WIRING

An alternate wiring method is to use a field prov ided 4 x 4 bo x and cover on the outside of the furnace. Route the furnace leads into the box usin pass throu

NOTE:

h the furnace panel.

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. Resecure loose wires to prevent contact with moving parts / hot surfaces and sheet metal edges.

a protective bushing where the wires

Some electronic ther mostats do not have adjustable

NOTE:

heat anticipators. They may have other types cycle rate adjustment. Follow the thermostat manufacturer's instructions.

The 24-Volt, 40 VA transformer is sized for the furnace components onl devices such as humidifiers, air cleaners, etc. The transformer ma contactor.

, and should not be connected to auxiliar

provide power for an air conditioning unit

If the furnace is installed with a condensing unit equipped with its own transformer, the condensing unit control circuit must be isolated from the furnace transformer. Refer to Figure 9 for connection details.

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To separate control circuits, use one of the fo llo wng methods:

1. Install an isolation rela condensin

2. Use a thermostat equipped with separate “R-H” and “R- C” contacts.

Remove the jumper between these contacts of the

NOTE:

unit transformer.

between the thermostat and the

thermostat, if so equipped. .

The blower motor pow er supply will not be deenergized when the blower door is removed. Turn main power disconnect switch to OFF to remove power to motor.

Blower and burner must never be operated withou t the blower panel in place.

Electrical suppl covers the blower compartment bein positioned.

to the unit is dependent upon the panel that

in place and properl

Main power supply(s) to the unit must still be interrupted at the main power disconnect switch(s) before any service or repair work is to be done to the unit.

Do not rely upon the interlock switch

as a main power disconnect.

Rollout Switch Controls:

the burner assembl partment exceeds its set point, the i valve are de-ener must be reset before operation can continue.

These controls are mounted on

. If the temperature in the burner com-

niter control and the gas

ized. This is a manual reset control and

FIGURE 9 : TYPICAL THERMOSTAT WRIING

WITH COMMERCIAL CONDENSING UNIT

This furnace is equipped with a “Time-On” Delay Relay to protect the belt-drive motor and start rela ates, (1) under continuous fan mode, or (2) when installin twinning kit 2TC03700124. Application of twinning kit also requires use of “Accessor

Sensor Kit 2TS03700106.

if furnace oper-

SAFETY CONTROLS

Blower Door Safety Switch:

electrical interlock switch mounted in the blower compartment. This switch interrupts the 115 volt control power at the unit when the blower door panel is removed..

This unit is equipped with an

The operation of this control indicates a malfunction in the combustion air blower or a blocked vent pipe condition.

Pressure Switch:

pressure switch which monitors the flow throu and ventin control module and the tions are present:

1. Blocka

2. Blocka

3. Failure of combustion air blower / motor.

Limit Controls:

located on the furnace ve stibul e panel ju st to the left and ri of the heat exchan provides over temperature protection due to reduced airflow, such as a dirty filter or a blower motor malfunction.

Control Circuit Fuse:

the 24 volt transformer from overload caused b cuit wirin is located on the furnace control.

errors. This is an ATO-3, automotive type fuse and

This furnace is supplied with a differential

h the furnace

stem. This switch de-energizes the ignition

as valve if any of the following condi-

e of internal flue gas passageways. e of vent piping.

Two hi

h temperature limit controls are

er. This is an automatic reset control and

A 3-amp fuse is provided to protect

control cir-

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035-17443-000 Rev. A (800)

y g

g by

START-UP AND ADJUSTMENTS

The initia l start-up of the fu rnace re quires the follo wing additional procedures.

1. When the the it is recommended that the ened until the odor of detected, immediatel leaks. Allow five minutes for an continuin

2. All electrical connections made in the field and in the factor

IGNITION SYSTEM CHECKOUT / ADJUSTMENT

1. Turn the gas supply ON at external m anual shutoff va lv e and main

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

stem start-up will occur as follows:

3. S a. The venter motor will start and come up to speed.

b. After this warm-up c

Burner ignition may not be satisfactory on first start-

NOTE:

up due to residual air in gas line, or until gas pressure (manifold) is adjusted. The control will make three (3) attempts to light before locking out.

4. With the furnace in operation, paint the pipe joints and valve Bubbles indicate a stop the leaks. If the leak persists, replace the component.

as supply is initially connected to the furnace,

as piping may be full of air . In order to purge this air ,

round joint union be loos-

as is detected. When gas is

retighten the union and check for

as to dissipate before

with the start-up procedure.

should be checked for proper tightness.

as valve.

after venter start-up, the hot surface igniter

Shortl

low for about 17 seconds.

will

cle, the ignition module will

ener

ize (open) the main gas valve for seven sec-

onds.

asket lines with a rich soap and water solution.

as leak. Take appropriate steps to

The accuracy of the gas meter is affected by both the temperature and barometric pressure. Gas meter readin should be ac curate at 60º F and 30.0”h. sure. However, temperatures hi meter to speed up resultin readin

while lower temperatures will result in lower con-

sumption readin

reater than 30” h.g. will slow the meter while a value less

than 30” h. tions, an error of

If weather conditions si the time when the meter correct ion factor can be easil more accurate input rate adjustment. To calculate a meter correction factor, use the following formula:

(Barometric Pressure) x 520

(Temperature + 460) x 30

Using the information from above, calculate the gas input ratin consumed per hour b Btu conten t (heatin localit calculated.

NOTE:

multiplying the number of cubic feet of gas

. Use 1 for a meter correction factor if it was not

Contact your gas company for the actual heating

s. For the barometric pressure, a value

. speeds up the meter. Depending on the condi-

5% is not uncommon.

nificantly differ from these values at

as input rate is being determined, a gas

the meter correction factor and by the

value) of the gas in your particular

her than 60º F will cause the

in a higher gas consumption

= Meter Correction Factor

. barometric pres-

calculated to provide for

value of the gas in your locality as it varies widely from city to city.

Example - Checking Gas Input

It is found b on the 1 cubic foot dial to make a revolution with onl 120,000 Btuh furnace runnin 26 seconds in the first column of Table 5 on pa across to the colum n he ad ed that 138 cubic feet of nace at that rate.

measure that it takes 26 seconds for the hand

. Using this information, locate

e15. Read

1 cubic foot

as per hour are consumed by the fur-

where

ou will see

DO NOT

omit this test! NEVER use a flame to

check for gas leaks.

CHECKING GAS INPUT

1. Turn off all other gas appliances con nec ted to gas meter.

2. With the furnace turned on, meas ure the time needed for one revolution of the hand on the smallest dial on the meter. A t 1 cubic foot test dial.

3. Usin size of the test dial increment, find the cubic feet of consumed per hour from Table 5.

14 Unitar

pical domestic gas meter usually has a 1/2 or

the number of seconds fo r each revol ution and t he

With the barometer at 28.9” and a 70º F temperature, the correction factor will be .945. If the local 935 BTU per cubic foot the calculations will be as follows:

(Gas Rate) x (MCF) x (Heatin (138ft3/hr)(0.945)(935 Btuh/ft3) = 121,933 Btuh

The calculated firin the

+2%

tolerance of our nominal 120,000 furnace.

If the actual input is not within allowance bein

ulator setting (0.3 inches W.C.), replace the orifice spuds

re with spud of the proper size.

rate of 121,933 BTU per hour is within

made for the permissible range of the

Value) = Hourly Input Rate

+2%

as heating value is

of the furnace rating, with

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035-17443-000 Rev. A (800)

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

ADJUSTMENT OF MANIFOLD GAS PRESSURE

1. Turn gas off at main gas valve. Remove 1/8" plug/outlet pressure tap in the main proper manometer tu be adapter fitt in

as valve tap to manometer.

as valve body and install

. Connect line from

FIGURE 10 : GAS VALVES

TOP - WHITE-RODGERS 36F52-252 BOTTOM - HONEYWELL VR8205

TABLE 5: GAS RATE (CUBIC FEET PER HOUR)

ECONDS FOR

EVOLUTION

ONE R

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

IZE OF TEST DIAL

CUBIC FOOT

2. Refer to Fi sure. Tap pressure re on main

The screw-off cap for the pressure regulator must be

NOTE

ure 10 on page 15 for location of outlet pres -

ulator adjustment cap and screw

as valve.

removed entirely to gain access to the adjustment screw.

The cap must be replaced in order for the furnace to operate properly.

3. Turn gas and electrical supplies ON. Turn gas valve switch to “ON” position. Start furnace and observe manifold pressure on manifold.

4. If necessar valve re

, adjust manifold pressure by adjusting gas

ulator screw to agree with Table 6 values.

TABLE 6: MANIFOLD PRESSURE

Natural Gas 3.5" W.C.

Propane (LP) 10.0" W.C.

be necessary to re-adjust the gas valve inl et press ure

It ma (see Table 4 for values) usin the inlet pressure tap on valve - adjust line regulator.

If gas valve regulator is turned in, or clockwise, manifold pressure is increased. If screw is turned out, or counterclockwise, manifold pressure will decrease.

The manifold pressure must be checked with the screw-off cap in place on the pressure regulator.

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.

a similar proced ure but usin

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035-17443-000 Rev. A (800)

5. Once the correct gas pressure to the burners has been established, turn the the electrical suppl sure tap at the compound (on the threads) resistant to the action of LP

ases.

6. Turn the electrical and the burners in operation, check for the plu

with a soap and water solution.

as valve switch to OFF and turn

switch OFF; then, remove the pres-

as valve and re-install the plug using a

as supplies back on, and, with

as leakage around

Be sure that the gas valve pressure regulator cap is replaced.

ADJUSTMENT OF TEMPERATURE RISE

The temperature rise, or temperature difference between the return air and the heated air from the furnace, must be within the range shown on the furnace rating plate and within the application limitat ions s hown in Table 3. After the temperature rise has been determined, the airflow (cfm) can be calculated. Refer to Blower Performance Matrix, Table 7 on pa

22.

6. Repeat the pulle desired temperature rise is obtained.

adjustment procedure until the

ADJUSTMENT OF FAN-OFF CONTROL SETTINGS

This furnace is equipped with a time-on / time-off heating fan control. The fan on dela

is field adjustable from 60 to 180 seconds. The fan off

dela dela

is factory set to 120 seconds.

The “fan-off” settin the furnace, but not so lon heated space. The “fan-off” timin

the jumper (refer to Figure 11 ) located on the con-

tionin trol board.

is fixed at 30 seconds. the fan off

must be long enough to adequately cool

that cold air is blown into the

may be adjusted by posi-

After about 20 minutes of operation, determine the furnace temperature rise. Take readin heated air in the ducts, about six feet from the furnace where

will not be affected by radiant heat.

the Increase the blower speed to decrease the temperature rise;

decrease the blower speed to increase the rise. Blower speed adjustment is made as follows:

1. Remove the belt and loosen the set screw in the adjustable flan

2. Close the pulle the pulle

3. Position the set screw with one of the flats on the pulle hub and ti

4. Ali pulle

e of the motor pulley.

to decrease the temperature rise; open

to increase the rise.

hten it.

n the fixed flange of the motor pulley with the blower

s of both the return air and the

Improper alignment will cause excessive noise, belt wear and bearing failure.

5. Adjust the belt tensio n wi th the motor adjustin the belt can be depressed 1" with a fin

between the two pulleys. Loosen the (4) motor

wa mount bolts to permit adjustment. Reti adjustin

hten bolts after

bolt until

er at a point half-

FIGURE 11 : FAN-OFF TIME ADJUSTMENT

ACCESSORY CONNECTIONS

The furnace control will allow power switching control of various accessories. Refer to Fi

Electronic Air Cleaner Connection:

nals (EAC and EAC N) for electronic air cleaner connections are located on the control board. The terminals provide 115 VAC (1.0 amp maxi mum) durin

Humidifier Connection:

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:

duct s latin before the second blower, the duct s surized wit h air and the se cond blower wi ll be made to t urn backwards. During heating operation, this will cause overheatin condition and dama

When two furnaces are installed using the same

stem, it is very important that the two furnaces circu-

air blowers operate simultaneously. If one blower starts

of the second furnace, possibly causing an unsafe

e to the furnace. If twinning of two fur-

ure 12 for connection details.

Two 1/4" spade termi-

circulating blower operation.

Two 1/4" spade terminals (HUM

stem will become pres-

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naces is desired, it is necessary to use the accessory twinin kit that is designed for use with these furnaces.

This furnace is equipped with a “Time-On” Delay Relay which is required to protect the belt-drive motor/starter if operated (1) under continuous fan mode, or (2) when installin

kit 2TC03700124. Application of twinning kit also

nin requires use of “Accessor

Sensor Kit 2TS03700106.

twin-

FIGURE 12 : ACCESSORY CONNECTIONS

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OPERATION AND MAINTENANCE

SEQUENCE OF OPERATION

The following describes the sequence of operation of the furnace. See “WIRING DIAGRAM” Fi location. Refer to Fi

ure 13 for event schedule.

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 ener selected speed.

ized through the contactor and runs at the

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 coolin minals. The motor is ener runs at the selected speed. The No “On-Dela tin

, a circuit is compl ete d b etwe en the R , Y an d G ter-

ized through the contactor and

is fixed at 60 seconds for SEER enhancement.

HEATING CYCLE

When the system switch is set on HEAT, the fan is set on AUTO, and the room thermostat calls for heat, a circuit is completed between the terminals R and W of the thermostat. When the proper amount of combustion air is bein a pressure switch activates the i

ure 14, for component

” “Fan-Off” set-

provided,

nition control.

After the 60-second wait, the i with an additional 10 seconds of i i

nition attempt is unsuccessful, one more re-try will be

made before lockout. A momentar

or open condition in the flame probe circuit will be sensed within 0.8 seconds.

as valve will de-energize and the control will restart the

The

nition sequence immediately. Recycles will begin and the

i burner will operate normall fault condition is corrected prior to the last i Otherwise, the control will lockout.

The control will repeat the i

cles if flame is lost within the first 10 seconds of

rec establishment.

If flame is esta bli sh ed fo r m ore t han 1 0 seconds after i the control will clear the i flame is lost after 10 seconds, it will restart the i sequence. This can occur a maximum of five times.

Durin millseconds or lon the power is restored, the and a restart of the i

loss of gas supply, flame blowout, or a shorted

burner operation, a momentary loss of power of 50

er will drop out the main gas valve. W h en

nition sequence will begin immediately.

nition sequence is restarted

niter warm-up time. If this

if the gas supply returns, or the

nition attempt.

nition sequence for a total of two

nition,

nition attempt (retry) counter. If

nition

as valve will remain de-energized

HOT SURFACE IGNITION SYSTEM

The ignition control provides a 17-second warm-up period.

as valve then opens for seven seconds.

The As gas starts to flow and ignition occurs, the flame sensor

ins its sensing function. If a flame is detect ed withi n seve n

be seconds after i until the thermostat circuit between R and W is opened. After flamme is present for 30 seconds, the circulatin ener

ized.

When the thermostat circuit opens, the i ener

ized. With the ignition control de-energized, the gas flow stops and the burner flames are extin ventor continues to operate for 15 seconds after the stops.

The blower motor contin ue s to o pera te fo r the a mo unt o f tim e set b

the fan-off del ay switches located o n th e c ontrol board. The heatin the start of the next heatin

If the flame is not detected within the seven second sensin period, the gas valve is de-energized. The control is equipped with a re-tr followin detected).

an unsuccessful ignition attempt (flame not

nition, normal furnace operation continues

blower is

nition control is de-

uished. The

as flow

cle is then complete and the unit is ready for

cle.

option. This provides a 60-second wait

Do not attempt to light this furnace by hand (with a match or any other means). There may be a potential shock ha zar d from the com ponent s of th e hot surface ignition system. The furnace can only be lit automatically by its hot surface ignition system.

MAINTENANCE

AIR FILTERS

The filters should be checked periodically for dirt accumulation. Dirt the s

Clean (or rep lace) th e filter s at least ev er new construction, check the filters ever

filters greatly restrict the flow of air and overburden

stem.

three months. On

week for the first

18 Unitar

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035-17443-000 Rev. A (800)

g ig

four weeks. Inspect the filters every three weeks after that, especiall

if the system is running constantly.

When replacing filters,

DO NOT

use a type with excessively high pressure drop. Some high efficiency filters available will cause the furnace to operate improperly and could result in a safety hazard.

LUBRICATION

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

BLOWER CARE

Even with good filters properly in place, blower wheels and motors will become dust laden after lon tion. The entire blower assembl all

. If the motor an d w h eel ar e he a vi ly coated with dust, the

can be brushed and cleaned with a vacuum cleaner. The procedure for removing the blower assembly for cleanin

is as follows:

should be inspected annu-

months of opera-

BURNER REMOVAL / CLEANING

The main burners should be checked periodically for dirt accumulation.

If cleanin

1. Turn off the electrical power to the unit and turn off

2. Remove the blower and burner compartment access

3. Unplu

4. Note the location and then disconnect the senser and

5. Remo ve the two screws securin

6. To re-assemble - reverse the procedure. Restore power

is required, follow this procedure:

at the shutoff valve.

suppl

doors.

niter from the wire harness and remove the

niter / bracket assembly from the burner air shield.

i Handle the i ken.

rollout switch wires located on the top of the air shield and remove the shield.

burner assembl

ed side down) before removing. Burners may be

(flan cleaned b cleaner.

and verif

niter carefully as it is fragile and easily bro-

each burner to the

. Note the orientation of the burner

rinsing in hot water or by using a vacuum

operation.

1. Turn off electrical power suppl nect switch(s). Remove access doors. Remove motor harness usin

2. Remove the screws holdin blower. Swin removal of the blower.

3. Remove blower/motor assembl and deck screws; Stop and slide the blower assembl out of the slots in the deck.

4. When cleanin NOT remove or chan wheel.

3 wires on panel.

the control box out of the way to allow

or servicing the blower assembly, DO

e the balance clips on the blower

to the furnace at discon-

the control box to the

, shipping screws (2),

This blower motor assembly weighs 90 lbs. Have adequate support to prevent injury.

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

6. To re-assemble, reverse the procedure, restore power and verify operation.

CLEANING THE HEAT EXCHANGER

If heat exchanger is sooted, it is recommended that

NOTE:

the heat exchanger be replaced due to difficulty in cleaning.

Lower Heat Exchanger Access

1. Turn off the electrical power to the unit and turn off at the shutoff valve.

suppl

2. Remove the blower and burner compartment access

doors. Disconnect the gas supply piping at the union to permit removal of the entire burner and assembl on the

3. Unplu

senser and rollout switch wires located on top of the air shield. Identify and note the loc atio n o f al l l ead s for ease of reinstallation. Also disconnect the wires at the side rollout switches (upflow onl

4. Remove the screws holdin

vestibule panel and remove this assembl assembl fra exchan assembl as outlined in burner cleanin

from the vestibule panel. Use the wren ch boss

as valve when removing or installing this piping.

the igniter from the wire harness. Disconnect

) and the gas valve wires.

the burner assembly to the

carefully since it cont ains the igniter which is

ile and easily broken. The lower portion of the heat

er will now be exposed. To clean the burner

, use a vacuum cle aner, or remove the burners

, and clean in hot water.

as control

. Handle the

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Products Group 19

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035-17443-000 Rev. A (800)

Upper Heat Exchanger Access

1. Perform steps 1-4 above.

2. Disconnect vent pipin the top panel on the furnace.

3. Unplu

NOTE:

the venter motor wires and ground wire. Remove the pressure switch tubin housin

It is recommended that replacement gaskets be

from the vent motor assembly at

at the tap on the venter motor

available before removing venter motor.

4. Remove six mounting screws that hold the venter motor to the restr ictor plate. The surface is ket can be reused if it is carefull

to remove this assembly to gain access to the

sar restrictor plate mountin vacuumed if cleanin parts are dama (except for

5. Remove the perimeter screws attachin plate assembl

asketed. The assembly, including the flue baffle

also plate (rear) ma if necessar

6. The upper portion of the heat exchan ble. With a lon tube at both the top and bottom. The brush must pass around the rear heat exchanger tubes. Vacuum loose scale and dirt from each tube.

7. Clean - Replace all components in reverse orde r. Re ket all surfaces which required a

. Reattach vent pipe and gas supply lines before

wirin restorin check operation.

as supply piping for leaks, then verify furnace

ed, replace with an entire new assembly

askets).

to the vestibule panel. The surface is

be vacuumed or cleaned with hot water

flexible wire brush, clean inside each

service to furnace. Restore electrical power,

holes. The assembly may be

is necessary. If any vent assembly

asketed and gas-

removed. It is neces-

the restrictor

er is now accessi-

as-

asket. Reconnect all

TROUBLESHOOTING

The following visual checks should be made before troubleshootin

1. Check to see that the power to the furnace and the igni-

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

3. Make sure all wirin

4. Review the sequence of operation.

Start the s temperature. Observe the s troubleshootin operation.

tion control module is ON.

must be open.

connections are secure.

stem by setting the thermostat above the room

stem's response. Then use the

section in this manual to check the system's

FURNACE CONTROL DIAGNOSTICS

The furnace has a built-in, self diagnostic capability. If a system problem occurs, a fault code is shown b It is loca ted behind a clear view port in t he blower c ompartment 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 continuousl operation of the s cate the failure code. If the fa ilure i s inte rnal to the co ntrol, th e

ht will stay on continuously. In this case, the entire control

li should be replaced as the control is not field repairable.

Flash sequence codes 1 thou 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 b period.

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

Normal flame sense current is approximately

Low flame signal and control lockout point is

CONTINUOUS FLASH: This indicates the 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 suppl blower. This fault would t that leaks throu

2 FLASH: 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

cle. This would indicate a faulty pressure switch or m

heat c is-wirin

3 FLASH: This indicates the normally open pressure switch contact did not close at the be could be caused b blocked vent pipe, broken pressure switch hose or fault pressure swit ch.

4 FLASH: This indicates that a primary or auxiliary limit switch has opened its normall fault code the control will operate the suppl inducer. This condition m a erl incorrect firin

5 FLASH: This fault is indicated if the normall tacts in the rollout switch opens. The rollout control is manually reset. If it has opened, check for proper combustion air, proper inducer operation, primar burner problem. Be sure to reset the switch after correctin the failure condition.

sized duct system, incorrect blower speed setting,

h or is slow closing.

rate or faulty blower motor.

monitors its own operation and the

stem. If a failure occurs, the LED will indi-

h 11 are as follows; LED will

3.7 microamps DC (

0.9 microamps DC (

pically be caused by a gas valve

inning of the heat cycle. This

a number of problems; faulty inducer,

closed contacts. With this

be caused by: dirty filter , im pro p-

heat exchanger f ailure or

a blinking LED.

a 2 second “off”

air blower and

closed con-

air

20 Unitar

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035-17443-000 Rev. A (800)

y g

6 FLASH: This indicates that after the unit was opening, the pressure switch open ed 4 time s d urin main blower is in a “Dela

subsequent delay off period. The ventor continues to

an operate until the pressusre switch re-closes or a call for heat is removed.

7 FLASH: This fault code in dicates that t he flame could not be established. This no-li retries) durin be caused by low gas pressure, faulty gas valve, fau lty hot surface i

8 FLASH: This fault in indicated if the flame is lost 5 times (4 rec

cles) durin the heating cycle. This could be caused b

low gas pressure or faulty gas valve. 9 FLASH: Indicates reversed line volta

and cooling operations will be affected. Check polarity at

in furnace and branch.

11 FLASH: 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 ma also occur in installations when an improper ground is present. Prior to replacin erl

rounded.

STEADY ON: This fault occurs if the when there is no call for heat. If this happens the ventor is energized and will remain energized for 5 seconds or until the fault clears itself at which point the ventor de-ener

the call for heat before locking out. This ma

nitor or burner problem.

On” mode, it will co mplete it and

ht condition occurred 3 times (2

control, verify that the unit is prop-

the call for heat. If the

e polarity. Both heat-

as valve is energized

izes. This

failure is counted as a rec for proper operation.

60 MINUTE AUTOMATIC RESET FROM LOCKOUT: This control includes a “wat chdo lockout condition after 60 minutes. Operational faults 1,6,7,8 and Stead unoccupied structure if a temporar a furnace malfunction. An example would be a low incomin

as supply pressure preventing unit operation. When the gas pressure is restored, at some point the “watchdo restart the unit and provide heat for the house.

NOTE:

On will be reset. This provides protection to an

If a flame is detected, the control flashes the LED for

cle. Check the valve and control

” type circuit that will reset from a

condition exists causin

” would

1/8 of a second and then enters a flame stabilization period.

jumper the pressure switch to allow furnace

Never

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 Part s.

Never adjust pressure switch setpoint to allow furnace operation.

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FIGURE 13 : FURNACE EVENT CONTROL SCHEDULE

035-17443-000 Rev. A (800)

TABLE 7: BLOWER PERFORMANCE CFM -UPFLOW/HORIZONTAL (WITHOUT FILTER)

: Data below reflects airflows with bottom return opening.

Note

MOTOR

VOLTAGE

230 VAC

VOLTAGE

208 VAC

PULLEY

TURNS

Closed 1 Open 3820 3687 3550 3406 3240 3066 2846 2589 2 Open 3575 3433 3269 3096 2913 2700 2449 3 Open 3375 3205 2996 2807 2585 2293 4 Open 2805 2715 2570 2351 2017

MOTOR

PULLEY

TURNS

Closed 1 Open 3674 3555 3423 3283 3144 2990 2789 2555 2 Open 3543 3379 3213 3055 2888 2673 2420 3 Open 3375 3210 3035 2850 2633 2334 4 Open 3100 2919 2708 2498 2226

0.30 0. 40 0.50 0.60 0.70 0.80 0.90

++ + +

0.30 0. 40 0.50 0.60 0.70 0.80 0.90

++ + +

Operation at these conditions will cause motor overload.

Operation in the shaded area ma

NOTES:

Airflow is expressed in standard cubic feet per minute.

EXTERNAL STATIC PRESSURE, INCHES W.C.

3467 3318 3163 2950

1307 -- --

EXTERNAL STATIC PRESSURE, INCHES W.C.

3383 3242 3100 2890

1724 -- --

cause excessive furnace temperature rise.

1.00

2049

1860 1026

1.00

1804

1889 --

22 Unitar

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035-17443-000 Rev. A (800)

FILTER PERFORMANCE The airflow capacit

data published in Table 7 represents blower performance WITHOUT filters. To determine the approximate blower performance of the s ter drop value for the filter bein

used or select an appropri-

stem, apply the fil-

The filter drop valu es in Table 8 are t of filter listed and should onl pressure drop ratin

s for each filter type vary between filter

be used as a gu ideline. Actual

manufacturer.

pical values for the type

ate value from Table 8.

TABLE 8: FILTER PERFORMANCE - PRESSURE DROP INCHES W.C.

FIL TE R TYPE - BELT DRIVE FURNACE BOTTOM RETURN

FIBERGLASS PLEATED

Hogs Hair

Air Flow Range

(SCFM) 1500-2300 0.05 0.05 0.05 0.05 2300-2800 0.10 0.075 0.10 0.10 2800-3100 0.20 0.10 0.15 0,15 3100-3500 0.25 0.20 0.20 0.20

1” THICK 1” THICK 2” THICK 4” THICK

Note: Data includes pressure drop of bottom filter rack.

APPLYING FILTER PRESSURE DROP TO DETERMINE SYSTEM AIRFLOW

To determi ne t he a pproximate airflow of the un it w i th a fil ter i n place, follow the steps below:

1. Select the filter t

2. Determine the External S

pe.

stem Static Pressure (ESP)

without the filter.

3. Select a filter pressure drop from the table and add to the ESP from Step 3 to determine the total s

stem static.

High Velocity Disposable High Velocity

3. Subtract the total s difference b

0.60”-0.50”, to obtain a percenta

stem static from 0.50” and divide this

the difference in ESP values in the table,

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

4. Multipl

percentage by airflow differenc e to obtain airflow

reduction. (0.8) x -144) = -115

Subtract airflow reduction value to airflow @0.50” to obtain actual airflow @0.58” ESP.

3550 - 115 = 3435

4. If total s flow table (i.e., 0.20, 0.60, etc.) the s

stem static measures an ESP value in the air-

stem airflow corresponds to the intersection of the ESP c olumn and Blower Speed row.

5. If the total s in the table (i.e., 0.58, 0.75, etc.) the stati c pressure ma be rounded to the nearest value in the table determinin the airflow usin the followin

Example: It is fouond that the total s

1-turn pulley. To determine the system airflow, com-

usin plete the f ollowin

stem static falls between ESP ESP values

Step 5 or calculate the airflow by using

example.

stem stati c is 0 .58” w.c.

steps:

1. Ob tain the airflow v alues at 0.50” and 0.60” ESP.

Airflow @ 0.50”: 3550 CFM Airflow@0.60”: 3406 CFM

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

3406 - 3550 = -144

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Products Group 23

Page 24

FIGURE 14 : WIRING DIAGRAM

NOTE:

The furnace’s control s

stem depends on correct polarity of the power supply.

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