Unitary products group PV9, FL9V, FC9V Installation Manual
INSTALLATION MANUAL
HIGH EFFICIENCY
TUBULAR HEAT EXCHANGER SERIES
MODELS: PV9 / FC9V / FL9V
(Two Stage Variable Speed Upflow)
40 - 120 MBH INPUT
(11.7 - 35.1 KW) INPUT
TABLE OF CONTENTS
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LIST OF FIGURES
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Furnace Base Rectangular Blockoff Panel . . . . . . . . . . . . . . . . . . . . . 6
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Line Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Single Stage Heat Thermostat Connections . . . . . . . . . . . . . . . . . . . . 9
Single Stage Heating and Two-Stage Cooling
Thermostat Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Two Stage Heating and Two-Stage Cooling Thermostat Connections 9
Accessory Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Home Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Termination Configuration - 1 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Termination Configuration - 2 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Termination Configuration - 2 Pipe Basement . . . . . . . . . . . . . . . . . .12
EFFICIENCY
RATING
CERTIFIED
This product was manufactured
in a plant whose quality system
is certified/registered as being
in conformity with ISO 9001.
COMBUSTION AIR AND VENT SYSTEM . . . . . . . . . . . . . . . . . . . . . .9
CONDENSATE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . .17
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Double Horizontal Sealed Combustion Air and Vent Termination . . .13
Double Vertical Sealed Combustion Air and Vent Termination . . . . .13
External Horizontal Vent Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Sealed Combustion Air Intake Connection and Vent Connection . . .13
Combustion Airflow Path Through The Furnace Casing to the Burner
Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Outside and Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . .15
Attic and Crawl Space Combustion Air Termination . . . . . . . . . . . . . .16
Condensate Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Pressure Switch Tube Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Furnace Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
CFM / Timer Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
LIST OF TABLES
Unit Clearances to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Minimum Duct Sizing For Proper Airflow . . . . . . . . . . . . . . . . . . . . . . . 4
Round Duct Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Filter Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
High Altitude Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electrical and Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Combustion Air Intake and Vent Connection Size at Furnace
(All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
SECTION I: SAFETY
This is a safety alert symbol. When you see this symbol on
labels or in manuals, be alert to the potential for personal
injury.
Understand and pay particular attention to the signal words DANGER,
WARNING, or CAUTION.
DANGER indicates an imminently hazardous situation, which, if not
avoided, will result in death or serious injury
WARNING indicates a potentially hazardous situation, which, if not
avoided, could result in death or serious injury
CAUTION indicates a potentially hazardous situation, which, if not
avoided may result in minor or mo derate injury.
alert against unsafe practices and hazards involving only property damage.
.
.
It is also used to
Combustion Air Supply and Vent Piping . . . . . . . . . . . . . . . . . . . . . . .10
Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Unconfined Space Minimum Area in Square Inch . . . . . . . . . . . . . . .14
Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Air Flow Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Filter Performance - Pressure Drop Inches W.C. and (kPa) . . . . . . . .23
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 for additional information, consult a qualified contractor, installer or service agency.
This product must be installed in strict compliance with the installation instructions and any applicable local, state, and national codes
including, but not limited to building, electrical, and mechanical
codes.
035-20499-001 Rev. B (1004)
035-20499-001 Rev. B (1004)
SPECIFIC SAFETY RULES AND PRECAUTIONS
1. Only Natural gas or Propane (LP) gas are approved for use with
this furnace. Refer to the furnace rating plate or Section IV of
these instructions.
2. Install this furnace only in a location and position as specified in
SECTION I of these instructions.
3. A gas-fired furnace for installation in a residential garage must be
installed as specified in SECTION I of these instructions.
4. Provide adequate combustion and ventilation air to the furnace
space as specified in SECTION VI of these instructions.
5. Combustion products must be discharged outdoors. Connect this
furnace to an approved vent system only, as specified in SECTION VI of these instructions.
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warnings exactly could result in serious
injury, death or property damage.
Never test for gas leaks with an open flame. Use a commercially
available soap solution made specifically for detection of leaks to
check all connections. A fire or explosion may result causing property damage, personal injury or loss of life.
6. Tests for gas leaks as specified in SECTION IX of these instructions.
7. Always install the furnace to operate within the furnace’s intended
temperature rise range. Only connect the furnace to a duct system
which has an external static pressure within the allowable range,
as specified on the furnace rating plate.
8. When a furnace is installed so that supply ducts carry air circulated
by the furnace to areas outside the space containing the furnace,
the return air shall also be handled by duct(s) sealed to the furnace casing and terminating outside the space containing the furnace.
9. The furnace is not to be used for temporary heating of buildings or
structures under construction.
10. When installed in a Non-HUD-Approved Modular Home or building
constructed on-site, combustion air shall not be supplied from
occupied spaces.
11. The size of the unit should be based on an acceptable heat loss
calculation for the structure. ACCA, Manual J or other approved
methods may be used.
SAFETY REQUIREMENTS
• This furnace should be installed in accordance with all national
and local building/safety codes and requirements, local plumbing
or wastewater codes, and other applicable codes. In the absence
of local codes, install in accordance with the National Fuel Gas
Code ANSI Z223.1/NFPA 54, National Fuel Gas Code, and/or
CAN/CGA B149.1 Natural Gas and Propane Installation Code
(latest editions). Furnaces have been certified to the latest edition
of standard ANSI Z21-47 • CSA 2.3.
• Refer to the unit rating plate for the furnace model number, and
then see the dimensions page of this instruction for return air plenum dimensions in Figure 1. The plenum must be installed
according to the instructions.
• Provide clearances from combustible materials as listed under
Clearances to Combustibles.
• Provide clearances for servicing ensuring that service access is
allowed for both the burners and blower.
• These models ARE NOT
into a HUD Approved Modular Home
(Mobile) Home.
• This furnace is not approved for installation in trailers or recreational vehicles.
• Failure to carefully read and follow all instructions in this
manual can result in furnace malfunction, death, personal
injury and/or property damage.
• Furnaces for installation on combustible flooring shall not be
installed directly on carpeting, tile or other combustible material
other than wood flooring.
• Check the rating plate and power supply to be sure that the electrical characteristics match. All models use nominal 115 VAC, 1
Phase, 60-Hertz power supply. DO NOT CONNECT THIS APPLIANCE TO A 50 HZ POWER SUPPLY OR A VOLTAGE ABOVE
130 VOLTS.
• Furnace shall be installed so the electrical components are protected from water.
• Installing and servicing heating equipment can be hazardous due
to the electrical components and the gas fired components. Only
trained and qualified personnel should install, repair, or service
gas heating equipment. Untrained service personnel can perform
basic maintenance functions such as cleaning and replacing the
air filters. When working on heating equipment, observe precautions in the manuals and on the labels attached to the unit and
other safety precautions that may apply.
• These instructions cover minimum requirements and conform to
existing national standards and safety codes. In some instances
these instructions exceed certain local codes and ordinances,
especially those who have not kept up with changing residential
and non-HUD modular home construction practices. These
instructions are required as a minimum for a safe installation.
CSA listed or approved for installation
or a Manufactured
COMBUSTION AIR QUALITY
(LIST OF CONTAMINANTS)
The furnace will require OUTDOOR AIR for combustion when the furnace is located in any of the following environments.
• Restricted Environments
• Commercial buildings
• Buildings with indoor pools
• Furnaces installed in laundry rooms
• Furnaces installed in hobby or craft rooms
• Furnaces installed near chemical storage areas
• Chemical Exposure
The furnace will require OUTDOOR AIR for combustion when the furnace is located in an area where the furnace is being exposed to the following substances and / or chemicals.
• Permanent wave solutions
• Chlorinated waxes and cleaners
• Chlorine based swimming pool chemicals
• Water softening chemicals
• De-icing salts or chemicals
• Carbon tetrachloride
• Halogen type refrigerants
• Cleaning solvents (such as perchloroethylene)
• Printing inks, paint removers, varnishes, etc.
• Hydrochloric acid
• Cements and glues
• Antistatic fabric softeners for clothes dryers
• Masonry acid washing materials
When outdoor air is used for combustion, the combustion air intake pipe
termination must be located external to the building and in an area
where there will be no exposure to the substances listed above.
2 Unitary Products Group
035-20499-001 Rev. B (1004)
Installation in freezing temperatures:
1. Furnace shall be installed in an area where ventilation facilities
The furnace area must not be used as a broom closet or for any
other storage purposes, as a fire hazard may be created. Never
store items such as the following on, near or in contact with the 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.
INSPECTION
As soon as a unit is received, it should be inspected for 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 shipping or spacer brackets
which need to be removed.
FURNACE LOCATION AND CLEARANCES
The furnace shall be located using the following 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 the appliance is not using outdoor combustion air).
4. Where it will not interfere with proper air circulation in the confined
space.
5. Where the outdoor combustion air/vent terminal will not be blocked
or restricted. Refer to “COMBUSTION AIR / VENT CLEARANCES” located in SECTION VI of these instructions. These minimum clearances must be maintained in the installation.
6. Where the unit will be installed in a level position with no more
than 1/4” (6.4 mm) slope side-to-side and front-to-back to provide
proper condensate drainage.
TABLE 1:
APPLICATION
Unit Clearances to Combustibles
TOP FRONT REAR LEFT SIDE RIGHT SIDE FLUE
In. (mm) In. (mm) In. (mm) In. (mm) In. (mm) In. (mm)
UPFLOW 1 (25.4) 3 0 (0) 0 (0) 0 (0) 0 (0) COMBUSTIBLE YES YES
provide for safe limits of ambient temperature under normal operating conditions. Ambient temperatures must not fall below 32°F
(0°C) unless the condensate system is protected from freezing.
2. Do not allow return air temperature to be below 55º F (13° C) for
extended periods. To do so may cause condensation to occur in
the main heat exchanger, leading tp premature heat exchanger
failure.
Improper installation in an ambient below 32ºF (0.0° C) could create
a hazard, resulting in damage, injury or death.
3. If this furnace is installed in any area where the ambient temperature may drop below 32° F (0° C), a UL listed self-regulated heat
tape must be installed on any condensate drain lines. It is required
that self regulating heat tape rated at 3 watts per foot be used.
This must be installed 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, Armaflex or other heat resistant insulating material.
4. 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 unit until inspection and
repairs are performed.
Clearances for access:
Ample clearances should be provided to permit easy access to the unit.
The following minimum clearances are recommended:
1. Twenty-four (24) inches (61 cm) between the front of the furnace
and an adjacent wall or another appliance, when access is
required for servicing and cleaning.
2. Eighteen (18) inches (46 cm) at the side where access is required
for passage to the front when servicing or for inspection or
replacement of flue/vent connections.
In all cases, accessibility clearances shall take precedence over clearances for combustible materials where accessibility clearances are
greater.
Installation in a residential garage:
1. A gas-fired furnace for installation in a residential garage must be
installed so the burner(s) and the ignition source are located not
less than 18 inches (46 cm) above the floor, and the furnace must
be located or protected to avoid physical damage by vehicles.
FLOOR/
BOTTOM
CLOSET
ALCOVE
ATTIC
SECTION II: DUCTWORK
DUCTWORK GENERAL INFORMATION
The duct system’s design and installation must:
1. Handle an air volume appropriate for the served space and within
the operating parameters of the furnace specifications.
2. Be installed in accordance with standards of NFPA (National Fire
Protection Association) as outlined in NFPA pamphlets 90A and
90B (latest editions) or applicable national, provincial, or state, and
local fire and safety codes.
3. Create a closed duct system. For residential and Non-HUD Modular Home installations, when a furnace is installed so that the supply ducts carry air circulated by the furnace to areas outside the
space containing the furnace, the return air shall also be handled
by a duct(s) sealed to the furnace casing and terminating outside
the space containing the furnace.
Unitary Products Group 3
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 may not be passed over the heat
exchanger.
When the furnace is used in conjunction with a cooling coil, the coil
must be installed parallel with, or in the supply air side of the furnace to
avoid condensation in the primary heat exchanger. When a parallel flow
arrangement is used, dampers or other means used to control airflow
must be adequate to prevent chilled air from entering the furnace. If
manually operated, the damper must be equipped with means to prevent the furnace or the air conditioner from operating unless the damper
is in full heat or cool position.
035-20499-001 Rev. B (1004)
The duct system is a very important part of the installation. If the duct
system is improperly sized the furnace will not operate properly.
The ducts attached to the furnace plenum, should be of sufficient size
The duct system must be properly sized to obtain the correct airflow
for the furnace size that is being installed.
Refer to Table 7 and the furnace rating plate for the correct rise
range and static pressures
If the ducts are undersized, the result will be high duct static pressures and/or high temperature rises which can result in a heat
exchanger OVERHEATING CONDITION. This condition can result
in premature heat exchanger failure, which can result in personal
injury, property damage, or death.
DUCTWORK INSTALLATION AND 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 metal plenum is used. The use of an
approved flexible duct connector is recommended on all
installations. This connection should be sealed to prevent
air leakage. The sheet metal should be crosshatched to
eliminate any popping of the sheet metal when the indoor
fan is energized.
When replacing an existing furnace, if the existing plenum is not the
same size as the new furnace then the existing plenum must be
removed and a new plenum installed that is the proper size for the new
furnace. The minimum plenum height is 12” (30 cm). If the plenum is
shorter than 12” (30 cm) the turbulent air flow may cause the limit controls not to operate as designed, or the limit controls may not operate at
all.
TABLE 2:
40,000 (17.58) 1,200 (33.98) 280 (711) 14 x 20 (35.6 x 50.8) 18 (45.7) 216 (549) 12 x 18 (30.5 x 45.7) 16 (40.6)
60,000 (17.58) 1,200 (33.98) 280 (711) 14 x 20 (35.6 x 50.8) 18 (45.7) 216 (549) 12 x 18 (30.5 x 45.7) 16 (40.6)
80,000 (23.44) 1,200 (33.98) 280 (711) 14 x 20 (35.6 x 50.8) 18 (45.7) 216 (549) 12 x 18 (30.5 x 45.7) 16 (40.6)
80,000 (23.44) 1,600 (45.31) 360 (914) 18 x 20 (45.7 x 50.8) 22 (55.8) 280 (711) 14 x 20 (35.6 x 50.8) 18 (45.7)
100,000 (29.31) 2,000 (56.63) 440 (1,118) 20 x 22 (50.8 x 55.8) 24 (60.9) 390 (991) 16 x 22 (40.6 x 55.8) 22 (55.8)
120,000 (35.17) 2,000 (56.63) 440 (1,118) 20 x 22 (50.8 x 55.8) 24 (60.9) 390 (991) 16 x 22 (40.6 x 55.8) 22 (55.8)
NOTE: This chart does not replace proper duct sizing calculations or take into account static pressure drop for run length and fittings. Watch out for the temperature rise and static pressures.
1. Maximum return air velocity in rigid duct @ 700 feet per minute (19.82 m3 / minute).
2. Example return main trunk duct minimum dimensions.
3. Maximum supply air velocity in rigid duct @ 900 feet per minute (25.49 m
TABLE 3:
1. The Air Temperature Rise is determined by subtracting the Return
2. The External Static Pressure is determined by adding the Supply
Minimum Duct Sizing For Proper Airflow
Input Airflow
BTU/H (kW) CFM (m³) In² (cm²) in. x in. (cm x cm) in. (cm) dia. In² (cm²) in. x in. (cm x cm) in. (cm) dia.
Return
1
Rectangular
3
/ minute).
2
Round Duct Size
Round Duct Size Calculated Area For Each Round Duct Size
inches (cm)
5 (13) 19.6 (126)
6 (15) 28.2 (182)
7 (18) 38.4 (248)
8 (20) 50.2 (324)
9 (23) 63.6 (410)
10 (25) 78.5 (506)
11 (28) 95 (613)
12 (30) 113.1 (730)
13 (33) 132.7 (856)
14 (36) 153.9 (993)
Sq.in (cm
2
)
Air Temperature Reading from the Supply Air Temperature Reading.
Duct Static Pressure reading to the Return Duct Static Pressure
reading and adding the pressure drop across any applied coil.
so that the furnace operates at the specified external static pressure
and within the air temperature rise specified on the nameplate.
Table 2 is a guide for determining whether the rectangular duct system
that the furnace is being connected to be of sufficient size for proper furnace operation.
Use the Example below to help you in calculating the duct area to determine whether the ducts have sufficient area so that the furnace operates at the specified external static pressure and within the air
temperature rise specified on the nameplate.
Example: The furnace input is 80,000 BTUH, The recommended duct
area is 248 sq.in, there are two 8 x 12 rectangular ducts attached to the
plenum and there are two 7 inch round ducts attached to the furnace.
1. Take 8 x 14, which equals 112 sq.in. X 2, which equals 224 square
inch then go to round duct size located in Table 3.
2. The square inch area for 7 inch round pipe is 38.4, multiply by 2 for
two round ducts which equals 76.8 square inch,
3. Then take the 224 square inch from the rectangular duct and add it
to the 76.8 sq.in. of round duct. The total square inch of duct
attached to the furnace plenum is 300.8 square inch. This exceeds
the recommended 280 square inch of duct.
In this example, the duct system attached to the plenum has a sufficient
area so that the furnace operates at the specified external static pressure and within the air temperature rise specified on the nameplate.
Round
2
Supply
3
Rectangular
2
Round
TABLES 2 AND 3 are to be used as a guide only to help the installer
determine if the duct sizes are large enough to obtain the proper air flow
(CFM) through the furnace. TABLES 2 and 3 ARE NOT to be used to
design ductwork for the building where the furnace is being installed.
There are several variables associated with proper duct sizing that are
not included in the tables. To properly design the ductwork for the building, Refer to the ASHRAE Fundamentals Handbook, Chapter on
“DUCT DESIGN” or a company that specializes in Residential and Modular Home duct designs.
IMPORTANT: The minimum plenum height is 12” (30 cm). The furnace
will not operate properly on a shorter plenum height. The minimum recommended rectangular duct height is 4” (10 cm) attached to the plenum.
IMPORTANT: The air temperature rise should be taken only after the
furnace has been operating for at least 15 minutes. Temperatures and
external static pressures should be taken 6” (15 cm) past the first bend
from the furnace in the supply duct and the return duct. If an external filter box or an electronic air cleaner is installed, take the return air readings before the filter box or air cleaner.
2
4 Unitary Products Group
The supply air temperature MUST NEVER exceed the Maximum
Supply Air Temperature, specified on the nameplate.
Operating the furnace above the maximum supply air temperature
will cause the heat exchanger to overheat, causing premature heat
exchanger failure. Improper duct sizing, dirty air filters, incorrect
manifold pressure, incorrect gas orifice and/or a faulty limit switch
can cause the furnace to operate above the maximum supply air
temperature. Refer to sections II and III for additional information on
correcting the problem.
035-20499-001 Rev. B (1004)
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.
26-1/2
24-5/8
1-1/2” GAS
PIPE ENTRY
7/8” JUNCTION
BOX HOLE
T-STAT WIRING
7/8” K.O.
CONDENSATE
DRAIN 7/8” K.O.
OPTIONAL RETURN AIR
CUT-OUT (either side)
FOR USE WITH
EXTERNAL FILTER
FRAME
7/8
LEFT SIDE
23-3/4
30-1/8
21-1/2
13-7/8
11
7
7/8
26-3/4
BOTTOM IMAGE
RETURN END
30-7/8
1-3/8
C
1-1/4
1-3/4
A
FRONT
D
40
24-3/8
20
26-1/2
TOP IMAGE
SUPPLY END
28-3/8
21-1/2
5/8
11
8
5/8
B
26-1/2
25-3/8
1-1/2” GAS
PIPE ENTRY
7/8” JUNCTION
BOX HOLE
T-STAT WIRING
7/8” K.O.
CONDENSATE
DRAIN 7/8” K.O.
RIGHT SIDE
FIGURE 1: Dimensions
BTUH (kW)
Input/Output
m
CFM
3
/min)
Cabinet
Size
A (in.) A (cm) B (in.) B (cm) C (in.) C (cm) D (in.) D (c m)
Cabinet Dimension Air Intake
40/38 (11.7/10.8) 1200 (33.98) A 14-1/2 36.8 13-1/4 33.7 12-1/8 30.8 6-1/4 15.9
60/56 (17.8/16.4) 1200 (33.98) B 17-1/2 44.4 16-1/4 41.3 15-1/8 38.4 8-1/2 21.6
80/75 (12.4/21.96) 1200 (33.98) B 17-1/2 44.4 16-1/4 41.3 15-1/8 38.4 8-1/2 21.6
80/75 (23.42/21.96) 1600 (45.31) C 21 53.3 19-3/4 50.2 18-1/2 47.0 8-7/8 22.5
100/93 (29.28/27.25) 2000 (56.63) C 21 53.3 19-3/4 50.2 18-1/2 47.0 8-7/8 22.5
120/112 (35.14/32.80) 2000 (56.63) D 24-1/2 62.2 23-1/4 59.4 21-7/8 55.6 10-5/8 27.0
RESIDENTIAL AND NON HUD MODULAR HOME
RETURN PLENUM CONNECTION
Return air may enter the furnace through the side(s) or bottom depending on the type of application. Return air may not be connected into the
rear panel of the unit. In order to achieve the airflow indicated, it is recommended those applications over 1800 CFM (57 m³/min) 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.
BOTTOM RETURN AND ATTIC INSTALLATIONS
Bottom return applications normally pull return air through a base platform or return air plenum. Be sure the return platform structure or return
air plenum is suitable to support the weight of the furnace.
Unitary Products Group 5
The furnace base is equipped with a rectangular blockoff panel that can
be removed by performing the following steps:
1. Lay the furnace on its back.
2. Remove the toe plate. See Figure 2.
3. Slide the blockoff panel out and then replace the toe plate.
4. Bend the 3/4” flanges that will be used to attach the return air ple-
num using the scribe marks in the furnace base. Refer to Figure 1
“Bottom Image Return End”.
5. Be sure to seal the furnace to plenum connections to prevent air
leakage. Refer to Figure 1 for unit and plenum dimensions.
Attic installations must meet all minimum clearances to combustibles
and have floor support with required service accessibility.
035-20499-001 Rev. B (1004)
Removable Rectangular
Base Panel.
Toe Plate
FIGURE 2: Furnace Base Rectangular Blockoff Panel
IMPORTANT: If an external mounted filter rack is being used see the
instructions provided with that accessory for proper hole cut size.
SECTION III: FILTERS
FILTER INSTALLATION
All applications require the use of a filter. A high velocity filter and a side
return filter rack are provided for field installation. Replacement filter
size is shown in Table 4.
Filters must be installed external to the furnace cabinet. DO NOT
attempt to install filters inside the furnace.
TABLE 4:
Input / Output
BTU/H (kW)
40/38/1200
60/56/1200
(17.57/16.40)
80/75/1200
(23.42/21.96)
80/75/1600
(23.42/21.96)
100/93/2000
(29.28/27.25)
120/112/2000
(35.14/32.80)
SIDE RETURN - FILTER INSTALLATION
Locate and mark the side return opening. Refer to Figure 1 for dimensions of the cutout.
Install the side filter rack following the instructions provided with that
accessory. If a filter(s) is provided at another location in the return air
system, the ductwork may be directly attached to the furnace side
panel.If not provided with the furnace, an accessory filter rack is available for mounting the filter external to the cabinet.
IMPORTANT: Some accessories such as electronic air cleaners and
pleated media may require a larger side opening. Follow the instructions supplied with that accessory for side opening requirements. Do
not cut the opening larger than the dimensions shown in Figure 1.
All installations must have a filter installed.
Filter Sizes
(11.7/10.8)
(m
CFM
3
/min)
1200
(34)
1200
(34)
1200
(34)
1600
(45)
2000
(57)
2000
(57)
Cabinet
Size
A
B
B
C
C
D
Side Return
Filter in. (cm)
16 x 25
(41 x 64)
16 x 25
(41 x 64)
16 x 25
(41 x 64)
16 x 25
(41 x 64)
16 x 25
(41 x 64)
(2) 16 x 25
(2) (41 x 64)
Bottom Return
Filter in. (cm)
14 x 25
(36 x 64)
16 x 25
(41 x 64)
16 x 25
(41 x 64)
20 x 25
(51 x 64)
20 x 25
(51 x 64)
22 x 25
(56 x 64)
SECTION IV: GAS PIPING
GAS SAFETY
An overpressure protection device, such as a pressure regulator,
must be installed in the gas piping system upstream of the furnace
and must act to limit the downstream pressure to the gas valve so it
does not exceed 0.5 PSI (14" w.c. (3.48 kPa). Pressures exceeding
0.5 PSI (14” w.c. (3.48 kPa) at the gas valve will cause damage to
the gas valve, resulting in a fire or explosion or cause damage to
the furnace or some of its components that will result in property
damage and loss of life.
HIGH STAGE REGULATOR
OUTLET
PRESSURE
PORT
INLET
WRENCH
BOSS
INLET
PRESSURE
PORT
FIGURE 3: Gas Valve
IMPORTANT: Plan your gas supply before 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.
CHECKING THE GAS PRESSURES
1. The pressure ports on the gas valve are marked OUT P and IN
P.
2. The manifold pressure must be taken at the port marked OUT P.
3. The inlet gas supply pressure must be taken at the port marked
IN P.
4. Using a 3/32” (0.2 cm) Allen wrench, loosen the set screw by
turning it 1 turn counter clockwise. DO NOT REMOVE THE
SET SCREW FROM THE PRESSURE PORT.
5. Push one end the 3/8” (0.9 cm) ID flexible tubing over the pressure port so that the body of the port is inside the tubing.
6. Use a reducer connector to connect the 3/8” (0.9 cm) ID flexible
tube to a 1/4” (0.6 cm) ID flexible tube that is connected to a "U”
tube manometer or digital pressure measuring equipment.
TABLE 5:
IMPORTANT: The inlet gas pressure operating range table specifies
what the minimum and maximum gas line pressures must be for the
furnace to operate safely. The gas line pressure MUST BE
in order to obtain the BTU input specified on the rating plate and/or
the nominal manifold pressure specified in these instructions and on
the rating plate.
Inlet Gas Pressure Range
INLET GAS PRESSURE RANGE
Minimum 4.5” W.C. (1.12 kPa) 8.0” W.C. (1.99 kPa)
Maximum 10.5” W.C. (2.61 kPa) 13.0” (3.24 kPa) W.C.
• 7” W.C. (1.74 kPA) for Natural Gas
• 11” W.C. (2.74 kPA) for Propane (LP) Gas
ADJUSTMENT
ON OFF
SWITCH
Natural Gas Propane (LP)
LOW STAGE REGULATOR
ADJUSTMENT
VENT
PORT
OUTLET
6 Unitary Products Group
035-20499-001 Rev. B (1004)
GAS PIPING INSTALLATION
Properly sized wrought iron, approved flexible or steel pipe must be
used when making gas connections to the unit. If local codes allow the
use of a flexible gas appliance connection, always use a new listed connector. Do not use a connector that has previously serviced another gas
appliance.
Some utility companies or local codes require pipe sizes larger than the
minimum sizes listed in these instructions and in the codes. The furnace
rating plate and the instructions in this section specify the type of gas
approved for this furnace - only use those approved gases. The installation of a drip leg and ground union is required. Refer to Figure 4.
EXTERNAL MANUAL
SHUTOFF VALVE
TO GAS
SUPPLY
DRIP
LEG
GROUNDED JOINT UNION
MAY BE INSTALLED
INSIDE OR OUTSIDE UNIT.
FIGURE 4: Gas Piping
IMPORTANT: An accessible manual shutoff valve must be installed
upstream of the furnace gas controls and within 6 feet (1.8 m) of the furnace.
The furnace must be isolated from the gas supply piping system by
closing its individual external manual shutoff valve during any pressure
testing of the gas supply piping system at pressures equal to or less
than 1/2 psig (3.5 kPa).
TO GAS
SUPPLY
The gas orifices on this furnace must be changed in order to maintain
proper and safe operation, when the furnace is installed in a location
where the altitude is greater than 2,000 ft. (610 m) above sea level on
natural gas or the altitude is greater than 4,000 ft. (1219 m) above sea
level on propane (LP) gas. Refer to Table 6 or the instructions in the
high altitude conversion kit for the proper gas orifice size.
The unit may also be converted for altitudes up to 10,000 ft. (3048 m)
on natural and propane (LP) gas with additional derate as shown in
Table 6 or refer to ANSI Z223.1 NFPA 54 National Fuel Gas Code or in
Canada CAN/CGA-B149.1-00 Natural Gas and Propane Installation
Code.
HIGH ALTITUDE PRESSURE SWITCH CONVERSION
For installation in locations where the altitude is less than 4,500 feet
(1372 m), it is not required that the pressure switch be changed, provided the maximum vent/intake pipe lengths are adjusted as shown in
the notes to Table 9. For altitudes above 4,500 feet (137 m), refer to
Instructions in the Accessory High Altitude Kit.
TABLE 6:
High Altitude Conversion
Type
Of Gas
Natural #45 #46 #47 #47
Propane #55 #55 #55 #55
Type
Of Gas
Natural #47 #48 #48 #49
Propane #56 #56 #56 #56
Type
Of Gas
Natural #49 #50
Propane #56 #57
Orifice at
Sea Level
5,000 ft.
(1524 m)
9,000 ft.
(2743 m)
2,000 ft.
(610 m)
6,000 ft.
(1829 m)
10,000 ft.
(3048 m)
3,000 ft.
(914 m)
7,000 ft.
(2134 m)
4,000 ft.
(1219 m)
8,000 ft.
(2438 m)
The gas valve body is a very thin casting that cannot take any
external pressure. Never apply a pipe wrench to the body of the gas
valve when installing piping. A wrench must be placed on the octagon hub located on the gas inlet side of the valve. Placing a wrench
to the body of the gas valve will damage the valve causing improper
operation and/or the valve to leak.
Gas piping may be connected from either side of the furnace using any
of the gas pipe entry knockouts on both sides of the furnace. Refer to
Figure 1 dimensions.
The inlet to the gas valve lines up directly with the opening in the left
side of the furnace casing. To line up with the opening in the right side
of the casing, two street ells should be used.
GAS ORIFICE CONVERSION FOR PROPANE (LP)
This furnace is constructed at the factory for natural gas-fired operation,
but may be converted to operate on propane (LP) gas by using a factory-supplied LP conversion kit. Follow the instructions supplied with
the LP kit. Refer to Table 6 or the instructions in the propane (LP) conversion kit for the proper gas orifice size.
HIGH ALTITUDE GAS ORIFICE CONVERSION
This furnace is constructed at the factory for natural gas-fired operation
at 0 – 2,000 ft. (0 m – 610 m) above sea level.
PROPANE AND HIGH ALTITUDE CONVERSION KITS
It is very important to choose the correct kit and/or gas orifices for
the altitude and the type of gas for which the furnace is being
installed.
Only use natural gas in furnaces designed for natural gas. Only use
propane (LP) gas for furnaces that have been properly converted to
use propane (LP) gas. Do not use this furnace with butane gas.
Incorrect gas orifices or a furnace that has been improperly converted will create an extremely dangerous condition resulting in premature heat exchanger failure, excessive sooting, high levels of
carbon monoxide, personal injury, property damage, a fire hazard
and/or death.
High altitude and propane (LP) conversions are required in order
for the appliance to satisfactory meet the application.
An authorized distributor or dealer must make all gas conversions.
In Canada, a certified conversion station or other qualified agency,
using factory specified and/or approved parts, must perform the
conversion.
The installer must take every precaution to insure that the furnace
has been converted to the proper gas orifice size when the furnace
is installed. Do not attempt to drill out any orifices to obtain the
proper orifice size. Drilling out a gas orifice will cause misalignment
of the burner flames, causing premature heat exchanger burnout,
high levels of carbon monoxide, excessive sooting, a fire hazard,
personal injury, property damage and/or death.
Unitary Products Group 7
035-20499-001 Rev. B (1004)
SECTION V: ELECTRICAL POWER
TABLE 7:
Electrical and Performance Data
Input
High/Low
MBH kW MBH k W CFM
40/26 12/8 38/24 11/7 1200 34 92.0 35-65 19-36 165 74 1/2 7.7 11x8 254x203 9 20 14
60/39 18/11 56/36 16/11 1200 34 93.2 40-70 22-39 170 77 1/2 7.7 11x8 279x203 9 20 14
80/52 23/15 75/49 22/14 1200 34 92.5 45-75 25-42 175 79 1/2 7.7 11x8 279x203 9 20 14
80/52 23/15 75/49 22/14 1600 45.3 92.8 45-75 25-42 175 79 3/4 9.6 11x10 279x254 12 20 14
100/65 29/19 93/60 27/18 2000 56.6 92.8 45-75 25-42 175 79 1 12.8 11x11 279x279 14 20 12
120/78 35/23 112/73 33/21 2000 56.6 93.2 40-70 22-39 170 77 1 12.8 11x11 279x279 14 20 12
Annual Fuel Utilization Efficiency (AFUE) numbers are determined in accorda nce with DOE Test procedures.
Wire size and over current protection must comply with the National Electrical Code (NFPA-70-latest edition) and all local codes.
The furnace shall be installed so that the electrical components are protected from water.
ELECTRICAL POWER CONNECTIONS
Field wiring to the unit must be grounded. Electric wires that are field
installed shall conform to the temperature limitation for 63°F (35°C) rise
wire when installed in accordance with instructions. Refer to Table 7 in
these instructions for specific furnace electrical data.
Output
High/Low
Nominal Airflow AFUE Air Temp. Rise
3
m
% °F °C °F °C HP Amps In. mm Amps
/min
Max. Outlet
Air Temp.
Blower Blower Size Total Unit
L1
HOT
N
GND
WHT
GRN
BLK
Max.
Over-current
Protect
Min. Wire Size
(awg) @ 75 ft.
One Way
Use copper conductors only.
SUPPLY VOLTAGE CONNECTIONS
1. Provide a power supply separate from all other circuits. Install
overcurrent protection and disconnect switch per local/national
electrical codes. The switch should be close to the unit for convenience in servicing. With the disconnect or fused switch in the OFF
position, check all wiring against the unit wiring label. Refer to the
BLK/BLK
WHT/WHT
GRN/GRN
CLASS 2 SYSTEM
CONTROL WIRING
TO THERMOSTAT
wiring diagram in this instruction.
2. Remove the screws retaining the wiring box cover. Route the
power wiring through the opening in the unit into the junction box
with a conduit connector or other proper connection. In the junction box there will be three wires, a Black Wire, a White Wire and a
Green Wire. Connect the power supply as shown on the unit-wiring label on the inside of the blower compartment door or the wiring schematic in this section. The black furnace lead must be
connected to the L1 (hot) wire from the power supply. The white
furnace lead must be connected to neutral. Connect the green furnace lead (equipment ground) to the power supply ground. An
alternate wiring method is to use a field provided 2” (51 mm) x 4”
(102 mm) box and cover on the outside of the furnace. Route the
furnace leads into the box using a protective bushing where the
wires pass through the furnace panel. After making the wiring connections replace the wiring box cover and screws. A power shutoff
switch may be installed in this box. Refer to Figure 5.
3. The furnace's control system requires correct polarity of the power
supply and a proper ground connection. Refer to Figure 6.
IMPORTANT: The power connection leads and wiring box 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.
BLOWER
COMPARTMENT
DOOR SWITCH
TRANSFORMER
IGNITION
MODULE
CFM
BOARD
FIGURE 5: Electrical Wiring
LOW VOLTAGE CONTROL WIRING CONNECTIONS
Install the field-supplied thermostat by following the instructions that
come with the thermostat. With the thermostat set in the OFF position
and the main electrical source disconnected, connect the thermostat
wiring from the wiring connections on the thermostat to the terminal
strip on the furnace control board, as shown in Figures 7, 8, or 9. Electronic thermostats may require the common wire to be connected to the
"C" terminal as shown in Figures 7, 8 or 9. Apply strain relief to thermostat wires passing through cabinet. If air conditioning equipment is
installed, use thermostat wiring to connect the Y and C terminals on the
furnace control board to the condensing unit (unit outside) as shown in
Figures 7, 8 or 9.
IMPORTANT: Set the heat anticipator in the room thermostat to 0.10
amps. Setting it lower will cause short cycles. Setting it higher will cause
the room temperature to exceed the set points.
8 Unitary Products Group
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