Unitary products group PS9, FC9S, FL9S Installation Manual
INSTALLATION MANUAL
HIGH EFFICIENCY
TUBULAR HEAT EXCHANGER SERIES
MODELS: PS9 / FC9S / FL9S
(Single Stage Downflow/Horizontal)
40 - 120 MBH INPUT
(11.72 - 35.17 KW) INPUT
TABLE OF CONTENTS
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TWINNING AND STAGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
LIST OF FIGURES
Transition Kit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Accessory Downflow Filter Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Return Filter Grill and Return Duct Installation . . . . . . . . . . . . . . . . . . . . 7
Typical Attic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Typical Suspended Furnace / Crawl Space Installation . . . . . . . . . . . . . 8
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Downflow Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Horizontal Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Polarity Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Heating and Cooling Thermostat Connections . . . . . . . . . . . . . . . . . . . 11
Accessory Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Typical Twinned Furnace Application . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Single Stage Twinning Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 12
Two-Stage Twinning Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Home Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Downflow/Horizontal Vent Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
External Horizontal Vent Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Termination Configuration - 1 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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 . . . . . . . . . . . . . . . . . . . . .13
CONDENSATE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
CONDENSATE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . .23
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Termination Configuration - 2 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Termination Configuration - 2 Pipe Horizontal . . . . . . . . . . . . . . . . . . . . 17
Crawl Space Termination Configuration - 2Pipe . . . . . . . . . . . . . . . . . .17
Double Horizontal Sealed Combustion Air and Vent Termination . . . . . 17
Double Vertical Sealed Combustion Air and Vent Termination . . . . . . .17
Sealed Combustion Air Intake Connection and Vent Connection . . . . . 18
Combustion Airflow Path Through The Furnace Casing
to the Burner Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Outside and Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . .19
Attic Combustion Air Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Condensate Drain Internal Hose Routing . . . . . . . . . . . . . . . . . . . . . . .20
Downflow Condensate Drain Hose Configuration . . . . . . . . . . . . . . . . . 20
Horizontal Left Condensate Drain Hose Configuration . . . . . . . . . . . . . 21
Horizontal Right Condensate Drain Hose Configuration . . . . . . . . . . . . 22
Pressure Switch Tubing Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Typical Heat/Cool Speed Tap Connections . . . . . . . . . . . . . . . . . . . . . .27
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
LIST OF TABLES
Unit Clearances to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Minimum Duct Sizing For Proper Airflow . . . . . . . . . . . . . . . . . . . . . . . . . 4
Round Duct Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Filter Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
High Altitude Pressure Switch Application . . . . . . . . . . . . . . . . . . . . . . . 9
High Altitude Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical and Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Combustion Air Intake and Vent Connection Size at Furnace
(All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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 . . . . . . . . . . . . . . . . . . . . . . . . 14
Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Unconfined Space Minimum Area in Square Inch . . . . . . . . . . . . . . . . . 18
Condensate Drain Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Blower Performance CFM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Filter Performance - Pressure Drop Inches W.C. and (kPa) . . . . . . . . .28
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.
035-20646-001 Rev. A (1004)
035-20646-001 Rev. A (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 VII of these instructions.
5. Combustion products must be discharged outdoors. Connect this
furnace to an approved vent system only, as specified in SECTION VII 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 XI 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
035-20646-001 Rev. A (1004)
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 VII of these instructions. These minimum clearances must be maintained in the installation.
6. Where the unit will be installed in a level position with no more
than 1/4” (6.4 mm) slope side-to-side and front-to-back to provide
proper condensate drainage.
Installation in freezing temperatures:
1. Furnace shall be installed in an area where ventilation facilities
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 to premature heat exchanger
failure, leading to premature heat exchanger failure.
TABLE 1:
Unit Clearances to Combustibles
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.
Downflow/Horizontal furnaces for installation on combustible flooring only when installed on the accessory combustible floor base on
wood flooring only and shall not be installed directly on carpeting,
tile or other combustible material.
Check the rating plate and power supply to be sure that the electrical characteristics match. All models use nominal 115 VAC, 1
Phase 60Hz power supply.
Furnace shall be installed so the electrical components are protected from water.
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.
APPLICATION
TOP FRONT REAR LEFT SIDE RIGHT SIDE FLUE
In. (mm) In. (mm) In. (mm) In. (mm) In. (mm) In. (mm) In. (mm)
DOWNFLOW
HORIZONTAL
1. Combustible floor base or air conditioning coil required for use on combustible floor.
2. Minimum of 8” clearance required to install condensate removal system.
3. Line contact only permitted between lines formed by the intersection of the rear panel (top in horizontal position) of the furnace jacket and building joists, studs or framing.
1 (25.4) 3 (76.2 0 (0) 0 (0) 0 (0) 0 (0)
1 (25.4) 3 (76.2
0 (0)
Unitary Products Group 3
FLOOR/
BOTTOM
1 (25.4)
2
0 (0)
2
0 (0) 0 (0) 1 (25.4) NO YES YES
CLOSET ALCOVE ATTIC
1
YES YES YES NO
LINE
CONTACT
3
YES
035-20646-001 Rev. A (1004)
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.
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.
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.
FLOOR BASE AND DUCTWORK INSTALLATION
Downflow Combustible Floor Base
Installations on combustible materials require the use a
combustible floor base shown in Figure 1.
The floor base must be secured to the floor. A supply air
duct plenum with 1" (2.54 cm) flange is installed through the
opening provided. The supply air duct is then secured to the
duct system with screws and sealed to prevent leaks. Do
not shoot screws through the flanges of the supply air duct
into the top of the combustible floor base. Install the furnace on the
combustible floor base so that the corners of the furnace are parallel
with the corner brackets of the floor base. Follow the instructions supplied with the combustible floor base accessory.
This combustible floor base can be replaced with a matching cooling
coil, properly sealed to prevent leaks. Follow the instructions supplied
with the cooling coil cabinet for installing the cabinet to the duct connector. Refer to the installation instructions for additional information.
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 duct system is a very important part of the installation. If the duct
system is improperly sized the furnace will not operate properly.
The ducts attached to the furnace plenum, should be of sufficient size
so that the furnace operates at the specified external static pressure
and within the air temperature rise specified on the nameplate.
Table 2 is a guide for determining whether the rectangular duct system
that the furnace is being connected to be of sufficient size for proper 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, 1,200 CFM. The recommended duct area is 280 sq.in, there are two 8 x 14 rectangular ducts
attached to the plenum and there are two 7 inch round ducts attached to
the furnace.
1. Take 8 x 14, which equals 112 sq.in. X 2, which equals 224 square
inch then go to round duct size located in Table 3.
2. The square inch area for 7 inch round pipe is 38.5, multiply by 2 for
two round ducts which equals 76.9 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 300.9 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.
TABLE 2:
Input Airflow
BTU/H
(kW)
60000
(17.58)
80000
(23.44)
80000
(23.44)
100000
(29.31)
120000
(35.17)
NOTE: This chart does not replace proper duct sizing calculat ions or t ake into ac count st atic 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 min i mum dimensions.
3. Maximum supply air velocity in rigid duct @ 900 feet per minute (25.49 m3 / minute).
TABLE 3:
Minimum Duct Sizing For Proper Airflow
CFM
(m³)
1,200
(33.98)
1,200
(33.98)
1,600
(45.31)
2,000
(56.63)
2,000
(56.63)
Return
In²
(cm²)
280
(711)
280
(711)
360
(914)
440
(1,118)
440
(1,118)
1
Rectangular
(cm x cm)
(35.6 x 50.8)
(35.6 x 50.8)
(45.7 x 50.8)
(50.8 x 55.8)
(50.8 x 55.8)
in. x in.
14 x 20
14 x 20
18 x 20
20 x 22
20 x 22
2
Round2Supply
in. (cm)
dia.
18
(45.7)
18
(45.7)
22
(55.8)
24
(60.9)
24
(60.9)
3
Rectangular2Round
In²
(cm²)
216
(549)
216
(549)
280
(711)
390
(991)
390
(991)
in. x in.
(cm x cm)
12 x 18
(30.5 x 45.7)
12 x 18
(30.5 x 45.7)
14 x 20
(35.6 x 50.8)
16 x 22
(40.6 x 55.8)
16 x 22
(40.6 x 55.8)
in. (cm)
dia.
16
(40.6)
16
(40.6)
18
(45.7)
22 (
55.8)
22
(55.8)
Round Duct Size
Round Duct Size Calculated Area Fo r 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
)
1. The Air Temperature Rise is determined by subtracting the Return
Air Temperature Reading from the Supply Air Temperature Reading.
2. The External Static Pressure is determined by adding the Supply
Duct Static Pressure reading to the Return Duct Static Pressure
reading.
2
4 Unitary Products Group
035-20646-001 Rev. A (1004)
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: If the supply air duct is being connected to the furnace
without the use of an accessory duct connector, then a transition duct
must be installed with flanges or tabs that are securely attach and
sealed to the supply air duct and to the base of the furnace. The transition duct must have insulation between the transition duct and any combustible material.
The transition duct must be the same dimensional size as the rectangular opening in the base of the furnace.
DOWNFLOW
FURNACE
WARM AIR PLENUM
WITH 1” FLANGES
FIBERGLASS
INSULATION
FIBERGLASS TAPE
UNDER FLANGE
• If the transition kit has been installed on the cooling coil cabinet it
must be secured to the cooling coil cabinet with screws. The supply air side of the furnace is then placed on the cooling coil cabinet and then sealed for leaks.
• If the transition kit has been installed on the supply air side of the
furnace it must be secured to the furnace with screws. The furnace and the transition kit are then placed on the cooling coil cabinet and then sealed for leaks.
NOTE: Refer to instructions packed out with coil cabinet, for securing
and sealing to the furnace.
IMPORTANT: The furnace, transition kit, and the cooling coil cabinet
MUST BE SEALED as needed to prevent leaks, AND SECURED. Refer
to the assembly drawing in Figures 2.
IMPORTANT: On all installations without a coil, a removable access
panel is recommended in the outlet duct such that smoke or reflected
light would be observable inside the casing to indicate the presence of
leaks in the heat exchanger. This access cover shall be attached in
such a manner as to prevent leaks.
AIRFLOW
TRANSITION
DOWNFLOW
FURNACE
AIRFLOW
KIT
AIRFLOW
COOLING
COIL
CABINET
REFRIGERANT
LINES
DRAIN
CONNECTIONS
COMBUSTIBLE FLOOR
BASE ACCESSORY
FIGURE 1 : Combustible Floor Base Accessory
The supply air temperature MUST NEVER exceed the Maximum
Supply Air Temperature, specified on the nameplate.
Operating the furnace above the maximum supply air temperature
will cause the heat exchanger to overheat, causing premature heat
exchanger failure. Improper duct sizing, dirty air filters, incorrect
manifold pressure, incorrect gas orifice and/or a faulty limit switch
can cause the furnace to operate above the maximum supply air
temperature. Refer to sections II, III and XI for additional information on correcting the problem.
Downflow Air Conditioning Coil Cabinet
The Cooling Coil Cabinet can be used in place of the combustible floor
base for downflow installations on combustible materials. The furnace
should be installed with the cooling coil cabinet specifically intended for
downflow applications. The cooling coil cabinet must be secured to the
floor. A supply air duct plenum is installed through the opening provided. The supply air duct is then secured to the duct system with
screws and sealed to prevent leaks. If a matching cooling coil is used, it
may be placed directly on the furnace outlet using the accessory transition kit and sealed to prevent leakage. The transition kit must be used to
secure the cooling coil cabinet to the furnace casing when installed in a
downflow configuration.
This transition kit may be installed in one of two ways. The transition kit
may be installed and secured to either the furnace or the cooling coil
cabinet by the use of screws and then it must be sealed to prevent
leaks.
TRANSITION
KIT
AIRFLOW
FIGURE 2: Transition Kit Assembly
Horizontal Models
Horizontal Installations With a Cooling Coil Cabinet
The furnace should be installed with the cooling coil cabinet specifically
intended for horizontal applications. If a matching cooling coil is used, it
may be placed directly on the supply air side of the furnace and sealed
to prevent leakage. A warm air duct plenum with 1" (2.54 cm) is
installed through the opening provided. The supply air duct system is
connected to the warm air plenum and sealed to prevent leaks.
IMPORTANT: The furnace, the cooling coil cabinet, and all duct work
MUST BE SEALED as needed to prevent leaks, AND SECURED. Refer
to the assembly drawing in Figure 2.
Attach the supply plenum to the air conditioning coil cabinet outlet duct
flanges through the use of S cleat material when a metal plenum is
used. The use of an approved flexible duct connector is recommended
on all installations. The connection to the furnace, air conditioning coil
cabinet and the supply plenum should be sealed to prevent air leakage.
The sheet metal plenum should be crosshatched to eliminate any popping of the sheet metal when the indoor fan is energized. The minimum
plenum height is 12" (30.5 cm). If the plenum is shorter than 12" (30.5
cm) the turbulent air flow may cause the limit controls not to operate as
designed, or the limit controls may not operate at all. Also the plastic
drain pan in the under the air conditioning coil can overheat and melt
Refer to the installation instructions supplied with the air conditioning
coil for additional information.
Unitary Products Group 5
035-20646-001 Rev. A (1004)
Horizontal Installations Without a Cooling Coil Cabinet
When installing this appliance, the furnace must be installed so as to
create a closed duct system, the supply duct system must be connected to the furnace outlet and the supply duct system must terminate
outside the space containing the furnace. When replacing an existing
furnace, if the existing plenum is not the same size as the new furnace
then the existing plenum must be removed and a new plenum installed
that is the proper size for the new furnace.
22-3/4
7/8
T-STAT WIRING 7/8” K.O.
HORIZONTAL CONDENSATE
DRAIN OPENING 1-3/4”
21-5/8
18-1/2
11-3/4
7-1/2
2-1/4
19-1/4
29
22-3/4
1-1/4
13-7/8
7/8
HORIZONTAL CONDENSATE
DRAIN OPENING 2”
JUNCTION BOX
HOLE 7/8”
GAS PIPE ENTRY 1-1/2”
CONDENSATE DRAIN
HOLE 7/8”
SIDE PIPING HOLE 3-3/8”
22-1/4
LEFT SIDE
25-3/8
26-1/2
27-1/8
30-1/8
1-1/4
Attach the supply plenum to the furnace outlet duct flanges through the
use of S cleat material when a metal plenum is used. The use of an
approved flexible duct connector is recommended on all installations.
This connection should be sealed to prevent air leakage. The sheet
metal should be crosshatched to eliminate any popping of the sheet
metal when the indoor fan is energized. On all installations without a
coil, a removable access panel is recommended in the outlet duct such
that smoke or reflected light would be observable inside the casing to
indicate the presence of leaks in the heat exchanger. This access cover
shall be attached in such a manner as to prevent leaks.
A
T-STAT WIRING 7/8” K.O.
HORIZONTAL CONDENSATE
DRAIN OPENING 1-3/4”
FRONT
D
40
29
22-3/4
23-5/8
21-1/4
5/8
18-1/2
9-1/8
8-1/2
5/8
HORIZONTAL
CONDENSATE
DRAIN OPENING 1-3/4”
JUNCTION BOX
HOLE 7/8”
GAS PIPE
ENTRY 1-1/2”
CONDENSATE DRAIN
HOLE 7/8”
RIGHT SIDE
C
BOTTOM IMAGE
RETURN END
2-1/4
B
20
23-1/4
TOP IMAGE
SUPPLY END
FIGURE 3: Dimensions
BTUH (kW)
Input/Output
CFM
Cabinet
Size
A (in.) A (cm) B (in.) B (cm) C (in.) C (cm) D (in.) D (cm)
Cabinet Dimension
60/55 (17.57/16.10) 1200 (33.98) B 17-1/2 44.4 16-1/4 41.3 15 38.1 1-3/4 4.44
80/75 (23.42/21.96) 1200 (33.98) B 17-1/2 44.4 16-1/4 41.3 15 38.1 1-3/4 4.44
80/75 (23.42/21.96) 1600 (45.31) C 21 53.3 19-3/4 50.2 18-1/2 47.0 2-1/8 5.40
100/95 (29.28/27.82) 1600 (45.31) C 21 53.3 19-3/4 50.2 18-1/2 47.0 2-1/8 5.40
100/95 (29.28/27.82) 2000 (56.63) C 21 53.3 19-3/4 50.2 18-1/2 47.0 2-1/8 5.40
120/112 (35.14/32.80) 2000 (56.63) D 24-1/2 62.2 23-1/4 59.1 22 55.9 2-1/2 6.35
RESIDENTIAL AND NON HUD MODULAR HOME
DOWNFLOW AND HORIZONTAL RETURN PLENUM
CONNECTION
The return duct system must be connected to the furnace inlet and the
return duct system must terminate outside the space containing the furnace. When replacing an existing furnace, if the existing plenum is not
the same size as the new furnace then the existing plenum must be
removed and a new plenum installed that is the proper size for the new
furnace.
Attach the return plenum to the furnace inlet duct 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. The connection of the plenum to the furnace and all the
ducts connecting to the plenum must be sealed to prevent air leakage.
The sheet metal should be crosshatched to eliminate any popping of
the sheet metal when the indoor fan is energized.
The duct system is a very important part of the installation. If the duct
system is improperly sized the furnace will not operate properly. The
ducts attached to the furnace must be of sufficient size so that the furnace operates at the specified external static pressure and within the air
temperature rise specified on the nameplate.
Attic installations must meet all minimum clearances to combustibles
and have floor support with required service accessibility.
IMPORTANT: If an external mounted filter rack is being used see the
instructions provided with that accessory for proper hole cut size.
6 Unitary Products Group
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 on GM9 and GY9
models. GF9 models must have a field-supplied filter and mounting
hardware. A field supplied side return filter rack and filter are available
through Source 1 using 1 SF0101. Replacement filter size is shown in
Table 4.
TABLE 4:
100/95 (29.28/27.82) 1600 (45) C (2) 14 x 20 (36 x 51)
100/95 (29.28/27.82) 2000 (57) C (2) 20 x 20 (51 x 51)
120/112 (35.14/32.80) 2000 (57) D (2) 20 x 20 (51 x 51)
FIGURE 4: Accessory Downflow Filter Rack
Downflow Filters
A top return filter rack is supplied with the furnace. Two standard filters
are supplied with some units. Downflow furnaces typically are installed
with the filters located above the furnace, extending into the return air
plenum or duct. Any branch duct (rectangular or round duct) attached to
the plenum must attach to the vertical plenum above the filter height.
Refer to Figure 4 for proper installation.
Filters(s) may be located in the duct system external to the furnace
using an external duct filter box attached to the furnace plenum or at the
end of the duct in a return filter grille(s). The use of straps and / or supports is required to support the weight of the external filter box. Refer to
Figure 5.
If the accessory electronic air cleaner is installed, be sure the air
cleaner is designed to accommodate the furnace CFM (cm/m) and the
air cleaner is installed so it does not obstruct the return airflow. Consideration should be given when locating the air cleaner for maintenance
and temperatures should the indoor fan motor fail to operate. The use
of straps and / or supports is required to support the weight of the electronic air cleaner. It is recommended that the air cleaner not be located
within 12 inches (30.5 cm) from the top of the return air opening on the
furnace. Refer to the instructions supplied with the electronic air
cleaner.
Filter Sizes
Input / Output
BTU/H (kW)
(m
CFM
3
/min)
Cabinet
Size
Top Return
Filter in (cm)
60/55 (17.57/16.10) 1200 (34) B (2) 14 x 20 (36 x 51)
80/75 (23.42/21.96) 1200 (34) B (2) 14 x 20 (36 x 51)
80/75 (23.42/21.96) 1600 (45) C (2) 14 x 20 (36 x 51)
FILTER RACK
(factory supplied with some furnaces)
RACK AND FILTERS SECURED
INSIDE BLOWER SECTION
FOR SHIPMENT
DUCTWORK
CASING SIZE
16-1/4”
22-1/4”
26-1/4”
NOTE: FILTER ACCESS THROUGH
DUCTWORK MUST BE PROVIDED
FOR REMOVALAND CLEANING
FILTERS
FILTER
RACK
CROSS SECTION A-A
(with Plenum and filters)
DIMENSION FH
12-3/4”
11”
8-1/4”
BRANCH
DUCTS
FH
035-20646-001 Rev. A (1004)
All loose accessories shipped with the furnace must be removed
from the blower compartment, prior to installation.
If pleated media air filters or any filter that has a large pressure drop is
installed in the return air duct system be sure that the pressure drop
caused by the air filter will not prevent the furnace from operating within
the rise range specified on the rating plate. If the furnace does not operate within the specified rise range then a larger air filter or an air filter
that has a lower pressure drop must be installed. Refer to Figures 4, 5
and furnace accessories for accessory external filter kit options.
IMPORTANT: For easier filter access in a downflow configuration, a
removable access panel is recommended in the vertical run of the
return air plenum immediately above the furnace.
CLOSET
COMBUSTION
AIR
VENT
PIPE
ELECTRICAL
SUPPLY
GAS SUPPLY
(EITHER SIDE)
RETURN
AIR
AIR
FILTERS
FIGURE 5: Return Filter Grill and Return Duct Installation
Accessory External Filter Installation
1. Install the return filter rack on the top of the furnace return air
opening. Secure the filter rack to the front and back flanges with
screws. The return air plenum can be placed over the filter rack
and the branch ducts (rectangular ducts and / or round ducts) can
be attached to the plenum. Route the combustion air and the vent
PVC pipes around the access panels for the filters.
2. Install the filter(s) provided or you may install Permanent washable
filters. Filter should extend through the entire length of the filter
rack to prevent air from bypassing the filter. Make sure that any air
filter that is installed in the furnace does not cause an excessive
amount of pressure drop. Refer to Table 16 for air filter performance and pressure drops.
IMPORTANT: Air velocity through throwaway type filters must not
exceed 300 feet per minute (1.52 m/m). All velocities over this require
the use of high velocity filters. Refer to Table 16.
All installations must have a filter installed.
HORIZONTAL APPLICATION
Horizontal Filters
All filters and mounting provision must be field supplied. Filters(s) may
be located in the duct system external to the furnace or in a return filter
grille(s). Filters(s) may be located in the duct system using an external
duct filter box attached to the furnace plenum. Filters must be a minimum distance of 18” (45.8 cm) from the furnace. Any branch duct (rectangular or round duct) attached to the plenum must attach to the
vertical plenum above the filter height. The use of straps and / or supports is required to support the weight of the external filter box.
An accessory filter rack is available. Refer to Figure 4 and the instructions supplied with the furnace accessory external filter kit options.
Unitary Products Group 7
035-20646-001 Rev. A (1004)
ATTIC INSTALLATION
LINE CONTACT ONLY PERMISSIBLE
BETWEEN LINES FORMED BY THE
INTERSECTION OF FURNACE TOP
AND TWO SIDES AND BUILDING
JOISTS, STUDS OR FRAMING
GAS
PIPING
SUPPLY
AIR
12” CLEARANCE
FOR SERVICE
COMBUSTION
AIR
30” MIN.
WORK AREA
FIGURE 6: Typical Attic Installation
This appliance is design certified for line contact when the furnace is
installed in the horizontal left or right position. The line contact is only
permissible between lines are formed by the intersection of the top and
two sides of the furnace and the building joists, studs or framing. This
line may be in contact with combustible material.
IMPORTANT: In either a horizontal left or right installation, a minimum
of 8" (20.3 cm) clearance is required beneath the furnace to allow for
the installation of the condensate trap and drain pipe. Refer to "CONDENSATE PIPING" section of this manual for more information.
FILTER RACK MUST BE A
MINIMUM DISTANCE
OF 18” (45.7 cm)
FROM THE FURANCE
RETURN
AIR
VENT PIPE
(maintain required
clearances to
combustible)
In any application where temperatures below freezing are possible,
see “BELOW FREEZING LOCATIONS”.
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.
OUTLET
PRESSURE
PORT
INLET
WRENCH
BOSS
INLET
PRESSURE
PORT
OFF
ON
ON/OFF SWITCH
(Shown in ON position)
VENT PORT
OUTLET
MAIN REGULATOR
ADJUSTMENT
When a furnace is installed in an attic or other insulated space,
keep all insulating materials at least 12 inches (30.5 cm) away from
furnace and burner combustion air openings.
If this furnace is installed over a finished space, a condensate
safety pan must be installed.
SUSPENDED FURNACE / CRAWL SPACE
INSTALLATION
The furnace can be hung from floor hoists or installed on suitable blocks
or pad. Blocks or pad installations shall provide adequate height to
ensure the unit will not be subject to water damage. Units may also be
suspended from rafters or floor joists using rods, pipe angle supports or
straps. Angle supports should be placed at the supply air end and near
the blower deck. Do not support at return air end of unit. All four suspension points must be level to ensure quite furnace operation. When
suspending the furnace use a secure a platform constructed of plywood
or other building material secured to the floor joists. Refer top Figure 7
for typical crawl space installation.
ANGLE IRON
BRACKET
1” MAX. BETWEEN
ROD & FURNACE
6” MIN. BETWEEN
ROD & FURNACE
1” MAX. BETWEEN
ROD & FURNACE
SUPPORT
BRACKET
FIGURE 8: 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
Natural Gas Propane (LP)
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
FIGURE 7: Typical Suspended Furnace / Crawl Space Installation
8 Unitary Products Group
035-20646-001 Rev. A (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 9.
EXTERNAL MANUAL
SHUTOFF VALVE
TO GAS
SUPPLY
GROUNDED JOINT UNION
DRIP
LEG
MAY BE INSTALLED
INSIDE OR OUTSIDE UNIT.
FIGURE 9: Downflow Gas Piping
MANUAL
SHUT-OFF
VALV E
GAS
PIPE
GAS
PIPE
DRIP
LEG
MANUAL
SHUT-OFF VALVE
FIGURE 10: Horizontal Gas Piping
IMPORTANT: An accessible manual shut-off 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 shut-off valve during any pressure
testing of the gas supply piping system at pressures equal to or less
than 1/2 psig (3.5 kPa).
The gas valve body is a very thin casting that can take any limited
external force. 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.
TO GAS
SUPPLY
DRIP
LEG
GAS BURNERS
GAS VALVE
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 2 dimensions.
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.
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 7 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
Table 9. For altitudes above 4,500 feet (137 m), refer to Instructions in
the Accessory High Altitude Kit.
TABLE 6:
TABLE 7:
High Altitude Pressure Switch Application
Input (MBH)
Upflow Models
Output
(MBH)
4,500 To
10,000 Ft.
60/1200 55 1PS0901
80/1200 74 1PS0902
80/1600 74 1PS0903
100/1600 93 1PS0901
100/2000 93 1PS0901
120/2000 112 1PS0901
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)
Unitary Products Group 9
035-20646-001 Rev. A (1004)
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 pro-
pane (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.
SECTION V: ELECTRICAL POWER
TABLE 8:
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.
* Wire size and overcurrent protection must comply with the National Electric Code.
NOTES:
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.
Use copper conductors only.
SUPPLY VOLTAGE CONNECTIONS
1. Provide a power supply separate from all other circuits. Install
2. Remove the screws retaining the wiring box cover. Route the
Electrical and Performance Data
Input Output Nominal Airflow Cabinet Width AFUE Air Temp. Rise
MBH kW MBH kW CFM
3
m
/min
In. mm % °F °C
60 18 55 16.1 1200 34.0 17-1/2 444 92 35 - 65 19 - 36
80 23 74 21.7 1200 34.0 17-1/2 444 91 35 - 65 19 - 36
80 23 74 21.7 1600 45.3 21 533 92 35 - 65 19 - 36
100 29 93 27.3 1600 45.3 21 533 92 35 - 65 19 - 36
100 29 93 27.3 2000 56.6 21 533 92 35 - 65 19 - 36
120 35 112 32.8 2000 56.6 24-1/2 622 92 35 - 65 19 - 36
Input
Max. Outlet
Air Temp.
Blower Blower Size Total Unit
MBH kW °F °C HP Amps In. mm Amps
Max.
Over-current
Protect
Min. Wire Size
(awg) @ 75 ft.
One Way
60 18 170 76.7 1/2 7.0 11 x 8 279 x 203 9 20 14
80 23 165 76.7 1/2 7.0 11 x 8 279 x 203 9 20 14
80 23 170 76.7 3/4 10.2 11 x 10 279 x 254 12 20 14
100 29 165 79.4 3/4 10.2 11 x 10 254 x 254 12 20 14
100 29 165 79.4 1 12.7 11 x 11 279 x 279 14 20 12
120 35 165 76.7 1 12.7 11 x 11 279 x 279 14 20 12
1. For altitudes above 2000 ft. (609 m) reduce capacity 4% for each 1000 ft. above sea level.
2. Wire size based on copper conductors, 140° F (60°C), 3% voltage drop.
3. Continuous return air temperature must not be below 55°F (12.8° C).
alternate wiring method is to use a field provided 2” (5.08 cm) x 4”
(10.2 cm) 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. Refer to Figure
10.
3. The furnace's control system requires correct polarity of the power
supply and a proper ground connection. Refer to Figure 11.
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.
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
wiring diagram in this instruction.
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
COMBUSTION
AIR
CLASS 2 SYSTEM
CONTROL WIRING
TO THERMOSTAT
(BLK) LI (HOT)
(WHT) N
(GRN)GND
FIGURE 11: Electrical Wiring
JUNCTION
BOX
BLOWER
COMPARTMENT
VENT PIPE
IGNITION
MODULE
TRANSFORMER
10 Unitary Products Group
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