York GM9S-DH, GF9S-DH, GY9S-DH User Manual

INSTALLATION MANUAL

HIGH EFFICIENCY
TUBULAR HEAT EXCHANGER SERIES

MODELS: GY9S*DH / GM9S*DH / GF9S*DH
(Single Stage Downflow/Horizontal)

40 - 120 MBH INPUT
(11.72 - 35.17 KW) INPUT

LIST OF SECTIONS

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

DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Transition Kit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Return Filter Grill and Return Duct Installation . . . . . . . . . . . . . . . . . . . 8

Typical Attic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Typical Suspended Furnace / Crawl Space Installation . . . . . . . . . . . . 9

Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Downflow Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Horizontal Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Thermostat Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Accessory Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Typical Twinned Furnace Application . . . . . . . . . . . . . . . . . . . . . . . .13

Single Stage Twinning Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . 14

Two-Stage Twinning Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 14

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Home Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Downflow/Horizontal Vent Assembly . . . . . . . . . . . . . . . . . . . . . . . . .18

Termination Configuration - 1 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . .18

Termination Configuration - 2 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . .18

Termination Configuration - 2 Pipe Horizontal . . . . . . . . . . . . . . . . . . 18

Crawl Space Termination Configuration - 2Pipe . . . . . . . . . . . . . . . .19

Double Horizontal Sealed Combustion Air and Vent Termination . . . 19

Double Vertical Sealed Combustion Air and Vent Termination . . . . . 19

Unit Clearances to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Minimum Duct Sizing For Proper Airflow . . . . . . . . . . . . . . . . . . . . . . .5

Round Duct Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Cabinet and Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Recommended Filter Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Electrical and Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Maximum Equivalent Pipe Length . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Equivalent Length of Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Elbow Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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 m inor or moderate injury.
alert against unsafe practices and hazards involving only property dam­age.

.

.

LIST OF FIGURES

LIST OF TABLES

It is also used to

EFFICIENCY
RATING
CERTIFIED

ISO 9001

Certified Quality

Management System

TWINNING AND STAGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

COMBUSTION AIR AND VENT SYSTEM . . . . . . . . . . . . . . . . . . . . .14

CONDENSATE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . .31

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Sealed Combustion Air Intake Connection and Vent Connection . . .19
Combustion Airflow Path Through The Furnace Casing to the Burner

Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Outside and Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . .21

Attic Combustion Air Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Condensate Drain Internal Hose Routing . . . . . . . . . . . . . . . . . . . . . .22

Downflow Condensate Drain Hose Configuration . . . . . . . . . . . . . . .23

Horizontal Left Condensate Drain Hose Configuration . . . . . . . . . . . .24

Horizontal Left Condensate Drain Hose Configuration . . . . . . . . . . . .25

Horizontal Right Condensate Drain Hose Configuration

(Option 1 - Front of Casing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Horizontal Right Condensate Drain Hose Configuration

(Option 1 - Front of Casing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Horizontal Right Condensate Drain Hose Configuration

(Option 2 - Back of Casing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Horizontal Right Condensate Drain Hose Configuration

(Option 2 - Back of Casing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Pressure Switch Tubing Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Furnace Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Combustion Air Intake and Vent Connection Size at Furnace

(All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Free Area - Outdoor Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Unconfined Space Minimum Area in Square Inches . . . . . . . . . . . . .20

Condensate Drain Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Blower Performance CFM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Filter Performance - Pressure Drop Inches W.C. and (kPa) . . . . . . . .37

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.

268890-UIM-B-0607

268890-UIM-B-0607

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 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 X 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. It is permitted to use the furnace for heating of buildings or struc­tures under construction. Installation must comply with all manu­facturer’s installation instructions including:

• Proper vent installation;

• Furnace operating under thermostatic control;

• Return air duct sealed to the furnace;

• Air filters in place;

• Set furnace input rate and temperature rise per rating plate

marking;

• Means for providing outdoor air required for combustion;

• Return air temperature maintained between 55ºF (13ºC) and

80ºF (27ºC);

• The air filter must be replaced upon substantial completion of

the construction process;

• Clean furnace, duct work and components upon substantial

completion of the construction process, and verify furnace­operating conditions including ignition, input rate, temperature
rise and venting, according to the manufacturer’s instructions.

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 3. The plenum must be installed
according to the instructions.

• Provide clearances from combustible materials as listed under
Clearances to Combustibles in Table 1.

• 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

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.

FOR FURNACES INSTALLED IN THE COMMON­WEALTH OF MASSACHUSETTS ONLY

For all side wall horizontally vented gas fueled equipment installed in
every dwelling, building or structure used in whole or in part for resi­dential purposes, including those owned or operated by the Com­monwealth and where the side wall exhaust vent termination is less
than seven (7) feet above finished grade in the area of the venting,
including but not limited to decks and porches, the following require­ments shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At
the time of installation of the side wall horizontal vented gas
fueled equipment, the installing plumber or gasfitter shall
observe that a hard wired carbon monoxide detector with an
alarm and battery back-up is installed on the floor level where
the gas equipment is to be installed. In addition, the installing
plumber or gasfitter shall observe that a battery operated or
hard wired carbon monoxide detector with an alarm is installed
on each additional level of the dwelling, building or structure
served by the side wall horizontal vented gas fueled equipment.
It shall be the responsibility of the property owner to secure th e
services of qualified licensed professionals for the installation of
hard wired carbon monoxide detectors

a. In the event that the side wall horizontally vented gas

fueled equipment is installed in a crawl space or an attic,
the hard wired carbon monoxide detector with alarm and
battery back-up may be installed on the next adjacent floor
level.

b. In the event that the requirements of this subdivision can

not be met at the time of completion of installation, the
owner shall have a period of thirty (30) days to comply with
the above requirements; provided, however, that during
said thirty (30) day period, a battery operated carbon mon­oxide detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS. Each car­bon monoxide detector as required in accordance with the
above provisions shall comply with NFPA 720 and be ANSI/UL
2034 listed and IAS certified.

3. SIGNAGE. A metal or plastic identification plate shall be perma­nently mounted to the exterior of the building at a minimum
height of eight (8) feet above grade directly in line with the
exhaust vent terminal for the horizontally vented gas fueled
heating appliance or equipment. The sign shall read, in print
size no less than one-half (1/2) inch in size, "GAS VENT

DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUC­TIONS".

4. INSPECTION. The state or local gas inspector of the side wall
horizontally vented gas fueled equipment shall not approve the
installation unless, upon inspection, the inspector observes car­bon monoxide detectors and signage installed in accordance
with the provisions of 248 CMR 5.08(2)(a)1 through 4.

268890-UIM-B-0607

INSPECTION

As soon as a unit is received, it should be inspected for possib le 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” (0.6 cm) 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.

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.

Unitary Products Group 3

268890-UIM-B-0607

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.

TABLE 1:

Application Downflow Horizontal

Top In. (cm) 1 (2.5) 0 (0)
Front In. (cm) 3 (7.6) 3 (7.6)
Rear In. (cm) 0 (0) 0 (0)
Left Side In. (cm) 0 (0) 1 (2.5)
Right Side In. (cm) 0 (0) 1 (2.5)
Flue In. (cm) 0 (0) 0 (0)

Floor / Bottom In. (cm)
Closet Yes Yes

Alcove Yes Yes
Attic Yes Yes

Line Contact NA

1. Combustible floor base or air conditioning coil required for use on combusti-

2. Line contact only permitted between lines formed by the intersection of the

Unit Clearances to Combustibles

1

1 (2.5)

ble floor.
rear panel (top in horizontal position) of the furnace jacket and building

joists, studs or framing.

0 (0)

Yes

2

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 contro l 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.

Ductwork Installation

NOTE: When attaching duct flange, do not shoot the screw down into

the casing. Use the formed flange intended for duct flange attachment.
A proper Heat Loss/Gain Calculation should be done on all installations

for proper application of equipment. From this the ductwork sizing can
be calculated, ACCA Manual J and D and industry standards are help­ful.

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 plenum should be if 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.

4 Unitary Products Group

268890-UIM-B-0607

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.

The following are general duct sizing guidelines that may not serve to
requirements of every application.

Example: The furnace input is 80,000 BTUH, 1,200 CFM blower
requirement. The recommended duct area is 216 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.

2. The square inch area for 7 inch round ducts, 38.4 square inch x 2
= 76.8 square inches,

3. Then take the 192 square inch from the rectangular duct and add it
to the 76.8 square inch of round duct. The total square inch of duct
attached to the furnace supply plenum is 268.8 square inches.
This exceeds the recommended 216 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.
Providing the return duct is properly sized as well.

1. Take 8 x 12, which equals 96 square inch x 2 = 192 square inches
then go to round duct size located in Table 3.

TABLE 2:

Minimum Duct Sizing For Proper Airflow

Input Nominal Airflow

Return

1

Rectangular

2

Round

2

Supply

3

Rectangular

2

Round

BTU/H(kW) CFM(m³/min) In² (cm²) in. x in.(cm x cm) in. (cm)dia. In²(cm²) in. x in.(cm x cm) in. (cm)dia.

40,000 (11.7) 1,200 (34.0) 280 (1806) 14 x 20 (35.6 x 90.8) 18 (45.7) 216 (1394) 12 x 18 (30.5 x 45.7) 16 (40.6)
60,000 (17.6) 1,200 (34.0) 280 (1806) 14 x 20 (35.6 x 50.8) 18 (45.7) 216 (1394) 12 x 18 (30.5 x 45.7) 16 (40.6)
80,000 (23.4) 1,200 (34.0) 280 (1806) 14 x 20 (35.6 x 50.8) 18 (45.7) 216 (1394) 12 x 18 (30.5 x 45.7) 16 (40.6)
80,000 (23.4) 1,600 (45.3) 360 (2322) 18 x 20 (45.7 x 50.8) 22 (55.8) 280 (1806) 14 x 20 (35.6 x 50.8) 18 (45.7)

100,000 (29.3) 1,600 (45.3) 360 (2322) 18 x 20 (45.7 x 50.8) 22 (55.8) 280 (1806) 14 x 20 (35.6 x 50.8) 18 (45.7)
100,000 (29.3) 2,000 (56.6) 440 (2839) 20 x 22 (50.8 x 55.8) 24 (60.9) 390 (2516) 16 x 22 (40.6 x 55.8) 22 (55.8)
120,000 (35.2) 2,000 (56.6) 440 (2839) 20 x 22 (50.8 x 55.8) 24 (60.9) 390 (2516) 16 x 22 (40.6 x 55.8) 22 (55.8)

NOTE: This chart does not replace proper duct sizing calculat ions or t a ke into accou nt st atic pressure drop f or run lengt h and fitt i ngs. Maint ai n prope r te mperatur e rise

and static pressures.

1. Maximum return air velocity in rigid duct @ 700 feet per minute (213 m/min).

2. Example return main trunk duct minimum dimensions.

3. Maximum supply air velocity in rigid duct @ 900 feet per minute (274m/min).

TABLE 3:

Round Duct Size

The transition duct must be the same dimensional size as the rectangu­lar opening in the base of the furnace.

Round Duct Size Calculated Area For Each Round Duct Size

Inches (cm)

Sq.in (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)

2

)

DOWNFLOW
FURNACE

WARM AIR PLENUM
WITH 1” FLANGES

FIBERGLASS
INSULATION

11 (28) 95 (613)
12 (30) 113.1 (730)
13 (33) 132.7 (856)
14 (36) 153.9 (993)

1. The Air Temperature Rise is determined by subtracting the Return
Air Temperature Reading from the Supply Air Temperature Read­ing.

FIBERGLASS TAPE
UNDER FLANGE

COMBUSTIBLE FLOOR
BASE ACCESSORY

2. The External Static Pressure is determined by adding the Supply
Duct Static Pressure reading to the Return Duct Static Pressure
reading.

FIGURE 1 : Combustible Floor Base Accessory

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

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, IX & X for additional informa­tion on correcting the problem.

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.

2

Unitary Products Group 5

268890-UIM-B-0607

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.

These kits are required in downflow application when using G*F* series
coils. These kits are not required with MC/FC series coils, but please
ensurethat the coil and furnace are sucured and that there are noair
leaks.

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.

• 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 Figure 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

TRANSITION
KIT

FIGURE 2: Transition Kit Assembly

KIT

AIRFLOW

COOLING
COIL
CABINET

AIRFLOW

REFRIGERANT
LINES

DRAIN
CONNECTIONS

Horizontal Models

IMPORTANT: This furnace may be installed in a horizontal position on
either side as shown above. It must not be installed on its back.

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.

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.

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.

6 Unitary Products Group

T-STAT WIRING 7/8” K.O.

HORIZONTAL CONDENSATE
DRAIN OPENING 1-3/4”

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”

28-1/2

LEFT SIDE

1-1/4

19-1/4

268890-UIM-B-0607

A

T-STAT WIRING 7/8” K.O.

HORIZONTAL CONDENSATE
DRAIN OPENING 1-3/4”

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

5/8

40

FRONT

1-1/4

D

C

23-5/8

5/8

B

20

BOTTOM IMAGE

SUPPLY END

2-1/4

23-1/4

TOP IMAGE

RETURN END

FIGURE 3: Dimensions
TABLE 4:

Cabinet and Duct Dimensions

BTUH (kW)

Input/Output

CFM

Cabinet

Size

Cabinet Dimension

A (in.) A (cm) B (in.) B (cm) C (in.) C (cm) D (in.) D (cm)

40/37 (11.7/10.8) 1200 (34.0) A 14-1/2 36.8 13-1/4 33.7 12 30.5 1-3/4 4.44
60/56 (17.6/16.4) 1200 (34.0) B 17-1/2 44.4 16-1/4 41.3 15 38.1 1-3/4 4.44
80/75 (23.4/22.0) 1200 (34.0) B 17-1/2 44.4 16-1/4 41.3 15 38.1 1-3/4 4.44

80/75 (23.4/22.0) 1600 (45.3) C 21 53.3 19-3/4 50.2 18-1/2 47.0 2-1/8 5.40
100/95 (29.3/27.8) 1600 (45.3) C 21 53.3 19-3/4 50.2 18-1/2 47.0 2-1/8 5.40
100/95 (29.3/27.8) 2000 (56.6) C 21 53.3 19-3/4 50.2 18-1/2 47.0 2-1/8 5.40

120/112 (35.1/32.8) 2000 (56.6) 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

IMPORTANT: If an external mounted filter rack is being used see the
instructions provided with that accessory for proper hole cut size.

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.

SECTION III: FILTERS

FILTER INSTALLATION

All applications require the use of a filter. Replacement filter size is
shown in Table 5.

TABLE 5:

NOTES:

Recommended Filter Sizes

Input / Output

BTU/H (kW)

(m

CFM

3

/min)

Cabinet

Size

Top Return

Filter in(cm)

40 (11.7) 1200 (34) A (2) 14 x 20 (36 x 51)
60 (17.8) 1200 (34) B (2) 14 x 20 (36 x 51)
80 (23.4) 1200 (34) B (2) 14 x 20 (36 x 51)

80 (23.4) 1600 (45) C (2) 14 x 20 (36 x 51)
100 (29.3) 1600 (45) C (2) 14 x 20 (36 x 51)
100 (29.3) 2000 (57) C (2) 14 x 20 (36 x 51)
120 (35.1) 2000 (57) D (2) 14 x 20 (36 x 51)

1. Air velocity through throwaway type filters may not exceed 300 feet
per minute. All velocities over this require the use of high velocity fil­ters.

Unitary Products Group 7

268890-UIM-B-0607

Downflow Filters

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.

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.

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.

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.

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

RETURN
AIR

AIR
FILTERS

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. 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.

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

FIGURE 5: 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.

COMBUSTION
AIR

30” MIN.
WORK AREA

FILTER RACK

VENT PIPE
(maintain required
clearances to
combustible)

RETURN
AIR

When a furnace is installed in an attic or other insulated space,

ELECTRICAL
SUPPLY

GAS SUPPLY
(EITHER SIDE)

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

FIGURE 4: Return Filter Grill and Return Duct Installation
IMPORTANT: Air velocity through throwaway type filters must not

exceed 300 feet per minute (91 m/min). All velocities over this require
the use of high velocity filters. Refer to Table 19.

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

All installations must have a filter installed.

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 to Figure 6
for typical crawl space installation.

8 Unitary Products Group

EXTERNAL MANUAL
SHUTOFF VALVE

268890-UIM-B-0607

ANGLE IRON
BRACKET

1” MAX. BETWEEN
ROD & FURNACE

6” MIN. BETWEEN
ROD & FURNACE

1” MAX. BETWEEN
ROD & FURNACE

SUPPORT
BRACKET

FIGURE 6: Typical Suspended Furnace / Crawl Space Installation

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

ON/OFF SWITCH
(Shown in ON position)

OFF

ON

FIGURE 7: 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.

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 8.

VENT PORT

OUTLET

MAIN REGULATOR
ADJUSTMENT

TO GAS
SUPPLY

DRIP
LEG

TO GAS
SUPPLY

GROUNDED JOINT UNION
MAY BE INSTALLED
INSIDE OR OUTSIDE UNIT.

FIGURE 8: Downflow Gas Piping

MANUAL
SHUT-OFF

GAS
PIPE

VALV E

DRIP
LEG

GAS
PIPE

MANUAL
SHUT-OFF VALVE

DRIP
LEG

GAS BURNERS

GAS VALVE

FIGURE 9: Horizontal 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).

Never apply a pipe wrench to the body of the gas valve when
installing piping. A wrench must be placed on the octagonal 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 3 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 – 8,000 feet (0-m – 2,438 m) above sea level.

The manifold pressure must be changed in order to manitain proper
and safe operation when the furnace is installed in a location where the
altitude is greater than 8,000 feet (2,438 m) above sea level. Refer to to
Table 6 for proper manifold pressure settings.

HIGH ALTITUDE PRESSURE SWITCH CONVERSION

For installation where the altitude is less than 8,000 feet (2,438 m), it is
not required that the pressure switch be changed. For altitudes above
8,000 feet (2,438 m), see Field Installed Accessories - High Altitude
pressure Switch.

Unitary Products Group 9

268890-UIM-B-0607

TABLE 6:

Nominal Manifold Pressure

Manifold Pressures (in wc) Manifold Pressures (kpa)

Altitude (feet) Altitude (m)

0-7999 8000-8999 9000-9999 0-2437 2438-2742 2743-3048

800 3.5 3.5 3.5

29.8 0.87 0.87 0.87
850 3.5 3.5 3.5 31.7 0.87 0.87 0.87
900 3.5 3.5 3.5 33.5 0.87 0.87 0.87
950 3.5 3.5 3.3 35.4 0.87 0.87 0.81

1000 3.5 3.2 2.9 37.3 0.87 0.80 0.73

(MJ/cu m)

Gas Heating Value

Gas Heating Value

(BTU/cu ft.)

1050 3.5 2.9 2.7 39.1 0.87 0.73 0.67
1100 3.2 2.7 2.4 41.0 0.80 0.66 0.61

2500 (LP) 9.8 8.2 7.5 93.2 (LP) 2.44 2.03 1.86

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.

SECTION V: ELECTRICAL POWER

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.

TABLE 7:

Electrical and Performance Data

Input/Cabinet Output Nominal Airflow Cabinet Width Total Unit AFUE Air Temp. Rise

MBH kW MBH kW CFM

3

m

/min

In. mm Amps % °F °C

40/A 12 37 10.8 1200 34 14-1/2 368 9 94 35 - 65 19 - 36
60/B 18 55 16.1 1200 34.0 17-1/2 444 9 92 35 - 65 19 - 36
80/B 23 74 21.7 1200 34.0 17-1/2 444 9 92 35 - 65 19 - 36

80/C 23 74 21.7 1600 45.3 21 533 12 92 35 - 65 19 - 36
100/C 29 93 27.3 1600 45.3 21 533 12 92 35 - 65 19 - 36
100/C 29 93 27.3 2000 56.6 21 533 14 92 35 - 65 19 - 36
120/D 35 112 32.8 2000 56.6 24-1/2 622 14 92 35 - 65 19 - 36

Input/Cabinet

Max. Outlet

Air Temp.

Blower Blower Size

MBH kW °F °C HP Amps In. cm Lbs. Kg.

40/A 12 165 73.9 1/2 7.0 11 x 8 27.9 x 20.3 20 14 120 54.5
60/B 18 165 73.9 1/2 7.0 11 x 8 27.9 x 20.3 20 14 130 59.0
80/B 23 165 73.9 1/2 7.0 11 x 8 27.9 x 20.3 20 14 145 65.9

80/C 23 165 73.9 3/4 10.2 11 x 10 27.9 x 25.4 20 14 155 70.5
100/C 29 165 73.9 3/4 10.2 11 x 10 25.4 x 25.4 20 14 170 77.3
100/C 29 165 73.9 1 12.7 11 x 11 27.9 x 27.9 20 12 175 79.5
120/D 35 165 73.9 1 12.7 11 x 11 27.9 x 27.9 20 12 180 81.8

Annual Fuel Utilization Efficiency (AFUE) numbers are determined in accordance 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.

NOTES:

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).

Use copper conductors only.

Max.

Over-current

Protect

Min. Wire Size
(awg) @ 75 ft.

One Way

Operation

Weight

10 Unitary Products Group

SUPPLY VOLTAGE CONNECTIONS

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.

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
wiring diagram shown in Figure 41.

2. Remove the screws retaining the junction 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 Figure

10. 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” (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.

3. The furnace's control system requires correct polarity of the power
supply and a proper ground connection. If the power supply polar­ity is reversed, the control board will flash 9 times. The furnace will
not operate until the polarity is corrected. Refer to “Furnace Diag­nostics” section of the “User’s Information, Maintenance, & Ser­vice Manual” provided with this furnace.

268890-UIM-B-0607

COMBUSTION
AIR

CLASS 2 SYSTEM
CONTROL WIRING
TO THERMOSTAT

(BLK) LI (HOT)

(WHT) N

(GRN)GND

FIGURE 10: Electrical Wiring

JUNCTION
BOX

BLOWER
COMPARTMENT

VENT PIPE

IGNITION
MODULE

TRANSFORMER

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
board on the ignition module, as shown in Figure 11. Electronic thermo­stats may require the common wire to be connected as shown with the
dashed line in Figure 11. 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 yellow and brown wires on the condensing unit (unit out­side). Refer to Figure 11.

IMPORTANT: Set the heat anticipator in the room thermostat to 0.45
amps. Setting it lower will cause short cycles. Setting it higher will cause
the room temperature to exceed the set points.Some electronic thermo­stats do not have adjustable heat anticipators. They may have other
type cycle rate adjustments. Follow the thermostat manufacturer's
instructions.

The 24-volt, 40 VA transformer is sized for the furnace components
only, and should not be connected to power auxiliary devices such as
humidifiers, air cleaners, etc. The transformer may provide power for an
air conditioning unit contactor.

For additional connection diagrams for all UPG equipment refer to “Low
Voltage System Wiring” document available online at www.upgnet.com
in the Product Catalog Section.

Unitary Products Group 11

268890-UIM-B-0607

SINGLE STAGE

AIR CONDITIONING

Y

C

24-Volt Common

Single Stage Cool

24V HUMIDIFIER

HEAT PUMP

SINGLE STAGE

Y

C

24-Volt Common

Single Stage Heat/Cool

R

24-Volt Hot

O

W

W1/66

First Stage Heat

First Stage Heat Out

X/L

Malfunction Light

Reversing Valve–Energized in Cool

PSC

C

FURNACE CONTROL

Optional w/Batteries

C

*BN11C01124

*DP11C40124

*DN11C00124

R

Y/Y2

24-Volt Common

24-Volt Hot

Single/Second Stage Cool

Y

RH

First Stage Cool

24-Volt Hot (Heat XFMR)

Y

RH

First Stage Cool

24-Volt Common

24-Volt Hot (Heat XFMR)

G

W

Fan

Single Stage Heat

RC

Fan

G

W

First Stage Heat

24-Volt Hot (Cool XFMR)

RC

Fan

G

W

First Stage Heat

24-Volt Hot (Cool XFMR)

HM1

Humidistat

on thermostat not necessary

Selection of GAS/ELEC switch

PSC

FURNACE CONTROL

C

C

R

Y/Y2

24-Volt Common

24-Volt Common

24-Volt Hot

Single/Second Stage Cool

Y

R

24-Volt Hot

First Stage Heat/Cool

G

W

Single Stage Heat

E

W1

G

Emergency Heat

Second Stage Heat

Fan

L

O

Fan

Malfunction Light

must be set to Heat Pump 1

Reversing Valve–Energized in Cool

Step 1 of Thermostat User Configuration Menu

must be set to Pump OFF

Step 9 of Thermostat User Configuration Menu

*BN21H00124

*DP21H40124

*DN21H00124

Y

R

RC

First Stage Cool

24-Volt Hot (Cool XFMR)

24-Volt Hot (Heat XFMR)

G

W

Fan

First Stage Heat

*DN22U00124 *BP21H50124 *PP32H70124

System Type - must be set to 0

Thermostat Installer Setup Number 1 -

Thermostat Installer Setup Number 15 -

Compressor Protection - must be set to 5

THERMOSTAT THERMOSTAT THERMOSTAT

Single Stage H/P - E*RD, E*BD, ERHS, HPX13 - w/Single Stage Furnace, 1 Stage Cooling Ready - (G,L)*8/9S, XYF80-U, XYF80-U*L, XYF90-U

N/A N/A

*BN11C00124 *BP11C50124 *PP11C70224

THERMOSTAT THERMOSTAT THERMOSTAT

C

24-Volt Common

W/031-01975- Series Demand Control

HP1

AC1 Single Stage A/C w/Single Stage Furnace, 1 Stage Cooling Ready - (G,L)*8/9S, XYF80-U, XYF80-U*L, XYF90-U

FIGURE 11: Thermostat Chart

12 Unitary Products Group