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

EFFICIENCY

RATING

CERTIFIED

ISO 9001

Certified Quality

Management System

LIST OF SECTIONS

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

TWINNING AND STAGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 COMBUSTION AIR AND VENT SYSTEM . . . . . . . . . . . . . . . . . . . . .14 CONDENSATE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . .31 WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

LIST OF FIGURES

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

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

LIST OF TABLES

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

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

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 moderate injury. It is also used to alert against unsafe practices and hazards involving only property damage.

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.

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	SPECIFIC SAFETY RULES AND PRECAUTIONS							•	Provide clearances from combustible materials as listed under
	1.	Only Natural gas or Propane (LP) gas are approved for use with							Clearances to Combustibles in Table 1.
		this furnace. Refer to the furnace rating plate or Section IV of						•	Provide clearances for servicing ensuring that service access is
		these instructions.							allowed for both the burners and blower.
	2.	Install this furnace only in a location and position as specified in						•	These models ARE NOT CSA listed or approved for installation
		SECTION I of these instructions.							into a HUD Approved Modular Home or a Manufactured
	3.	A gas-fired furnace for installation in a residential garage must be							(Mobile) Home.
		installed as specified in SECTION I of these instructions.						•	This furnace is not approved for installation in trailers or recre-
	4.	Provide adequate combustion and ventilation air to the furnace							ational vehicles.
		space as specified in SECTION VI of these instructions.						•	Failure to carefully read and follow all instructions in this
	5.	Combustion products must be discharged outdoors. Connect this							manual can result in furnace malfunction, death, personal
		furnace to an approved vent system only, as specified in SEC-							injury and/or property damage.
		TION VII of these instructions.						•	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 elec-
									trical characteristics match. All models use nominal 115 VAC, 1
	FIRE OR EXPLOSION HAZARD
									Phase, 60-Hertz power supply. DO NOT CONNECT THIS APPLI-
	Failure to follow the safety warnings exactly could result in serious
									ANCE TO A 50 HZ POWER SUPPLY OR A VOLTAGE ABOVE
	injury, death or property damage.
									130 VOLTS.
	Never test for gas leaks with an open flame. Use a commercially
								• Furnace shall be installed so the electrical components are pro-
	available soap solution made specifically for detection of leaks to
									tected from water.
	check all connections. A fire or explosion may result causing prop-
								•	Installing and servicing heating equipment can be hazardous due
	erty damage, personal injury or loss of life.
									to the electrical components and the gas fired components. Only
	6.	Tests for gas leaks as specified in SECTION X of these instruc-							trained and qualified personnel should install, repair, or service
		tions.							gas heating equipment. Untrained service personnel can perform
	7.	Always install the furnace to operate within the furnace’s intended							basic maintenance functions such as cleaning and replacing the
		temperature rise range. Only connect the furnace to a duct system							air filters. When working on heating equipment, observe precau-
		which has an external static pressure within the allowable range,							tions in the manuals and on the labels attached to the unit and
		as specified on the furnace rating plate.							other safety precautions that may apply.
	8.	When a furnace is installed so that supply ducts carry air circulated						•	These instructions cover minimum requirements and conform to
		by the furnace to areas outside the space containing the furnace,							existing national standards and safety codes. In some instances
		the return air shall also be handled by duct(s) sealed to the fur-							these instructions exceed certain local codes and ordinances,
		nace casing and terminating outside the space containing the fur-							especially those who have not kept up with changing residential
		nace.							and non-HUD modular home construction practices. These
	9.	It is permitted to use the furnace for heating of buildings or struc-							instructions are required as a minimum for a safe installation.
		tures under construction. Installation must comply with all manu-						COMBUSTION AIR QUALITY
		facturer’s installation instructions including:
								(LIST OF CONTAMINANTS)
		•	Proper vent installation;
								The furnace will require OUTDOOR AIR for combustion when the fur-
		• Furnace operating under thermostatic control;
		• Return air duct sealed to the furnace;						nace is located in any of the following environments.
		• Air filters in place;						•	Restricted Environments
		•	Set furnace input rate and temperature rise per rating plate
								•	Commercial buildings
			marking;
								• Buildings with indoor pools
		• Means for providing outdoor air required for combustion;
								• Furnaces installed in laundry rooms
		• Return air temperature maintained between 55ºF (13ºC) and
								• Furnaces installed in hobby or craft rooms
			80ºF (27ºC);
								•	Furnaces installed near chemical storage areas
		• The air filter must be replaced upon substantial completion of
			the construction process;					•	Chemical exposure
		•	Clean furnace, duct work and components upon substantial					The furnace will require OUTDOOR AIR for combustion when the fur-
			completion of the construction process, and verify furnace-					nace is located in an area where the furnace is being exposed to the fol-
			operating conditions including ignition, input rate, temperature
								lowing substances and / or chemicals.
			rise and venting, according to the manufacturer’s instructions.
								•	Permanent wave solutions
	10.	When installed in a Non-HUD-Approved Modular Home or building
								• Chlorinated waxes and cleaners
		constructed on-site, combustion air shall not be supplied from
								•	Chlorine based swimming pool chemicals
		occupied spaces.
	11.	The size of the unit should be based on an acceptable heat loss						•	Water softening chemicals
		calculation for the structure. ACCA, Manual J or other approved						•	De-icing salts or chemicals
		methods may be used.						•	Carbon tetrachloride
	SAFETY REQUIREMENTS							•	Halogen type refrigerants
								• Cleaning solvents (such as perchloroethylene)
	• This furnace should be installed in accordance with all national
								• Printing inks, paint removers, varnishes, etc.
			and local building/safety codes and requirements, local plumbing
								•	Hydrochloric acid
			or wastewater codes, and other applicable codes. In the absence
								•	Cements and glues
			of local codes, install in accordance with the National Fuel Gas
			Code ANSI Z223.1/NFPA 54, National Fuel Gas Code, and/or					•	Antistatic fabric softeners for clothes dryers
			CAN/CGA B149.1 Natural Gas and Propane Installation Code					•	Masonry acid washing materials
			(latest editions). Furnaces have been certified to the latest edition

	268890-UIM-B-0607	When outdoor air is used for combustion, the combustion air intake pipe
	of standard ANSI Z21-47 • CSA 2.3.	termination must be located external to the building and in an area
	• Refer to the unit rating plate for the furnace model number, and
		where there will be no exposure to the substances listed above.
	then see the dimensions page of this instruction for return air ple-
	num dimensions in Figure 3. The plenum must be installed
	according to the instructions.

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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 the 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.

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” (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.

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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: Unit Clearances to Combustibles

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)	1 (2.5)1	0 (0)
Closet		Yes	Yes
Alcove		Yes	Yes
Attic		Yes	Yes
Line Contact		NA	Yes2

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

2.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.

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.

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.

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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.

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.

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.

TABLE 2: Minimum Duct Sizing For Proper Airflow

Input	Nominal Airflow	Return1	Rectangular2	Round2	Supply3	Rectangular2	Round2
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 calculations or take into account static pressure drop for run length and fittings. Maintain proper temperature 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

Round Duct Size	Calculated Area For Each Round Duct Size
Inches (cm)	Sq.in (cm2)
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)

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.

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

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

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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	KIT
FURNACE
		REFRIGERANT
	AIRFLOW	LINES
	COOLING	DRAIN
	COIL
		CONNECTIONS
	CABINET
AIRFLOW
TRANSITION	AIRFLOW
KIT

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.

FIGURE 2: Transition Kit Assembly

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			268890-UIM-B-0607
		A
	T-STAT WIRING 7/8” K.O.		T-STAT WIRING 7/8” K.O.
	HORIZONTAL CONDENSATE		HORIZONTAL CONDENSATE
	DRAIN OPENING 1-3/4”
			DRAIN OPENING 1-3/4”
	HORIZONTAL CONDENSATE	40	HORIZONTAL
	DRAIN OPENING 2”
			CONDENSATE
	JUNCTION BOX		DRAIN OPENING 1-3/4”
	HOLE 7/8”
			JUNCTION BOX
	GAS PIPE ENTRY 1-1/2”		HOLE 7/8”
	CONDENSATE DRAIN		GAS PIPE
			ENTRY 1-1/2”
	HOLE 7/8”
	SIDE PIPING HOLE 3-3/8”
			CONDENSATE DRAIN
			HOLE 7/8”
	28-1/2
	LEFT SIDE	FRONT	RIGHT SIDE
			23-5/8
	19-1/4	1-1/4	5/8
	1-1/4	D	5/8
			B
	C
			20
		2-1/4
			23-1/4
	BOTTOM IMAGE		TOP IMAGE
	SUPPLY END		RETURN END
	FIGURE 3: Dimensions

TABLE 4: Cabinet and Duct Dimensions

	BTUH (kW)	CFM	Cabinet				Cabinet Dimension
	Input/Output		Size
				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 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.

SECTION III: FILTERS

FILTER INSTALLATION

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

TABLE 5: Recommended Filter Sizes

Input / Output	CFM	Cabinet	Top Return
BTU/H (kW)	(m3/min)	Size	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)

NOTES:

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.

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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	RETURN
AIR	AIR
VENT	AIR
PIPE	FILTERS

ELECTRICAL

SUPPLY

GAS SUPPLY (EITHER SIDE)

FIGURE 4: Return Filter Grill and Return Duct Installation

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

COMBUSTION AIR

30” MIN. WORK AREA

FILTER RACK

RETURN

AIR

VENT PIPE (maintain required clearances to combustible)

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.

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.

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.

All installations must have a filter 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 to Figure 6 for typical crawl space installation.

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ANGLE IRON		SUPPORT
BRACKET		BRACKET
1” MAX. BETWEEN
ROD & FURNACE	6” MIN. BETWEEN
		1” MAX. BETWEEN
	ROD & FURNACE
		ROD & FURNACE

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

FIGURE 7: Gas Valve

	VENT PORT
	OUTLET
OFF
ON	MAIN REGULATOR
ON/OFF SWITCH	ADJUSTMENT
(Shown in ON position)

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.

268890-UIM-B-0607

EXTERNAL MANUAL

SHUTOFF VALVE

TO GAS	TO GAS
SUPPLY	SUPPLY

GROUNDED JOINT UNION

DRIP

MAY BE INSTALLED

LEG

INSIDE OR OUTSIDE UNIT.

FIGURE 8: Downflow Gas Piping

MANUAL

SHUT-OFF

VALVE

GAS

PIPE

DRIP

LEG

GAS BURNERS

GAS GAS VALVE

PIPE

DRIP	MANUAL
LEG	SHUT-OFF 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 fac- tory-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.

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TABLE 6:

Gas Heating Value (BTU/cu ft.)

Nominal Manifold Pressure

Manifold Pressures (in wc)

		Altitude (feet)
	0-7999	8000-8999	9000-9999
800	3.5	3.5	3.5
850	3.5	3.5	3.5
900	3.5	3.5	3.5
950	3.5	3.5	3.3
1000	3.5	3.2	2.9
1050	3.5	2.9	2.7
1100	3.2	2.7	2.4
2500 (LP)	9.8	8.2	7.5

Heating Value	(MJ/cu m)
Gas

Manifold Pressures (kpa)

		Altitude (m)
	0-2437	2438-2742	2743-3048
29.8	0.87	0.87	0.87
31.7	0.87	0.87	0.87
33.5	0.87	0.87	0.87
35.4	0.87	0.87	0.81
37.3	0.87	0.80	0.73
39.1	0.87	0.73	0.67
41.0	0.80	0.66	0.61
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

Use copper conductors only.

	Input/Cabinet		Output		Nominal Airflow		Cabinet Width		Total Unit	AFUE	Air Temp. Rise
	MBH	kW	MBH	kW	CFM	m3/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		Blower		Blower Size		Max.	Min. Wire Size	Operation
			Air Temp.						Over-current	(awg) @ 75 ft.	Weight
									Protect	One Way
	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).

10	Unitary Products Group

268890-UIM-B-0607

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-wir- ing 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.

	COMBUSTION	BLOWER
		COMPARTMENT
	AIR
		VENT PIPE
	CLASS 2 SYSTEM
	CONTROL WIRING	IGNITION
	TO THERMOSTAT	MODULE

TRANSFORMER

(BLK) LI (HOT)
(WHT) N
(GRN)GND	JUNCTION
	BOX

FIGURE 10: Electrical Wiring

LOW VOLTAGE CONTROL WIRING CONNECTIONS

Install the field-supplied thermostat by following the instructions that come with the thermostat. With the thermostat set in the OFF position and the main electrical source disconnected, connect the thermostat wiring from the wiring connections on the thermostat to the terminal 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

12

Group Products Unitary

Chart Thermostat 11: FIGURE

AC1	Single Stage A/C w/Single Stage Furnace, 1 Stage Cooling Ready - (G,L)*8/9S, XYF80-U, XYF80-U*L, XYF90-U
		THERMOSTAT	THERMOSTAT	THERMOSTAT		PSC		SINGLE STAGE
		*BN11C00124	*BP11C50124	*PP11C70224		FURNACE CONTROL		AIR CONDITIONING
			*BN11C01124
			*DP11C40124
			*DN11C00124
		C	C	Optional w/Batteries		C			C
		24-Volt Common	24-Volt Common			24-Volt Common		24-Volt Common
		Y	Y	Y		Y/Y2			Y
		First Stage Cool	First Stage Cool	First Stage Cool		Single/Second Stage Cool		Single Stage Cool
		R	RH	RH		R
		24-Volt Hot (Heat XFMR)	24-Volt Hot (Heat XFMR)	24-Volt Hot (Heat XFMR)		24-Volt Hot
		RC	RC	RC
		24-Volt Hot (Cool XFMR)	24-Volt Hot (Cool XFMR)	24-Volt Hot (Cool XFMR)
		W	W	W		W		24V HUMIDIFIER
		First Stage Heat	First Stage Heat	First Stage Heat		Single Stage Heat
		G	G	G		G
		Fan	Fan	Fan		Fan
				HM1
				Humidistat
		Thermostat Installer Setup Number 1 -	Selection of GAS/ELEC switch
		System Type - must be set to 0	on thermostat not necessary
		Thermostat Installer Setup Number 15 -
		Compressor Protection - must be set to 5

HP1		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
	W/031-01975- Series Demand Control
		THERMOSTAT	THERMOSTAT	THERMOSTAT		PSC		SINGLE STAGE
		*DN22U00124	*BP21H50124	*PP32H70124		FURNACE CONTROL		HEAT PUMP
			*BN21H00124
			*DP21H40124
			*DN21H00124
				C		C		C
				24-Volt Common		24-Volt Common		24-Volt Common
				Y		Y/Y2		Y
				First Stage Heat/Cool		Single/Second Stage Cool		Single Stage Heat/Cool
				R		R		R
				24-Volt Hot		24-Volt Hot		24-Volt Hot
				W1
		N/A	N/A	Second Stage Heat
				E		W		W1/66
				Emergency Heat		Single Stage Heat		First Stage Heat Out
				G		G		W
				Fan		Fan		First Stage Heat
				O				O
				Reversing Valve–Energized in Cool				Reversing Valve–Energized in Cool
				L				X/L
				Malfunction Light				Malfunction Light
				Step 1 of Thermostat User Configuration Menu
				must be set to Heat Pump 1
				Step 9 of Thermostat User Configuration Menu
				must be set to Pump OFF

0607-B-UIM-268890