Unitary products group Gy8s*uh User manual

166753-UIM-C-0706

EFFICIENCY

RATING

CERTIFIED

ISO 9001

Certified Quality

Management System

HIGH EFFICIENCY

TUBULAR HEAT EXCHANGER SERIES

MODELS: GY8S*UH / GM8S*UH / GR8S*UH / LY8S*UH / LM8S*UH / LF8*UH

(Single St ge Upflow / Horizont l / Low NOx)

40 - 130 MBH INPUT

(11.72 - 38.10 KW) INPUT

INSTALLATION MANUAL

INSTALLATION MANUALINSTALLATION MANUAL

INSTALLATION MANUAL

SECTION I: SAFETY

SECTION I: SAFETYSECTION I: SAFETY

SECTION I: SAFETY

This is a safety alert symbol. When you see this symbol on

labels or in manuals, be alert to the otential for ersonal

injury.

Understand and ay articular attention to the signal words DANGER,

WARNING, or CAUTION.

DANGER indicates an imminently hazardous situation, which, if not

avoided, will result in de th or serious injury.

WARNING indicates a potenti lly hazardous situation, which, if not

avoided, could result in de th or serious injury.

CAUTION indicates a otentially hazardous situation, which, if not

avoided m y result in minor or moder te injury. It is also used to

alert against unsafe ractices and hazards involving only ro erty dam-

age.

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 mainte-

nance can cause injury or property damage. Refer to this manual

for assistance or for additional information, consult a qualified con-

tractor, installer or service agency.

This product must be installed in strict compliance with the installa-

tion instructions and any applicable local, state, and national codes

including, but not limited to building, electrical, and mechanical

codes.

LIST OF SECTIONS

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

DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

TWINNING AND STAGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

VENT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . .20

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAFETY 1

LIST OF FIGURES

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Ty ical Attic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Ty ical Sus ended Furnace / Crawl S ace Installation . . . . . . . . . . . . 7

Side Return Cutout Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Gas Valve - All Exce t GR Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Gas Valve - GR Models Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

U flow Gas Pi ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Horizontal Gas Pi ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Thermostat Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Accessory Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Ty ical Twinned Furnace A lication . . . . . . . . . . . . . . . . . . . . . . . . 12

Single Stage Twinning Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . 13

Two-Stage Twinning Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 13

Vent Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Ty ical Sidewall Vent A lication . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Ty ical Sidewall Vent and Termination Configuration . . . . . . . . . . . .15

Home Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Combustion Airflow Path Through The Furnace

Casing to the Burner Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Alternate Air Intake, Air Outlet and Chimney Connections . . . . . . . . .17

Air Inlet, Outlet and Chimney Connections . . . . . . . . . . . . . . . . . . . . .17

Ty ical Chimney Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Horizontal Air Inlet, Outlet and Chimney Connections . . . . . . . . . . . .18

Outside and Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . .18

Pressure Switch Tubing Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Gas Valve - GR Models Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Ty ical Heat/Cool S eed Ta Connections . . . . . . . . . . . . . . . . . . . .24

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

LIST OF TABLES

Unit Clearances to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Minimum Duct Sizing For Pro er Airflow . . . . . . . . . . . . . . . . . . . . . . . 4

Round Duct Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Cabinet and Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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

Nominal Manifold Pressure - High Fire . . . . . . . . . . . . . . . . . . . . . . . . 9

Ratings & Physical / Electrical Data - U flow Models . . . . . . . . . . . . . 9

Roof Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Unconfined S ace Minimum Area in Square Inch . . . . . . . . . . . . . . .18

Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Nominal Manifold Pressure - All Exce t GR Models . . . . . . . . . . . . .22

Nominal Manifold Pressure - GR Models . . . . . . . . . . . . . . . . . . . . . .23

Filter Performance - Pressure Dro Inches W.C. and (kPa) . . . . . . . .24

Field Installed Accessories - Non Electrical . . . . . . . . . . . . . . . . . . . .25

Blower Performance CFM - U flow/Horizontal (without filter) -

Bottom Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Blower Performance CFM - U flow/Horizontal (without filter) -

Left Side Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

166753-UIM-C-0706

2 Unitary Products Grou

SPECIFIC SAFETY RULES AND PRECAUTIONS

SPECIFIC SAFETY RULES AND PRECAUTIONSSPECIFIC SAFETY RULES AND PRECAUTIONS

SPECIFIC SAFETY RULES AND PRECAUTIONS

1. Only Natural gas or Pro ane (LP) gas are a roved for use with

this furnace.

2. Install this furnace only in a location and osition as s ecified in

SECTION I of these instructions.

3. A gas-fired furnace for installation in a residential garage must be

installed as s ecified in SECTION I of these instructions.

4. Provide adequate combustion and ventilation air to the furnace

s ace as s ecified in SECTION VII of these instructions.

5. Combustion roducts must be discharged outdoors. Connect this

furnace to an a roved vent system only, as s ecified in SEC-

TION VII of these instructions.

6. Test for gas leaks as s ecified in SECTION IX of these instruc-

tions.

7. Always install the furnace to o erate within the furnace’s intended

tem erature-rise range. Only connect the furnace to a duct system

which has an external static ressure within the allowable range,

as s ecified on the furnace rating late.

8. When a furnace is installed so that su ly ducts carry air circulated

by the furnace to areas outside the s ace containing the furnace,

the return air shall also be handled by duct(s) sealed to the fur-

nace casing and terminating outside the s ace containing the fur-

nace.

9. The furnace is not to be used for tem orary heating of buildings or

structures under construction.

10. When installed in a Non-HUD-A roved Modular Home or building

constructed on-site, combustion air shall not be su lied from

occu ied s aces.

11. The size of the unit should be based on an acce table heat loss

calculation for the structure. ACCA, Manual J or other a roved

methods may be used.

SAFETY REQUIREMENTS

SAFETY REQUIREMENTSSAFETY REQUIREMENTS

SAFETY REQUIREMENTS

• This furnace should be installed in accordance with all national

and local building/safety codes and requirements, local lumbing

or wastewater codes, and other a licable 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 Pro ane 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 late for the furnace model number, and

then see the dimensions age of this instruction for return air le-

num dimensions in Figure 1. The lenum must be installed

according to the instructions.

• Provide clearances from combustible materials as listed under

Clearances to Combustibles.

• Provide clearances for servicing ensuring that service access is

allowed for both the burners and blower.

• These models ARE NOT CSA listed or a roved for installation

into a HUD Approved Modul r Home or a M nuf ctured

(Mobile) Home.

• This furnace is not a roved for installation in trailers or recre-

ational vehicles.

• F ilure to c refully re d nd follow ll instructions in this

m nu l c n result in furn ce m lfunction, de th, person l

injury nd/or property d m ge.

• Furnaces for installation on combustible flooring shall not be

installed directly on car eting, tile or other combustible material

other than wood flooring.

• Check the rating late and ower su ly to be sure that the elec-

trical characteristics match. All models use nominal 115 VAC, 1

Phase, 60-Hertz ower su ly. DO NOT CONNECT THIS APPLI-

ANCE TO A 50 HZ POWER SUPPLY OR A VOLTAGE ABOVE

130 VOLTS.

• Furnace shall be installed so the electrical com onents are ro-

tected from water.

• Installing and servicing heating equi ment can be hazardous due

to the electrical com onents and the gas fired com onents. Only

trained and qualified ersonnel should install, re air, or service

gas heating equi ment. Untrained service ersonnel can erform

basic maintenance functions such as cleaning and re lacing the

air filters. When working on heating equi ment, observe recau-

tions in the manuals and on the labels attached to the unit and

other safety recautions that may a ly.

• 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,

es ecially those who have not ke t u with changing residential

and non-HUD modular home construction ractices. These

instructions are required as a minimum for a safe installation.

COMBUSTION AIR QUALITY

COMBUSTION AIR QUALITY COMBUSTION AIR QUALITY

COMBUSTION AIR QUALITY

(LIST OF CONTAMINANTS)

(LIST OF CONTAMINANTS)(LIST OF CONTAMINANTS)

(LIST OF CONTAMINANTS)

The furnace will require OUTDOOR AIR for combustion when the fur-

nace is located in any of the following environments.

• Restricted Environments

• Commercial buildings

• Buildings with indoor ools

• Furnaces installed in laundry rooms

• Furnaces installed in hobby or craft rooms

• Furnaces installed near chemical storage areas

• Chemical Ex osure

The furnace will require OUTDOOR AIR for combustion when the fur-

nace is located in an area where the furnace is being ex osed to the fol-

lowing substances and / or chemicals.

• Permanent wave solutions

• Chlorinated waxes and cleaners

• Chlorine based swimming ool chemicals

• Water softening chemicals

• De-icing salts or chemicals

• Carbon tetrachloride

• Halogen ty e refrigerants

• Cleaning solvents (such as erchloroethylene)

• Printing inks, aint 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 duct

system termination must be located external to the building and in an

area where there will be no ex osure to the substances listed above.

FIR OR XPLOSION 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 prop-

erty damage, personal injury or loss of life.

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 fur-

nace.

1. S ray or aerosol cans, rags, brooms, dust mo s, vacuum

cleaners or other cleaning tools.

2. Soa owders, bleaches, waxes or other cleaning com-

ounds; lastic items or containers; gasoline, kerosene, ciga-

rette lighter fluid, dry cleaning fluids or other volatile fluid.

3. Paint thinners and other ainting com ounds.

4. Pa er bags, boxes or other a er roducts

Never operate the furnace with the blower door removed. To

do so could result in serious personal injury and/or equipment

damage.

166753-UIM-C-0706

Unitary Products Grou 3

INSPECTION

INSPECTIONINSPECTION

INSPECTION

As soon as a unit is received, it should be ins ected for ossible dam-

age during transit. If damage is evident, the extent of the damage

should be noted on the carrier’s freight bill. A se arate request for

ins ection 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 shi ing or s acer brackets

which need to be removed.

FURNACE LOCATION AND CLEARANCES

FURNACE LOCATION AND CLEARANCESFURNACE LOCATION AND CLEARANCES

FURNACE LOCATION AND CLEARANCES

The furn ce sh ll be loc ted using the following guidelines:

1. Where a minimum amount of air intake/vent i ing and elbows will

be required.

2. As centralized with the air distribution as ossible.

3. Where adequate combustion air will be available ( articularly

when the a liance is not using outdoor combustion air).

4. Where it will not interfere with ro er air circulation in the confined

s ace.

5. Where the outdoor vent terminal will not be blocked or restricted.

Refer to “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 osition with no more

than 1/4” (6.4 mm) slo e side-to-side and front-to-back to rovide

ro er condensate drainage.

Inst ll tion in freezing temper tures:

1. Furnace shall be installed in an area where ventilation facilities

rovide for safe limits of ambient tem erature under normal o er-

ating conditions. Ambient tem eratures may fall below 32° F (0° C)

roviding the flue tem erature does not fall below 260° F (127° C)

at any oint in the flue i e between the furnace and the chimney

or a B-Vent. The flue roducts will condense in the vent i e if the

flue tem erature falls below 260° F (127° C) causing the vent i e

to deteriorate ra idly.

2. Do not allow return air tem erature to be below 55º F (13° C) for

extended eriods. To do so may cause condensation to occur in

the main heat exchanger, leading to remature heat exchanger

failure.

3. If this furnace is installed in an unconditioned s ace and an

extended ower failure occurs, there will be otential damage to

the internal com onents. Following a ower failure situation, do

not o erate the unit until ins ection and re airs are erformed.

Cle r nces for ccess:

Am le clearances should be rovided to ermit 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 a liance, when access is

required for servicing and cleaning.

2. Eighteen (18) inches (46 cm) at the side where access is required

for assage to the front when servicing or for ins ection or

re lacement of flue/vent connections.

In all cases, accessibility clearances shall take recedence over clear-

ances for combustible materials where accessibility clearances are

greater.

Inst ll tion in residenti l g r ge:

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 rotected to avoid hysical damage by vehicles.

SECTION II: DUCTWORK

SECTION II: DUCTWORKSECTION II: DUCTWORK

SECTION II: DUCTWORK

DUCTWORK GENERAL INFORMATION

DUCTWORK GENERAL INFORMATIONDUCTWORK GENERAL INFORMATION

DUCTWORK GENERAL INFORMATION

The duct system’s design nd inst ll tion must:

1. Handle an air volume a ro riate for the served s ace and within

the o erating arameters of the furnace s ecifications.

2. Be installed in accordance with standards of NFPA (National Fire

Protection Association) as outlined in NFPA am hlets 90A and

90B (latest editions) or a licable national, rovincial, or state, and

local fire and safety codes.

3. Create a closed duct system. For residential and Non-HUD Modu-

lar Home installations, when a furnace is installed so that the su -

ly ducts carry air circulated by the furnace to areas outside the

s ace containing the furnace, the return air shall also be handled

by a duct(s) sealed to the furnace casing and terminating outside

the s ace containing the furnace.

4. Com lete a ath for heated or cooled air to circulate through the

air conditioning and heating equi ment and to and from the condi-

tioned s ace.

When the furnace is used in conjunction with a cooling coil, the coil

must be installed arallel with, or in the su ly air side of the furnace to

avoid condensation in the rimary heat exchanger. When a arallel flow

arrangement is used, dam ers or other means used to control airflow

must be adequate to revent chilled air from entering the furnace. If

manually o erated, the dam er must be equi ed with means to re-

vent the furnace or the air conditioner from o erating unless the dam er

is in full heat or cool osition.

Improper installation in an ambient below 32ºF (0.0° C) could create

a hazard, resulting in damage, injury or death.

TABLE 1:

Unit Clearances to Combustibles (All Dimensions in Inches, and All Surfaces Identified with the Unit in an U flow Configuration)

Applic tion Top Front Re r Left Side Right Side Flue Floor/

Bottom Closet Alcove Attic Line

Cont ct

In. (cm) In. (cm) In. (cm) In. (cm) In. (cm) In. (cm)

U flow 1 (25.4) 6 (15.24) 0 (0.0) 0 (0.0) 3 (7.62) 6 (15.24) Combustible Yes Yes Yes No

U flow B-Vent 1 (25.4) 3 (7.62) 0 (0.0) 0 (0.0) 0 (0.0) 1 (25.4) Combustible Yes Yes Yes No

Horizontal 1 (25.4) 6 (15.24) 0 (0.0) 0 (0.0) 3 (7.62) 6 (15.24) Combustible No Yes Yes Yes

1. Line contact only ermitted between lines formed by the intersection of the rear anel and side anel (to in horizontal osition) of the furnace jacket and building

joists, studs or framing.

Horizontal B-Vent 1 (25.4) 3 (7.62) 0 (0.0) 0 (0.0) 0 (0.0) 1 (25.4) Combustible No Yes Yes Yes

The cooling coil must be installed in the supply air duct, down-

stream of the furnace. Cooled air may not be passed over the heat

exchanger.

166753-UIM-C-0706

4 Unitary Products Grou

DUCTWORK INSTALLATION AND SUPPLY PLENUM

DUCTWORK INSTALLATION AND SUPPLY PLENUM DUCTWORK INSTALLATION AND SUPPLY PLENUM

DUCTWORK INSTALLATION AND SUPPLY PLENUM

CONNECTION

CONNECTIONCONNECTION

CONNECTION

Attach the su ly lenum to the furnace outlet duct connec-

tion flanges. This is ty ically through the use of S cleat

material when a metal lenum is used. The use of an

a roved flexible duct connector is recommended on all

installations. This connection should be sealed to revent

air leakage. The sheet metal should be crosshatched to

eliminate any o ing of the sheet metal when the indoor

fan is energized.

When re lacing an existing furnace, if the existing lenum is not the

same size as the new furnace then the existing lenum must be

removed and a new lenum installed that is the ro er size for the new

furnace. If the lenum is shorter than 12” (30.5 cm) the turbulent air flow

may cause the limit controls not to o erate as designed, or the limit con-

trols may not o erate at all.

The duct system is a very im ortant art of the installation.

If the duct

system is improperly sized the furn ce will not oper te properly.

The ducts attached to the furnace lenum, should be of sufficient size

so that the furnace o erates at the s ecified external static ressure

and within the air tem erature rise s ecified on the name late.

Table 2 is a guide for determining whether the rectangular duct system

that the furnace is being connected to be of sufficient size for ro er fur-

nace o eration.

Use the Exam le below to hel you in calculating the duct area to deter-

mine whether the ducts have sufficient area so that the furnace o er-

ates at the s ecified external static ressure and within the air

tem erature rise s ecified on the name late.

Ex. The furnace in ut is 80,000 BTUH and 1,200 CFM. The recom-

mended duct area is 280 sq.in, there are two 8 x 14 rectangular ducts

attached to the lenum and there are two 7 inch round ducts attached to

the furnace.

1. Take 8 x 14, which equals 112 sq.in. X 2, which equals 224 square

inch then go to round duct size located in Table 3.

2. The square inch area for 7 inch round i e is 38.4, multi ly by 2 for

two round ducts which equals 76.8 square inch,

3. Then take the 224 square inch from the rectangular duct and add it

to the 76.8 sq.in. of round duct. The total square inch of duct

attached to the furnace lenum is 300.8 square inch. This exceeds

the recommended 280 square inch of duct.

In this exam le, the duct system attached to the lenum has a sufficient

area so that the furnace o erates at the s ecified external static res-

sure and within the air tem erature rise s ecified on the name late.

1. The Air Tem erature Rise is determined by subtracting the Return

Air Tem erature Reading from the Su ly Air Tem erature Read-

ing.

2. The External Static Pressure is determined by adding the Su ly

Duct Static Pressure reading to the Return Duct Static Pressure

reading, adding the ressure across any a lied a-coil and the

dro across the return air filter.

TABLES 2 & 3 are to be used as a guide only to hel the installer deter-

mine if the duct sizes are large enough to obtain the ro er air flow

(CFM) through the furnace. TABLES 2 & 3 ARE NOT to be used to

design ductwork for the building where the furnace is being installed.

There are several variables associated with ro er duct sizing that are

not included in the tables. To ro erly design the ductwork for the build-

ing, refer to the ASHRAE Fundamentals Handbook, Cha ter on “DUCT

DESIGN” or a com any that s ecializes in Residential and Modular

Home duct designs.

The duct system must be properly sized to obtain the correct airflow

for the furnace size that is being installed.

Refer to 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 pres-

sures and/or high temperature rises which can result in a heat

exchanger OV RH ATING CONDITION. This condition can result

in premature heat exchanger failure, which can result in personal

injury, property damage, or death.

TABLE 2:

Minimum Duct Sizing For Pro er Airflow

Input Airflow Return

Rect ngul r

Round

Supply

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

40,000(11.7) 1,200(34.0) 280 (711) 14 x 20 (35.6 x 50.8) 18 (45.7) 216 (549)

60,000 (17.6) 1,200 (34.0) 280 (711) 14 x 20 (35.6 x 50.8) 18 (45.7) 216 (549)

80,000 (23.4) 1,200 (34.0) 280 (711) 14 x 20 (35.6 x 50.8) 18 (45.7) 216 (549)

80,000 (23.4) 1,600 (45.3) 360 (914) 18 x 20 (45.7 x 50.8) 22 (55.8) 280 (711)

80,000 (23.4) 2,000 (56.6)

2,200 (62.3) 440 (1,118) 20 x 22 (50.8 x 55.8) 24 (60.9) 390 (991)

100,000 (29.3) 1,200 (34.0) 320 (813) 16 x 20 (40.6 x 50.8) 20 (50.8) 336 (853)

100,000 (29.3) 1,600 (45.3) 360 (914) 18 x 20 (45.7 x 50.8) 22 (55.8) 280 (711)

100,000 (29.3) 2,000 (56.6) 440 (1,118) 20 x 22 (50.8 x 55.8) 24 (60.9) 390 (991)

115,000 (35.2) 1,600 (45.3) 360 (914) 18 x 20 (45.7 x 50.8) 22 (55.8) 280 (711)

115,000 (35.2) 2,000 (56.6) 440 (1,118) 20 x 22 (50.8 x 55.8) 24 (60.9) 390 (991)

130,000 (41.0) 2,000 (56.6) 440 (1,118) 20 x 22 (50.8 x 55.8) 24 (60.9) 390 (991)

NOTE: This chart does not re lace ro er duct sizing calculations or take into account static ressure dro for run length and fittings. Watch out for the tem erature rise and static ressures.

1. Maximum return air velocity in rigid duct @ 700 feet er minute (19.82 m

/ minute).

2. Exam le return main trunk duct minimum dimensions.

3. Maximum su ly air velocity in rigid duct @ 900 feet er minute (25.49 m

/ minute).

TABLE 3:

Round Duct Size

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)

11 (28) 95 (613)

12 (30) 113.1 (730)

13 (33) 132.7 (856)

14 (36) 153.9 (993)

166753-UIM-C-0706

Unitary Products Grou 5

IMPORTANT:

The minimum lenum height is 12” (30.5 cm). The fur-

nace will not o erate ro erly on a shorter lenum height. The mini-

mum recommended rectangular duct height is 4 inches (10 cm)

attached to the lenum.

IMPORTANT:

The air tem erature rise should be taken only after the

furnace has been o erating for at least 15 minutes. Tem eratures and

external static ressures should be taken 6” (15 cm) ast the first bend

from the furnace in the su ly duct and the return duct. If an external fil-

ter box or an electronic air cleaner is installed, take the return air read-

ings before the filter box or air cleaner.

If a matching cooling coil is used, it may be laced directly on the fur-

nace outlet and sealed to revent leakage. Follow the coil instructions

for installing the su ly lenum. On all installations without a coil, a

removable access anel is recommended in the outlet duct such that

smoke or reflected light would be observable inside the casing to indi-

cate the resence of leaks in the heat exchanger. This access cover

shall be attached in such a manner as to revent leaks.

The supply air temperature MUST N V R exceed the Maximum

Supply Air Temperature, specified on the nameplate.

Operating the furnace above the maximum supply air temperature

will cause the heat exchanger to overheat, causing premature heat

exchanger failure. Improper duct sizing, dirty air filters, incorrect

manifold pressure, incorrect gas orifice and/or a faulty limit switch

can cause the furnace to operate above the maximum supply air

temperature. Refer to sections II, III and IX for additional informa-

tion on correcting the problem.

FIGURE 1:

Dimensions

FRONT LEFT SIDE RIGHT SIDE

B20

A28-1/2

3/4

14-3/4

5-3/8

(VENT CONNECTIONS)

POWER WIRING

7/8” HOLE

2-1/2

ACCESS

WIRING

7/8” K.O.

8-3/4

T’STAT WIRING 7/8” K.O.

1-1/8

2-1/4

23-1/2

32-1/2

13-3/4

GAS INLET

1-1/4 x 2-1/2

26-1/2

1-3/8

1-1/4

20 5/8

5/8

24-3/4

BOTTOM IMAGE

RETURN END TOP IMAGE

SUPPLY END

4” Diameter

TABLE 4:

Cabinet and Duct Dimensions

BTUH (kW)

Input/Output CFM (m

/min) C binet

Size

C binet Dimension

A A (cm) B B (cm) C C (cm) D D (cm)

40/32 (11.7/9.4) 1200 (34.0) A 14 1/2 36.8 13 1/4 33.6 11 1/2 29.1 10 1/8 25.7

60/48 (17.6/14.1) 1200 (34.0) A 14 1/2 36.8 13 1/4 33.6 11 1/2 29.1 10 1/8 25.7

80/64 (23.4/18.8) 1200 (34.0) A 14 1/2 36.8 13 1/4 33.6 11 1/2 29.1 10 1/8 25.7

80/64 (23.4/18.8) 1600 (45.3) B 17 1/2 44.4 16 1/4 41.3 14 3/8 36.5 11 5/8 29.5

80/64 (23.4/18.8) 1600 (45.3) C 2 53.3 19 3/4 50.2 17 3/4 45.1 13 3/8 34.0

80/64 (23.4/18.8) 2000 (56.6)

2200 (62.3) C 21 53.3 19 3/4 50.2 17 3/4 45.1 13 3/8 34.0

100/80 (29.3/23.4) 1200 (34.0) B 17 1/2 44.4 16 1/4 41.3 14 3/8 36.5 11 5/8 29.5

100/80 (29.3/23.4) 1600 (45.3) B 17 1/2 44.4 16 1/4 41.3 14 3/8 36.5 11 5/8 29.5

100/80 (29.3/23.4) 1600 (45.3) C 21 53.3 19 3/4 50.2 17 3/4 45.1 13 3/8 34

100/80 (29.3/23.4) 2000 (56.6) C 21 53.3 19 3/4 50.2 17 3/4 45.1 13 3/8 34

115/92 (33.7/27.0) 1600 (45.3) C 21 53.3 19 3/4 50.2 17 3/4 45.1 13 3/8 34

115/92 (33.7/27.0) 2000 (56.6) C 21 53.3 19 3/4 50.2 17 3/4 45.1 13 3/8 34

130/104 (38.1/30.5) 2000 (56.6) D 24 1/2 62.2 23 1/4 59.1 21 3/8 54.3 15 1/8 27.6

166753-UIM-C-0706

6 Unitary Products Grou

RESIDENTIAL AND NON HUD MODULAR HOME

RESIDENTIAL AND NON HUD MODULAR HOME RESIDENTIAL AND NON HUD MODULAR HOME

RESIDENTIAL AND NON HUD MODULAR HOME

UPFLOW RETURN PLENUM CONNECTION

UPFLOW RETURN PLENUM CONNECTIONUPFLOW RETURN PLENUM CONNECTION

UPFLOW RETURN PLENUM CONNECTION

Return air may enter the furnace through the side(s) or bottom de end-

ing on the ty e of a lication. Return air may not be connected into the

rear anel of the unit. In order to achieve the airflow indicated, it is rec-

ommended those a lications over 1800 CFM (57 m³/min) use return

air from two sides, one side and the bottom or bottom only. For single

return a lication, see data and notes on blower erformance data

tables in this manual.

BOTTOM RETURN AND ATTIC INSTALLATIONS

BOTTOM RETURN AND ATTIC INSTALLATIONSBOTTOM RETURN AND ATTIC INSTALLATIONS

BOTTOM RETURN AND ATTIC INSTALLATIONS

Bottom return a lications normally ull return air through a base lat-

form or return air lenum. Be sure the return latform structure or return

air lenum is suitable to su ort the weight of the furnace.

The furnace base is equi ed with a rectangular anel that can be

removed by erforming the following ste s:

1. Lay the furnace on its back.

2. Remove the screws from the toe late.

3. Remove the toe late.

4. Pull the base late out of the furnace base.

5. Reinstall the toe late and secure with the screws that were

removed.

Attic installations must meet all minimum clearances to combustibles

and have floor su ort with required service accessibility.

IMPORTANT:

If an external mounted filter rack is being used see the

instructions rovided with that accessory for ro er hole cut size.

HORIZONTAL

HORIZONTALHORIZONTAL

HORIZONTAL MODELS

MODELS MODELS

MODELS

Horizont l Inst ll tions With Cooling Coil C binet

The furnace should be installed with coil cabinet art number s ecifi-

cally intended for Horizontal a lication. If a matching cooling coil is

used, it may be laced directly on the furnace outlet and sealed to re-

vent leakage. Follow the coil instructions for installing the su ly le-

num. For details of the coil cabinet dimensions and installation

requirements, refer to the installation instructions su lied with the coil

cabinet

Attach the su ly lenum to the air conditioning coil cabinet outlet duct

flanges through the use of S cleat material when a metal lenum is

used. The use of an a roved flexible duct connector is recommended

on all installations. The connection to the furnace, air conditioning coil

cabinet and the su ly lenum should be sealed to revent air leakage.

The sheet metal should be crosshatched to eliminate any o ing of

the sheet metal when the indoor fan is energized.

The minimum lenum height is 12” (30.5 cm). If the lenum is shorter

than 12” (30.5 cm) the turbulent air flow may cause the limit controls not

to o erate as designed, or the limit controls may not o erate at all. Also

the lastic drain an in the air conditioning coil can overheat and melt.

Refer to the installation instructions su lied with the air conditioning

coil for additional information.

Horizont l Inst ll tions Without Cooling Coil C binet

When installing this a liance, the furnace must be installed so as to

create a closed duct system, the su ly duct system must be con-

nected to the furnace outlet and the su ly duct system must terminate

outside the s ace containing the furnace. When re lacing an existing

furnace, if the existing lenum is not the same size as the new furnace

then the existing lenum must be removed and a new lenum installed

that is the ro er size for the new furnace.

Attach the su ly lenum to the furnace outlet duct flanges through the

use of S cleat material when a metal lenum is used. The use of an

a roved flexible duct connector is recommended on all installations.

This connection should be sealed to revent air leakage. The sheet

metal should be crosshatched to eliminate any o ing of the sheet

metal when the indoor fan is energized. On all installations without a

coil, a removable access anel is recommended in the outlet duct such

that smoke or reflected light would be observable inside the casing to

indicate the resence of leaks in the heat exchanger. This access cover

shall be attached in such a manner as to revent leaks.

Residenti l nd Non Hud Modul r Home Horizont l Return

Plenum Connections

The return duct system must be connected to the furnace inlet and the

return duct system must terminate outside the s ace containing the fur-

nace. When re lacing an existing furnace, if the existing lenum is not

the same size as the new furnace then the existing lenum must be

removed and a new lenum installed that is the ro er size for the new

furnace.

Attach the return lenum to the furnace inlet duct flanges. This is ty i-

cally through the use of S cleat material when a metal lenum is used.

The use of an a roved flexible duct connector is recommended on all

installations. The connection of the lenum to the furnace and all the

ducts connecting to the lenum must be sealed to revent air leakage.

The sheet metal should be crosshatched to eliminate any o ing of

the sheet metal when the indoor fan is energized.

The duct system is a very im ortant art of the installation. If the duct

system is im ro erly sized the furnace will not o erate ro erly. The

ducts attached to the furnace must be of sufficient size so that the fur-

nace o erates at the s ecified external static ressure and within the air

tem erature rise s ecified on the name late.

Attic installations must meet all minimum clearances to combustibles

and have floor su ort with required service accessibility.

IMPORTANT:

if an external mounted filter rack is being used see the

instructions rovided with that accessory for ro er hole cut size.

ATTIC INSTALLATION

ATTIC INSTALLATIONATTIC INSTALLATION

ATTIC INSTALLATION

FIGURE 2:

Ty ical Attic Installation

RETURN AIR SEDIMENT

TRAP

GAS PIPING

SUPPLY AIR

VENT (Maintain

required clearances

to combustibles)

SHEET METAL

IN FRONT OF

FURNACE

COMBUSTION AIR

OPENINGS IS

RECOMMENDED

LINE CONTACT ONLY PERMISSIBLE

BETWEEN LINES FORMED BY THE

INTERSECTION OF FURNACE TOP

AND TWO SIDES AND BUILDING

JOISTS, STUDS OR FRAMING

12”

30” MIN.

WORK AREA

FILTER RACK

MUST BE A MINIMUM

DISTANCE

OF 18” (45.7 cm)

FROM THE

FURNACE

166753-UIM-C-0706

Unitary Products Grou 7

This a liance is design certified for line contact when the furnace is

installed in the horizontal left or right osition. The line contact is only

ermissible between lines that are formed by the intersection of the to

and two sides of the furnace and the building joists, studs or framing.

This line may be in contact with combustible material. Refer to Figure 3.

SUSPENDED FURNACE / CRAWL SPACE

SUSPENDED FURNACE / CRAWL SPACE SUSPENDED FURNACE / CRAWL SPACE

SUSPENDED FURNACE / CRAWL SPACE

INSTALLATION

INSTALLATIONINSTALLATION

INSTALLATION

The furnace can be hung from floor joists or installed on suitable blocks

or ad. Blocks or ad installations shall rovide adequate height to

ensure the unit will not be subject to water damage. Units may also be

sus ended from rafters or floor joists using rods, i e angle su orts or

stra s. Angle su orts should be laced at the su ly air end and near

the blower deck. Do not su ort at return air end of unit. All four sus-

ension oints must be level to ensure quite furnace o eration. When

sus ending the furnace use a secure latform constructed of lywood

or other building material secured to the floor joists. Refer to Figure 4

for ty ical crawl s ace installation.

SECTION III: FILTERS

SECTION III: FILTERSSECTION III: FILTERS

SECTION III: FILTERS

FILTER INSTALLATION

FILTER INSTALLATIONFILTER INSTALLATION

FILTER INSTALLATION

All a lications require the use of a field installed accessory filter. All fil-

ters and mounting rovision must be field su lied. Refer to Tables 5 &

16 for accessory external filter kit o tions.

NOTES:

1. Air velocity through throwaway ty e filters may not exceed 300 feet er minute (91.4 m/min). All velocities over this require the use of high velocity filters.

2. Air flows above 1800 CFM require either return from two sides or one side lus bottom.

SIDE RETURN - EXTERNAL INSTALLATION

SIDE RETURN - EXTERNAL INSTALLATIONSIDE RETURN - EXTERNAL INSTALLATION

SIDE RETURN - EXTERNAL INSTALLATION

Locate and knock out the square corner locators. These indicate the

size of the cutout to be made in the furnace side anel. Refer to Figure 5.

Install the side filter rack following the instructions rovided with that

accessory. If a filter(s) is rovided at another location in the return air

system, the ductwork may be directly attached to the furnace side

anel. An accessory filter rack is available for mounting the filter exter-

nal to the cabinet.

IMPORTANT:

Some accessories such as electronic air cleaners and

leated media may require a larger side o ening. Follow the instruc-

tions su lied with that accessory for side o ening requirements. Do

not cut the o ening larger than the dimensions shown in Figure 1.

HORIZONTAL APPLICATION

HORIZONTAL APPLICATIONHORIZONTAL APPLICATION

HORIZONTAL APPLICATION

Horizont l Filters

All filters and mounting rovision must be field su lied. 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 lenum. Any branch duct (rectan-

gular or round duct) attached to the lenum must attach to the vertical

lenum above the filter height. The use of stra s and / or su orts is

required to su ort the weight of the external filter box.

IMPORTANT:

Air velocity through throwaway ty e filters must not

exceed 300 feet er minute (1.52 m/m). All velocities over this require

the use of high velocity filters. Refer to Table 15.

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.

FIGURE 3:

Ty ical Sus ended Furnace / Crawl S ace Installation

In any application where temperatures below freezing are possible,

see “B LOW FR ZING LOCATIONS”.

1” MAX. BETWEEN

ROD & FURNACE

SUPPORT

ROD

6” MIN BETWEEN

ROD & FURNACE

1” MAX. BETWEEN

ROD & FURNACE

ANGLE IRON

BRACKET

TABLE 5:

Filter Sizes

CFM

(m³/min)

C binet

Size

Side

(in)

Side

(cm)

Bottom

(in)

Bottom

(cm)

1200 (33.98) A 16 x 25 40.6 x 63.5 14 x 25 35.6 x 63.5

1200 (33.98) B 16 x 25 40.6 x 63.5 16 x 25 40.6 x 63.5

1600 (45.31) B 16 x 25 40.6 x 63.5 16 x 25 40.6 x 63.5

1600 (45.31) C 16 x 25 40.6 x 63.5 20 x 25 50.8 x 63.5

2000 (56.63) C (2) 16 x 25 (2) 40.6 x 63.5 20 x 25 50.8 x 63.5

2200 (62.30) C (2) 16 x 25 (2) 40.6 x 63.5 20 x 25 50.8 x 63.5

2000 (56.63) D (2) 16 x 25 (2) 40.6 x 63.5 22 x 25 55.9 x 63.5

FIGURE 4:

Side Return Cutout Markings

FRONT OF

FURNACE

CORNER

MARKINGS

All installations must have a filter installed.

166753-UIM-C-0706

8 Unitary Products Grou

SECTION IV: GAS PIPING

SECTION IV: GAS PIPINGSECTION IV: GAS PIPING

SECTION IV: GAS PIPING

GAS SAFETY

GAS SAFETYGAS SAFETY

GAS SAFETY

IMPORTANT:

Plan your gas su ly before determining the correct gas

i e entry. Use 90-degree service elbow(s), or short ni les and con-

ventional 90-degree elbow(s) to enter through the cabinet access holes.

GAS PIPING INSTALLATION

GAS PIPING INSTALLATIONGAS PIPING INSTALLATION

GAS PIPING INSTALLATION

Pro erly sized wrought iron, a roved flexible or steel i e must be

used when making gas connections to the unit. If local codes allow the

use of a flexible gas a liance connection, always use a new listed con-

nector. Do not use a connector that has reviously serviced another gas

a liance.

Some utility com anies or local codes require i e sizes larger than the

minimum sizes listed in these instructions and in the codes. The furnace

rating late and the instructions in this section s ecify the ty e of gas

a roved for this furnace - only use those a roved gases. The instal-

lation of a dri leg and ground union is required. Refer to Figure 8.

IMPORTANT:

An accessible manual shutoff valve must be installed

u stream of the furnace gas controls and within 6 feet (1.8 m) of the fur-

nace.

The furnace must be isolated from the gas su ly i ing system by

closing its individual external manual shutoff valve during any ressure

testing of the gas su ly i ing system at ressures equal to or less

than 1/2 sig (3.5 kPa).

Gas i ing may be connected from either side of the furnace using any

of the gas i e entry knockouts on both sides of the furnace. Refer to

Figure 1 dimensions.

GAS ORIFICE CONVERSION FOR PROPANE (LP)

GAS ORIFICE CONVERSION FOR PROPANE (LP)GAS ORIFICE CONVERSION FOR PROPANE (LP)

GAS ORIFICE CONVERSION FOR PROPANE (LP)

This furnace is constructed at the factory for natural gas-fired o eration,

but may be converted to o erate on ro ane (LP) gas by using a fac-

tory-su lied LP conversion kit. Follow the instructions su lied with

the LP kit. Refer to Table 6 or the instructions in the ro ane (LP) con-

version kit for the ro er gas orifice size.

HIGH ALTITUDE GAS ORIFICE CONVERSION

HIGH ALTITUDE GAS ORIFICE CONVERSIONHIGH ALTITUDE GAS ORIFICE CONVERSION

HIGH ALTITUDE GAS ORIFICE CONVERSION

This furnace is constructed at the factory for natural gas-fired o eration

at 0 – 8,000 feet (0-m – 2,438 m) above sea level.

The manifold ressure must be changed in order to manitain ro er

and safe o eration 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 ro er manifold ressure settings.

HIGH ALTITUDE PRESSURE SWITCH CONVERSION

HIGH ALTITUDE PRESSURE SWITCH CONVERSIONHIGH ALTITUDE PRESSURE SWITCH CONVERSION

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 ressure switch be changed. For altitudes above

8,000 feet (2,438 m), see Table 16 Field Installed Accessories - High

Altitude Pressure Switch

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.

FIGURE 5:

Gas Valve - All Exce t GR Models

FIGURE 6:

Gas Valve - GR Models Only

FIGURE 7:

U flow Gas Pi ing

INLET

WRENCH

BOSS

INLET

PRESSURE

PORT

OFF

ON/OFF SWITCH

(Shown in ON position)

MAIN REGULATOR

ADJUSTMENT

OUTLET

PRESSURE

PORT

VENT PORT

INLET

WRENCH

BOSS

ON/OFF SWITCH

(shown in OFF position)

MAIN REGULATOR

ADJUSTMENT

OUTLET

SUPPLY

PRESSURE

TAP

OUTLET

(MANIFOLD)

PRESSURE

TAP

ELECTRICAL

CONNECTIONS

EXTERNAL MANUAL

SHUTOFF VALVE

TO GAS

SUPPLY

TO GAS

SUPPLY

GROUNDED JOINT UNION

MAY BE INSTALLED

INSIDE OR OUTSIDE UNIT.

DRIP

LEG

FIGURE 8:

Horizontal Gas Pi ing

The gas valve body is a very thin casting that cannot take any

external pressure. Never apply a pipe wrench to the body of the gas

valve when installing piping. A wrench must be placed on the octa-

gon 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.

LoNOx furnaces requiring propane (LP) gas must have the LoNOx

screens removed prior to installation and operation. See propane

instructions 035-14445-000 or the start up procedure at the back of

these instructions on proper removal of the NOx screens.

MANUAL

SHUT-OFF

VALVE

GAS

PIPE

GAS

PIPE

DRIP

LEG

MANUAL

SHUT-OFF VALVE

GAS VALVE

GAS BURNERS

DRIP

LEG

166753-UIM-C-0706

Unitary Products Grou 9

SECTION V: ELECTRICAL POWER

SECTION V: ELECTRICAL POWERSECTION V: ELECTRICAL POWER

SECTION V: ELECTRICAL POWER

Electric l Power Connections

Field wiring to the unit must be grounded. Electric wires that are field

installed shall conform to the tem erature limitation for 63°F (35°C) rise

wire when installed in accordance with instructions. Refer to Table 7 in

these instructions for s ecific furnace electrical data.

Annual Fuel Utilization Efficiency (AFUE) numbers are determined in accordance with DOE Test rocedures.

Wire size and over current rotection must com ly with the National Electrical Code (NFPA-70-latest edition) and all local codes.

The furnace shall be installed so that the electrical com onents are rotected from water.

TABLE 6:

Nominal Manifold Pressure - High Fire

Single/Second St ge M nifold Pressures (in wc) Single/Second St ge M nifold Pressures (kp )

Altitude (feet) Altitude (m)

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

Gas Heating Value

(BTU/cu ft.)

800 3.5 3.5 3.5

Gas Heating Value

(MJ/cu m)

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

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

PROPAN AND HIGH ALTITUD CONV RSION KITS

It is very important to choose the correct kit and/or gas orifices for the altitude and the type of gas for which the furnace is being installed.

Only use natural gas in furnaces designed for natural gas. Only use propane (LP) gas for furnaces that have been properly converted to use pro-

pane (LP) gas. Do not use this furnace with butane gas.

Incorrect gas orifices or a furnace that has been improperly converted will create an extremely dangerous condition resulting in premature heat

exchanger failure, excessive sooting, high levels of carbon monoxide, personal injury, property damage, a fire hazard and/or death.

High altitude and propane (LP) conversions are required in order for the appliance to satisfactory meet the application.

An authorized distributor or dealer must make all gas conversions.

In Canada, a certified conversion station or other qualified agency, using factory specified and/or approved parts, must perform the conversion.

The installer must take every precaution to insure that the furnace has been converted to the proper gas orifice size when the furnace is installed.

Do not attempt to drill out any orifices to obtain the proper orifice size. Drilling out a gas orifice will cause misalignment of the burner flames,

causing premature heat exchanger burnout, high levels of carbon monoxide, excessive sooting, a fire hazard, personal injury, property damage

and/or death.

Use copper conductors only.

TABLE 7:

Ratings & Physical / Electrical Data - U flow Models

Input Output Nomin l

Airflow C binet Width Tot l Unit

Amps AFUE Air Temp. Rise

MBH kW MBH kW CFM cmm In. cm °F °C

40 11.7 32 9.4 1200 34.0 14-1/2 36.8 9.0 80.0 25-55 13-31

60 17.6 48 14.1 1200 34.0 14-1/2 36.8 9.0 80.0 25-55 13-31

80 23.5 64 18.8 1200 34.0 14-1/2 36.8 9.0 80.0 35-65 19-36

80 23.5 64 18.8 1600 45.3 17 1/2 44.5 12.0 80.0 25-55 13-31

80 23.5 64 18.8 1600 45.3 21 53.3 12.0 80.0 25-55 13-31

80 23.5 64 18.8 2000

2200

56.6

62.3 21 53.3 14.0 80.0 25-55 13-31

100 29.3 80 23.4 1200 34.0 17 1/2 44.5 12.0 80.0 40-70 22-39

100 29.3 80 23.4 1600 45.3 17 1/2 44.5 12.0 80.0 35-65 19-36

100 29.3 80 23.4 1600 45.3 21 53.3 12.0 80.0 35-65 19-36

100 29.3 80 23.4 2000 56.6 21 53.3 14.0 80.0 25-55 13-31

115 33.7 92 26.9 1600 45.3 21 53.3 12.0 80.0 35-65 19-36

115 33.7 92 26.9 2000 56.6 21 53.3 14.0 80.0 30-60 17-33

130 38.1 104 30.5 2000 56.6 24-1/2 62.2 14.0 80.0 35-65 19-36

Input M x. Outlet

Air Temp Blower Blower

Size

M x

Over-Current

Protect

Min. wire Size

( wg) @ 75 ft

one w y

Oper tion

WGT.

Oper tion

WGT.

MBH kW °F °C H Am s In. cm LBS Kg

40 11.7 155 68.3 1/2 7.1 10 x 8 25.4 x 17.7 20 14 105 47.6

60 17.6 155 68.3 1/2 7.1 10 x 8 25.4 x 17.7 20 14 110 49.9

80 23.5 170 76.7 1/2 7.1 10 x 8 25.4 x 17.7 20 14 117 53.1

80 23.5 155 68.3 3/4 11.5 11 x 8 27.9 x 20.3 20 14 126 57.2

80 23.5 155 68.3 3/4 11.5 10 x 10 25.4 x 25.4 20 14 130 59.0

80 23.5 165 73.9 1.0 14.0 11 x 11 27.9 x 25.4 20 12 140 63.5

100 29.3 170 76.7 1/2 7.1 10 x 8 25.4 x 20.3 20 14 128 58.1

100 29.3 165 73.9 3/4 11.5 11 x 8 25.4 x 25.4 20 14 134 60.8

100 29.3 165 73.9 3/4 11.5 10 x 10 25.4 x 25.4 20 14 140 63.5

100 29.3 155 68.3 1.0 14.0 11 x 11 27.9 x 25.4 20 12 145 65.8

115 33.7 170 76.7 3/4 11.5 10 x 10 25.4 x 25.4 20 14 145 65.8

115 33.7 170 76.7 1.0 14.0 11 x 11 27.9 x 25.4 20 12 147 66.7

130 38.1 165 73.9 1.0 14.0 11 x 11 27.9 x 25.4 20 12 158 71.7

166753-UIM-C-0706

10 Unitary Products Grou

SUPPLY VOLTAGE CONNECTIONS

SUPPLY VOLTAGE CONNECTIONSSUPPLY VOLTAGE CONNECTIONS

SUPPLY VOLTAGE CONNECTIONS

1. Provide a ower su ly se arate from all other circuits. Install

overcurrent rotection and disconnect switch er local/national

electrical codes. The switch should be close to the unit for conve-

nience in servicing. With the disconnect or fused switch in the OFF

osition, check all wiring against the unit wiring label. Refer to the

wiring diagram in this instruction.

2. Remove the screws retaining the wiring box cover. Route the

ower wiring through the o ening in the unit into the junction box

with a conduit connector or other ro er connection. In the junc-

tion box there will be three wires, a Black Wire, a White Wire and a

Green Wire. Connect the ower su ly as shown on the unit-wir-

ing label on the inside of the blower com artment door or the wir-

ing schematic in this section. The black furnace lead must be

connected to the L1 (hot) wire from the ower su ly. The white

furnace lead must be connected to neutral. Connect the green fur-

nace lead (equi ment ground) to the ower su ly ground. An

alternate wiring method is to use a field rovided 2” (5.1 cm) x 4”

(10.2 cm) box and cover on the outside of the furnace. Route the

furnace leads into the box using a rotective bushing where the

wires ass through the furnace anel. After making the wiring con-

nections re lace the wiring box cover and screws. Refer to Figure

10.

3. The furnace's control system requires correct olarity of the ower

su ly and a ro er ground connection. Refer to Figure 10.

IMPORTANT:

The ower connection leads and wiring box may be relo-

cated to the left side of the furnace. Remove the screws and cut wire tie

holding excess wiring. Re osition on the left side of the furnace and fas-

ten using holes rovided.

LOW VOLTAGE CONTROL WIRING CONNECTIONS

LOW VOLTAGE CONTROL WIRING CONNECTIONSLOW VOLTAGE CONTROL WIRING CONNECTIONS

LOW VOLTAGE CONTROL WIRING CONNECTIONS

Install the field-su lied thermostat by following the instructions that

come with the thermostat. With the thermostat set in the OFF osition

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 thermo-

stats may require the common wire to be connected as shown in Figure

11. A ly strain relief to thermostat wires assing through cabinet. If air

conditioning equi ment is installed, use thermostat wiring to connect

the Y and C terminals on the furnace control board to the ro er wires

on the condensing unit (unit outside).

IMPORTANT:

Set the heat antici ator in the room thermostat to 0.4

am s. Setting it lower will cause short cycles. Setting it higher will cause

the room tem erature to exceed the set oints.

IMPORTANT:

Some electronic thermostats do not have adjustable heat

antici ators. They may have other ty e cycle rate adjustments. Follow

the thermostat manufacturer's instructions.

The 24-volt, 40 VA transformer is sized for the furnace com onents

only, and should not be connected to ower auxiliary devices such as

humidifiers, air cleaners, etc. The transformer may rovide ower for an

air conditioning unit contactor.

For additional connection diagrams for all UPG equi ment refer to “Low

Voltage System Wiring” document available online at www.u gnet.com

in the Product Catalog Section.

FIGURE 9:

Electrical Wiring

YWRGC

CLASS 2 SYSTEM

CONTROL WIRING

TO THERMOSTAT

TRANSFORMER

IGNITION MODULE

BURNER COMPARTMENT

BLOWER COMPARTMENT

DOOR SWITCH

JUNCTION

BOX

BLK/BLK

WHT/WHT

GRN/GRN

HOT

WHT

NGND

GRN

BLK

166753-UIM-C-0706

Unitary Products Grou 11

FIGURE 10:

Thermostat Chart

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

HM1

Humidistat

Thermostat Installer Setup Number 1 -

System Type - must be set to 0

Selection of GAS/ELEC switch

on thermostat not necessary

Thermostat Installer Setup Number 15 -

Compressor Protection - must be set to 5

24V HUMIDIFIER

Fan

First Stage Heat

Single Stage Heat

24-Volt Hot (Cool XFMR)

24-Volt Hot (Heat XFMR)

24-Volt Hot

24-Volt Common

First Stage Cool

Y/Y2

Single/Second Stage Cool

Single Stage Cool

*DN11C00124

24-Volt Common

Optional w/Batteries

*BN11C01124

*DP11C40124

PSC

FURNACE CONTROL

SINGLE STAGE

AIR CONDITIONING

*BN11C00124 *BP11C50124 *PP11C70224

THERMOSTAT THERMOSTAT THERMOSTAT

HP1

W/031-01975- Series Demand Control

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

SINGLE STAGE

HEAT PUMP

*DN22U00124 *BP21H50124 *PP32H70124

THERMOSTAT THERMOSTAT THERMOSTAT PSC

FURNACE CONTROL

*BN21H00124

*DP21H40124

*DN21H00124

N/A N/A

24-Volt Common

24-Volt Hot

Emergency Heat

Reversing Valve–Energized in Cool

24-Volt Common

First Stage Heat/Cool

Y/Y2

Single/Second Stage Cool

Single Stage Heat/Cool

24-Volt Hot

Second Stage Heat

Single Stage Heat

W1/66

First Stage Heat Out

Fan

First Stage Heat

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

Reversing Valve–Energized in Cool

Malfunction Light

X/L

Malfunction Light

166753-UIM-C-0706

12 Unitary Products Grou

ACCESSORY CONNECTIONS

ACCESSORY CONNECTIONSACCESSORY CONNECTIONS

ACCESSORY CONNECTIONS

The furnace control will allow ower-switching control of various acces-

sories. Refer to Figure 12, for connection details.

ELECTRONIC AIR CLEANER CONNECTION

ELECTRONIC AIR CLEANER CONNECTIONELECTRONIC AIR CLEANER CONNECTION

ELECTRONIC AIR CLEANER CONNECTION

Two 1/4” (6.4 mm) s ade terminals (EAC and EAC N) for electronic air

cleaner connections are located on the control board. The terminals

rovide 115 VAC (1.0 am maximum) during circulating blower o era-

tion.

HUMIDIFIER CONNECTION

HUMIDIFIER CONNECTIONHUMIDIFIER CONNECTION

HUMIDIFIER CONNECTION

Two 1/4” (0.64 cm) s ade terminals (HUM and HUM N) for humidifier

connections are located on the control board. The terminals rovide 115

VAC (1.0 am maximum) during heating system o eration.

SECTION VI: TWINNING AND STAGING

SECTION VI: TWINNING AND STAGINGSECTION VI: TWINNING AND STAGING

SECTION VI: TWINNING AND STAGING

NOTE:

There are two different integrated control modules that can be

used on these models. They are art # 031-01933-000 and 031-01267-

001.

You can twin two 031-01933-000 integrated control modules or two

031-01267-001 integrated control modules. You

c nnot twin

one 031-

01933-000 integrated control module and one 031-01267-001 inte-

grated control module. The two integrated control modules do not com-

municate with each other so they will not work in a twinning a lication.

In a lications where more heating ca acity or more airflow ca acity is

needed than what one furnace can deliver, twinning can be used to

make two furnaces o erate in tandem. When two furnaces are installed

using the same duct system, it is very im ortant that the two furnace cir-

culating air blowers o erate in unison. If one blower starts before the

second blower, the duct system will become ressurized and the blower

on the second furnace will turn backwards causing the second furnace

to overheat, resulting in damage to the furnace. Twinning is used to

make two furnaces o erate in tandem, using one duct system, one

room thermostat and causing both furnaces to turn on and off simulta-

neously.

TWINNING DUCT SYSTEM

TWINNING DUCT SYSTEMTWINNING DUCT SYSTEM

TWINNING DUCT SYSTEM

Twinned furnaces must only be a lied on a common duct system. A

single air su ly lenum must be used for both furnaces and coil(s).

Se arate lenums and su ly ducts systems cannot be utilized. A sin-

gle return air lenum, common to both furnaces must be used. It is sug-

gested that a return latform be utilized, with bottom air entrance into

each furnace. If a side entrance return system is used, the common

return duct must be divided equally so as to su ly each furnace with

an equal amount of return air.

Both furnaces must be identical models in both heating ca acity and

CFM ca acity. Both furnaces must be o erated on the same motor

s eed ta . See ty ical a lication, Figure 13.

If furnace staging is desired with two single stage furnaces on a com-

mon duct, where the gas burner on the first furnace o erates on W1

and the gas burner on the second furnace o erates on W2, then the

use of an air-mixing device in the lenum to mix the air from both fur-

naces is strongly recommended. The mixing device must be installed

before any ducts that su ly air to occu ied s aces. Twinning causes

both indoor fans to o erate simultaneously. If a mixing device is not

used, any ducts that are connected down stream from the furnace that

o erates on W2, will be su lying cold air in the Heating mode to the

occu ied s aces unless W2 is energized.

IMPORTANT:

When two furnaces are twinned, ty ical system total air-

flow will be a roximately 85% of additive individual furnaces, i.e., two

2000 CFM units will yield a total 3400 CFM.

GAS PIPING

GAS PIPINGGAS PIPING

GAS PIPING

Furnace gas su lies must be rovided as s ecified with these instruc-

tions. Since the furnaces are side by side, with no s ace between, gas

su lies must enter on the right and left res ectively. All gas i ing

must be in accordance with the national fuel gas code, ANSI Z223.1,

latest edition, and/or all local code or utility requirements.

FIGURE 11:

Accessory Connections

Before installing the relay and wiring, disconnect electrical power to

both furnaces. Failure to cut power could result in electrical shock

or equipment damage.

The relay must not be installed in any location where it could be

exposed to water. If the relay has been exposed to water in any

way, it must not be used.

115 VOLT

HUMIDIFER

115 VOLT

ELECTRONIC

AIR CLEANER

EAC HOT

HUM. HOT

BLK

WHT

EAC

HUM

NEUTRALS

SWITCHED

CIRCUITS

BLK

WHT

FIGURE 12:

Ty ical Twinned Furnace A lication

If a return duct is connected to only one furnace (with a connection

between the two furnaces) an imbalance in the airflow will occur

and the furnace furthest from the return plenum will overheat.

VENT PIPE

ELECTRICAL

SUPPLY GAS SUPPLY

(both sides)

1 COIL FOR

EACH FURNACE

COMMON

SUPPLY

PLENUM

SUPPLY

AIR

166753-UIM-C-0706

Unitary Products Grou 13

TWINNING

TWINNINGTWINNING

TWINNING

In a lications where more heating ca acity or more airflow ca acity is

needed than what one furnace can deliver, twinning can be used to

make two furnaces o erate in tandem, using one duct system and one

room thermostat. When one duct system is used for two furnaces, it is

necessary that the two blowers o erate in unison. The twinning function

of the board in this furnace ensures that both blowers turn on and off

simultaneously, and o erate on the same blower s eed.

Single-Wire Twinning

The control in the furnace has the single-wire twinning feature. With this

feature, a single wire is connected between the TWIN terminal on one

furnace board to the TWIN terminal on the second furnace board. The

board then communicates the blower status from one furnace to the

other along this wire. This communication makes the second furnace

blower come on at the same time, and on the same s eed, as the first

furnace blower.

Single-Wire Twinning Instructions

Connect the control wiring as shown in Figure 14.

1. Connect the low voltage wiring from the wall thermostat to the ter-

minal stri on the control board of Furnace #1.

2. Connect a wire from the TWIN terminal of Furnace #1 to the TWIN

terminal of Furnace #2.

3. Install a se arate 24V relay as shown in the diagram below. Use of

this relay is required, as it ensures that the transformers of the two

furnaces are isolated, thus reventing the ossibility of any safety

devices being by assed.

Single-Wire Twinning Oper tion

Heating - On a call for heat (W signal) from the wall thermostat, both

furnaces will start the ignition sequence and the burners on both fur-

naces will light. About thirty seconds after the burners light, the blowers

on both furnaces will come on in heating s eed. When the thermostat is

satisfied, the burners will all shut off and, after the selected blower off

delay time, both blowers will shut off at the same time. The twinning

control ensures that both blowers come on and shut off at the same

time.

Cooling - On a call for cooling (Y signal) from the wall thermostat, both

furnace blowers will come on at the same time in cooling s eed. When

the thermostat is satisfied, both blowers will stay on for 60 seconds,

then will shut off at the same time.

Continuous Fan - On a thermostat call for continuous fan (G signal),

both furnace blowers will come on at the same time in cooling s eed

and will stay on until the G signal is removed.

STAGING

STAGINGSTAGING

STAGING

In a lications where more heating ca acity or more airflow ca acity is

needed than what one furnace can deliver, twinning can be used to

make two furnaces o erate in tandem, using one duct system and one

room thermostat. This control can also be used along with a two-stage

wall thermostat to stage two twinned furnaces, making them o erate

like a single two-stage furnace. This allows only one furnace to su ly

heat during times when the heat out ut from one furnace is sufficient to

satisfy the demand. When one duct system is used for two furnaces, it

is necessary that the two blowers o erate in unison. The twinning func-

tion of this board ensures that both blowers turn on and off simulta-

neously, and o erate on the same blower s eed. Even when only one

furnace is su lying heat, both furnace blowers must run.

Single-Wire St ging

The single-wire twinning feature of this board can also be used for stag-

ing of two furnaces. With this feature, a single wire is connected

between the TWIN terminal on one furnace board to the TWIN terminal

on the second furnace board. The board then communicates the blower

status from one furnace to the other along this wire. This communica-

tion makes the second furnace blower come on at the same time, and

on the same s eed, as the first furnace blower.

Single-Wire St ging Instructions

Connect the control wiring as shown in Figure 15.

1. Connect the low voltage wiring from the wall thermostat to the ter-

minal stri on the control board of Furnace #1. For staging a lica-

tions, the wire from thermostat W1 is connected to the W

connection on the board on Furnace #1. The wire from thermostat

W2 is connected to Furnace #2 through a se arate relay, as

described below.

2. Connect a wire from the TWIN terminal of Furnace #1 to the TWIN

terminal of Furnace #2.

3. Install a se arate 24V relay as shown in the diagram below. Use of

this relay is required, as it ensures that the transformers of the two

furnaces are isolated, thus reventing the ossibility of any safety

devices being by assed.

Single-Wire St ging Oper tion

Heating - On a call for first-stage heat (W1 signal) from the wall thermo-

stat, Furnace #1 will start the ignition sequence and the burners will

light. About thirty seconds after the burners light, the blowers on both

furnaces will come on in heating s eed. When the thermostat is satis-

fied, the burners will shut off and, after the selected blower off delay

time, both blowers will shut off at the same time. On a call for second

stage of heat, the burners of Furnace #2 will also light and both blowers

will run. The twinning control ensures that both blowers come on and

shut off at the same time.

Cooling - On a call for cooling (Y signal) from the wall thermostat, both

furnace blowers will come on at the same time. When the thermostat is

satisfied, both blowers will stay on for 60 seconds, then will shut off at

the same time.

Continuous Fan - On a thermostat call for continuous fan (G signal),

both furnace blowers will come on at the same time in cooling s eed

and will stay on until the G signal is removed.

FIGURE 13:

Single Stage Twinning Wiring Diagram

TWIN

TO A/C

WALL THERMOSTAT

W G RY

ISOLATION

RELAY

FURNACE 2 CONTROL BOARD

TWIN

FURNACE 1 CONTROL BOARD

FIGURE 14:

Two-Stage Twinning Wiring Diagram

TWIN

TO A/C

WALL THERMOSTAT

W1 G RY

ISOLATION

RELAY

FURNACE 2 CONTROL BOARD

TWIN

FURNACE 1 CONTROL BOARD

166753-UIM-C-0706

14 Unitary Products Grou

SECTION VII: VENT SYSTEM

SECTION VII: VENT SYSTEMSECTION VII: VENT SYSTEM

SECTION VII: VENT SYSTEM

VENT SAFETY

VENT SAFETYVENT SAFETY

VENT SAFETY

This Category I, furnace is designed for residential a lication. It may

be installed without modification in a basement, garage, equi ment

room, alcove, attic or any other indoor location where all required clear-

ance to combustibles and other restrictions are met.

CATEGORY - 450 F. MAX. VENT TEMP.

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

CATEGORY - 450 F. MAX. VENT TEMP.

The venting system must be installed in accordance with Section 5.3,

Air for Combustion and Ventilation, of the National Fuel Gas Code

Z223.1/NFPA 54 (latest edition), or Sections 7.2, 7.3 or 7.4 of CSA

B149.1, National Gas and Pro ane Codes (latest edition) or a licable

rovisions of the local building code and these instructions.

The furnace shall be connected to any ty e of B, BW or L vent connec-

tor, and shall be connected to a factory-built or masonry chimney.

The

furn ce sh ll not be connected to chimney flue serving sep -

r te ppli nce designed to burn solid fuel.

The furnace rating late lists the maximum vent gas tem erature. This

tem erature must be used to select the a ro riate venting materials

and clearances.

It is recommended that the a liance is installed in a location where the

s ace tem erature is 32 °F (0°C) or higher. If the a liance is installed

in a location where the ambient tem erature is below 32 °F (0°C), the

combustion by roducts could condense causing damage to the a li-

ance heat exchanger.

IMPORTANT:

The “VENT SYSTEM” must be installed as s ecified in

these instructions for Residential and Non HUD Modular Homes.

This a liance may be common vented with another gas a liance for

residential installations as allowed by the codes and standards listed in

these instructions.

Non-HUD a roved Modular Homes must be vented with an a roved

roof jack and may not be common vented with other a liances.

VENTING

VENTINGVENTING

VENTING

Category I venting consists of vertically venting one or more a liances

in B-vent or masonry chimney (as allowed), using single wall metal i e

or B-vent connectors. Ty e B-vent system extends in a general vertical

direction and does not contain offsets exceeding 45 degrees. A vent

system having not more than one 60 degree offset is ermitted.

If installing furnace at altitudes between 2000 - 4500 ft. (610 – 1372 m),

vent i e length must be reduced by 10 ft. (3.05 m). If the installation

requires the maximum allowable vent i e length, the furnace must be

converted for high altitude o eration. Refer to SECTION IV “GAS PIP-

ING” of these instructions and the ro er high altitude a lication

instruction for details.

VENTING INTO AN EXISTING CHIMNEY

VENTING INTO AN EXISTING CHIMNEYVENTING INTO AN EXISTING CHIMNEY

VENTING INTO AN EXISTING CHIMNEY

For Category I installations, the furnace shall be connected to a factory

built chimney or vent com lying with a recognized standard, or a

masonry or concrete chimney lined with a material acce table to the

authority having jurisdiction. Venting into an unlined masonry chimney

or concrete chimney is rohibited.

Whenever ossible, B-1 metal i e should be used for venting. Where

use of an existing chimney is unavoidable, the following rules must be

followed:

1. The masonry chimney must be built and installed in accordance

with nationally recognized building codes or standards and must

be lined with a roved fire clay tile flue liners or other a roved

liner material that will resist corrosion, softening, or cracking from

flue gases.

THIS FURNACE IS NOT TO BE VENTED INTO AN

UNLINED MASONRY CHIMNEY.

2. This furnace must be vented into a fire clay tile lined masonry

chimney only if a source of dilution air is rovided, such as by com-

mon venting with a draft hood equi ed water heater. If no source

of dilution air is available, Ty e B vent must be used, or masonry

chimney vent kit 1CK0603 or 1CK0604 must be used. Refer to the

instructions with the kit to ro erly a ly these masonry chimney

kits.

3. The chimney must extend at least 3 ft (0.91 m) above the highest

oint where it asses through a roof of a building and at least two

feet higher than any ortion of the building with a horizontal dis-

tance of ten feet.

4. The chimney must extend at least 5 ft (1.5 m) above the highest

equi ment draft hood or flue collar.

FIGURE 15:

Vent Termination

FIGURE 16:

Vent Termination

TABLE 8:

Roof Pitch

ROOF PITCH H(min) ft m

Flat to 6/12 1.0 0.30

6/12 to 7/12 1.25 0.38

Over 7/12 to 8/12 1.5 0.46

Over 8/12 to 9/12 2.0 0.61

Over 9/12 to 10/12 2.5 0.76

Over 10/12 to 11/12 3.25 0.99

Over 11/12 to 12/12 4.0 1.22

Over 12/12 to 14/12 5.0 1.52

Over 14/12 to 16/12 6.0 1.83

Over 16/12 to 18/12 7.0 2.13

Over 18/12 to 20/12 7.5 2.27

Over 20/12 to 21/12 8.0 2.44

WALL OR

PARAPET

CHIMNEY

NOTE: NO

HEIGHT ABOVE

PARAPET REQUIRED

WHEN DISTANCE

FROM WALLS OR

PARAPET IS MORE

THAN 10 FT (3.0 m).

3 FT (0.9 m)

MIN.

MORE THAN

10 FT (3.0 M)

2 FT(0.6 m)

MIN

RIDGE

CHIMNEY

HEIGHT ABOVE ANY

ROOF SURFACE WITHIN

10 FT (3.0 m) HORIZONTALLY

3 FT (0.9 m)

MIN

MORE THAN

10 FT (3.0 M)

LOWEST DISCHARGE OPENING

LISTED CAP

LISTED GAS

VENT

H (min) - MINIMUM HEIGHT FROM ROOF

TO LOWEST DISCHARGE OPENING

12 X

ROOF PITCH

IS X/12

166753-UIM-C-0706

Unitary Products Grou 15

HORIZONTAL SIDEWALL VENTING

HORIZONTAL SIDEWALL VENTINGHORIZONTAL SIDEWALL VENTING

HORIZONTAL SIDEWALL VENTING

For a lications where vertical venting is not ossible, the only

a roved method of horizontal venting is the use of an auxiliary ower

vent. A roved ower venters are Fields Controls Model SWG-4Y or

Tjernlund Model GPAK-JT. Follow all a lication and installation details

rovided by the manufacturer of the ower vent. This unit may be hori-

zontally vented using 4” (10.2 cm) diameter i e with a minimum length

of 4.5 feet (1.37 m) and a maximum length of 34.5 feet (10.82 m) with

u to 4 elbows.

VENT PIPING ASSEMBLY

VENT PIPING ASSEMBLYVENT PIPING ASSEMBLY

VENT PIPING ASSEMBLY

The final assembly rocedure for the vent i ing is as follows:

1. Cut i ing to the ro er length beginning at the furnace.

2. Deburr the i ing inside and outside.

3. Dry-fit the vent i ing assembly from the furnace to the termination

checking for ro er fit su ort and slo e. Pi ing should be su -

orted with i e hangers to revent sagging. The maximum s ac-

ing between hangers is 5 feet (1.5 m).

4. Assemble the vent i ing from the furnace to the termination

securing the i e connections with screws.

VENT CLEARANCES

VENT CLEARANCESVENT CLEARANCES

VENT CLEARANCES

IMPORTANT:

The vent must be installed with the following minimum

clearances as shown in Figure 20, must com ly with local codes and

requirements.

FIGURE 17:

Ty ical Sidewall Vent A lication

FAN ASSISTED FURNACE

& WATER HEATER

FAN ASSISTED

FURNACES

VENT

PIPE

HOT

WATER

TANK

FURNACE

OPTIONAL

SIDEWALL

VENT SYSTEM

(field supplied)

EXTERIOR

VENT HOOD

FIGURE 18:

Ty ical Sidewall Vent and Termination Configuration

VENT PIPE

FLUE

PIPE

BURNER

ACCESS

PANEL

CELLAR

WALL

OPTIONAL

SIDEWALL

VENT SYSTEM

(field supplied)

TOP

COVER

VENT

DAMPER

166753-UIM-C-0706

16 Unitary Products Grou

† A vent shall not terminate directly above a sidewalk or aved driveway that is located between two single family dwellings and serves both dwellings.

‡ Permitted only if veranda, orch, deck, or balcony is fully o en on a minimum of two sides beneath the floor. For clearance not s ecified in ANSI Z223.1 / NFPA 54 or CSA B149.1-00.

Clearance in accordance with local installation codes and the requirements of the gas su lier and the manufacturer’s Installation Manual.

Any fresh air or make u inlet for dryer or furnace area is considered to be forced air inlet.

Avoid areas where condensate dri age may cause roblems such as above lanters, atios, or adjacent to windows where steam may cause fogging.

A terminus of a vent shall be either:

Fitted with a ca in accordance with the vent manufacturer’s installation instructions, or In accordance with the installation instructions for a s ecial venting system.

* Does not a ly to multi le installations of this furnace model. Refer to "VENTING MULTIPLE UNITS" in this section of these instructions.

IMPORTANT: Consideration must be given for degradation of building materials by flue gases. Sidewall termination may require sealing or shielding of building surfaces with a corrosion resistant

material to rotect against combustion roduct corrosion. Consideration must be given to wind direction in order to revent flue roducts and/or condensate from being blown against

the building surfaces. If a metal shield is used it must be a stainless steel material at a minimum dimension of 20 inches. It is recommended that a retaining ty e collar be used that is

attached to the building surface to revent movement of the vent i e.

Res onsibility for the rovision of ro er adequate venting and air su ly for a lication shall rest with the installer.

Vent shall extend high enough above building, or a neighboring obstruction, so that wind from any direction will not create a ositive ressure in the vicinity of the vent.

HORIZONTAL VENT APPLICATIONS AND

HORIZONTAL VENT APPLICATIONS AND HORIZONTAL VENT APPLICATIONS AND

HORIZONTAL VENT APPLICATIONS AND

TERMINATION

TERMINATIONTERMINATION

TERMINATION

When selecting the location for a horizontal combustion air / vent termi-

nation, the following should be considered:

1. Observe all clearances listed in vent clearances in these instruc-

tions.

2. Termination should be ositioned where vent va ors will not dam-

age lants or shrubs or air conditioning equi ment.

3. Termination should be located where it will not be affected by wind

gusts, light snow, airborne leaves or allow recirculation of flue

gases.

4. Termination should be located where it will not be damaged or

ex osed to flying stones, balls, etc.

5. Termination should be ositioned where vent va ors are not objec-

tionable.

6. Horizontal ortions of the vent system must slo e u wards and be

su orted to revent sagging. The vent system may be su orted

by the use of clam s or hangers secured to a ermanent art of

the structure every 4 ft. (1.22 m).

FAN-ASSISTED COMBUSTION SYSTEM

FAN-ASSISTED COMBUSTION SYSTEMFAN-ASSISTED COMBUSTION SYSTEM

FAN-ASSISTED COMBUSTION SYSTEM

An a liance equi ed with an integral mechanical means to either

draw or force roducts of combustion through the combustion chamber

and/or heat exchanger.

Ambient Combustion Air Supply

This ty e installation will draw the air required for combustion from

within the s ace surrounding the a liance and from areas or rooms

adjacent to the s ace surrounding the a liance. This may be from

within the s ace in a non-confined location or it may be brought into the

furnace area from outdoors through ermanent o enings or ducts. A

single, ro erly sized i e from the furnace vent connector to the out-

doors must be rovided. For u flow models combustion air is brought

into the furnace through the unit to anel o ening.

FIGURE 19:

Home Layout

OPERABLE

FIXED

CLOSED

VENT TERMINAL

AIR SUPPLY

AREA WHERE TERMINAL IS NOT PERMITTED

FIXED

CLOSED

C n di n Inst ll tions

US Inst ll tion

A. Clearance above grade, veranda, orch, deck, or balcony 12 inches (30 cm) 12 inches (30 cm)

B. Clearance to window or door that may be o ened 12 inches (30 cm) for models <100,000 BTUH (30 kW),

36 inches (91 cm) for models > 100,000 BTUH (30 kW) 4 Feet

C. Clearance to ermanently closed window 4 Feet 4 Feet

D. Vertical clearance to ventilated soffit located

above the terminal within a horizontal distance

of 2 feet (61 cm) from the center line of the terminal

4 Feet 4 Feet

E. Clearance to unventilated soffit 12 Inches 12 Inches

F. Clearance to outside corner 12 Inches 12 Inches

G. Clearance to inside corner 6 Feet 6 Feet

H. Clearance to each side of center line extended

above meter/regulator assembly

3 feet (91 cm) within a height 15 feet (4.5 m) above the

meter/regulator assembly

3 feet (91 cm) within a height 15 feet (4.5 m) above the

meter/regulator assembly

I. Clearance to service regulator vent outlet 3 feet (91 cm) 3 feet (91 cm)

J. Clearance to nonmechanical air su ly inlet to building

or the combustion air inlet to any other a liance

12 inches (30 cm) for models <100,000 BTUH (30 kW),

35 inches (91 cm) for models >100,000 BTUH (30 kW) 4 Feet

K. Clearance to a mechanical su ly inlet 6 feet (1.83 m) 3 feet (91 cm) above if within 10 feet (3 cm) horizontally

L. Clearance above aved sidewalk or aved driveway located on ublic ro erty 7 feet (2.13 m)

†

7 feet (2.13 m)

†

M.Clearance under veranda, orch, deck, or balcony 12 inches (30.4 cm) 12 inches (30.4 cm)

Vent Termination from any Building Surface 12" (30.4 cm) 12" (30.4 cm)

Above antici ated snow de th 12" (30.4 cm) 12" (30.4 cm)

1. In accordance with the current CSA B149.1-00, Natural Gas and Pro ane Installation Code.

2. In accordance with the current ANSI Z223.1 / NFPA 54, National Gas Code.

166753-UIM-C-0706

Unitary Products Grou 17

unconfined sp ce

is not less than 50 cu.ft (1.42 m

) er 1,000 Btu/

hr (0.2928 kW) in ut rating for all of the a liances installed in that

area.

Rooms communicating directly with the s ace containing the a li-

ances are considered art of the unconfined s ace, if o enings are fur-

nished with doors.

confined sp ce

is an area with less than 50 cu.ft (1.42 m

) er 1,000

Btu/hr (0.2928 kW) in ut rating for all of the a liances installed in that

area. The following must be considered to obtain ro er air for combus-

tion and ventilation in confined s aces.

Combustion Air Source From Outdoors

The blocking effects of louvers, grilles and screens must be given con-

sideration in calculating free area. If the free area of a s ecific louver or

grille is not known, refer to Table 9, to estimate free area.

* Do not use less than 1/4”(0.635 cm) mesh

+ Free area of louvers and grille varies widely; the installer should follow louver or grille

manufacturer’s instructions.

D mpers, Louvers nd Grilles (C n d Only)

1. The free area of a su ly air o ening shall be calculated by sub-

tracting the blockage area of all fixed louvers grilles or screens

from the gross area of the o ening.

2. A ertures in a fixed louver, a grille, or screen shall have no dimen-

sion smaller than 0.25” (0.64 cm).

3. A manually o erated dam er or manually adjustable louvers are

not ermitted for use.

4. A automatically o erated dam er or automatically adjustable lou-

vers shall be interlocked so that the main burner cannot o erate

unless either the dam er or the louver is in the fully o en osition.

FIGURE 20:

Combustion Airflow Path Through The Furnace Casing to

the Burner Box

This type of installation requires that the supply air to the appli-

ance(s) be of a sufficient amount to support all of the appliance(s)

in the area. Operation of a mechanical exhaust, such as an exhaust

fan, kitchen ventilation system, clothes dryer or fireplace may cre-

ate conditions requiring special attention to avoid unsatisfactory

operation of gas appliances. A venting problem or a lack of supply

air will result in a hazardous condition, which can cause the appli-

ance to soot and generate dangerous levels of CARBON MONOX-

ID , which can lead to serious injury, property damage and / or

death.

FIGURE 21:

Alternate Air Intake, Air Outlet and Chimney Connections

COMBUSTION AIR VENT PIPE CEMENTS

INTO SOCKET JUST

ABOVE TOP PANEL

FURNACE

WATER

HEATER

OUTLET

AIR

VENTILATION LOUVERS

(each end of attic)

CHIMNEY OR

GAS VENT

INLET

AIR

ALTERNATE

AIR INLET

VENTILATION LOUVERS FOR UNHEATED CRAWL SPACE

FIGURE 22:

Air Inlet, Outlet and Chimney Connections

TABLE 9:

Estimated Free Area

Wood or Metal

Louvers or Grilles

Wood 20-25%*

Metal 60-70% *

Screens+ 1/4” (0.635 cm)

mesh or larger 100%

FIGURE 23:

Ty ical Chimney Connections

FURNACE

WATER

HEATER

OUTLET

AIR

VENTILATION LOUVERS

(each end of attic)

CHIMNEY OR

GAS VENT

INLET AIR DUCT

[ends 1 ft (30 cm)

above floor]

FURNACE

WATER

HEATER

CHIMNEY OR

GAS VENT

OPENING

166753-UIM-C-0706

18 Unitary Products Grou

FIGURE 24:

Horizontal Air Inlet, Outlet and Chimney Connections

When a Category I furnace is removed or replaced, the original

venting system may no longer be correctly sized to properly vent

the attached appliances.

An improperly sized vent system can cause CARBON MONOXID

to spill into the living space causing personal injury, and or death.

FURNACE

WATER

HEATER

OUTLET

AIR DUCT

INLET

AIR DUCT

TABLE 10:

Free Area

BTUH In ut

Rating

Minimum Free Area Required for Each O ening

Horizontal Duct

(2,000 BTUH)

Vertical Duct or

O ening to Outside

(4,000 BTUH)

Round Duct

(4,000 BTUH)

40,000 20 in

(129 cm

) 10 in

(64 cm

)4” (10 cm)

60,000 30 in

(193 cm

) 15 in

(97 cm

)5” (13 cm)

80,000 40 in

(258 cm

) 20 in

(129 cm

)5” (13 cm)

100,000 50 in

(322 cm

) 25 in

(161 cm

)6” (15 cm)

115,000 60 in

(387 cm

) 30 in

(193 cm

)7” (18 cm)

130,000 65 in

(419 cm

) 33 in

(213 cm

)7” (18 cm)

EXAMPLE: Determining Free Area.

A liance 1A liance 2Total In ut

100,000 + 30,000 = (130,000

4,000) = 32.5 Sq. In. Vertical

A liance 1A liance 2Total In ut

100,000 + 30,000 = (130,000

2,000) = 65 Sq. In. Horizontal

TABLE 11:

Unconfined S ace Minimum Area in Square Inch

BTUH In ut Rating Minimum Free Area in Square Feet

Required for Each O ening

40,000 250 (23.23 m

)

60,000 375 (34.84 m

)

80,000 500 (46.45 m

)

100,000 625 (58.06 m

)

115,000 750 (69.68 m

)

130,000 813 (75.53 m

)

EXAMPLE: Square feet is based on 8 foot ceilings.

28,000 BTUH X 50 Cubic Ft. = 1,400 = 175 Sq. Ft.

1,000 8’ Ceiling Height

FIGURE 25:

Outside and Ambient Combustion Air

GABLE

VENT

GAS

VENT

SOFFIT

VENT

VENTILATED

ATTIC

TOP ABOVE

INSULATION

OPTIONAL

INLET (a)

OUTLET

AIR (a)

VENTILATED

CRAWL SPACE

GAS

WATER

HEATER

VENTILATED

ATTIC

TOP ABOVE

INSULATION

GAS

VENT

GABLE

VENT

SOFFIT

VENT

GAS

WATER

HEATER INLET

AIR (a)

INLET

AIR (b)

GAS

VENT

OUTLET

AIR (a)

OUTLET

AIR (b)

INLET

AIR (a)

INLET

AIR (b)

GAS

WATER

HEATER

FURNACE

1. An opening may be used in lieu of a duct to provide to provide the outside air

supply to an appliance unless otherwise permitted by the authority having

jurisdiction. The opening shall be located within 12” (30.5 cm) horizontally from,

the burner level of the appliance. Refer to “AIR SOURCE FROM OUTDOORS

AND VENT AND SUPPLY AIR SAFETY CHECK” in these instructions for

additional information and safety check procedure.

2. The duct shall be either metal, or a material meeting the class 1

requirements of CAN4-S110 Standard for Air Ducts.

3. The duct shall be least the same cross-sectional area as the free

area of the air supply inlet opening to which it connects.

4. The duct shall terminate within 12 in (30.5 cm) above, and

within 24 in (61 cm) horizontally from, the burner level of

the appliance having the largest input.

5. A square or rectangular shaped duct shall only be used

when the required free area of the supply opening is

9 in (58.06 cm ) or larger. When a square or rectangular

duct is used, its small dimensionshall not be less than

3 in (7.6 cm).

2 2

6. An air inlet supply from outdoors shall be equipped with

a means to prevent the direct entry of rain and wind.

Such means shall not reduce the required free area of

the air supply opening.

7. An air supply inlet opening from the outdoors shall

be located not less than 12” (30.5 cm) above the

outside grade level.

AIR SUPPLY OPENINGS AND DUCTS

COMBUSTION AIR SOURCE FROM OUTDOORS

1. Two permanent openings, one within 12 in (30.5 mm) of the top and

one within 12 in (30.5 mm) of bottom of the confined space,

shall communicate directly or by means of ducts

with the outdoors, crawl spaces or attic spaces.

Two

permanent openings,

2. One permanent openings, commencing within 12 in (30.5 mm)of the

top of the enclosure shall be permitted where the equipment has

clearances of at least 1 in (2.54 cm) from the sides and back and

6 in (15.24 cm) from the front of the appliance. The opening shall

communicate directly with the outdoors and shall have a minimum

free area of:

3. The duct shall be least the same cross-sectional area as the free

area of the air supply inlet opening to which it connects.

1 square in per 3000 Btu per hour (6.45 cm 0.879 kW) of the total

input rating of all equipment located in the enclosure.

Not less than the sum of all vent connectors in the confined space.

4. The blocking effects of louvers, grilles and screens must be given

consideration in calculating free area. If the free area of a specific

louver aor grille is not known.

166753-UIM-C-0706

Unitary Products Grou 19

Ventil ted Combustion Air

The ventilated attic s ace or a crawl s ace from which the combustion

air is taken must com ly with the requirements s ecified in “AIR

SOURCE FROM OUTDOORS” in this instruction or in Section 5.3, Air

for Combustion and Ventilation of the National Fuel Gas Code, ANSI

Z223.1 (latest edition). This ty e installation requires two ro erly sized

i es. One brings combustion air from a ro erly ventilated attic s ace

or crawl s ace and a second i e that extends from the furnace vent

connection (to right of unit) to the exterior of the building.

Vent nd Supply (Outside) Air S fety Check Procedure

For Category I furnaces, vent installations shall be in accordance with

Parts 7 and 11 of the National Fuel Gas Code, ANSI Z223.1/NFPA 54,

and or Section 7 and A endix B of the CSA B149.1, Natural Gas and

Pro ane Installation Codes, the local building codes, furnace and vent

manufacture's instructions.

Multi-story or common venting systems are ermitted and must be

installed in accordance with the National Fuel Gas Code, ANSI Z223.1/

NFPA 54 and / or the CSA B149.1, Natural Gas and Pro ane Installa-

tion Codes, local codes, and the manufacture's instructions.

Vent connectors serving Category I furnaces shall not be connected

into any ortion of mechanical draft systems o erating under ositive

ressure.

Horizontal ortions of the venting system shall be su orted to revent

sagging using hangers or erforated stra s and must slo e u wards

not less than 1/4" er foot (0.635 cm/m) from the furnace to the vent ter-

minal.

It is recommended that you follow the venting safety rocedure below.

This rocedure is designed to detect an inadequate ventilation system

that can cause the a liances in the area to o erate im ro erly causing

unsafe levels of Carbon Monoxide or an unsafe condition to occur.

SECTION VIII: SAFETY CONTROLS

SECTION VIII: SAFETY CONTROLSSECTION VIII: SAFETY CONTROLS

SECTION VIII: SAFETY CONTROLS

CONTROL CIRCUIT FUSE

CONTROL CIRCUIT FUSECONTROL CIRCUIT FUSE

CONTROL CIRCUIT FUSE

A 3-am fuse is rovided on the control circuit board to rotect the 24-

volt transformer from overload caused by control circuit wiring errors.

This is an ATO 3, automotive ty e fuse and is located on the control

board.

BLOWER DOOR SAFETY SWITCH

BLOWER DOOR SAFETY SWITCHBLOWER DOOR SAFETY SWITCH

BLOWER DOOR SAFETY SWITCH

This unit is equi ed with an electrical interlock switch mounted in the

blower com artment. This switch interru ts all ower at the unit when

the anel covering the blower com artment is removed.

Electrical su ly to this unit is de endent u on the anel that covers the

blower com artment being in lace and ro erly ositioned.

ROLLOUT SWITCH CONTROLS

ROLLOUT SWITCH CONTROLSROLLOUT SWITCH CONTROLS

ROLLOUT SWITCH CONTROLS

These controls are mounted on the burner box assembly. If the tem er-

ature in the burner box exceeds its set oint, the ignition control and the

gas valve are de-energized. The o eration of this control indicates a

malfunction in the combustion air blower, heat exchanger or a blocked

vent i e connection. Corrective action is required. These are manual

reset controls that must be reset before o eration can continue.

PRESSURE SWITCHES

PRESSURE SWITCHESPRESSURE SWITCHES

PRESSURE SWITCHES

This furnace is su lied with a ressure switch, which monitors the flow

through the combustion air/vent i ing system. This switch de-ener-

gizes the ignition control module and the gas valve if any of the follow-

ing conditions are resent. Refer to Figure 27 for tubing connections.

1. Blockage of vent i ing or terminal.

2. Failure of combustion air blower motor.

CARBON MONOXID POISONING HAZARD

Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon-

monxide poisoning or death.

The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances

connected to the venting system are not in operation:

1. Ins ect the venting system for ro er size and horizontal itch. Determine that there is no blockage, restriction, leakage, corrosion or other

deficiencies, which could cause an unsafe condition

2. Close all building doors and windows and all doors.

3. Turn on clothes dryers and TURN ON any exhaust fans, such as range hoods and bathroom exhausts, so they shall o erate at maximum

s eed. O en the fire lace dam ers. Do not o erate a summer exhaust fan.

4. Follow the lighting instructions. Place the a liance being ins ected in o eration. Adjust thermostat so the a liance shall o erate contin-

uously.

5. Test each a liance (such as a water heater) equi ed with a draft hood for s illage (down-draft or no draft) at the draft hood relief o ening

after 5 minutes of main burner o eration. A liances that do not have draft hoods need to be checked at the vent i e as close to the

a liance as ossible. Use a combustion analyzer to check the CO2 and CO levels of each a liance. Use a draft gauge to check for a

downdraft or inadequate draft condition.

6. After it has been determined that each a liance ro erly vents when tested as outlined above, return doors, windows, exhaust fans, fire-

lace dam ers and any other gas burning a liance to their normal condition.

7. If im ro er venting is observed during any of the above tests, a roblem exists with either the venting system or the a liance does not

have enough combustion air (Su ly Air from outside) to com lete combustion. This condition must be corrected before the a liance can

function safely.

NOTE:

An unsafe condition exists when the CO reading exceeds 40 m and the draft reading is not in excess of - 0.1 in. W.C. (-25 kPa) with

all of the a liance(s) o erating at the same time.

8. Any corrections to the venting system and / or to the su ly (outside) air system must be in accordance with the National Fuel Gas Code

Z223.1 or CAN/CGA B149.1-00 Natural Gas and Pro ane Installation Code (latest editions). If the vent system must be resized, follow the

a ro riate tables in A endix G of the above codes or for this a liance.

Main power to the unit must still be interrupted at the main power

disconnect switch before any service or repair work is to be done to

the unit. Do not rely upon the interlock switch as a main power dis-

connect.

Blower and burner must never be operated without the blower

panel in place.

166753-UIM-C-0706

20 Unitary Products Grou

LIMIT CONTROLS

LIMIT CONTROLSLIMIT CONTROLS

LIMIT CONTROLS

There is a high tem erature limit control located on the furnace vesti-

bule anel near the gas valve. This is an automatic reset control that

rovides over tem erature rotection due to reduced airflow. This may

be caused by:

1. A dirty filter.

2. If the indoor fan motor should fail.

3. Too many su ly or retrn registers closed or blocked off.

The control module will lockout if the limit tri s 5 consecutive times.

Control will reset & try ignition again after 1 hour.

SECTION IX: START-UP AND

SECTION IX: START-UP AND SECTION IX: START-UP AND

SECTION IX: START-UP AND

ADJUSTMENTS

ADJUSTMENTSADJUSTMENTS

ADJUSTMENTS

The initi l st rt-up of the furn ce requires the following ddition l

procedures:

IMPORTANT:

All electrical connections made in the field and in the fac-

tory should be checked for ro er tightness.

When the gas su ly is initially connected to the furnace, the gas i ing

may be full of air. In order to urge this air, it is recommended that the

ground union be loosened until the odor of gas is detected. When gas is

detected, immediately retighten the union and check for leaks. Allow

five minutes for any gas to dissi ate before continuing with the start-u

rocedure. Be sure ro er ventilation is available to dilute and carry

away any vented gas.

TOOLS AND INFORMATION THAT WILL BE

TOOLS AND INFORMATION THAT WILL BE TOOLS AND INFORMATION THAT WILL BE

TOOLS AND INFORMATION THAT WILL BE

REQUIRED IN ORDER TO PROPERLY PERFORM THE

REQUIRED IN ORDER TO PROPERLY PERFORM THE REQUIRED IN ORDER TO PROPERLY PERFORM THE

REQUIRED IN ORDER TO PROPERLY PERFORM THE

FURNACE STARTUP PROCEDURE.

FURNACE STARTUP PROCEDURE.FURNACE STARTUP PROCEDURE.

FURNACE STARTUP PROCEDURE.

1. Call the local gas su lier to obtain heating value of the natural

gas. If you cannot obtain the heating valve of the gas from the gas

su lier, you may use a default value of 1030 BTU/SCF (38.8 MJ /

m³).

2. You will need a thermometer or ortable digital thermometer to

read the su ly and return air tem eratures.

3. You will need a U-tube manometer or digital equi ment that has

the ability to read ressures between 0 – 15” in.w.c (0 - 3.73 kPa)

in order to measure the gas line and the manifold ressures.

4. You will need a 3/32” Allen wrench for the ressure ort lugs in

the gas valve.

5. You will need 2 ieces of 1/8” (0.3 cm) ID flexible tubing that is 12”

(30 cm) in length, 2 – ieces of 1/8” (0.3 cm) tubing that are 4”

(10.0 cm) in length, a 1/8” (0.3 cm) tee and a 1/8” (0.3 cm) ada ter

to connect the U-tube manometer or the digital ressure measur-

ing equi ment to the gas valve ressure orts.

There is an accessory kit (1PK0601) available from Source 1, which

has the following items:

• 1 - 12” (30 cm) length x 1/8” (0.3 cm) diameter tubing

• 2 – ieces of 4” (10 cm) length x 1/8” (0.3 cm) diameter tubing

• 1 - 5/16” (0.8 cm) tee

• 1 – 5/16” (0.8 cm) x 1/8” (3.175 mm) reducing cou ling

• 1 – 1/8” (0.3 cm) ada ter

There is a accessory kit (1PK0602) available from Source 1, which has

the following items:

• 12” (30 cm) length x 1/8” (0.3 cm) diameter tubing

• 2 – ieces of 4” (10 cm) length x 1/8” (0.3 cm) diameter tubing

• 1 - 5/16” (0.8 cm) tee

• 1 – 5/16” (0.8 cm) x 1/8” (0.3 cm) reducing cou ling

• 1 – 1/8” (0.3 cm) ada ter

• 1 - Dwyer – Manometer

These items are required in order to ro erly erform the required star-

tu rocedure.

IGNITION SYSTEM SEQUENCE

IGNITION SYSTEM SEQUENCEIGNITION SYSTEM SEQUENCE

IGNITION SYSTEM SEQUENCE

1. Turn the gas su ly ON at external valve and main gas valve.

2. Set the thermostat above room tem erature to call for heat.

3. System start-u will occur as follows:

a. The induced draft blower motor will start and come u to

s eed. Shortly after inducer start-u , the hot surface igniter

will glow for about 17 seconds.

b. After this warm u , the ignition module will energize (o en)

the main gas valve.

c. After flame is established, the su ly air blower will start in

about 30 seconds.

IMPORTANT:

Burner ignition may not be satisfactory on first startu

due to residual air in the gas line or until gas manifold ressure is

adjusted. The ignition control will make 3 attem ts to light before lock-

ing out.

With furnace in o eration, check all of the i e joints, gas valve connec-

tions and manual valve connections for leakage using an a roved gas

detector, a non-corrosive leak detection fluid, or other leak detection

methods. Take a ro riate ste s to sto any leak. If a leak ersists,

re lace the com onent.

The furnace and its equi ment shutoff valve must be disconnected from

the gas su ly i ing system during any ressure testing of that system

at test ressures in excess of 1/2 PSI (3.45 kPa).

The furnace must be isolated from the gas su ly i ing system by

closing the equi ment shutoff valve during any ressure testing of the

gas su ly i ing system.

CALCULATING THE FURNACE INPUT

CALCULATING THE FURNACE INPUT CALCULATING THE FURNACE INPUT

CALCULATING THE FURNACE INPUT

(NATURAL GAS)

(NATURAL GAS)(NATURAL GAS)

(NATURAL GAS)

NOTE:

Burner orifices are sized to rovide ro er in ut rate using natu-

ral gas with a heating value of 1030 BTU/Ft

(38.4 MJ/m

). If the heat-

ing value of your gas is significantly different, it may be necessary to

re lace the orifices.

NOTE:

Front door of burner box must be secured when checking gas

in ut.

1. Turn off all other gas a liances connected to the gas meter.

2. At the gas meter, measure the time (with a sto watch) it takes to

use 2 cubic ft. (0.0566 m

.) of gas.

3. Calculate the furnace in ut by using one of the following equa-

tions.

FIGURE 26:

Pressure Switch Tubing Routing

FIR OR XPLOSION 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 the detection of leaks

to check all connections. A fire or explosion may result causing

property damage, personal injury or loss of life.

This manual suits for next models

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