Installation manual

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035-19599-001 Rev. A (1103)

EFFICIENCY

RATING

CERTIFIED

This product was manufactured

in a plant whose quality system

is certified/registered as being

in conformity with ISO 9001.

HIGH EFFICIENCY

TUBULAR HEAT EXCHANGER SERIES

MODELS: 90% P*DH / G9T-DH / FG9-DH (Downflow)

40 - 120 MBH INPUT

(11.72 - 35.17 KW) INPUT

INSTALLATION MANUAL

SECTION I: SAFETY

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

labels or in manuals, be alert to the potential for personal

injury.

Understand and pay particular attention to the signal words DANGER,

WARNING, or CAUTION.

DANGER indicates an imminently hazardous situation, which, if not

avoided, will result in death or serious injury

WARNING indicates a potentially hazardous situation, which, if not

avoided, could result in death or serious injury

CAUTION indicates a potentially hazardous situation, which, if not

avoided may result in minor or moderate injury.

It is also used to

alert against unsafe practices and hazards involving only property 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.

TABLE OF CONTENTS

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

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

FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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

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

TWINNING AND STAGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

COMBUSTION AIR AND VENT SYSTEM . . . . . . . . . . . . . . . . . . . . .12

CONDENSATE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

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

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

LIST OF FIGURES

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Furnace Base Rectangular Perforated Panel . . . . . . . . . . . . . . . . . . . 6

Filter Rack Assembly and Attachment . . . . . . . . . . . . . . . . . . . . . . . . . 7

Return Filter Grill and Return Duct Installation . . . . . . . . . . . . . . . . . . . 7

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

Typical Suspended Furnace / Crawl Space Installation . . . . . . . . . . . . 8

Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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

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

Polarity Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Accessory Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Heating and Cooling Thermostat Connections . . . . . . . . . . . . . . . . . 11

Typical Twinned Furnace Application . . . . . . . . . . . . . . . . . . . . . . . . 11

Single Stage Twinning Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . 12

Two-Stage Twinning Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 12

Home Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Horizontal Vent Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Termination Configuration - 1 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Termination Configuration - 2 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Termination Configuration - 2 Pipe Horizontal . . . . . . . . . . . . . . . . . .16

Double Horizontal Sealed Combustion Air and Vent Termination . . .16

Double Vertical Sealed Combustion Air and Vent Termination . . . . .16

Sealed Combustion Air Intake Connection and Vent Connection . . .16

Combustion Airflow Path Through The Furnace Casing

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

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

Attic Combustion Air Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Condensate Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Horizontal Condensate Drain Connections . . . . . . . . . . . . . . . . . . . . .20

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

Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

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

Typical Heat/Cool Speed Tap Connections . . . . . . . . . . . . . . . . . . . .24

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

LIST OF TABLES

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

Minimum Duct Sizing For Proper Airflow . . . . . . . . . . . . . . . . . . . . . . . 4

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

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

Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

High Altitude Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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

Combustion Air Intake and Vent Connection Size at Furnace

(All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Combustion Air Supply and Vent Piping . . . . . . . . . . . . . . . . . . . . . . .13

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

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

Unconfined Space Minimum Area in Square Inch . . . . . . . . . . . . . . .17

Horizontal Condensate Drain Hose Sizes . . . . . . . . . . . . . . . . . . . . .19

Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Blower Performance CFM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Filter Performance - Pressure Drop Inches W.C. and (kPa) . . . . . . . .25

Summary of content (28 pages)

PAGE 1
INSTALLATION MANUAL HIGH EFFICIENCY TUBULAR HEAT EXCHANGER SERIES EFFICIENCY RATING CERTIFIED MODELS: 90% P*DH / G9T-DH / FG9-DH (Downflow) 40 - 120 MBH INPUT (11.72 - 35.17 KW) INPUT This product was manufactured in a plant whose quality system is certified/registered as being in conformity with ISO 9001. TABLE OF CONTENTS SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 2
035-19599-001 Rev. A (1103) SPECIFIC SAFETY RULES AND PRECAUTIONS 1. Only Natural gas or Propane (LP) gas are approved for use with this furnace. Refer to the furnace rating plate or Section IV of these instructions. 2. Install this furnace only in a location and position as specified in SECTION I of these instructions. 3. A gas-fired furnace for installation in a residential garage must be installed as specified in SECTION I of these instructions. 4.
PAGE 3
035-19599-001 Rev. A (1103) The furnace area must not be used as a broom closet or for any other storage purposes, as a fire hazard may be created. Never store items such as the following on, near or in contact with the furnace. 1. Spray or aerosol cans, rags, brooms, dust mops, vacuum cleaners or other cleaning tools. 2. Soap powders, bleaches, waxes or other cleaning compounds; plastic items or containers; gasoline, kerosene, cigarette lighter fluid, dry cleaning fluids or other volatile fluid. 3.
PAGE 4
035-19599-001 Rev. A (1103) SECTION II: DUCTWORK DUCTWORK GENERAL INFORMATION The duct system’s design and installation must: 1. Handle an air volume appropriate for the served space and within the operating parameters of the furnace specifications. 2. Be installed in accordance with standards of NFPA (National Fire Protection Association) as outlined in NFPA pamphlets 90A and 90B (latest editions) or applicable national, provincial, or state, and local fire and safety codes. 3.
PAGE 5
035-19599-001 Rev. A (1103) 1. The Air Temperature Rise is determined by subtracting the Return Air Temperature Reading from the Supply Air Temperature Reading. 2. The External Static Pressure is determined by adding the Supply Duct Static Pressure reading to the Return Duct Static Pressure reading. TABLES 2 AND 3 are to be used as a guide only to help the installer determine if the duct sizes are large enough to obtain the proper air flow (CFM) through the furnace.
PAGE 6
035-19599-001 Rev. A (1103) Horizontal Installations Without a Cooling Coil Cabinet Attach the supply plenum to the furnace outlet duct flanges through the use of S cleat material when a metal plenum is used. The use of an approved flexible duct connector is recommended on all installations. This connection should be sealed to prevent air leakage. The sheet metal should be crosshatched to eliminate any popping of the sheet metal when the indoor fan is energized.
PAGE 7
035-19599-001 Rev. A (1103) TABLE 4: Filter Sizes CFM (m3/min) 1000 (28) 1200 (34) 1200 (34) 1600 (45) 2000 (57) 2000 (57) Input / Output BTU/H (kW) 40/37 (11.71/10.84) 60/55 (17.57/16.10) 80/75 (23.42/21.96) 80/75 (23.42/21.96) 100/95 (29.28/27.82) 120/112 (35.14/32.
PAGE 8
035-19599-001 Rev. A (1103) ATTIC INSTALLATION LINE CONTACT ONLY PERMISSIBLE BETWEEN LINES FORMED BY THE INTERSECTION OF FURNACE TOP AND TWO SIDES AND BUILDING JOISTS, STUDS OR FRAMING In any application where temperatures below freezing are possible, see “BELOW FREEZING LOCATIONS”. VENT (MAINTAIN REQUIRED CLEARANCES TO COMBUSTIBLES SHEET METAL IN FRONT OF FURNACE COMBUSTIBLE AIR OPENINGS IS RECOMMENDED GAS PIPING 30” MIN.
PAGE 9
035-19599-001 Rev. A (1103) GAS PIPING INSTALLATION Properly sized wrought iron, approved flexible or steel pipe must be used when making gas connections to the unit. If local codes allow the use of a flexible gas appliance connection, always use a new listed connector. Do not use a connector that has previously serviced another gas appliance. Some utility companies or local codes require pipe sizes larger than the minimum sizes listed in these instructions and in the codes.
PAGE 10
035-19599-001 Rev. A (1103) SECTION V: ELECTRICAL POWER TABLE 7: Electrical and Performance Data Input Output Nominal Airflow MBH kW MBH kW CFM 40 60 80 80 100 120 12 18 23 23 29 35 37 55 73 75 93 111 10.8 16.1 21.4 22.0 27.2 32.5 1000 1200 1200 1600 2000 2000 Max. Outlet Air Temp. Input MBH 40 60 80 80 100 120 kW 12 18 23 23 29 35 °F 155 165 165 160 170 170 °C 68.3 73.9 73.9 71.1 76.7 76.7 m3/min 28.3 28.3 45.3 45.3 56.6 56.6 Cabinet Width Amps 6.2 7 7 11.5 12.2 12.2 Air Temp.
PAGE 11
035-19599-001 Rev. A (1103) TWINNING DUCT SYSTEM ROOM THERMOSTAT CONDENSING UNIT FURNACE CONTROL R W G Y C R W G Y C TO AIR CONDITIONER CONTROLS FIGURE 11: Heating and Cooling Thermostat Connections IMPORTANT: Some electronic thermostats do not have adjustable heat anticipators. They may have other type cycle rate adjustments. Follow the thermostat manufacturer's instructions.
PAGE 12
035-19599-001 Rev. A (1103) Single-Wire Twinning Instructions Single-Wire Staging Instructions Connect the control wiring as shown in the diagram below. Connect the control wiring as shown in the Figure 11. 1. 1. 2. 3. Connect the low voltage wiring from the wall thermostat to the terminal strip on the control board of Furnace #1. Connect a wire from the TWIN terminal of Furnace #1 to the TWIN terminal of Furnace #2. Install a separate 24V relay as shown in the diagram below.
PAGE 13
035-19599-001 Rev. A (1103) This furnace may not be common vented with any other appliance, since it requires separate, properly sized air intake and vent lines. The furnace shall not be connected to any type of B, BW or L vent or vent connector, and not connected to any portion of a factorybuilt or masonry chimney The furnace shall not be connected to a chimney flue serving a separate appliance designed to burn solid fuel.
PAGE 14
035-19599-001 Rev. A (1103) 7. All joints must provide a permanent airtight and watertight seal. 9. 8. Support the combustion air and vent piping such that it is angled a minimum of 1/4” per foot (21 mm/m) so that condensate will flow back towards the furnace. Piping should be supported with pipe hangers to prevent sagging. Seal around the openings where the combustion air and / or vent piping pass through the roof or sidewalls.
PAGE 15
035-19599-001 Rev. A (1103) 3.00” MINIMUM LOOP DIAMENTER EAC HEAT Vertical vent system. This vent system can be installed completely vertical or a combination of horizontal, vertical, or offset using elbows. L1 2. HUM Horizontal vent system. This vent system can be installed completely horizontal or combinations of horizontal, vertical, or offset using elbows. NEUTRALS 1. PARK Connect the discharge end of the drain tube to the condensate disposal system externally to the furnace.
PAGE 16
035-19599-001 Rev. A (1103) 12” MIN 12” SEPARATION BETWEEN BOTTOM OF COMBUSTION AIR PIPE AND TOP OF VENT. MAINTAIN 12” MIN. CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL. 6” 12” MIN FIGURE 22: Double Vertical Sealed Combustion Air and Vent Termination COMBUSTION AIR SUPPLY FIGURE 20: Termination Configuration - 2 Pipe Horizontal VERTICAL VENT APPLICATIONS AND TERMINATION Roof mounted vertical terminals may be field fabricated. Standard PVC/ SRD fittings may be used.
PAGE 17
035-19599-001 Rev. A (1103) The combustion air intake pipe should be located either through the wall (horizontal or side vent) or through the roof (vertical vent). Care should be taken to locate side vented systems where trees or shrubs will not block or restrict supply air from entering the terminal. Also, the terminal assembly should be located as far as possible from a swimming pool or a location where swimming pool chemicals might be stored.
PAGE 18
035-19599-001 Rev. A (1103) 1. An opening may be used in lieu of a duct 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 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 OUTLET AIR (b) and safety check procedure.
PAGE 19
035-19599-001 Rev. A (1103) IMPORTANT: The condensate drain from the furnace may be connected in common with the drain from an air conditioning coil if allowed by local code. 12” MINIMUM BETWEEN BOTTOM OF BELOW AND ANY MATERIAL IMPORTANT: Condensate must be disposed of properly. Follow local plumbing or wastewater codes. The drain line must maintain a 1/4" per foot (0.635 cm per meter) slope to the drain. 12” MIN.
PAGE 20
035-19599-001 Rev. A (1103) ROLLOUT SWITCH CONTROLS Plug all unused condensate trap, condensate pan and inducer drain connection points using plugs provided. Drain Connection - The following steps apply to all models. For horizontal application, also follow the procedure for relocating the trap assembly and installing drain hoses. 1. It is recommended that either ½” (12.7 mm) or ¾” (19.05 mm) PVC or equivalent pipe be field installed as drain pipe.
PAGE 21
035-19599-001 Rev. A (1103) TOOLS AND INFORMATION THAT WILL BE REQUIRED IN ORDER TO PROPERLY PERFORM THE FURNACE STARTUP PROCEDURE. 1. Call the local gas supplier to obtain heating value of the natural gas. If you cannot obtain the heating valve of the gas from the gas supplier, you may use a default value of 1030 BTU/SCF (38.8 MJ / m³). 2. You will need a thermometer or portable digital thermometer to read the supply and return air temperatures. 3.
PAGE 22
035-19599-001 Rev. A (1103) For propane (LP) gas multiply the heat content of the gas BTU/SCF (or Default 2500 BTU/SCF, times 1 cubic ft. of gas measured at the gas meter, times a barometric pressure and temperature correction factor of 0.960; times 3600, then divided by the time (In seconds) it took to measure 1 cubic ft. of gas from the gas meter. In the USA use the following formula to calculate the furnace input.
PAGE 23
035-19599-001 Rev. A (1103) E. DO NOT ADJUST the manifold pressure regulator if the actual input is equal to or within 8% less than the furnace input specified on the rating plate or if the furnace rise is above the specified rise range on the rating plate. If the actual input is significantly higher than the furnace input specified on the rating plate then replace the gas orifice spuds with the gas orifice spuds of the proper size for the type of gas you are using. For altitudes above 2,000 ft.
PAGE 24
035-19599-001 Rev. A (1103) WITH BURNER BOX COVER IN PLACE WITH BURNER BOX COVER REMOVED BURNER BOX WITH COVER REMOVED BURNER BOX WITH COVER BURNER BOX PRESSURE REFERENCE HOSE BURNER BOX PRESSURE REFERENCE HOSE TEE FITTING OUTLET PRESSURE TAP OUTLET PRESSURE TAP FF O O N O N FF O GAS VALVE U-TUBE MANOMETER 6 5 4 3 2 1 0 1 2 3 4 5 6 GAS VALVE 3.5 IN WATER COLUMN GAS PRESSURE SHOWN U-TUBE MANOMETER 6 5 4 3 2 1 0 1 2 3 4 5 6 3.
PAGE 25
035-19599-001 Rev. A (1103) TABLE 16: Blower Performance CFM SINGLE SIDE RETURN (WITHOUT FILTER) MODELS Input/Output/ Airflow/cabinet EXTERNAL STATIC PRESSURE, INCHES W.C. (kPa) Speed Tap 0.1 0.025 0.2 0.050 0.3 0.075 0.4 0.099 0.5 0.124 0.6 0.149 0.7 0.174 0.8 0.199 0.9 (0.224 1.0 0.249 CFM m3/min CFM m3/min CFM m3/min CFM m3/min CFM m3/min CFM m3/min CFM m3/min CFM m3/min CFM m3/min CFM m3/min High 970 27.47 880 24.92 765 21.66 Med-High 970 27.47 1400 39.64 1350 38.23 1300 36.
PAGE 26
035-19599-001 Rev. A (1103) APPLYING FILTER PRESSURE DROP TO DETERMINE SYSTEM AIRFLOW To determine the approximate airflow of the unit with a filter in place, follow the steps below: Subtract the total system static from 0.50 w.c. (125 Pa) and divide this difference by the difference in ESP values in the table, 0.60 w.c. (150 Pa) - 0.50 w.c. (125 Pa), to obtain a percentage. (0.58 - 0.50) / (0.60 - 0.50) = 0.8 1. Select the filter type.
PAGE 27
035-19599-001 Rev.
PAGE 28
NOTES Subject to change without notice. Printed in U.S.A. Copyright © by York International Corp. 2003. All rights reserved. Unitary Product Group 035-19599-001 Rev. A (1103) Supersedes: 035-17477-002 Rev.