Installation manual

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271043-UIM-B-0707

HIGH EFFICIENCY

TUBULAR HEAT EXCHANGER SERIES

MODELS: PV9*UP / FC9V*UP / FL9V*UP

(Two Stage Variable Speed Upflow)

40 - 120 MBH INPUT

(11.7 - 35.1 KW) INPUT

INSTALLATION MANUAL

EFFICIENCY

RATING

CERTIFIED

ISO 9001

Certified Quality

Management System

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.

LIST OF SECTIONS

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

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

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

GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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

CONDENSATE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

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

START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . .19

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

LIST OF FIGURES

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

Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Thermostat Chart - AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Thermostat Chart - HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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

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

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

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

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 . . . . . . . . . .16

Outside and Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . .17

Attic and Crawl Space Combustion Air Termination . . . . . . . . . . . . . .18

Condensate Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Pressure Switch Tube Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

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

Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Furnace Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

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

LIST OF TABLES

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

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

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

Recommended Filter Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Nominal Manifold Pressure - High Fire . . . . . . . . . . . . . . . . . . . . . . . . 8

Nominal Manifold Pressure - Low Fire . . . . . . . . . . . . . . . . . . . . . . . . . 8

Electrical and Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Maximum Equivalent Pipe Length . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Equivalent Length of Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Elbow Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Combustion Air Intake and Vent Connection Size at Furnace

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

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

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

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

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

Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Air Flow Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Filter Performance - Pressure Drop Inches W.C. and (kPa) . . . . . . . .27

Field Installed Accessories - Non Electrical . . . . . . . . . . . . . . . . . . . .27

Summary of content (28 pages)

PAGE 1
INSTALLATION MANUAL HIGH EFFICIENCY TUBULAR HEAT EXCHANGER SERIES EFFICIENCY RATING CERTIFIED MODELS: PV9*UP / FC9V*UP / FL9V*UP (Two Stage Variable Speed Upflow) ISO 9001 Certified Quality Management System 40 - 120 MBH INPUT (11.7 - 35.1 KW) INPUT LIST OF SECTIONS SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 FILTERS . . . . . . . . . . . . . .
PAGE 2
71043-UIM-B-0707 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. Install this furnace only in a location and position as specified in SECTION I of these instructions. A gas-fired furnace for installation in a residential garage must be installed as specified in SECTION I of these instructions.
PAGE 3
271043-UIM-B-0707 INSPECTION 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
271043-UIM-B-0707 TABLE 1: Unit Clearances to Combustibles Application Upflow Top Front Rear Left Side Right Side Flue In. (mm) In. (mm) In. (mm) In. (mm) In. (mm) In. (mm) Floor/ Bottom Closet Alcove Attic 1 (2.5) 3 0 (0) 0 (0) 0 (0) 0 (0) Combustible Yes Yes SECTION II: DUCTWORK DUCTWORK GENERAL INFORMATION DUCTWORK INSTALLATION AND SUPPLY PLENUM CONNECTION A proper Heat Loss/Gain Calculation should be done on all installations for proper application of equipment.
PAGE 5
271043-UIM-B-0707 TABLE 2: Minimum Duct Sizing For Proper Airflow Input/Cabinet Airflow Return1 Rectangular2 Round2 Supply3 Rectangular2 Round2 BTU/H (kW) CFM (m³/min) In² (cm²) in. x in. (cm x cm) in. (cm) dia. In² (cm²) in. x in. (cm x cm) in. (cm) dia. 40,000 (17.58) 1,200 (33.98) 280 (1806) 14 x 20 (35.6 x 50.8) 18 (45.7) 216 (1394) 12 x 18 (30.5 x 45.7) 16 (40.6) 60,000 (17.58) 1,200 (33.98) 280 (1806) 14 x 20 (35.6 x 50.8) 18 (45.7) 216 (1394) 12 x 18 (30.5 x 45.
PAGE 6
271043-UIM-B-0707 A 1-1/2” GAS PIPE ENTRY 1-1/2” GAS PIPE ENTRY 7/8” JUNCTION BOX HOLE T-STAT WIRING 7/8” K.O. 7/8” JUNCTION BOX HOLE 40 CONDENSATE DRAIN 7/8” K.O. OPTIONAL RETURN AIR CUT-OUT (either side) FOR USE WITH EXTERNAL FILTER FRAME 7/8 23-3/4 30-1/8 T-STAT WIRING 7/8” K.O. 13-7/8 CONDENSATE DRAIN 7/8” K.O.
PAGE 7
271043-UIM-B-0707 SIDE RETURN - FILTER INSTALLATION Locate and mark the side return opening. Refer to Figure 1 for dimensions of the cutout. approved for this furnace - only use those approved gases. The installation of a drip leg and ground union is required. Refer to Figure 3. EXTERNAL MANUAL SHUTOFF VALVE Install the side filter rack following the instructions provided with that accessory.
PAGE 8
271043-UIM-B-0707 TABLE 5: Nominal Manifold Pressure - High Fire Second Stage Manifold Pressures (in wc) Second Stage Manifold Pressures (kpa) Altitude (m) 0-7999 8000-8999 9000-9999 800 3.5 3.5 3.5 850 3.5 3.5 3.5 900 3.5 3.5 3.5 950 3.5 3.5 3.3 1000 3.5 3.2 2.9 1050 3.5 2.9 2.7 1100 3.2 2.7 2.4 2500 (LP) 9.8 8.2 7.5 Gas Heating Value (MJ/cu m) Gas Heating Value (BTU/cu ft.) Altitude (feet) 0-2437 2438-2742 29.8 0.87 0.87 2743-3048 0.87 31.7 0.87 0.87 0.
PAGE 9
271043-UIM-B-0707 TABLE 7: Electrical and Performance Data Input High/Low Output High/Low Nominal Airflow Cabinet Width Total Unit AFUE High Fire Air Temp. Rise MBH kW MBH kW CFM m3/min In. cm Amps % °F °C 40/26 12/8 38/24 11/7 1200 34.0 14-1/2 36.8 9 94.0 35 - 65 19 - 36 Low Fire Air Temp. Rise °F °C 35 - 65 19 - 36 60/39 18/11 56/36 16/11 1200 34.0 17-1/2 44.4 9 95.0 40 - 70 22 - 39 20 - 50 11 - 28 80/52 23/15 75/49 22/14 1200 34.0 17-1/2 44.4 9 92.
PAGE 10
AC10 10 Y2 Second Stage Cool W First Stage Heat W2 Second Stage Heat G Fan Y2 Second Stage Cool R 24-Volt Hot (Heat XFMR) RC 24-Volt Hot (Cool XFMR) E/W1 First Stage Heat W2 Second Stage Heat G Fan Connection of the "C" Termainal, 24-Volt Common, is optional when used with batteries Thermostat Installer Setup Number 0170 System Type - must be set to 8 - 2 Heat/2 Cool Multistage Conventional Y2 Second Stage Cool R 24-Volt Hot (Heat XFMR) RC 24-Volt Hot (Cool XFMR) E/W1 First Stage Heat W2 Second Sta
PAGE 11
HP24 Unitary Products Group C 24-Volt Common Y1 First Stage Heat/Cool C 24-Volt Common Y First Stage Heat/Cool O Reversing Valve–Energized in Cool L Malfunction Light Y2 Second Stage Heat/Cool E/W1 First Stage Auxiliary Heat Selection of GAS/ELEC switch on thermostat not necessary Step 1 of Thermostat User Configuration Menu must be set to Heat Pump 2 O/B Reversing Valve L Malfunction Light Y2 Second Stage Heat/Cool AUX Auxiliary Heat Thermostat Installer Setup Number 0170 System Type - must be
PAGE 12
271043-UIM-B-0707 ACCESSORY CONNECTIONS The furnace control will allow power-switching control of various accessories. Refer to Figure 7, for connection details. When combustion air pipe is installed above a suspended ceiling or when it passes through a warm and humid space, the pipe must be insulated with 1/2” Armaflex or other heat resistant type insulation if two feet or more of pipe is exposed.
PAGE 13
271043-UIM-B-0707 TABLE 8: Maximum Equivalent Pipe Length TABLE 10: Elbow Dimensions Model Input BTUH (kW) Pipe Size Inches (cm) Maximum Equivalent length feet (m) 40,000 (11.7) 40,000 (11.7) 60,000 (17.6) 60,000 (17.6) 80,000 (23.4) 80,000 (23.4) 100,000 (29.3) 100,000 (29.3) 120,000 (29.3) 120,000 (29.3) 2 (5.1) 3 (7.6) 2 (5.1) 3 (7.6) 2 (5.1) 3 (7.6) 2 (5.1) 3 (7.6) 2 (5.1) 3 (7.6) 65 (19.8) 90 (27.4) 65 (19.8) 90 (27.4) 65 (19.8) 90 (27.4) 30 (9.2) 85 (25.9) NA 60 (18.
PAGE 14
271043-UIM-B-0707 VENT CLEARANCES G V A D V E B L V FIXED CLOSED B B F VENT TERMINAL X AIR SUPPLY B I V C V V V H V V B B M AREA WHERE TERMINAL IS NOT PERMITTED K X J X V FIXED CLOSED OPERABLE FIGURE 9: Home Layout Direct Vent Terminal Clearances Canadian Installations1,3 A. Clearance above grade, veranda, porch, deck, or 12 inches (30 cm) balcony US Installation2,3 12 inches (30 cm) B.
PAGE 15
271043-UIM-B-0707 VENT SYSTEM This furnace is certified to be installed with one of two possible vent configurations. 1. 2. 12” MIN. Horizontal vent system. This vent system can be installed completely horizontal or combinations of horizontal, vertical, or offset using elbows. 12” MIN. G Vertical vent system. This vent system can be installed completely vertical or a combination of horizontal, vertical, or offset using elbows. AN H ER V O HORIZONTAL VENT APPLICATIONS AND TERMINATION 2. 3. 4.
PAGE 16
271043-UIM-B-0707 CONNECTS TO COLLAR ON TOP OF BURNER BOX VENT VENT PIPE CEMENTS INTO SOCKET JUST ABOVE TOP PANEL OR VENT PIPE MAY BE CLAMPED INTO OUTLET OF DRAIN COUPLING COMBUSTION AIR 2” MIN. FIGURE 13: Double Horizontal Sealed Combustion Air and Vent Termination MIN. 6” FIGURE 15: Sealed Combustion Air Intake Connection and Vent Connection The combustion air intake pipe should be located either through the wall (horizontal or side vent) or through the roof (vertical vent).
PAGE 17
271043-UIM-B-0707 4. This type of installation requires that the supply air to the appliance(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 create conditions requiring special attention to avoid unsatisfactory operation of gas appliances.
PAGE 18
271043-UIM-B-0707 Vent and Supply (Outside) Air Safety Check Procedure Ventilated Combustion Air Termination Follow the procedure in ANSI Z223.1 National Fuel Gas Code. Refer to the section on the “Recommended Procedure for Safety Inspection of an Existing Appliance” or in Canada B149.1-00 Natural Gas and Propane Installation Code section on “Venting Systems and Air Supply for Appliances” and all local codes. In addition to the procedure specified in ANSI Z223.
PAGE 19
271043-UIM-B-0707 CONDENSATE DRAIN PRESSURE SWITCHES The condensate trap must be filled with water before putting the furnace into operation. Perform the following procedures only after the condensate trap has been properly piped to a drain connection using the procedure in this instruction. This furnace is supplied with two pressure switches which monitor the flow through the combustion air/vent piping system.
PAGE 20
271043-UIM-B-0707 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 (38.4 MJ / m³). 2. You will need a thermometer or portable digital thermometer to read the supply and return air temperatures. 3.
PAGE 21
271043-UIM-B-0707 In the USA use the following formula to calculate the furnace input. For natural gas multiply the heat content of the gas BTU/SCF or Default 1030 BTU/SCF (38.4 MJ/m3), times 2 cubic ft. (0.056 m) 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 2 cubic ft. (0.056 m) of gas from the gas meter.
PAGE 22
271043-UIM-B-0707 Be sure to relight any gas appliances that were turned off at the start of this input check. TABLE 15: Inlet Gas Pressure Range Minimum Maximum INLET GAS PRESSURE RANGE Natural Gas Propane (LP) 4.5” W.C. (1.12 kPa) 8.0” W.C. (1.99 kPa) 10.5” W.C. (2.61 kPa) 13.0” (3.24 kPa) W.C. IMPORTANT: The inlet gas pressure operating range table specifies what the minimum and maximum gas line pressures must be for the furnace to operate safely.
PAGE 23
271043-UIM-B-0707 WITH BURNER BOX COVER IN PLACE WITH BURNER BOX COVER REMOVED BURNER BOX PRESSURE REFERENCE HOSE BURNER BOX PRESSURE REFERENCE HOSE (not used) TEE FITTING BURNER BOX WITH COVER REMOVED BURNER BOX WITH COVER OUTLET PRESSURE TAP GAS VALVE U-TUBE MANOMETER 6 5 4 3 2 1 0 1 2 3 4 5 6 3.5 IN WATER COLUMN GAS PRESSURE SHOWN U-TUBE MANOMETER 6 5 4 3 2 1 0 1 2 3 4 5 6 OUTLET PRESSURE TAP GAS VALVE 3.
PAGE 24
271043-UIM-B-0707 Heating and Cooling Airflow Humidistat The heating and the cooling airflows are preset at the factory. The heating airflow is set to the maximum CFM. The cooling airflow is set to provide 90 percent of the maximum CFM. The heating and cooling airflows must be field adjusted to match the HVAC system at installation. See Table 17 for the HEAT, COOL and ADJ jumper settings to use for specific airflows.
PAGE 25
271043-UIM-B-0707 9 RED FLASHES: Indicates reversed line voltage polarity or grounding problem. Both heating and cooling operations will be affected. Check polarity at furnace and branch. Check furnace grounding. Check that flame probe is not shorted to chassis. 10 RED FLASHES: Gas valve energized with no call for heat. Check gas valve and gas valve wiring.
PAGE 26
271043-UIM-B-0707 TABLE 17: Air Flow Data 40,000 Input - 3 Ton CFM High Low 1340 995 1205 885 1255 920 1150 835 1170 855 1025 755 1045 780 835 625 950 705 785 590 865 665 725 605 80,000 Input - 3 Ton CFM High Low 1310 890 1100 740 1220 830 1000 670 1090 720 900 610 880 610 680 510 810 580 630 500 730 530 590 500 100,000 Input - 5 Ton CFM High Low 2210 1480 1780 1180 2040 1350 1620 1050 1840 1250 1560 1010 1470 940 1370 890 1460 930 1250 790 1310 810 1090 690 40,000 Input - 3 Ton CFM High Low 1045 740 905 64
PAGE 27
1043-UIM-B-0707 FILTER PERFORMANCE The airflow capacity data published in Table 17 represents blower performance WITHOUT filters. To determine the approximate blower performance of the system, apply the filter drop value for the filter being used or select an appropriate value from the Table 18. NOTE: The filter pressure drop values in Table 18 are typical values for the type of filter listed and should only be used as a guideline.