INSTALLATION HIGH EFFICIENCY

GAS-FIRED FURNACES
INSTRUCTION TUBULAR HEAT EXCHANGER SERIES
MODELS: P*UR / G9T-UP / FG9-UP (Upflow)
40 - 140 MBH INPUT
MODELS: P*DH / G9T-DH / FG9-DH (Downflow / Horizontal)
40 - 120 MBH INPUT

CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFIC UNIT INFORMATION . . . . . . . . . . . . . . . . . . 3
DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ELECTRICAL POWER CONNECTION . . . . . . . . . . . . 12
ELECTRICAL CONTROL CONNECTIONS . . . . . . . . . 13
COMBUSTION AIR AND VENT SYSTEM . . . . . . . . . . 14
CONDENSATE PIPING . . . . . . . . . . . . . . . . . . . . . . . . 24
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . 25
START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . 26
FURNACE ACCESSORIES . . . . . . . . . . . . . . . . . . . . . 31
OPERATION AND MAINTENANCE . . . . . . . . . . . . . . . 33
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 36

EFFICIENCY
RATING
CERTIFIED

CAUTION: READ ALL SAFETY GUIDES BEFORE YOU

START TO INSTALL YOUR FURNACE.
SAVE THIS MANUAL

035-17477-001 Rev. A (801)

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 035-17477-001 Rev. A (801)

GENERAL INFORMATION
DESCRIPTION
This Category IV, dual certified direct vent and 1-pipe vent
IMPROPER INSTALLATION MAY CREATE A
furnace is designed for residential or commercial applica-
CONDITION WHERE THE OPERATION OF THE
tion. It may be installed without modification to the conden-
PRODUCT COULD CAUSE PERSONAL INJURY
sate system in a basement, garage, equipment room, alcove,
OR PROPERTY DAMAGE.
attic or any other indoor location provided the space tempera-
IMPROPER INSTALLATION, ADJUSTMENT, ture is 32 °F or higher and where all required clearance to
ALTERATION, SERVICE OR MAINTENANCE combustibles and other restrictions are met. If the furnace is
CAN CAUSE INJURY OR PROPERTY DAMAGE. being installed where the space temperature is below 32°F,
REFER TO THIS MANUAL FOR ASSISTANCE refer to “BELOW FREEZING LOCATIONS” on page 4.
OR ADDITIONAL INFORMATION, CONSULT A
This furnace is constructed at the factory for natural gas-fired
QUALIFIED INSTALLER, SERVICE AGENCY OR
operation at 0 - 4,500 ft. above sea level, but may be con-
THE GAS SUPPLIER.
verted to operate on propane (LP) gas and at altitudes up to
10,000 ft. For applications at altitudes between 2,000 - 4,500
ft., see “COMBUSTION AIR AND VENT SYSTEM” on
page 14, for required vent length reductions. For applications
at altitudes greater than 4,500 feet, see high altitude instruc-
tions 035-14460-000.
THIS PRODUCT MUST BE INSTALLED IN
STRICT COMPLIANCE WITH THE ENCLOSED High altitude and propane (LP) changes or conversions
INSTALLATION INSTRUCTIONS AND ANY required in order for the appliance to satisfactory meet the
APPLICABLE LOCAL, STATE, AND NATIONAL application must be made by an authorized distributor or
CODES INCLUDING BUT NOT LIMITED TO, dealer. In Canada, a certified conversion station or other
BUILDING, ELECTRICAL AND MECHANICAL qualified agency, using factory specified and/or approved
CODES. parts, must perform the conversion.
INSPECTION
As soon as a unit is received, it should be inspected for possi-
ble damage during transit. If damage is evident, the extent of
the damage should be noted on the carrier's freight bill.
A separate request for inspection by the carrier's agent
The furnace area must not be used as a broom
should be made in writing. Also, before installation the unit
closet or for any other storage purposes, as a fire
should be checked for screws or bolts which may have loos-
hazard bay be created. Never store items such as
ened in transit. There are no shipping or spacer brackets
the following on, near or in contact with the fur-
which need to be removed.
nace.
1.Spray or aerosol cans, rags, brooms, dust mops, vac- NOTES, CAUTIONS & WARNINGS
uum cleaners or other cleaning tools. The installer should pay particular attention to the words:
1.Soap powders, bleaches, waxes or other cleaning NOTE, CAUTION and WARNING. NOTES are intended to
compounds; plastic items or containers; gasoline, clarify or make the installation easier. CAUTIONS are given
kerosene, cigarette lighter fluid, dry cleaning fluids to prevent equipment damage. WARNINGS are given to alert
or other volatile fluid. the installer that personal injury and/or equipment or property
damage may occur if installation procedures are not handled
1.Paint thinners and other painting compounds. properly.
1.Paper bags, boxes or other paper products
Never operate the furnace with the blower door
removed. To do so could result in serious personal
injury and/or equipment damage.
The cooling coil must be installed in the supply air
duct, downstream of the furnace. Cooled air may
not be passed over the heat exchanger.

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 035-17477-001 Rev. A (801)

VENT SAFETY CHECK PROCEDURE SPECIFIC UNIT INFORMATION

LIMITATIONS & LOCATION
This furnace should be installed in accordance with all
national and local building/safety codes and requirements, or
This furnace may not be common vented with any in the absence of local codes, with the National Fuel Gas
other appliance, since it requires separate, prop- Code ANSI Z223.1 or CAN/CGA B149.1 or.2 Installation
erly-sized air intake and vent lines. The furnace Code (latest editions), local plumbing or waste water codes,
shall not be connected to any type of B, BW or L and other applicable codes.
vent or vent connector, and not connected to any
portion of a factory-built or masonry chimney. Downflow/horizontal models when installed in a downflow
configuration are AGA/CGA listed for application into a manu-
If this furnace is replacing a common-vented fur- factured (mobile) home.
nace, it may be necessary to resize the existing
vent line and chimney to prevent oversizing prob- Upflow models or horizontal applications are not approved for
lems for the new combination of units. Refer to the mobile homes.
National Gas Code (ANSI Z223.1) or CAN/CGA CLEARANCES FOR ACCESS
B149.1 or .2 Installation Code (latest editions).
Ample clearances should be provided to permit easy access
The following steps shall be followed with each appliance to the unit. The following minimum clearances are recom-
connected to the venting system placed in operation, while mended:
any other appliances connected to the venting system are not 1. Twenty-four (24) inches between the front of the furnace
in operation: and an adjacent wall or another appliance, when access
1. Seal any unused openings in the venting system. is required for servicing and cleaning.
2. Inspect the venting system for proper size and horizontal 2. Eighteen (18) inches at the side where access is
pitch, as required in the National Fuel Gas Code, ANSI required for passage to the front when servicing or for
Z223.1, or the CAN/CGA B149 Installation Codes and inspection or replacement of flue/vent connections.
these instructions. Determine that there is no blockage
In all cases, accessibility clearances shall take precedence
or restriction, leakage, corrosion or other deficiencies
over clearances for combustible materials where accessibility
which could cause an unsafe condition.
clearances are greater.
3. Insofar as is practical, close all building doors and win-
dows and all doors between the space in which the appli-
ance(s) is located and other spaces of the building. Turn
on clothes dryers. Turn on any exhaust fans, such as
range hoods and bathroom exhausts, so they shall oper- Do not install the furnace in an unconditioned
ate at maximum speed. Do not operate a summer space or garage that could experience ambient
exhaust fan. Close fireplace dampers. temperatures of 32° F (0° C) or lower. For applica-
tion in below freezing locations, See “BELOW
4. Follow the lighting instructions. Place the appliance
FREEZING LOCATIONS” on page 4.
being inspected in operation. Adjust thermostat so the
appliance shall operate continuously. The furnace is not to be used for temporary heat-
ing of buildings or structures under construction.
5. Test for draft hood equipped appliance spillage at the
draft hood relief opening after 5 minutes of main burner This unit must be installed in a level (1/4”) position
operation. Use the flame of a match or candle. side-to-side and front-to-back to provide proper
condensate drainage.
6. After it has been determined that each appliance con-
nected to the venting system properly vents when tested Do not allow return air temperature to be below
as outlined above, return doors, windows, exhaust fans, 55°F for extended periods. To do so may cause
fireplace dampers and any other gas burning appliance condensation to occur in the main fired heat
to their previous conditions of use. exchanger.
7. If improper venting is observed during any of the above Only use natural gas in furnaces designed for nat-
tests, the venting system must be corrected. ural gas. Only use propane (LP) gas for furnaces
that have been properly converted to use propane
8. Any corrections to the common venting system must be
(LP) gas. Do not use this furnace with butane.
in accordance with the National Fuel Gas Code Z223.1
Using wrong gas could create a hazard, resulting
or CAN/CGA B149.1 or .2 Installation Code (latest edi-
in damage, injury or death.
tions). If the common vent system must be resized, it
should be resized to approach the minimum size as
determined using the appropriate tables in Appendix G
of the above codes.

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 035-17477-001 Rev. A (801)

The furnace shall be located using these guidelines:

1. Where a minimum amount of air intake/vent piping and
elbows will be required.
Furnaces shall not be installed directly on carpet- 2. As centralized with the air distribution as possible.
ing, tile or other combustible material other than
wood flooring. An accessory combustible floor 3. Where adequate combustion air will be available (partic-
base is available to allow direct installation of ularly when installing as 1-pipe system).
downflow models on combustible flooring. 4. In an area where ventilation facilities provide for safe lim-
Furnace shall be installed so the electrical compo- its of ambient temperature under normal operating condi-
nents are protected from water. tions. Ambient temperatures must not fall below 32°F
(0°C) unless the condensate system is protected from
A manufactured (mobile) home installation must conform with freezing (refer to “BELOW FREEZING LOCATIONS” on
the Manufactured Home Construction and Safety Standard, page 4).
Title 24 CFR, Part 3280, or when this standard is not applica- 5. Where it will not interfere with proper air circulation in the
ble, the Standard for Manufactured Home Installations (Man- confined space.
ufactured Home Sites, Communities and Set-Ups), ANSI
A225.1, and/or CAN/CSA-Z240 MH Series, Mobile Homes. 6. Where the outdoor combustion air/vent terminal will not
be blocked or restricted.
The size of the unit should be based on an acceptable heat
loss calculation for the structure. ACCA, Manual J or other CLEARANCES TO COMBUSTIBLES
approved methods may be used. Minimum clearances from combustible construction are
Refer to furnace rating plate for the type of gas approved for shown in Table 3, “UNIT CLEARANCES TO COMBUSTI-
this furnace - only use those approved gases. BLES,” on page 7. These minimum clearances must be
Check the rating plate and power supply to be sure that the maintained in the installation.
electrical characteristics match. All models use nominal 115 BELOW FREEZING LOCATIONS
VAC, 1 Phase, 60 Hertz power supply.
If this furnace is installed in any area where the ambient tem-
For installations above 2,000 feet, reduce input 4% for each perature may drop below 32° F, a UL listed self regulated
1,000 feet above sea level. heat tape must be installed on any condensate drain lines. It
For installation between 2000 and 4500 feet, it is not required is recommended that self regulating heat tape rated at 3
that the pressure switch be changed, provided the maximum watts per foot be used. This must be installed around the con-
vent/intake pipe lengths are adjusted as shown in the Note densate drain lines in the unconditioned space. Always install
from Tables 4, 5 and 7 on Pages 16 & 20. For altitudes above the heat tape per the manufacturer's instructions. Cover the
4,500 feet, refer to instructions 035-14460-000 for correct self-regulating heat tape with fiberglass or other heat resis-
pressure switch/orifice or other required conversion informa- tant, insulating material.
tion.
The furnace shall not be connected to a chimney flue serving
a separate appliance designed to burn solid fuel.
A furnace installed in a residential garage shall be located so If this unit is installed in an unconditioned space
that all burners and burner ignition devices are located not and an extended power failure occurs, there will
less that 18" above the garage floor, and located or protected be potential damage to the condensate trap, drain
to prevent damage by vehicles. lines and internal unit components. Following a
Allow clearances from combustible materials as listed under power failure situation, Do Not Operate the Unit
Clearances to Combustibles, ensuring that service access is Until Inspection and Repair Are Performed.
allowed for both the burners and blower.

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 035-17477-001 Rev. A (801)

6-3/8

20 1-1/4 B 3-1/8

2-3/4
6-1/8 4-1/8
8-7/8

1-3/4

45 6

T’STAT
WIRING
7/8” K.G.
OPTIONAL SIDE RETURN 1-3/4
CUT-OUT (EITHER SIDE) 22-3/4

9-7/8 20-5/8 14-1/2

CONDENSATE
DRAIN 6-7/8 3/4

28-1/2 A
A MODELS P*UR/
A B C D E
C
G9T-UP/ FG9-UP
B 40 / 37 / 1000 /”A” 14-1/2 16-1/4 13-1/8 2 2
60 / 55 / 1000 /”B” 17-1/2 19-3/4 16-5/8 2 2
80 / 75 / 1200 /”B” 17-1/2 19-3/4 16-5/8 2 2
28-1/2
WITH K.O. 80 / 75 / 1600 /”C” 21 23-1/4 20-1/8 3 2
1

20 23
REMOVED
100 / 95 / 1400 /”C” 21 23-1/4 20-1/8 3 2
100 / 95 / 2000 /”C” 21 23-1/4 20-1/8 3 2
3/4” 120 / 112 / 2000 /”D” 24-1/2 23-1/4 20-1/8 3 2
FLANGE
D 140 / 130 / 2000 /”D” 24-1/2 23-1/4 20-1/8 3 2
INTAKE FRONT E FRONT
VENT CONNECTION 1. Vent pipe must be increased to 3” on this unit.
CONNECTION TOP IMAGE BOTTOM IMAGE
(vent size)

FIGURE 1 : DIMENSIONS - UPFLOW MODELS: P*UR/G9T-UP/FG9-UP

Table 1: RATINGS & PHYSICAL / ELECTRICAL DATA - UPFLOW MODELS

MODELS P*UR / G9T-UP / MAX.
BLOWER MAX MIN WIRE
FG9-UP AIR OUTLET TOTAL OVER- SIZE (AWG)
CABINET *
AFUE TEMP AIR UNIT CURRENT @ 75 FT.
INPUT OUTPUT NOM. WIDTH
RISE °F TEMP. HP AMPS SIZE (IN.) AMPS
MBH MBH CFM °F PROTECT† ONE WAY†

40 37 1000 14-1/2 92.4 35 - 65 165 1/3 6.2 10 x 6 9.0 20 14

60 55 1000 17-1/2 92.2 45 - 75 175 1/3 6.2 10 x 6 9.0 20 14
80 74 1200 17-1/2 92.0 35 - 65 165 1/2 7.0 11 x 8 12.0 20 14
80 76 1600 21 94.3 30 - 60 160 3/4 11.5 11 x 8 12.0 20 14
100 93 1400 21 92.2 45 - 75 175 1/2 10.7 10 x 10 12.0 20 14
100 94 2000 21 93.0 30 - 60 160 1 12.2 11 x 10 14.0 20 12
120 112 2000 24-1/2 92.0 45 - 75 175 1 12.2 11 x 10 14.0 20 12
140 130 2000 24-1/2 92.0 45 - 75 175 1 12.2 11 x 10 14.0 20 12
*. AFUE numbers are determined in accordance with DOE test procedures
†. Wire size and overcurrent protection must comply with the National Electrical Code (NFPA-70-latest edition).
For altitudes above 2,000 ft., reduce capacity 4% for each 1,000 ft. above sea level. Refer to instruction 035-14460-000.
Wire size based on copper conductors, 60°C, 3% voltage drop.
Continuous return air temperature must not be below 55°F.

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B 20 D
3/4 VENT CONNECTION
T'STAT WIRING
7/8 K.O.
CONDENSATE
CONDENSATE DRAIN ACCESS
DRAIN ACCESS 1-3/4
3-1/4 x 3
3-1/4 x 3
5-1/4
35
16-3/4
45 AIR INTAKE 18-1/2 3-3/4
3-5/8 x 3-5/8 1-1/4 AIR INTAKE
(G CONN. SIZE/ 3-5/8 x 3-5/8
PIPE SIZE) 3-3/4 (G CONN. SIZE/
PIPE SIZE)
GAS INLET 7-1/2 1-1/4
1-1/4 x 2-1/2

6-1/4
4-1/8 ALT. GAS INLET
2-3/4 1-1/4 x 2-1/2

A 28-1/2
FRONT LEFT SIDE RIGHT SIDE

B A
1-3/8 MODELS P*DH /
G9T-DH / FG9-DH A B C D E F G
VENT CONNECTION 40/37/1000/A 14-1/2 13-1/4 11-3/4 2 5-1/8 2-1/2 2
(VENT SIZE
19-1/4
20 POWER 60/55/1200/B 17-1/2 16-1/4 14-3/4 2 6-5/8 2-1/4 2
WIRING C
7/8 K.O. 80/75/1200/B 17-1/2 16-1/4 14-3/4 2 6-5/8 2-1/4 2
80/75/1600/C 21 19-3/4 18-1/4 2 8-3/8 2-1/4 2
8 100/95/2000/C 21 19-3/4 18-1/4 2 8-3/8 2-1/4 2
1-7/8 5-3/8
120/112/2000/D 24-1/2 23-1/4 21-3/4 2 (3)1 10-1/8 2-1/4 3
H
E F
FRONT FRONT 1. VENT PIPE MUST BE INCREASED TO 3" ON THIS MODEL.

TOP IMAGE BOTTOM IMAGE ALL DIMENSION ARE IN INCHES, AND ARE APPROXIMATE.
RETURN END RETURN END

FIGURE 2 : DIMENSIONS - DOWNFLOW/HORIZONTAL MODELS: P*DH/G9T-DH/FG9-DH

Table 2: RATINGS & PHYSICAL / ELECTRICAL DATA - DOWNFLOW/HORIZONTAL MODELS

MODELS P*DH/ MIN WIRE
MAX. BLOWER MAX
FG9-DH/G9T—DH AIR TOTAL SIZE
CABINET * TEMP OUTLET
OVER-
AFUE UNIT CURRENT (AWG) @
INPUT OUTPUT NOM. WIDTH RISE °F
AIR
75 FT. ONE
°F HP AMPS SIZE (IN) AMPS
MBH MBH CFM TEMP. PROTECT†
WAY†
40 37 1000 14-1/2 91.0 25 - 55 155 1/3 6.2 10 x 6 9.0 20 14
60 55 1200 17-1/2 91.0 35 - 65 165 1/2 7.0 11 x 8 12.0 20 14
80 75 1200 17-1/2 91.0 35 - 65 165 1/2 7.0 11 x 8 12.0 20 14
80 75 1600 21 91.0 30 - 60 160 3/4 11.5 11 x 8 12.0 20 14
100 95 2000 21 91.0 40 - 70 170 1 12.2 11 x 10 14.0 20 12
120 112 2000 24-1/2 91.0 40 - 70 170 1 12.2 11 x 10 14.0 20 12
*. AFUE numbers are determined in accordance with DOE test procedures
†.
Wire size and overcurrent protection must comply with the National Electrical Code (NFPA-70-latest edition).
For altitudes above 2,000 ft., reduce capacity 4% for each 1,000 ft. above sea level. Refer to instruction 035-14460-000.
Wire size based on copper conductors, 60°C, 3% voltage drop.
Continuous return air temperature must not be below 55°F.

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Table 3: UNIT CLEARANCES TO COMBUSTIBLES

LINE
LEFT RIGHT FLOOR/
APPLICATION TOP FRONT REAR FLUE CLOSET ALCOVE ATTIC CON-
SIDE SIDE BOTTOM
TACT
UPFLOW MODELS (P*UR / G9T-UP / FG9-UP)
UPFLOW 1 3 0 0 0 0 COMBUSTIBLE YES YES YES NO
DOWNFLOW / HORIZONTAL MODELS (P*DH / G9T-DH / FG9-DH )
DOWNFLOW 1 3 0 0 0 0 1" * YES YES YES NO

HORIZONTAL 1 3 0 0† 0† 0 1” NO YES YES YES‡

*.
Special floor base or air conditioning coil required for use on combustible floor.
†.
Minimum of 8” clearance required to install condensate removal system.
‡. Line contact only permitted between lines formed by the intersection of the rear panel and side panel (top in horizontal position) of
the furnace jacket and building joists, studs or framing.

DUCTWORK UPFLOW MODELS

The duct system's design and installation must: SUPPLY PLENUM CONNECTION

1. Handle an air volume appropriate for the served space Attach the supply plenum to the fur-
and within the operating parameters of the furnace spec- nace outlet duct connection flanges.
ifications. This is typically through the use of S
cleat material when a metal plenum is
2. Be installed in accordance with standards of NFPA
used. The use of an approved flexible
(National Fire Protection Association) as outlined in
duct connector is recommended on all
NFPA pamphlets 90A and 90B (latest editions) or appli-
installations. This connection should be
cable national, provincial, local fire and safety codes.
sealed to prevent air leakage.
3. Create a closed duct system. The supply duct system
If a matching cooling coil is used, it
must be connected to the furnace outlet and the return
may be placed directly on the furnace
duct system must be connected to the furnace inlet. Both
outlet and sealed to prevent leakage.
supply and return duct systems must terminate outside
Follow the coil instructions for installing
the space containing the furnace.
the supply plenum.
4. Complete a path for heated or cooled air to circulate
On all installations without a coil, a removable access panel
through the air conditioning and heating equipment and
is recommended in the outlet duct such that smoke or
to and from the conditioned space.
reflected light would be observable inside the casing to indi-
cate the presence of leaks in the heat exchanger. This
access cover shall be attached in such a manner as to pre-
vent leaks.
The cooling coil must be installed in the supply air RETURN DUCT CONNECTION
duct downstream of the furnace. Cooled air must Return air may enter the furnace through the side(s) or bot-
not be passed over the heat exchanger. tom depending on the type of application. Return air may
not be connected into the rear panel of the unit. Refer to
When the furnace is used in conjunction with a cooling coil,
the "Filter Installation" section of this instruction for the type of
the coil must be installed parallel with, or in the supply air side
application desired for specific installation details.
of the furnace to avoid condensation in the primary heat
exchanger. NOTE: In order to achieve the airflow indicated in the table, it
is recommended those applications over 1800 CFM use
When a parallel flow arrangement is used, the dampers or return air from two sides, one side and the bottom or bottom
other means used to control air flow must be adequate to pre- only. For single return application, see data and notes on
vent chilled air from entering the furnace, and if manually blower performance data tables in this manual.
operated, must be equipped with means to prevent operating
of either unit unless the damper is in the full heat or cool posi-
tion.

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FILTER INSTALLATION - UPFLOW 4. Install the filter(s) if provided. Cut filter if necessary to
All applications require the use of a filter. A high velocity filter match air opening in cabinet. Filter should extend
and retainer are provided for field installation on P*UR & beyond opening edge as much as possible to prevent air
G9T-UP models. FG9-UP models must have a field-supplied from bypassing the filter. DO NOT remove stiffening rods
filter and mounting hardware. from inside the filter. Shorten the rods, if necessary, to
match final filter size.
Internal Installation
5. Position the filter between the wire retainer and the cabi-
1. Select desired filter position (left/right side, and/or bot- net wall (or floor) so it completely covers the cabinet air
tom). Remove the corresponding cabinet cut-outs per opening and secure the filter in place at the front of the
instructions provided. cabinet by fastening the closed (looped) end of the
2. Install snap-in retainer clips into the corresponding slots retainer wire under the flanged edge of the cabinet.
from the outside rear of the cabinet (Refer to Figure 3.) When properly installed the filter should fit flush with all
To prevent cabinet air leaks, install snap-in plugs (pro- four sides of the cabinet wall.
vided) into the unused slots at the outside rear of the NOTE: Air velocity through throw-away type filters may not
cabinet. exceed 300 feet per minute. All velocities over this require the
use of high velocity filters.
Side Return - External Filter
Locate and knock out the square corner locators. These indi-
cate the size of the cutout to be made in the furnace side
FURNACE
(REAR CABINET) LEFT panel. Refer to Figure 5.
SIDE
RIGHT SLOTS
SIDE
SLOTS

BOTTOM SLOTS

CABINET
SLOT
PLUG UNUSED
CABINET SLOTS
FILTER SUPPORT WITH PLUGS

FIGURE 3 : Furnace Filter Slot Locations

FRONT OF
CORNER FURNACE
POSITION WIRE RETAINER
MARKINGS
(IF PROVIDED) UNDER FLANGE

FIGURE 5 : Side Return Cutout Markings

Install the side filter rack following the instructions provided

with that accessory. If a filter(s) is provided at another loca-
IF FILTER
PROVIDED tion in the return air system, the ductwork may be directly
CLIPS attached to the furnace side panel.
An accessory filter rack (1SR0302BK) is available for mount-
ing the filter external to the cabinet.
RIGHT SIDE
INSTALLATION NOTE: Some accessories such as electronic air cleaners and
FURNACE
SHOWN FRONT pleated media may require a larger side opening. Follow the
instructions supplied with that accessory for side opening
requirements.

FIGURE 4 : Filter Retainer Placement

3. Install the wire retainer inside the cabinet (if provided).

Insert the open ends of the wire retainer into the clip All installations must have a filter installed.
loops at the rear of the blower compartment. The retainer
wire should pivot freely like a hinge, on the clips at the
rear of the cabinet. (Refer to Figure 4).

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The return duct may be attached to the furnace by S-cleat, Horizontal Installations
bend tabs or other approved methods. Be sure to seal the For installation of an air conditioning coil in a horizontal appli-
duct to the furnace to prevent air leakage. cation, the perforations in the wrapper flanges must be bent
Where the return duct system is not complete, the return con- away from the heat exchanger to create duct flanges so the
nection must run full size to a location outside the utility room air conditioning coil can be properly seated on the furnace.
or basement. For further details, consult Section 5.3 (Air for Refer to the installation instructions supplied with the air con-
Combustion and Ventilation) of the National Fuel Gas Code, ditioning coil for additional information and completion of the
ANSI Z223.1, or CAN/CGA B149.1 or .2, Installation Code - coil installation.
latest editions. NOTE: Duct pliers or other suitable tool can be used to bend
Bottom Return perforations. To help bend flanges in a straight line, scribe a
Bottom return applications normally pull return air through a line between the perforations prior to bending.
base platform or return air plenum. Be sure the return plat- DOWNFLOW APPLICATION
form structure is suitable to support the weight of the furnace.
Refer to Figure 1 on Page 5, for unit dimensions. Be sure to DOWNFLOW FILTERS
seal the furnace to plenum connection to prevent air leakage. A top return filter rack is supplied with
The bottom panel is equipped with a perforated opening for the furnace. Two 14" x 20" permanent
easy removal. Tabs must be cut with sheet metal snips to washable filters are supplied with each
allow removing knock-out. Scribe marks are included for unit.
forming flanges for attachment of the return air ductwork. Downflow furnaces typically are
NOTE: If an external mounted filter rack is being used, see installed with the filters located above
the instructions provided with that accessory for proper hole the furnace, extending into the return
cut size. air duct.
Upflow attic installations must meet all minimum clearances Any branch duct must attach to the ver-
to combustibles and have floor support with required service tical ductwork above the filter height
accessibility. (FH) and for proper installation refer to
Figure 6 .
DOWNFLOW/HORIZONTAL MODELS
The filter rack (provided) should be securemd to the center of
COOLING COIL TRANSITION the front and rear flanges at the furnace top. Drill a hole
These furnace models are equipped with perforations in the through the front and rear duct flange into the filter rack and
supply air wrapper flanges that allow for easy application of secure it with a sheet metal screw.
an air conditioning coil to the furnace without the use of sheet NOTE: For easier filter access in a downflow configuration, a
metal transition pieces. These perforations can be bent in removable access panel is recommended in the vertical run
either direction depending on the type of application - either of the return air duct immediately above the furnace.
downflow or horizontal left and right. Refer to either the
Refer to the unit rating plate for furnace model then see the
"Downflow Application" or "Horizontal Application" section
dimensions page of this instruction for return air plenum
below for specific instructions on how to install the coil.
dimensions. Install the plenum following instructions under
Downflow Installations “DUCTWORK” on page 7, in this instruction.
For installation of an air conditioning coil in a downflow appli- SUPPLY AIR DUCTS
cation, the perforations in the wrapper flanges must be bent
Installations on combustible material or floors must use a
in towards the heat exchanger to allow for the coil duct flange
combustible floor base (shown in Figure 7 - 1CB0314, 17, 21
to recess into the furnace. Refer to the installation instruc-
& 24) as specified on the rating plate. Follow the instructions
tions supplied with the air conditioning coil for additional infor-
supplied with the combustible floor base accessory.
mation and completion of the coil installation.
This base can be replaced with a matching cooling coil, prop-
NOTE: Duct pliers or other suitable tool can be used to bend
erly sealed to prevent leaks. Follow the cooling coil instruc-
perforations. To help bend flanges in a straight line, scribe a
tions for installing the plenum.
line between the perforations prior to bending.
All downflow application supply duct systems must be
designed and installed in accordance with the standards of
NFPA 90A and 90B, and/or all local codes.

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DOWNFLOW/HORIZONTAL MODELS
FILTER RACK
(FACTORY SUPPLIED) HORIZONTAL APPLICATION

A RACK AND FILTERS SECURED

INSIDE BLOWER SECTION
FOR SHIPMENT

A
CASING SIZE DIMENSION FH
16-1/4 12-3/4
22-1/4 11
26-1/4 8-1/4

NOTE: FILTER ACCESS THRU DUCT-

WORK MUST BE PROVIDED FOR BRANCH Downflow furnaces may be installed horizontally with the sup-
REMOVAL AND CLEANING DUCTS ply airflow toward the left or right by laying the unit on the left
or right side panel.
FILTERS

FILTER
DUCTWORK RACK
FH

Do not install the unit on the rear panel.

After determining the best orientation, lay the unit on top of

CROSS SECTION A-A
(WITH PLENUM AND FILTERS) the shipping carton to protect the finish. The appropriate elec-
trical knock-outs for power wiring, control wiring and gas pip-
FIGURE 6 : downflow filters ing should be removed at this time.
For horizontal application, return air must enter through the
end only. Return air may not be connected into the rear or
side panels of the unit.
HORIZONTAL FILTERS
DOWNFLOW All filters and mounting provision must be field supplied. Fil-
FURNACE ters(s) may be located in the duct system external to the fur-
nace or in a return filter grille(s). Refer to furnace accessories
on Page 31 for external filter kit options.
WARM AIR PLENUM
WITH 1" FLANGES ATTIC INSTALLATION

FIBERGLASS SUPPLY AIR

INSULATION LINE CONTACT ONLY PERMISSIBLE
BETWEEN LINES FORMED BY THE
INTERSECTION OF FURNACE TOP
AND TWO SIDES AND BUILDING
JOISTS, STUDS OR FRAMING VENT (Maintain
required clearances
to combustibles)

SHEET METAL
FIBERGLASS TAPE GAS PIPING IN FRONT OF
UNDER FLANGE FURNACE
COMBUSTION AIR
OPENINGS IS
RECOMMENDED
COMBUSTIBLE FLOOR 30” MIN.

BASE ACCESSORY
WORK AREA
12”

RETURN AIR SEDIMENT

FIGURE 7 : Combustible Floor Base Accessory TRAP

FIGURE 8 : typical attic installation

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 035-17477-001 Rev. A (801)

This appliance is design certified for line contact for furnaces When suspending the furnace from rafters or floor joists using
installed horizontally. The intersection of the furnace top and rod, pipe or straps, refer to the Physical and Rating Data
sides form a line. This line may be in contact with combustible Table for downflow/horizontal furnace weights to determine
material. Refer to the "SPECIFIC UNIT INFORMATION" sec- suitable means of suspension.
tion of this manual for further information on installation loca- Angle supports should be placed at the supply air end and
tion and limitations. near the blower deck (Refer to Figure 9 ). Do not support
at return air end of unit.
Units may also be suspended by using straps or other mate-
rial at the same location. All four suspension points must be
If this furnace is installed over a finished space, a level to ensure quiet furnace operation.
condensate safety pan must be installed.

In any application where temperatures below

freezing are possible, see “BELOW FREEZING
When a furnace is installed in an attic or other LOCATIONS” on page 4
insulated space, keep all insulating materials at
least 12" away from furnace and burner combus-
tion air openings.
GAS PIPING
The gas supply should be a separate line and must be
Secure a platform constructed of plywood or other building installed in accordance with the National Fuel Gas Code,
material to the floor joists. ANSI Z223.1 (latest edition), or the CAN/CGA B149.1 or .2
NOTE: In either a horizontal left or right installation, a mini- Installation Codes (latest edition) and all applicable local and
mum of 8" clearance is required beneath the furnace to allow utility requirements.
for the installation of the condensate trap and drain pipe. Some utility companies or local codes require pipe sizes
Refer to "CONDENSATE PIPING" section of this manual for larger than the minimum sizes listed in these instructions and
more information. in the codes. Properly sized wrought iron, approved flexible
NOTE: See crawl space installation for suspending the fur- or steel pipe must be used when making gas connections to
nace in attic installations. the unit. The installation of a drop leg and ground union is
required (refer to Figure 10).
Gas piping may be connected from either side of the furnace
using any of the gas pipe entry knockouts on both sides of
the furnace (refer to Figures 1 or 2 for locations and dimen-
sions).
NOTE: Plan your combustion air piping before determining
ANGLE IRON the correct gas pipe entry. Use 90 degree service elbow(s), or
BRACKET short nipples and conventional 90 degree elbow(s) to enter
SUPPORT through the cabinet access holes.
ROD

1” MAX. BETWEEN 6” MIN BETWEEN 1” MAX. BETWEEN

ROD & FURNACE ROD & FURNACE
ROD & FURNACE An overpressure protection device, such as a
pressure regulator, which conforms to the National
Fuel Gas Code, ANSI Z223.1 (U.S.) or CAN-
FIGURE 9 : Typical Furnace Installation Using
B149.1 or.2 (Canada) and acts to limit the down-
Suspension Materials
stream pressure to a value that does not exceed
CRAWL SPACE INSTALLATION 0.5 PSI (14" w.c.), must be installed in the gas pip-
ing system upstream of the furnace. Failure to do
The furnace can be hung from floor hoists or installed on suit- so may result in a fire or explosion or cause dam-
able blocks or pad. Blocks or pad installations shall provide age to the furnace or some of its components.
adequate height to ensure the unit will not be subject to water
damage.

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INLET GAS PRESSURE RANGE

Natural Gas Propane (LP)

Minimum 4.5 In. W.C. 11 In. W.C. Never apply a pipe wrench to the body of the com-
bination automatic gas valve. A wrench must be
Maximum 13.9 In. W.C. 13.9 In. W.C. placed on the projection or wrench boss of the
NOTE: An accessible manual shutoff valve must be installed valve when installing piping to it.
upstream of the furnace gas controls and within 6 feet of the
furnace. ELECTRICAL POWER CONNECTION
Field wiring to the unit must conform to and be grounded in
E X T E R N A L M A N U A L accordance with the provisions of the National Electrical
S H U T O F F V A L V E
T O G A S T O G A S
Code ANSI/NFPA No. 70-latest edition, Canadian Electric
S U P P L Y S U P P L Y Code C22.1 Part 1 - (latest edition) and/or local codes. Elec-
tric wires which are field installed shall conform with the tem-
G R O U N D J O IN T U N IO N perature limitation for 63°F/35°C rise wire when installed in
M A Y B E IN S T A L L E D
IN S ID E O R O U T S ID E U N IT accordance with instructions. Refer the rating plate or Physi-
cal and Rating Data Tables in these instructions for specific
furnace electrical data.
Provide a power supply separate from all other circuits. Install
overcurrent protection and disconnect switch per local/
national electrical codes. The switch should be close to the
unit for convenience in servicing. With the disconnect switch
D R O P L E G in the OFF position, check all wiring against the unit wiring
D R O P L E G
label. Also, see the wiring diagram in this instruction.
G A S V A L V E NOTE: The furnace’s control system depends on correct
polarity of the power supply and a proper ground connection.
Refer to the “FURNACE CONTROL DIAGNOSTICS” on
page 36 for symptoms of reversed power supply polarity.

FIGURE 10 : Gas Piping

NOTE: A 1/8” NPT plug is included in the inlet side of the gas
valve for measuring incoming gas pressure.
Use copper conductors only.
The furnace must be isolated from the gas supply piping sys-
tem by closing its individual external manual shutoff valve Connect the power supply as shown on the unit wiring label
during any pressure testing of the gas supply piping system on the inside of the blower compartment door. The black fur-
at pressures equal to or less than 1/2 psig (3.48 kPa). nace lead must be connected to the L1 (hot) wire from the
The furnace and its individual shutoff valve must be discon- power supply. The white furnace lead must be connected to
nected from the gas supply piping system during any pres- neutral. Also, the green equipment ground wire must be con-
sure testing of that system at test pressures in excess of 1/2 nected to the power supply ground.
psig (3.48 kPa). Remove the screws retaining the wiring box cover. Route the
power wiring through the opening in the unit into the junction
box with a conduit connector or other proper connection.
Make wiring connections and replace the wiring box cover
and screws. Refer to Figures 11or 12.
Compounds used on threaded joints of gas piping
An alternate wiring method is to use a field provided 2 x 4 box
must be resistant to the action of liquefied petro-
and cover on the outside of the furnace. Route the furnace
leum gases. After connections are made, leak-test
leads into the box using a protective bushing where the wires
all pipe connections.
pass through the furnace pane.
After all gas piping connections are completed,
leak test all joints, fittings and furnace connections
with rich soap and water solution, commercially
available bubble type leak detection fluid, or other
approved means.
Do not use an open flame or other source of
ignition for leak testing.

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L1
ELECTRICAL CONTROL CONNECTIONS
(HOT) N
BLK/BLK GND Install the field-supplied thermostat. The thermostat instruc-
WHT/WHT tions for wiring are packed with the thermostat. With the ther-
GRN/GRN WHT
mostat set in the OFF position and the main electrical source
BLK GRN
disconnected, complete the low-voltage wiring from the ther-
mostat to the terminal board on the ignition module. Connect
JUNCTION Class 2 control wiring as shown in Figure 14. Electronic ther-
BOX
mostats may require a common connection as shown dashed
in Figure 14.
BLOWER COMPARTMENT Apply strain relief to thermostat wires passing through cabi-
DOOR SWITCH net.

TRANSFORMER Y WR G C
Set the heat anticipator in the room thermostat to .45
amps. Setting it lower will cause short cycles. Setting
it higher will cause the room temperature to exceed
IGNITION MODULE
COOL
XFMR

PARK
HUM

L1

NEUTRALS

the setpoints
PARK

HEAT
EAC

CLASS 2 SYSTEM
CONTROL WIRING
TO THERMOSTAT
BURNER COMPARTMENT
BLK BLK (HOT)
NOMINAL
FIGURE 11 : Electrical Wiring - Upflow Models WHT WHT (NEUTRAL) 120 VOLT

NOTE: The power connection leads and wiring box on upflow GRN GRD
units may be relocated to the left side of the furnace. Remove
the screws and cut wire tie holding excess wiring. Reposition
on the left side of the furnace and fasten using holes pro- FIGURE 13 : Power Wiring Connections
vided.

L1
N WIRING INSIDE
HOT ROOM FURNACE CONDENSING
JUNCTION BOX
GRD THERMOSTAT CONTROL UNIT
BLK/BLK
WHT
WHT/WHT
R R
BLK
GRN
GRN/GRN W W TO AIR CONDITIONER
G G CONTROLS
JUNCTION Y Y
BOX
C C

BLOWER COMPARTMENT FIGURE 14 : Typical Heating and Cooling

VENT PIPE
NOTE: Some electronic thermostats do not have adjustable
heat anticipators. They may have other type cycle rate adjust-
HEAT

PARK

EAC
XFMR

CLASS 2 SYSTEM
COOL

PARK

HUM

NEUTRALS
L1

CONTROL WIRING
IGNITION MODULE TO THERMOSTAT
ments. Follow the thermostat manufacturer's instructions.
Y WR G C
The 24-volt, 40 VA transformer is sized for the furnace com-
FLUE CHASE
TRANSFORMER ponents only, and should not be connected to power auxiliary
devices such as humidifiers, air cleaners, etc. The trans-
former may provide power for an air conditioning unit
DOOR contactor.
SWITCH BURNER COMPARTMENT

FIGURE 12 : Electrical Wiring - Downflow / Horizontal

Models

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ACCESSORY CONNECTIONS Be sure to follow the appropriate venting section details,

related information and limitations for your type of installation.
The furnace control will allow power switching control of vari-
ous accessories. Refer to Figure 15, for connection details.
Furnace Intake / Vent Connection Size (All Models)
ELECTRONIC AIR CLEANER CONNECTION
40 - 100 MBH 120 - 140 MBH
Two 1/4" spade terminals (EAC and EAC N) for electronic air
cleaner connections are located on the control board. The Intake 2” 3"
terminals provide 115 VAC (1.0 amp maximum) during circu- Vent 2” 2"*
lating blower operation.
*. Vent must be increased to 3" on this model.
HUMIDIFIER CONNECTION
Note 1:Any vent pipe size change must be made out-
Two 1/4" spade terminals (HUM and HUM N) for humidifier side furnace casing in a vertical pipe section
connections are located on the control board. The terminals to allow proper drainage of condensate.
provide 115 VAC (1.0 amp maximum) during heating system Note 2: An offset using two 45 degree elbows will be
operation. required for plenum clearance when the vent
is increased to 3”.
TWINNING
When two furnaces are installed using the same duct system, METHOD ONE: TWO PIPE SEALED
it is very important that the two furnace circulating air blowers
COMBUSTION AIR & VENT SYSTEM
operate simultaneously. If one blower starts before the sec-
ond blower, the duct system will become pressurized with air COMBUSTION AIR INTAKE/VENT CONNECTIONS
and the second blower will be made to turn backwards. Dur- This type installation requires outdoor combustion air. Two
ing heating operation, this will cause overheating of the separate, properly-sized pipes must be used. One bringing
second furnace, possibly causing an unsafe condition and air from the outdoors to the furnace combustion air intake col-
damage to the furnace. If twinning of two furnaces is desired, lar on the burner box, and a second pipe from the furnace
it is necessary to use the accessory twinning kit that is vent connection (top right of unit) back to the outdoors.Figure
designed for use with these furnaces. 16 or 17.

HUM. HOT
BLK
115 VOLT
HUMIDIFIER WHT VENT PIPE
COMBUSTION AIR CEMENTS
EAC SWITCHED PIPE PASSES INTO SOCKET
HUM
CIRCUITS THROUGH TOP PANEL JUST UNDER
TOP PANEL
EAC HOT

CONNECTS TO
COLLAR ON TOP
115 VOLT BLK OF BURNER BOX
ELECTRONIC WHT
AIR CLEANER EAC
NEUTRALS
HUM

FIGURE 15 : Accessory Connections

COMBUSTION AIR AND VENT SYSTEM

This furnace is certified to be installed with one of three
possible intake/vent configurations.
1. Two-pipe with a sealed combustion intake/vent system FIGURE 16 : Air Intake and Vent Locations - Upflow
using outdoor combustion air.
2. Single pipe vent system using combustion air from the
area surrounding the furnace.
3. Two-pipe intake/vent system using combustion air from a
ventilated attic space and a vent pipe to the outside.

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4. Three vent terminal elbows (two for vent pipe and one for
VENT PIPE PASSES
THROUGH TOP PANEL
air intake pipe) are already accounted for and should not
be counted in the allowable total indicated in the table
(see vent termination section). These parts are shown
shaded.
For downflow/horizontal models, the two additional
elbows required for the air intake pipe entry into the
burner box are also accounted for and should not be
counted. These parts are shown shaded.
For downflow/horizontal models only two additional
OPTIONAL elbows are also accounted for and also should not be
LEFT SIDE
COMBUSTION counted. These parts are shown shaded.
AIR PIPE
ROUTING COMBUSTION 5. Combustion air and vent piping must be of the same
AIR PIPE diameter.
CONNECTS TO
COLLAR ON 6. All combustion air/vent pipe and fittings must conform to
BOTTOM OF American National Standards Institute (ANSI) standards
BURNER BOX
and American Society for Testing and Materials (ASTM)
standards D1785 (Schedule 40 PVC), D2665 (PVC-
FIGURE 17 : Air Intake and Vent Locations - DWV), F891 (PVC-DWV Cellular Core). D2241 (SDR-21
Downflow/Horizontal and SDR-26 PVC), D2261 (ABS-DWV), or F628 (Sched-
The intake/vent should be located either through the wall ule 40 ABS. Pipe cement and primer must conform to
(horizontal or side vent) or through the roof (vertical vent). ASTM Standards D2564 (PVC) or D2235 (ABS).
Care should be taken to locate side vented systems where 7. The use of flexible connectors or no hub connectors in
trees or shrubs will not block or restrict supply air from enter- the vent system is not allowed. This type connection is
ing or combustion products from leaving the terminal. allowed in the combustion air pipe near the furnace for
Also, the terminal assembly should be located as far as pos- air conditioning coil accessibility.
sible from a swimming pool or a location where swimming Table 4: INTAKE/VENT PIPING - 2 PIPE SYSTEM
pool chemicals might be stored. Be sure the terminal assem-
bly follows the outdoor clearances listed in Table 3 for U.S. Max. Elbows vs. One Way Vent
Models P*UR/ Pipe
installations. In Canada, refer to CAN/CGA-B149.1 or.2 Length (Ft.)*
FG9-UP/G9T-UP Size
Installation Code (latest edition-Venting Systems and Air 5 - 40 45 50 75
Supply).
40 / 37 / 1000 / A
COMBUSTION AIR/VENT PIPE SIZING
60 / 55 / 1000 / B
To select the propeTable 4 or Table 5. The size will be deter- 80 / 75 / 1200 / B
mined by a combination of furnace model, total length of run, 2” 6 5 4 N/A
80 / 75 / 1600 / C
and the number of elbows required. The following rules must
also be observed.Long radius elbows are required for all 100 / 95 / 1400 / C
units. 100 / 95 / 2000 / C
1. Long radius elbows are required for all units. 40 / 37 / 1000 / A
2. Elbows are assumed to be 90 degrees. Two 45 degree 60 / 55 / 1000 / B
elbows count as one 90 degree elbow. 80 / 75 / 1200 / B
3” 8 7 6 5
3. Elbow count refers to combustion air piping and vent pip- 80 / 75 / 1600 / C
ing separately. For example, if the table allows for 5
100 / 95 / 1400 / C
elbows, this will allow a maximum of 5 elbows in the
combustion air piping and a maximum of 5 elbows in the 100 / 95 / 2000 / C
vent piping. 120 / 112 / 2000 / D
3" Only 6 5 4 N/A
140 / 130 / 2000 / D

*. Elbow count does not include the elbows required for

the termination. See Step 4 under Combustion Air/Vent
Pipe Sizing

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Table 5: INTAKE/VENT PIPING 2-PIPE SYSTEM 4. Termination should be located where it will not be dam-
aged or exposed to flying stones, balls, etc.
Max. Elbows vs. One Way
Models P*DH/
Pipe Size Vent Length (Ft.)*
5. Termination should be positioned where vent vapors are
FG9-DH/G9T-DH not objectionable.
5-30 35 40 60
40 /37 / 1000 / A VENT CLEARANCES (2-PIPE) U.S. ONLY
60 /55 / 1200 / B Dryer Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ft.
80 /75 / 1200 / B 2” 6 5 4 N/A Plumbing Vent Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ft.
80 /75 / 1600 / C
Gas Appliance Vent Terminal . . . . . . . . . . . . . . . . . . . 3 ft.*
100 /95 / 2000 / C
40 /37 / 800 / A From any mechanical fresh air intake . . . . . . . . . . . . . . 1 ft.
60 /55 / 1200 / B From any door, window or non-mechanical fresh air or
80 /75 / 1200 / B 3” 8 7 6 5 combustion air intake . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ft.
80 /75 / 1600 / C Above grade and anticipated snow depth . . . . . . . . . . . 1 ft.
100 /95 / 2000 / C
Above grade when adjacent to public walkway . . . . . . 7 ft.
120 /112 / 2000 / D 3" Only 6 5 4 N/A
From electric, gas meters, regulators and relief equipment -
*.
Elbow count does not include (2) 90 ° elbows required min. horizontal distance . . . . . . . . . . . . . . . . . . . . . . . . 4 ft.
to pipe intake into burner box or those required for the
* Does not apply to multiple installations of this furnace
termination. See Step 4 under Combustion Air/Vent
model. Refer to “VENTING MULTIPLE
Pipe Sizing
UNITS" Section on page 17 .

NOTE: If installing furnace at altitudes between 2000 - 4500 In Canada, refer to CAN/CGA-B149.1 or .2 Installation
ft., intake and vent pipe length must be reduced by 10 ft. If the Code (latest edition - Venting Systems and Air Supply)
installation requires the maximum allowable intake and vent
pipe length, the furnace must be converted for high altitude
NOTE: Consideration must be given for degradation of build-
operation. Refer to the proper high altitude application
ing materials by flue gases.
instruction for details.
NOTE: Shaded components of the combustion air/vent sys-
VENT TERMINATION (2-PIPE)
tem shown in Figures 18 to Figure 23 are considered to be
Side wall horizontal vent terminals and roof mounted vertical part of the termination. These components should not be
terminals may be field fabricated. Standard PVC/SRD fittings counted when determining piping limitations. Sidewall termi-
may be used. Terminal configuration must comply as detailed nation may require sealing or shielding of building surfaces
in this section. with a corrosive resistance material to protect against com-
NOTE: Combustion air and vent pipes must terminate bustion product corrosion.
together in the same atmospheric zone, either through a roof
or sidewall. OVERHANG

NOTE: Accessory concentric intake/vent terminations,

models 1CT0302 and 1CT0303 are available and 12” MINIMUM

approved for use with these furnaces. Refer to Form

VENT
650.75-N2.4V for installation details.
90° 12 SEPARATION BETWEEN
BOTTOM OF COMBUSTION AIR
When selecting the location for combustion air/vent termina- AND BOTTOM OF VENT
tion the following should be considered:
MAINTAIN 12” CLEARANCE ABOVE
1. Comply with all clearance requirements as listed below. HIGHEST ANTICIPATED SNOW LEVEL
OR GRADE WHICHEVER IS GREATER
2. Termination should be positioned where vent vapors will
not damage plants or shrubs or air conditioning equip-
ment. COMBUSTION AIR
3. Termination should be located where it will not be
affected by wind gusts, light snow, airborne leaves or
FIGURE 18 : Horizontal Termination Configuration with 12”
allow recirculation of flue gases.
Minimum Clearance

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OVERHANG

VENT
12” MINIMUM

VENT

90° 12 SEPARATION BETWEEN

BOTTOM OF COMBUSTION AIR
AND BOTTOM OF VENT

MAINTAIN 12” CLEARANCE ABOVE

HIGHEST ANTICIPATED SNOW LEVEL
OR GRADE WHICHEVER IS GREATER

COMBUSTION AIR

COMBUSTION AIR
2”

FIGURE 19 : Horizontal Termination Raised

FIGURE 22 : Double Sidewall Termination
Configuration for Additional Clearance

OVERHANG

12” MINIMUM

VENT 6”

90° 12 SEPARATION BETWEEN

BOTTOM OF COMBUSTION AIR
AND BOTTOM OF VENT

MAINTAIN 12” CLEARANCE ABOVE

HIGHEST ANTICIPATED SNOW LEVEL
OR GRADE WHICHEVER IS GREATER

18” MAX. COMBUSTION AIR

FIGURE 20 : Horizontal Termination Configuration with Hori- FIGURE 23 : Double Rooftop Termination
zontal Extension
VENTING MULTIPLE UNITS
Each unit must have its own intake/vent piping and termina-
tion. Do not use common pipes for combustion air or venting.
The vent terminals must be located as shown in Figure 22 or
Figure 23.
PIPING ASSEMBLY
12” VERTICAL SEPARATION COMBUSTION AIR
BETWEEN COMBUSTION The final assembly procedure for the vent/combustion air pip-
AIR AND VENT ing is as follows:
VENT
1. Cut piping to the proper length, beginning at the furnace.
2. Deburr the piping inside and outside.
MAINTAIN 12” MINIMUM 3. Chamfer the outer edges of the piping.
CLEARANCEABOVE HIGHEST
ANTICIPATED SNOWLEVEL. 4. Dry-fit the entire vent/combustion air piping assembly.
MAXIMUM OF 24” ABOVE ROOF.
5. Disassemble the piping and apply cement primer and
FIGURE 21 : Vertical Termination cement per the cement manufacturer's instructions.
Primer and cement must conform to ASTM D2564 for
PVC, or ASTM D2235 for ABS piping.

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VENT PIPE CEMENTS

COMBUSTION AIR INTO SOCKET JUST
UNDER TOP PANEL
Solvent cements are flammable and must be used
in well-ventilated areas only. Keep them away from
heat, sparks and open flames (including pilots). Do
not breathe vapors and avoid contact with skin and
eyes.

6. All joints must be made to provide a permanent, air-tight,

water-tight seal.
7. Support the combustion air and vent piping such that it is
angled 1/4” per linear foot so that condensate will flow
back toward the furnace. Piping should be supported
with pipe hangers to prevent sagging. Maximum spacing
between hangers is five (5) feet, except SDR-PVC pip-
ing, where maximum spacing is three (3) feet. FIGURE 24 : Vent Pipe Connection - Upflow
8. Seal around the openings where the combustion air and
vent piping pass through the roof of side wall.
VENT PIPE PASSES
THROUGH TOP PANEL

Vent piping must be insulated with 1/2” Armaflex

insulation if it will be subjected to freezing temper-
atures such as routing through unheated areas or
through an unused chimney.
When combustion air pipe is installed above a sus- GAS PIPING
pended ceiling, the pipe must be insulated with 1/ KNOCKOUTS

2” Armaflex type insulation. The combustion air

pipe should also be insulated when it passes
through a warm, humid space.

NOTE: Vent pipe must be sloped 1/4” per foot to allow con-
densate to flow back to the furnace. COMBUSTION AIR

METHOD TWO: ONE PIPE SYSTEM

FIGURE 25 : Vent Pipe Connection -
This type installation will use combustion air from within the Downflow/Horizontal
space surrounding the furnace. This may be from within the
space in a non-confined location or it may be brought into the COMBUSTION AIR
furnace area from outdoors. It is not directly ducted into the All installations must comply with Section 5.3, Air for Com-
furnace. A single, properly sized pipe from the furnace vent bustion and Ventilation of the National Fuel Gas Code, ANSI
connector to the outdoors must be provided. Z223.1 or Sections 7.2, 7.3 or 7.4 of CAN/CGA B149.1 or .2
For upflow models combustion air is brought into the furnace Installation Code - latest editions.
through the unit top panel opening. Do not install a pipe into An unconfined space is not less than 50 cubic feet per 1000
the intake collar on top of the burner box. Figure 24 . Btu/hr input rating for all appliances installed in that area.
For downflow/horizontal models, remove a minimum of two Rooms communicating directly with the space containing the
gas piping knockouts for combustion air access. Do not appliances are considered part of the unconfined space, if
install a pipe into the intake collar on bottom of the burner openings are not furnished with doors.
box. For details, refer to Figure 25. A confined space is an area with less than 50 cubic feet per
1000 Btu/hr input rating for all appliances installed in that
area.
The following must be considered to obtain proper air for
combustion and ventilation in confined spaces.

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 035-17477-001 Rev. A (801)

Air Source from Inside the Building 3. Louvers, Grilles and Screens
Two permanent openings, one within 12 inches of the top of a. In calculating free area, consideration must be given
the confined space and one within 12 inches of the bottom, to the blocking effects of louvers, grilles and
shall each have a free area of not less than one square inch screens.
per 1,000 Btuh of total input rating of all appliances located in
b. If the free area of a specific louver or grille is not
the space. The openings shall communicate freely with inte-
rior areas having adequate infiltration from the outside. known, refer to Table 6, to estimate free area.

NOTE: At least 100 square inches free area shall be used for NOTE: If mechanically operated louvers are used, a means
to prevent main burner ignition and operation must be pro-
each opening.
vided should louvers close during startup or operation.
Air Source from Outdoors
Table 6: ESTIMATED FREE AREA
1. Two permanent openings, one within 12 inches of the
top of the confined space and one within 12 inches of the Wood or Metal Wood 20-25%*
bottom, shall communicate directly, or by means of Louvers or Grilles Metal 60-70%*
ducts, with the outdoors or to such crawl or attic spaces † 1/4 in. mesh or larger 100%
Screens
that freely communicate with the outdoors.
*.
a. Vertical Ducts - Each opening must have a free Do not use less than 1/4 in. mesh
†.
area of not less than one square inch per 4,000 Btuh Free area or louvers an grilles varies widely; installer should
of total input of all appliances located in the space. follow louver or grille manufacturer’s instructions.

EXAMPLE: Special Combustion and Ventilation Considerations

Total Input of All Appliances Operation of a mechanical exhaust, such as an exhaust fan,
= Square Inches Free Area kitchen ventilation system, clothes dryer or fireplace may cre-
4000 ate conditions requiring special attention to avoid unsatisfac-
tory operation of gas appliances.
b. Horizontal Ducts - Each opening must have a free
area of not less than one square inch per 2,000 Btuh Specially Engineered Installations
of total input of all appliances located in the space. The above requirements shall be permitted to be waived
NOTE: Ducts must have the same cross-sectional area as where special engineering, approved by the authority having
the free area in the opening to which they are connected. The jurisdiction, provides an adequate supply of air for combus-
minimum dimension of rectangular ducts shall be three tion, ventilation and dilution of flue gases.
inches. Combustion Air Quality
2. One permanent opening, commencing within 12 inches The recommended source of combustion air is to use the out-
of the top of the enclosure shall be permitted where the door air supply. Excessive exposure to contaminated com-
equipment has clearances of at least 1 inch from the bustion air will result in safety and performance related
sides and back and 6 inches from the front of the appli- problems. However, the use of indoor air in most applications
ance. The opening shall communicate through a vertical is acceptable, except as follows:
or horizontal duct to the outdoors, or spaces (crawl or 1. If the furnace is installed in a confined space it is recom-
attic) that freely communicate with the outdoors and shall mended that the necessary combustion air come from
have a minimum free area of: the outdoors by way of attic, crawl space, air duct or
a. 1 sq. in. per 3000 Btu per hr of the total input rating direct opening.
of all equipment located in the enclosure. 2. If indoor combustion air is used, there must be no expo-
b. Not less than the sum of the areas of all vent con- sure to the installations or substances listed in 3 below.
nectors in the confined space.

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 035-17477-001 Rev. A (801)

3. The following types of installations may require OUT- 4. All vent pipe and fittings must conform to American
DOOR AIR for combustion, due to chemical exposure. National Standards Institute (ANSI) standards and Amer-
ican Society for Testing and Materials (ASTM) standards
a. Commercial buildings
D1785 (Schedule 40 PVC), D2665 (PVC-DWV), F891
b. Buildings with indoor pools (PVC-DWV Cellular Core), D2241 (SDR-21 and SDR-26
c. Furnaces installed in laundry rooms PVC), D2261 (ABS-DWV), or F628 (Schedule 40 ABS.
Pipe cement and primer must conform to ASTM Stan-
d. Furnaces installed in hobby or craft rooms
dards D2564 (PVC) or D2235 (ABS).
e. Furnaces installed near chemical storage areas
5. The use of flexible connectors or no hub connectors in
f. Permanent wave solutions the vent system is not allowed.
g. Chlorinated waxes and cleaners Table 7: VENT PIPING / 1-PIPE SYSTEM (ALL MODELS)
h. Chlorine based swimming pool chemicals Max. Elbows vs. One Way Vent
i. Water softening chemicals Model Pipe Size Length (Ft.)
j. De-icing salts or chemicals 5-40 45 50 75
All Models Except:
k. Carbon tetrachloride 120 / 112 / 2000 / D 2” 6 5 4 N/A
l. Halogen type refrigerants 140 / 130 / 2000 / D
All Models Except:
m. Cleaning solvents (such as perchloroethylene)
120 / 112 / 2000 / D 3” 8 7 6 5
n. Printing inks, paint removers, varnishes, etc. 140 / 130 / 2000 / D
o. Hydrochloric acids 120 / 112 / 2000 / D
3” Only 6 5 4 N/A
140 / 130 / 2000 / D
p. Cements and glues
q. Antistatic fabric softeners for clothes dryers NOTE: If installing furnace at altitudes between 2000 - 4500
ft., intake and vent pipe length must be reduced by 10 ft. If the
r. Masonry acid washing chemicals
installation requires the maximum allowable intake and vent
VENT PIPE SIZING (1-PIPE SYSTEM) pipe length, the furnace must be converted for high altitude
operation. Refer to the proper high altitude application
Refer to Table 7 to select the proper size piping for venting. instruction for details.
The size will be determined by a combination of furnace
model, total length of run, and the number of elbows required. VENT TERMINATION (1-PIPE SYSTEM)
The following rules must also be observed. Side wall horizontal vent terminals and roof mounted vertical
NOTE: Furnace vent pipe connections are sized for 2-in. terminals may be field fabricated. Standard PVC/SRD fittings
pipe. Any pipe size change must be made outside the fur- may be used. Terminal configuration must comply as detailed
nace casing in a vertical pipe section to allow proper drainage in this section.
of vent connections. When selecting the locations for vent termination, the follow-
ing should be considered:
NOTE: An offset using two 45 degree elbows may be
required for plenum clearance when the vent is increased to 1. Comply with all clearance requirements. Refer to Figure
3". 26 on page 21.
1. Long radius elbows are required for all units. 2. Termination should be positioned where vent vapors will
not damage plants or shrubs or air conditioning equip-
2. Elbows are assumed to be 90 degrees. Two 45 degree
ment.
elbows count as one 90 degree elbow.
3. Termination should be located where it will not be
3. One Vent terminal elbow is already accounted for and
affected by wind gusts, light snow, airborne leaves or
should not be counted in the allowable total indicated in
allow recirculation of flue gases.
the table. See “VENT TERMINAL LOCATION
CLEARANCES" Section on page 21 . This part is shown 4. Termination should be located where it will not be dam-
shaded. aged or exposed to flying stones, balls, etc.
5. Termination should be positioned where vent vapors are
not objectionable.

In Canada, refer to CAN/CGA-B149.1 or .2 Installation

Code (latest edition - Venting Systems and Air Supply).

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 035-17477-001 Rev. A (801)

VENT TERMINAL LOCATION CLEARANCES

The vent must be installed with the following minimum clear-
ances (refer to Figure 26), and complying with local codes or
utility requirements or other authority having jurisdiction.

SOFFIT
VENTS RST
4” 4”
OPQHIPQHJRSTJUKGPVPHUGJPLMFG
WQXWGYIJPHIQUQZPIG[JYHMNJKGFGK
6”
MVJXVP[G\JNWQUWGFGVJQYJXVGPIGV
(10” RECOMMENDED)
ELECTRIC
METER 4” 4”
FGHIJGKLMN
4” FORCED
FURNACE VENT
AIR
INSIDE 3” INTAKE FIGURE 27 : Horizontal Termination Configuration with
CORNER 4” 10” 12” Minimum Clearance
1’ PLUS
SNOW CLEARANCE

FIGURE 26 : Minimum Vent Terminal Clearances

RSTJOQHQO`O
(1-Pipe System) - U.S. Only

1. 1 foot above grade and above normal snow levels.

2. Not above any walkway. ]^_

3. 4 feet below, 4 feet horizontally from, or 1 foot above any FGHI

OPQHIPQHJRSTJUKGPVPHUGJPLMFG
door/window or gravity air inlet to the building, or from WQXWGYIJPHIQUQZPIG[JYHMNJKGFGK
gas or electric meters. MVJXVP[G\JNWQUWGFGVJQYJXVGPIGV

4. 6 feet from any inside corner formed by two exterior

walls. 10 feet is recommended where possible.
5. At least 4 feet horizontally from any soffit or undereave FIGURE 28 : Horizontal Termination Raised
vent. Configuration for Additional Clearance
6. 10 feet from any forced air inlet to the building. Any fresh
air or make up inlet as for a dryer or furnace area is con-
sidered to be a forced air inlet.
7. Avoid areas where condensate drippage may cause
problems such as above planters, patios, or adjacent to
windows where steam may cause fogging.
NOTE: Consideration must be given for degradation of build-
ing materials by flue gases. FGHI

NOTE: Shaded components of the vent system shown in Fig-

ures 27 through 29 are considered to be part of the termina-
tion. These components should not be counted when OPQHIPQHJRSTJOQHQO`O
UKGPVPHUGJPLMFGJWQXWGYI
determining piping limitations. Sidewall termination may PHIQUQZPIG[JYHMNJKGFGKa
require sealing or shielding of building surfaces with a corro- OPbQO`OJMcJSdTJPLMFGJVMMc
sive resistant material to protect against combustion product
corrosion. FIGURE 29 : Rooftop Termination

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 035-17477-001 Rev. A (801)

PIPING ASSEMBLY METHOD THREE: TWO PIPE SYSTEM USING COM-

The final assembly procedure for the vent piping is as follows: BUSTION AIR FROM A VENTILATED ATTIC SPACE
1. Cut piping to the proper length, beginning at the furnace. This type installation requires two properly sized pipes. One
brings combustion air from a properly ventilated attic space
2. Deburr the piping inside and outside. and a second pipe from the furnace vent connection (top right
3. Chamfer the outer edges of the piping. of unit) exits to the outdoors.
4. Dry-fit the entire vent piping system. In Canada, refer to CAN/CGA-B149.1 or .2 Installation
5. Disassemble the piping and apply cement primer and Code (latest edition - Venting Systems and Air Supply)
cement per the cement manufacturer's instructions.
Primer and cement must conform to ASTM D2564 for COMBUSTION AIR INTAKE
PVC, or ASTM D2235 for ABS piping. Table 4 on page 15, for intake pipe sizing, allowable length
and elbow usage. Follow all notes, procedures and required
materials in the Two-Pipe Sealed Combustion section
(Method 1) when installing the combustion air pipe within the
unit and into the ventilated attic space.
Solvent cements are flammable and must be used
in well-ventilated areas only. Keep them away from COMBUSTION AIR TERMINATION
heat, sparks and open flames (including pilots). Do Refer to Figure 30 for required termination method and con-
not breathe vapors and avoid contact with skin and figuration for the intake pipe. For attic termination, use two 90
eyes. elbows with the open end in a downward position. Be sure to
maintain 12" clearance above any insulation, flooring or other
6. All joints must be made to provide a permanent, air tight. material.
water tight seal.
7. Support the vent piping such that it is angled 1/4” per lin-
ear foot so that condensate will flow back towards the
furnace. Piping should be supported with pipe hangers to
prevent sagging. Maximum spacing between hangers is
5 feet, except SDR-PVC piping, where maximum spac-
ing is 3 feet.
8. Seal around the openings where the vent piping passes
through the roof or side wall.

Vent piping must be insulated with 1/2” Armaflex FIGURE 30 : Attic Combustion Air Termination
insulation if it will be subjected to freezing temper-
atures such as routing through unheated areas or
through an unused chimney.

NOTE: Vent pipe must be sloped 1/4” per foot to allow con- Be sure to instruct the owner not to block this
densate to flow back to the furnace. intake pipe.

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 035-17477-001 Rev. A (801)

COMBUSTION AIR REQUIREMENTS

The ventilated attic space from which the combustion air is
taken must comply with the requirements shown on page 18
in this instruction or in Section 5.3, Air for Combustion and
Ventilation of the National Fuel Gas Code, ANSI Z223.1 (lat-
est edition).
VENT PIPE

HEAT

PARK

EAC
XFMR
COOL

PARK

HUM
NEUTRALS

L1
For vent pipe sizing, allowable length and elbow usage, see 3.00” MINIMUM
Table 7 on Page 20. Follow all notes, installation procedures LOOP DIA.
Y WR G C

and required materials in the “METHOD TWO ONE PIPE

SYSTEM, on page 18” to install the vent pipe from the unit to
ATTACH THIS END
the outdoors. TO CONDENSATE
DRAIN SYSTEM
VENT TERMINATION
The vent pipe termination must be installed within the allow-
able locations shown in Figure 26 and Section 7.8 in the
National Fuel Gas Code, ANSI Z223.1 (current edition). Fol-
low all local agency and utility requirements if more restrictive
than those shown. Vent termination must be as shown in Fig-
ures 27 through 29.

In Canada, refer to CAN/CGA-B149.1 or .2 Installation

Code (latest edition - Venting Systems and Air Supply).

HORIZONTAL VENT APPLICATIONS

If installing a horizontal venting system through any uncondi-
tioned space such as an attic or crawl space, it is recom-
mended, that a vent drain be added to the vent pipe to FIGURE 32 : Horizontal Vent Drain -
prevent the accumulation of excess condensate in the Downflow/Horizontal Models
inducer motor during operational cycles, refer to Figures 31 To install the vent drain, complete the following steps:
or 32.
1. Place a tee of the proper diameter for the vent system
being installed (2" or 3") in the horizontal run closest to
the furnace.
2. Place a reducer bushing of proper diameter in the stem
portion of the tee. The recommended size for the
reducer is 5/8”.
3. Place a piece of 5/8” diameter or other selected size pipe
3.00” MINIMUM a minimum of 3" long into the reducer to serve as a nip-
LOOP DIA. ple.
NOTE: Tee, reducer and nipple must be properly cemented
ATTACH THIS END together using the appropriate method and materials speci-
TO CONDENSATE
DRAIN SYSTEM fied in the Combustion Air Intake/Vent Connections section of
these instructions.
4. Connect a piece of flexible drain tubing such as EPDM
rubber, Vinyl or PVC to the nipple.
5. Loop the drain tubing to provide a trap.
6. Connect the discharge end of the drain tube to the con-
densate disposal system externally to the furnace.

FIGURE 31 : Horizontal Vent Drain - Upflow Models

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 035-17477-001 Rev. A (801)

CONDENSATE PIPING Refer to Figure 35 for hose locations and Table 8 for hose cut
lengths. All hoses are identified as shown in Figure 35.
The condensate drain connection is packed in the furnace for
field installation. It consists of a formed hose with a 1/2” NPT For horizontal left airflow (inducer and vent low) or horizontal
male connection. A 1/2” FM x 3/4” PVC slip coupling is pro- right airflow (inducer and vent high), install condensate drain
vided. hoses as follows:

This drain hose may be installed to allow left or right side con- RIGHT AIRFLOW (Inducer High) - Three hoses are required.
densate drain connection, refer to Figures 33 and 34. Cut the Hoses are supplied with furnace. Refer to Figure 35 and
hose to allow for proper fit for left or right exit. Table 8 for application.
LEFT AIRFLOW (Inducer Low) - Two hoses are required.
Inducer outlet to trap is supplied. Condensate pan to trap
must be field supplied using 5/8” I.D. hose material. Refer to
Figure 35 and Table 8, for hose placement and sizing..
Table 8: HORIZONTAL CONDENSATE DRAIN HOSE SIZES -
MODELS P*DH / FG9-DH / G9T-DH
LH DRAIN CABINET SIZE (IN.)
DIMEN. RIGHT AIRFLOW (INDUCER HIGH)
14-1/2 17-1/2 21 24-1/2
A 4-1/2 4-3/4 3-1/2 5-1/4
RH DRAIN
B 7-1/2 10-1/2 14 17-1/2
C 13-1/2 16-1/2 20 23-1/2
LEFT AIRFLOW (INDUCER LOW)

FIGURE 33 : Condensate Piping - Upflow Models D 3-3/8 3-1/4 3-1/4 3-1/4

Plug all unused condensate trap, condensate pan

and inducer drain connection points using plugs
provided.
CONDENSATE
TRAP TUBING Drain Connection: The following steps apply to all models.
For horizontal application, also follow the procedure for relo-
cating the trap assembly and installing drain hoses.
1. It is recommended that either 1/2” or 3/4” PVC or equiva-
lent pipe be field installed as drain pipe. The condensate
piping may be tied together with the air conditioning con-
densate drain if the air conditioning condensate drain
line is trapped upstream of the tie-in and the combined
drains are constructed of the same material.
2. All pipe joints must be cleaned, de-burred and cemented
FIGURE 34 : Downflow/Horizontal Models using PVC primer and cement.

To install the drain hose assembly, remove the 7/8” knockout 3. The furnace contains an internal trap. Therefore, no
in the side panel. Remove the conduit nut from the 1/2” male external trap should be used.
fitting. Push the male fitting through the hole and reinstall the 4. If a condensate pump is used, it must be suitable for use
nut. The use of the 3/4” PVC coupling is optional. with acidic water.
CONVERSION FOR HORIZONTAL APPLICATIONS 5. Where required, a field-supplied neutralizer can be
(DOWNFLOW MODELS ONLY) installed in the drain line, external to the furnace.

Remove the condensate trap and its mounting bracket from NOTE: The condensate drain from the furnace may be con-
the unit side panel. Remove all drain hoses. nected in common with the drain from an air conditioning coil
if allowed by local code. Follow the instructions with the coil
Reinstall the trap/bracket on the side panel which will be on for trapping the drain.
the bottom when the unit is located horizontally. Use the orig-
inal mounting screws.

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HOSE IDENTIFIER NUMBERS:

RIGHT AIRFLOW 1. CONDENSATE PAN TO TRAP “A” DIMENSIONS.

(INDUCER HIGH) C 2. INDUCER BOTTOM TO TRAP “B” DIMENSIONS.
3. INDUCER OUTLET TO TRAP “C” DIMENSIONS.
B

A
3 1 2

HOSE IDENTIFIER NUMBERS:

LEFT AIRFLOW
(INDUCER HIGH) 1. INDUCER OUTLET TO TRAP USE AS PROVIDED.
5. CONDENSATE PAN TO TRAP “D” DIMENSIONS.

D
4
5

FIGURE 35 : Horizontal Application Condensate Drain Connection (Models P*DH / FG9-DH / G9T-DH)

SAFETY CONTROLS Rollout Switch Controls: These controls are mounted on

the burner box assembly. If the temperature in the burner
Control Circuit Fuse: A 3 amp. fuse is provided to protect compartment exceeds its set point, the igniter control and the
the 24 volt transformer from overload caused by control cir- gas valve are de-energized. The operation of this control indi-
cuit wiring errors. This is an ATO 3, automotive type fuse and cates a malfunction in the combustion air blower, heat
is located on the ignition control module. exchanger or a blocked vent pipe connection. Corrective
Blower Door Safety Switch: This unit is equipped with an action is required. This is a manual reset control and must be
electrical interlock switch mounted in the blower compart- reset before operation can continue.
ment. This switch interrupts all power at the unit when the
Pressure Switches: This furnace is supplied with pressure
panel covering the blower compartment is removed.
switches which monitor the flow through the combustion air/
vent piping system. These switches de-energize the ignition
control module and the gas valve if any of the following condi-
tions are present. Refer to Figure 36 for tubing connections.
Blower and burner must never be operated without 1. Blockage of combustion air piping or terminal. (1LP)
the blower panel in place.
2. Blockage of vent piping or terminal (1LP).
Electrical supply to this unit is dependent upon the panel that 3. Failure of combustion air blower motor (1LP).
covers the blower compartment being in place and properly
4. Blockage of condensate drain piping:
positioned.
• Upflow units (1LP)
• Downflow/Horizontal Units
• Downflow (1LP)
Main power to the unit must still be interrupted at • Horizontal Left (1LP)
the main power disconnect switch before any ser- • Horizontal Right (2LP).
vice or repair work is to be done to the unit. Do not Limit Controls: There is high temperature limit control
rely upon the interlock switch as a main power dis- located on the furnace vestibule panel near the gas valve.
connect. This is a automatic reset control that provide over tempera-
ture protection due to reduced airflow, such as a dirty filter.

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 035-17477-001 Rev. A (801)

Perform the following procedures only after the

1LP
condensate trap has been properly piped to a
drain connection using the procedure in this
instruction.
2. The condensate trap must be filled with water before put-
UPFLOW ting the furnace into operation. The recommended pro-
cedure is as follows:
a. Disconnect the condensate drain hose from the
induced draft blower discharge.
b. Elevate this hose and fill with water using a funnel.
c. Replace the condensate drain hose and clamps.
NOTE: If this procedure is not followed, the unit may not
properly drain on initial start up.
3. All electrical connections made in the field and in the fac-
tory should be checked for proper tightness.
IGNITION SYSTEM SEQUENCE
1. Turn the gas supply ON at external valve and main gas
valve.
DOWNFLOW / HORIZONTAL 2. Set the thermostat above room temperature to call for
heat.
FIGURE 36 : Pressure Switch Tubing Routing 3. System start-up will occur as follows:
Auxiliary Limit Controls: Downflow/horizontal units have a a. The induced draft blower motor will start and come
single limit switch mounted on the blower assembly. This is a up to speed. Shortly after venter start-up, the hot
manual reset control and gives high temperature protection in surface igniter will glow for about 17 seconds.
the event of a blower motor failure.
b. After this warm up, the ignition module will energize
START-UP AND ADJUSTMENTS (open) the main gas valve for seven seconds.

The initial start-up of the furnace requires the following addi- c. After flame is established, the supply air blower will
tional procedures: start in about 30 seconds.

1. When the gas supply is initially connected to the furnace, NOTE: Burner ignition may not be satisfactory on first startup
the gas piping may be full of air. In order to purge this air, due to residual air in the gas line or until gas manifold pres-
it is recommended that the ground union be loosened sure is adjusted. The ignition control will make 3 attempts to
until the odor of gas is detected. When gas is detected, light before locking out.
immediately retighten the union and check for leaks. 4. With furnace in operation, paint the pipe joints and valve
Allow five minutes for any gas to dissipate before con- gasket lines with a rich soap and water solution, Bubbles
tinuing with the start-up procedure. indicate a gas leak. Take appropriate steps to stop the
leak. If the leak persists, replace the component.

Be sure proper ventilation is available to dilute and

carry away any vented gas. DO NOT omit this test! Never use a flame to check
for gas leaks.

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 035-17477-001 Rev. A (801)

Read across to the column headed 1 Cubic Foot where you

will see that 138 cubic feet of gas per hour are consumed by
the furnace at that rate. Multiply 138 by 850 (the BTU rating

OFF

ON
of the gas obtained from the local gas company). The result is
INLET 117,300 Btuh, which is close to the 120,000 Btuh rating of the
OUTLET furnace.
If the actual input is not within +2% of the furnace rating, with
WRENCH allowance being made for the permissible range of the regu-
BOSS
lator setting (0.3 inches W.C.), replace the orifice spuds with
spuds of the proper size.
MAIN REGULATOR
ON/OFF SWITCH ADJUST

Be sure to relight any gas appliances that were

turned off at the start of this input check.

Table 9: GAS RATE (CUBIC FEET PER HOUR)

SIZE OF TEST DIAL

SECONDS FOR
ONE REVOLUTION 1/2 CUBIC
1 CUBIC FOOT
FOOT
10 180 360
12 150 300
14 129 257
16 113 225
18 100 200
FIGURE 37 : Gas Valves - (Top) White-Rodgers 20 90 180
(Bottom) Honeywell (Approved for Field 22 82 164
Replacement) 24 75 150
CHECKING GAS INPUT (NATURAL GAS) 26 69 138
NOTE: Front door of burner box must be secured when 28 64 129
checking gas input. 30 60 120
1. Turn off all other gas appliances connected to the gas 32 56 113
meter. 34 53 106
2. With the furnace turned on, measure the time needed for 36 50 100
one revolution of the hand on the smallest dial on the
38 47 95
meter. A typical domestic gas meter usually has a 1/2 or
1 cubic foot test dial. 40 45 90

3. Using the number of seconds for each revolution and the 42 43 86

size of the test dial increment, find the cubic feet of gas 44 41 82
consumed per hour, (Table 9 on Page 27). 46 39 78
NOTE: To find the Btuh input, multiply the number of cubic 48 37 75
feet of gas consumed per hour by the BTU content of the gas
50 36 72
in your particular locality. Contract your gas company for this
information, as it varies widely from city to city. 52 35 69

EXAMPLE: It is found by measurement that it takes 26 sec- 54 34 67

onds for the hand to turn on the 1 cubic foot dial to make a 56 32 64
revolution with only a 120,000 Btuh furnace running. Using 58 31 62
this information, locate 26 seconds in the first column of.
60 30 60

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 035-17477-001 Rev. A (801)

3. Refer to Figure 37 on page 27, for location of pressure

regulator adjustment cap and screw on main gas valve.
4. Turn gas and electrical supplies ON. Start furnace and
Be sure to relight any gas appliances that were observe manifold pressure on manometer.
turned off at the start of this input check. 5. Adjust manifold pressure by adjusting gas valve regula-
tor screw for the appropriate gas per the following:
ADJUSTMENT OF MANIFOLD GAS PRESSURE
Manifold gas pressure may be measured by two different pro- Nominal Manifold Pressure
cedures. It may be measured with the burner box cover in
Natural Gas 3.5” w.c.
place or it may be measured with the burner box cover
removed. Follow the appropriate section, 2a or 2b in the Propane (LP) Gas 10.0” w.c.
instructions below.
1. Turn gas off at main gas valve. Remove 1/8" NPT plug If gas valve regulator is turned in, or clockwise, manifold
from the outlet pressure tap in the main gas valve body pressure is increased. If screw is turned out, or counter-
and install a proper manometer tube adapter fitting (refer clockwise, manifold pressure will decrease.
to Figure 37). Connect line from gas valve tap to a 6. Once the correct gas pressure to the burners has been
manometer. established, turn the gas valve to OFF and turn the elec-
2. Read the inlet gas pressure using either of the two meth- trical supply switch to OFF; then remove th pressure tap
ods below. at the gas valve and reinstall the plug, using a compound
(on the threads) resistant to teh action of LP gases.
a. Reading the gas pressure with the burner box
Replace the burner box front cover or the pressure refer-
cover in place - Disconnect the pressure reference
ence hose.
hose from the right side of the burner box. Using a
tee fitting and a short piece of hose, connect the 7. Turn the electrical and gas supplies back on, and with
negative side of the manometer to the burner box the burners in operation, check for gas leakage around
pressure reference port. Connect the positive side the plug with a soap and water solution.
of the manometer to the adapter previously installed
in the gas valve Refer to Figures 38 and 39 on page
29 for connection details.
b. Reading the gas pressure with the burner box The manifold pressure must be checked with the
cover removed - Remove the screws securing the screw-off cap for the gas valve pressure regulator
burner box front cover plate. Remove the cover. It is in place. If not, the nominal manifold pressure set-
gasketed and may stick in place. Connect the posi- ting will result in an over-fire condition.
tive side of the manometer to the adapter previously
If manifold pressure is too high, an over-fire condi-
installed in the gas valve. There will be no second
tion exists which could cause heat exchanger fail-
connection to the manometer as it will reference
ure. If the manifold pressure is too low, sooting
atmospheric pressure.
and eventual clogging of the heat exchanger could
NOTE: The screw-off cap for the pressure regulator must be occur.
removed entirely to gain access to the adjustment screw.
Be sure that gas valve regulator cap is replaced
Loosening or tightening the cap does not adjust the flow of and burner box to gas valve pressure reference
gas. hose is reconnected.

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 035-17477-001 Rev. A (801)

WITH BURNER BOX COVER IN PLACE WITH BURNER BOX COVER REMOVED

GAS VALVE
OUTLET GAS VALVE
PRESSURE TAP
BURNER BOX
BURNER BOX PRESSURE PRESSURE
REFERENCE HOSE OUTLET REFERENCE HOSE
PRESSURE TAP (NOT USED)

TEE
FITTING
BURNER BOX
WITH COVER
6
BURNER BOX 5
WITH COVER 4
3
6 REMOVED 2 3.5 IN
U-TUBE 5
4
1
WATER COLUMN
0
MANOMETER 3 3.5 IN
2
1 GAS PRESSURE
1 WATER COLUMN 2
0 3 SHOWN
1 GAS PRESSURE 4
2 5
3 SHOWN U-TUBE 6
4
5 MANOMETER
6

FIGURE 38 : Upflow Models (P*UR/ FG9-UP / G9T-UP) - Reading Gas Pressure

WITH BURNER BOX COVER IN PLACE WITH BURNER BOX COVER REMOVED

BURNER BOX BURNER BOX WITH

WITH COVER COVER REMOVED
BURNER BOX
BURNER BOX PRESSURE
PRESSURE REFERENCE
REFERENCE HOSE HOSE

TEE
FITTING

OUTLET
OUTLET PRESSURE
PRESSURE TAP
TAP

6 6
5 5
4 4
3 3
GAS VALVE 2 3.5 IN GAS VALVE 2 3.5 IN
1 1
0 WATER COLUMN 0 WATER COLUMN
1 GAS PRESSURE 1 GAS PRESSURE
2 2
3 SHOWN SHOWN
3
U-TUBE 4 4
5 5
MANOMETER 6 6
U-TUBE
MANOMETER

FIGURE 39 : downflow/Horizontal Models (P*DH/ FG9-DH / G9T-DH) - Reading Gas Pressure

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 035-17477-001 Rev. A (801)

ADJUSTMENT OF TEMPERATURE RISE ADJUSTMENT OF FAN-OFF CONTROL SETTINGS

The temperature rise, or temperature difference between the This furnace is equipped with a time-on/time-off heating fan
return air and the heated air from the furnace, must be within control. The fan on delay is fixed at 30 seconds. The fan off
the range shown on the furnace rating plate and within the delay is field adjustable from 60 to 180 seconds. The fan off
application limitations are shown in Tables 1 or 2. After the delay is factory set to 120 seconds.
temperature rise has been determined, the airflow (cfm) can The fan-off setting must be long enough to adequately cool
be calculated. the furnace, but not so long that cold air is blown into the
After about 20 minutes of operation, determine the furnace heated space.
temperature rise. Take readings of both the return air and the The fan-off timing may be adjusted by positioning the jumper
heated air in the ducts, about six feet from the furnace where located on the control board. Refer to Figure 40.
they will not be affected by radiant heat.
Increase the blower speed to decrease the temperature rise; RED - LOW SPEED
decrease the blower speed to increase the rise. BLU - MEDIUM SPEED MOTOR LEADS
BLK - HIGH SPEED
All direct-drive blowers have multi-speed motors. The blower
motor speed taps are located in the control box in the blower
compartment. Refer to Figure 40, and the unit wiring label to
change the blower speed. BLK
COOL
BLU HEAT
You may select a heating speed and a cooling speed. They RED
PARK
may be the same speed or a different speed.
PARK

To use the same speed tap for heating and cooling, the heat LINE

terminal and cool terminal must be connected using a jumper 60 XM

wire and connected to the desired motor lead. Place all

120

90
unused motor leads on Park terminals. Two are provided. 180

FAN OFF
ADJUSTMENT
SWITCHES

Do not energize more than one motor speed at a

time or damage to the motor will result.
FIGURE 40 : Typical Heat/Cool Speed Tap
Connections

FURNACE ACCESSORIES
ELECTRICAL
*ET03700324 Single Stage Thermostat, One-Stage Heat/One-Stage Cool, Non-Programmable
*ET03700124 Deluxe Single Stage Theromstat, One Stage Heat /One Stage Cool, Programmable
2TH13700424 Single Stage Thermostat, One Stage Heat, Round - 2TB17700424 Heat/Cool Subbase
6TH13701024 Single Stage Thermostat, One Stage Heat, Round - 2TB17700424 Heat/Cool Subbase
2TC03700124 Twinning Control
NON-ELECTRICAL
1NP0347 Propane (LP) Conversion Kit
1NP0349 Propane (LP) Conversion Kit
1PS0306
1PS0307
1PS0308 High Altitude Pressure Switch (See Form 650.75-N2.1V for proper application)
1PS0309
1PS0310
1SR0302BK External Side Filter Rack (6-Pack)
1BR0314 External Bottom or Horizontal Filter Rack - Cabinet “A”
1BR0317 External Bottom or Horizontal Filter Rack - Cabinet “B”
1BR0321 External Bottom or Horizontal Filter Rack - Cabinet “C”
1BR0324 External Bottom or Horizontal Filter Rack - Cabinet “D”
1CT0302 Concentric Vent Termination - 2” Vent Pipe
1CT0303 Concentric Vent Termination - 3” Vent Pipe
1CB0314 Combustible Floor Base - Cabinet “A”
1CB0317 Combustible Floor Base - Cabinet “B”
1CB0321 Combustible Floor Base - Cabinet “C”
1CB0324 Combustible Floor Base - Cabinet “D”

* Substitute 2 for York brands and 6 for non York brands.

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 035-17477-001 Rev. A (801)

BLOWER PERFORMANCE CFM- UPFLOW (WITHOUT FILTER)

MODELS EXTERNAL STATIC PRESSURE, INCHES WC
Input/Output/Airflow/ SPEED TAP
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
cabinet
HIGH 1330 1260 1210 1150 1090 1025 955 880 775 645
MED-HIGH 985 970 965 935 900 860 800 740 665 535
40 / 37 / 1000 / "A"
MED-LOW 790 780 760 740 715 685 635 575 485 365
LOW 635 625 610 590 565 535 490 435 360 250
HIGH 1360 1330 1290 1250 1190 1130 1055 970 865 735
MED-HIGH 980 970 960 945 920 870 830 775 685 575
60 / 55 / 1000 / "B"
MED-LOW 765 755 740 725 710 680 645 590 510 405
LOW 635 625 610 590 565 540 500 440 375 290
HIGH 1465 1440 1390 1365 1315 1255 1190 1125 1055 940
80 / 75 / 1200 / "B” MED 1085 1075 1060 1045 1030 1000 960 910 830 755
LOW 805 795 785 770 755 730 700 655 615 565
HIGH 1940 1905 1870 1815 1760 1700 1620 1555 1460 1305
80 / 75 / 1600 / "C” MED 1400 1390 1380 1370 1355 1320 1285 1255 1210 1135
LOW 1245 1225 1205 1185 1165 1145 1125 1095 1050 970
HIGH 1785 1720 1650 1575 1495 1405 1315 1190 1050 880
100 / 95 / 1400 / "C” MED 1430 1405 1375 1340 1290 1220 1130 1025 885 730
LOW 1150 1135 1120 1080 1045 1000 925 825 700 575
HIGH 2355 2285 2205 2145 2080 1995 1905 1820 1715 1610
100 / 95 / 2000 / "C" MED 1950 1915 1870 1830 1780 1710 1640 1560 1475 1375
LOW 1575 1555 1540 1505 1470 1430 1380 1315 1245 1150
HIGH 2375 2315 2245 2175 2100 2020 1935 1840 1755 1650
120 / 112 / 2000 / "D” MED 1990 1955 1920 1875 1835 1775 1715 1630 1550 1450
LOW 1565 1550 1530 1505 1480 1445 1405 1350 1280 1200
HIGH 2410 2340 2265 2200 2125 2035 1960 1860 1775 1670
140 / 130 / 2000 / "D” MED 2020 1975 1940 1895 1855 1790 1725 1655 1570 1470
LOW 1580 1565 1550 1520 1495 1460 1420 1360 1295 1210
NOTE: Data below reflects airflows with two return openings - two sides or one side and bottom.
HIGH 2365 2295 2215 2155 2090 2005 1915 1830 1725 1620
100 / 95 / 2000 / "C" MED 1965 1930 1885 1845 1795 1725 1655 1575 1490 1390
LOW 1595 1575 1560 1525 1490 1450 1400 1335 1265 1170
HIGH 2385 2325 2255 2185 2110 2030 1945 1850 1765 1660
120 / 112 / 2000 / "D” MED 2005 1970 1935 1890 1850 1790 1730 1645 1565 1465
LOW 1585 1570 1550 1525 1500 1465 1425 1370 1300 1220
HIGH 2420 2350 2275 2210 2135 2045 1970 1870 1785 1680
140 / 130 / 2000 / "D” MED 2035 1990 1955 1910 1870 1805 1740 1670 1585 1485
LOW 1600 1585 1570 1540 1515 1480 1440 1380 1315 1230
Airflow expressed in standard cubic feet per minute.
Notes: 1. Return air is through side opposite motor (left side).
2. Air flows above 1800 CFM require either return from two sides or one side plus bottom.
3. Motor voltage at 115 V.

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 035-17477-001 Rev. A (801)

AIRFLOW DATA - DOWNFLOW/HORIZONTAL MODELS: P*DH/G9T-DH/FG9-DH

MODELS EXTERNAL STATIC PRESSURE, INCHES WC
Input/Output/Airflow/ SPEED TAP
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
cabinet
HIGH 1400 1350 1300 1250 1200 1135 1060 970 880 765
MED-HIGH 970 955 945 935 915 885 840 780 705 600
40 / 37 / 1000 / "A”
MED-LOW 770 760 750 735 710 680 640 595 535 450
LOW 595 585 575 560 540 520 485 455 400 270
HIGH 1605 1590 1570 1545 1510 1470 1415 1360 1285 1205
60 / 55 / 1200 / "B"
MED 1260 1245 1225 1205 1180 1150 1110 1065 1005 930
80 / 75 / 1200 / "B”
LOW 930 915 895 880 860 835 810 770 695 620
HIGH 2030 1980 1925 1870 1830 1755 1675 1600 1515 1435
80 / 75 / 1600 / "C” MED 1505 1490 1475 1460 1440 1420 1380 1340 1280 1215
LOW 1295 1285 1260 1240 1215 1190 1160 1130 1080 1000
HIGH 2330 2270 2200 2130 2060 1985 1890 1810 1710 1625
100 / 95 / 2000 / "C” MED 2005 1965 1920 1870 1820 1750 1680 1600 1500 1395
LOW 1580 1560 1535 1510 1480 1440 1390 1325 1255 1175
HIGH 2335 2280 2215 2145 2065 2000 1905 1820 1720 1620
120 / 112 / 2000 / "D” MED 1975 1930 1885 1830 1775 1720 1655 1580 1500 1400
LOW 1515 1495 1475 1450 1415 1380 1330 1275 1210 1135
Airflow expressed in standard cubic feet per minute.
Notes: 1. Air filter installed. All filters must be high velocity, cleanable type.
2. Motor voltage at 115 V.

FILTER PERFORMANCE NOTE: The filter pressure drop values in Table 10 are typical
values for the type of filter listed and should only be used as a
The airflow capacity data published in Tables 8 & 9 repre-
guideline. Actual pressure drop ratings for each filter type
sents blower performance WITHOUT filters. To determine the
vary between filter manufacturer.
approximate blower performance of the system, apply the fil-
ter drop value for the filter being used or select an appropri-
ate value from the Table 10.

Table 10: FILTER PERFORMANCE - PRESSURE DROP INCHES W.C.

Minimum Opening Size Filter Type
Airflow Range (in.2) Disposable Hogs Hair* Pleated
1 Opening 2 Openings 1 Opening 2 Openings 1 Opening 2 Openings 1 Opening 2 Openings
0 - 750 230 0.01 0.01 0.15
751 - 1000 330 0.04 0.03 0.20
1001 - 1250 330 0.08 0.07 0.20
1251 - 1500 330 0.08 0.07 0.25
1501 - 1750 380 658 0.14 0.08 0.13 0.06 0.30 0.17
1751 - 2000 380 658 0.17 0.09 0.15 0.07 0.30 0.17
2001 & Above 463 658 0.17 0.09 0.15 0.07 0.30 0.17
*.
Hogs Hair Filters are the type supplied with furnace (if supplied).

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 035-17477-001 Rev. A (801)
APPLYING FILTER PRESSURE DROP TO DETERMINE OPERATION AND MAINTENANCE
SYSTEM AIRFLOW
SEQUENCE OF OPERATION
To determine the approximate airflow of the unit with a filter in
place, follow the steps below: The following describes the sequence of operation of the fur-
nace. Refer to the schematic wiring diagrams in the back of
1. Select the filter type.
this manual for component location.
2. Select the number of return air openings or calculate the
return opening size in square inches to determine the CONTINUOUS BLOWER
proper filter pressure drop. On cooling/heating thermostats with fan switch, when the fan
3. Determine the External System Static Pressure (ESP) switch is set in the ON position, a circuit is completed
without the filter. between terminals R and G of the thermostat. The blower
motor is energized through the cool terminal and runs on the
4. Select a filter pressure drop from the table based upon selected speed. This allows constant air circulation at lower
the number of return air openings or return air opening flow rate.
size and add to the ESP from Step 3 to determine the
total system static. INTERMITTENT BLOWER - COOLING
5. If total system static matches a ESP value in the airflow On cooling/heating thermostats with fan switch, when the fan
table (i.e. 0.20, 0.60, etc,) the system airflow corre- switch is set in the auto position and the thermostat calls for
sponds to the intersection of the ESP column and Model/ cooling, a circuit is completed between the R, Y and G termi-
Blower Speed row. nals.
6. If the total system static falls between ESP values in the The motor is energized through the cool fan terminal and
table (i.e. 0.58, 0.75, etc.), the static pressure may be runs on the selected speed. The fan off setting is fixed at 60
rounded to the nearest value in the table determining the seconds for SEER enhancement.
airflow using Step 5 or calculate the airflow by using the
following example. HEATING CYCLE
Example: For a 130,000 Btuh furnace with 2 return openings
and operating on high speed blower, it is found that total sys-
tem static is 0.58" w.c. To determine the system airflow, com-
plete the following steps: Label all wires prior to disconnecting when servic-
1. Obtain the airflow values at 0.50" & 0.60" ESP. ing controls. Wiring errors can cause improper and
dangerous operation. Verify proper operation after
Airflow @ 0.50": 2125 CFM servicing.
Airflow @ 0.60": 2035 CFM
2. Subtract the airflow @ 0.50" from the airflow @ 0.60" to When the system switch is set on HEAT and the fan is set on
obtain airflow difference. AUTO, and the room thermostat calls for heat, a circuit is
completed between terminals R and W of the thermostat.
2035 - 2125 = -90 CFM When the proper amount of combustion air is being provided,
3. Subtract the total system static from 0.50" and divide this a pressure switch activates the ignition control.
difference by the difference in ESP values in the table, The ignition control provides a 17-second warm-up period.
0.60" - 0.50", to obtain a percentage. The gas valve then opens for 10 seconds.
(0.58 - 0.50) / (0.60 - 0.50) = 0.8 As the gas starts to flow and ignition occurs, the flame sensor
begins its sensing function. If a flame is detected during the
4. Multiply percentage by airflow difference to obtain airflow 10 second flame stabilization period the circulating blower will
reduction. energize 30 seconds after the gas valve opens (20 seconds
(0.8) x (-90) = -72 after the flame stabilization period ends). Normal furnace
operation will continue until the thermostat circuit between R
5. Subract airflow reduction value to airflow @ 0.50" to
and W is opened. When the thermostat circuit opens, the
obtain actual airflow @ 0.58" ESP.
ignition control is de-energized. When the ignition control is
2125 - 72 = 2053 de-energized, the gas flow stops, and the burner flames are
extinguished. The ventor continues to operate for 15 seconds
after the gas flow stops.

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 035-17477-001 Rev. A (801)

The blower motor continues to operate for the amount of time All filters used with the furnace are the high-velocity, clean-
set by the fan-off delay "Jumper" located on the ignition con- able type. Clean these filters by washing in warm water.
trol board (Figure 16). The heating cycle is complete, and the Make sure to shake all the water out of the filter and have it
furnace is ready for the start of the next heating cycle. reasonably dry before installing it in the furnace. When
If the flame is not detected within 2 seconds of the gas valve replacing filters, be sure to use the same size and type as
opening, the gas valve is shut off and a retry operation originally supplied.
begins. If the flame is lost for 2 seconds during the 10 second FILTER REMOVAL - UPFLOW MODELS
stabilization period, the gas valve is shut off and a retry oper-
To remove a filter from the side or bottom location, push the
ation begins. During a retry operation the ventor starts a 15
closed end of the filter retainer to the left until it clears the lip
second inter-purge and the ignitor warm-up time is extended
on the front of the furnace base, which acts as a catch for the
to 27 seconds. If the flame is established for more than 10
retainer. When the retainer is clear of the flange, it will pivot in
seconds after ignition, during a retry, the control will clear the
the loops.
ignition attempt (retry) counter. If three retries occur during a
call for heat, the furnace will shut down for one hour. If at the Swing the retainer toward the center of the furnace. This will
end of the one hour shut down there is a call for heat, the fur- expose the filter to allow removal. To reinstall the filter, simply
nace will initiate a normal start cycle. If the problem has not reverse this procedure.
been corrected the furnace will again lockout after three
retries.
A momentary loss of gas supply, flame blowout, or a faulty
flame probe circuit will result in a disruption in the flame and
be sensed within 0.8 seconds. The gas valve will de-energize
and the control will begin a recycle operation. A normal igni-
tion sequence will begin after a 15 second inter-purge. If dur-
ing the five recycles the gas supply does not return, or the
fault condition is not corrected the ignition control will lock-out
for 60 minutes.
During burner operation, a momentary loss of power for 50
milliseconds or longer will de-energize the gas valve. When
the power is restored, the gas valve will remain de-energized
and the ignition sequence will immediately restart.
HOT SURFACE IGNITION SYSTEM

FIGURE 41 : Upflow Filter Retainer

Do not attempt to light this furnace by hand (with a
match or any other means). There may be a FILTER REMOVAL - DOWNFLOW MODELS
potential shock hazard from the components of the
1. Turn off electrical power supply to the furnace at discon-
hot surface ignition system. The furnace can only
nect switch. Remove access doors.
be lit automatically by its hot surface ignition
system. 2. Filters are installed in the plenum area above the blower
assembly. Filters rest against the side of the plenum wall
MAINTENANCE and are supported in the middle by a frame. Lift filter
slightly to dislodge and remove for service.
AIR FILTERS
3. Remove the filter and follow the cleaning instructions
The filters must be checked periodically for dirt accumulation.
above. DO NOT remove the filter stiffener rods, if pro-
Dirty filters greatly restrict the flow of air and may cause dam-
vided. When reinstalling the filter(s) be sure it completely
age to the system.
covers the plenum opening.
Clean the filters at least every three months. On new con-
To reinstall the filters, simply reverse this procedure.
struction, check the filters every week for the first four weeks.
Inspect the filters every three weeks after that, especially if
the system is running constantly.

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 035-17477-001 Rev. A (801)

HORIZONTAL APPLICATIONS LUBRICATION

In most horizontal applications the filter is located in the Blower motors in these furnaces are permanently lubricated
return air duct near the furnace or in a filter grille. and do not require periodic oiling.

When replacing filters, DO NOT use a type with

excessively high pressure drop. Some high
efficiency filters available will cause the furnace to
operate improperly and could result in a safety
hazard.

FIGURE 42 : Furnace Control Event Schedule

BLOWER CARE 4. Remove blower assembly mounting screws and slide the
Even with good filters properly in place, blower wheels and blower assembly out of the slots in the deck. If the two
motors will become dust laden after long months of operation. shipping screws were not previously removed, also
The entire blower assembly should be inspected annually. If remove and discard these two screws located on each
the motor and wheel are heavily coated with dust, they can front corner of the blower assembly.
be brushed and cleaned with a vacuum cleaner. 5. On downflow models only, note the wire/terminal location
The procedure for removing the direct drive blower assembly and then remove the blower wiring from the furnace con-
for cleaning is as follows: trol. Remove the protective boot and disconnect run
capacitor wires. Remove the screws securing the electri-
1. Disconnect the electrical supply to the furnace and cal panel to the blower housing. Pull blower assembly
remove remove the access doors. out of the unit. When cleaning or servicing the blower
2. On downflow/horizontal models only, remove the two assembly, DO NOT remove or change the balance clips
wires leading to the auxiliary limit mounted on the blower on the blower wheel.
housing. 6. To reassemble, reverse the procedure, restore power to
3. On downflow/horizontal models only, remove four top the furnace and verify operation.
panel screws and lift the top panel enough to disengage
and remove the flue chase assembly.

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 035-17477-001 Rev. A (801)

BURNER REMOVAL/CLEANING CLEANING THE SECONDARY HEAT EXCHANGER

The main burners should be checked periodically for dirt 1. Follow steps 1 thru 10 under Cleaning the Primary Heat
accumulation. Exchanger.
If cleaning is required, follow this procedure: 2. Remove the vent piping from the venter housing. Discon-
1. Turn off the electrical power to the unit. nect the drain lines from the venter and from the conden-
sate drain pan. Remove the venter blower and the
2. Turn off the gas supply at the external manual shutoff condensate pan. The turbulators can then be gently
valve and loosen the ground union joint. removed from the secondary heat exchanger.
3. Remove the upper access panel and remove the burner 3. With a stiff wire brush, brush out loose scale or soot.
box cover.
4. Vacuum the secondary heat exchanger.
4. Remove the screws that hold the burner box assembly to
the vest panel and remove the assembly. 5. Finish the cleaning procedure by following steps 10 thru
12 under Cleaning the Primary Heat Exchanger.
5. Remove burners from the burner assembly.
VENT/AIR INTAKE
6. Burners may be cleaned by rinsing in hot water.
Should it be necessary to service the vent/air intake system,
7. Reassemble the burners in the reverse order. the manufacturer recommends this service be conducted by
CLEANING THE HEAT EXCHANGER a qualified service agency.
1. Turn off the main manual gas valve external to the The operation of this appliance requires the reassembly and
furnace. resealing of the vent/air intake system as specified on Page
11.
2. Turn off electrical power to the furnace.
3. Remove the upper access panel and remove the burner TROUBLESHOOTING
box cover.
The following visual checks should be made before trouble-
4. Disconnect wires from flame sensor, rollout switch and shooting:
HSI igniter. Remove igniter carefully, as it is easily
broken. 1. Check to see that the power to the furnace and the igni-
tion control module is ON.
2. The manual shutoff valves in the gas line to the furnace
must be open.
3. Make sure all wiring connections are secure.
Label all wires prior to disconnection when servic-
ing controls. Wiring errors can cause improper and 4. Review the sequence of operation.
dangerous operation. Verify proper operation after Start the system by setting the thermostat above the room
servicing. temperature. Observe the system's response. Then use the
troubleshooting section in this manual to check the system's
5. Remove the screws that hold the burner box assembly to
operation.
the vestibule panel and remove the assembly. The upper
portion of the heat exchanger will now be exposed. FURNACE CONTROL DIAGNOSTICS
6. Remove the upper cover plate at the top of the furnace. The furnace has built-in, self diagnostic capability. If a system
Remove the internal baffle. problem occurs, a fault code is shown by a blinking red LED.
7. The upper portion of the heat exchanger is now It is located behind a clear view port in the blower compart-
exposed. ment door. DO NOT remove the furnace blower compartment
panel OR turn off furnace power as either action will clear the
8. With a long flexible wire brush, clean inside each tube at control's memory of the fault.
both the top and bottom. The brush must pass around
the rear heat exchanger tubes. Vacuum loose scale and The control continuously monitors its own operation and the
dirt from each tube. operation of the system. If a failure occurs, the LED will indi-
cate the failure code. If the failure is internal to the control, the
9. Clean - vacuum all burners. light will stay on continuously. In this case, the entire control
10. Replace all components in reverse order. Reconnect all should be replaced as the control is not field repairable.
wiring. Flash sequence codes 1 through 11 are as follows: LED will
11. Restore electrical power and gas supply to the furnace. turn “on” for one second and “off” for one second. This pat-
12. Check furnace operation. tern will be repeated the number of times equal to the code.
For example, six “on” flashes equals a number 6 fault code.

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 035-17477-001 Rev. A (801)

All flash code sequences are broken by a 2 second “off” 8 FLASH: This fault is indicated if the flame is lost 5 times (4
period. recycles) during the heating cycle. This could be caused by
low gas pressure or faulty gas valve.
IGNITION CONTROL (P/N 031-01267-001)
9 FLASH: Indicates reversed line voltage polarity. Both
Normal flame sense current is approximately heating and cooling operations will be affected. Check polar-
ity at furnace and branch.
3.7 microamps DC (υa)
11 FLASH: This fault will be indicated if the rollout jumper
Low flame signal control lockout point is wire connection soldered into the board, is broken. If this fault
occurs the control will have to be replaced. This fault may
0.9 microamps DC (υa)
also occur in installations where an improper ground is
present. Prior to replacing control, verify that unit is properly
CONTINUOUS FLASH: This indicates that flame was grounded.
sensed when there was not a call for heat. With this fault
code the control will turn on both the inducer motor and sup- STEADY ON: This fault occurs if the gas valve is energized
ply air blower. This fault would typically be caused by a gas when there is no call for heat. If this happens the ventor is
valve that leaks through or is slow closing. energized and will remain energized for 5 seconds or until the
fault clears itself at which point the ventor de-energizes. This
2 FLASH: This indicates that the normally open pressure failure is counted as a recycle. Check the gas valve and con-
switch contacts are stuck in the closed position. The control trol for proper operation.
confirms these contacts are open at the beginning of each
heat cycle. This would indicate a faulty pressure switch or 60 MINUTE AUTOMATIC RESET FROM LOCKOUT: This
mis-wiring. control includes a "watchdog" type circuit that will reset from
a lockout condition after 60 minutes. Operational faults
3 FLASH: This indicates the normally open pressure switch 1,6,7,8 and Steady On will be reset. This provides protection
contact did not close at the beginning of the heat cycle. This to an unoccupied structure if a temporary condition exists
could be caused by a number of problems; faulty inducer, causing a furnace malfunction. An example would be a low
blocked vent pipe, broken pressure switch hose or faulty incoming gas supply pressure preventing unit operation.
pressure switch. When the gas pressure is restored , at some point the
4 FLASH: This indicates that a primary or auxiliary limit "watchdog" would restart the unit and provide heat for the
switch has opened its normally closed contacts. With this house.
fault code the control will operate the supply air blower and NOTE: If a flame is detected the control flashes the LED for
inducer. This condition may be caused by: dirty filter, improp- 1/8 of a second and then enters a flame stabilization period.
erly sized duct system, incorrect blower speed setting, incor-
rect firing rate or faulty blower motor.
5 FLASH: This fault is indicated if the normally closed con-
tacts in the rollout switch opens. The rollout control is manu-
ally reset. If it has opened, check for proper combustion air, Never jump pressure switch to allow furnace oper-
proper inducer operation, primary heat exchanger failure or ation. To do so will allow furnace to operate under
burner problem. Be sure to reset the switch after correcting potentially hazardous conditions.
the failure condition. Do not try to repair controls. Replace defective
6 FLASH: This indicates that after the unit was operating, controls with UPG Source 1 Parts.
the pressure switch opened 4 times during the call for heat. If Never adjust pressure switch to allow furnace
the main blower is in a "Delay on" mode it will complete it, operation.
and any subsequent delay off period. The ventor continues to
operate until the pressure switch re-closes or a call for heat is
removed.
7 FLASH: This fault code indicates that the flame could not
be established. This no-light condition occured 3 times (2
retries) during the call for heat before locking out. This may
be caused by low gas pressure, faulty gas valve, faulty hot
surface ignitor or burner problem.

Unitary Products Group 37

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 38
BLK (HI)
BLOWER SPEED CHART CONNECTION DIAGRAM BLU (MED/MED HI) GRN
INPUT CFM COOL HEAT PARK PARK SEE CHART
FOR DESIRED YEL (MED LOW) BRN
040 1000 BLK BLU YEL RED BLOWER
BLOWER SPEED RED (LOW) MOTOR BRN
060 1000 BLK BLU YEL RED
ROS1 WHT (NEUT) GND
080 1200 BLK* BLK BLU RED 1RC
080 1600 BLK* BLK BLU RED BRN BLK
EAC
100 1400 BLK BLU RED --- BLK DOOR
HUM N.O.SW
100 2000 BLK* BLK BLU RED BRN BLK 115VAC
YEL NO C LINE
120 2000 BLK* BLK BLU RED 1 2
140 2000 BLK* BLK BLU RED WHT 115VAC
GAS
NEUT.
VALVE

EAC
* UNITS SHIPPED WITH HEAT

HEAT
PARK
NEUTRALS
WHT

L1
AND COOL TERMINALS FLAME

HUM

PARK
XFMR

COOL
PRP
JUMPERED. WHT
2 1 HOT SURFACE
SENSOR
BLK IGNITER
BLU 4 P3/S3
FURNACE CONTROL WHT
3
BLK 2
1LP 2

P2/S2
YEL BLK BLK
NO C 1 VENTOR
1 MOTOR

WHT P4/S4

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LS1
RED GRN
WHT BLU
GND
24V SEC
WHT

BLK
12 9 6 3
GRN
GND
11 8 5 2 BRN PRI
115V COM
10 7 4 1
P1/S1
ELEMENTARY DIAGRAM

N.O.SW POWER SUPPLY 115-1-60

DS Y W R G C GRN
DOOR SWITCH SEE NOTE 1
NO C
GND

COOL LEGEND
HEAT/COOL FUSE
BLOWER DS DISCONNECT SWITCH
RELAY
HEAT MOTOR GV GAS VALVE 1LP PRESSURE SW, BURNER BOX/VENTOR
GND IGN HOT SURFACE IGNITOR 1RC RUN CAPACITOR
1RC
P1/S1 12 PIN PLUG & SOCKET ON IGNITION 1T TRANSFORMER, 40VA
EAC EAC
EAC CONTROL BOARD IDENTIFIED RUN CAPACITOR
WIRING DIAGRAM - UPFLOW MODELS: P*UR / FG9-UP / G9T-UP

P2/S2 4 PIN PLUG & SOCKET ON IGNITION 24V CONNECTION ROOM THERMOSTAT
HUM HUM CONTROL BOARD
FIELD CONNECTION
HUMIDIFIER P3/S3 2 PIN PLUG & SOCKET AT HOT SURFACE
HUMIDIFIER IGNITOR FACTORY WIRING AND DEVICES
RELAY
P4/S4 2 PIN PLUG & SOCKET AT INDUCER ----- FIELD WIRING AND DEVICES
MOTOR
VENTOR
VENTOR MOTOR LS1 PRIMARY LIMIT SWITCH RELAY CONTACTS ON IGNITION
RELAY ROS1 ROLL OUT SWITCH CONTROL BOARD
IGN - CAUTION -
IGNITER OPEN ALL DISCONNECTS BEFORE
RELAY 120V COM SERVICING THIS UNIT
PRI
NOTES:
3A 1T (40VA)
R R
ON 24V SEC 1. ALL FIELD WIRING PER: (A) NATIONAL ELEC. CODE (NEC) AND/OR
G G (B) CANADIAN ELEC. CODE (CEC) AND/OR
AUTO GAS VALVE
RELAYS (C) LOCAL OR CITY CODES.
Y Y 2. IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE FURNACE MUST BE
GV REPLACED, IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A
COOL GND TEMPERATURE RATING OF AT LEAST 221ßF (105ßC).
C ROS1
OFF 3. CONNECTORS SUITABLE FOR COPPER CONDUCTORS ONLY.
HEAT 4. ALL REPLACEMENT COMPONENTS MUST BE PROPERLY GROUNDED.
NOTE: THE FURNACE’S CONTROL SYSTEM REQUIRES CORRECT POLARITY OF THE POWER SUPPLY.

1LP LS1
W W NO C 5. PROVIDE DISCONNECTS FOR ALL POWER SUPPLIES.
HEAT/COOL THERMOSTAT
6. MOTORS ARE INHERENTLY PROTECTED.
90+ UPFLOW FURNACE 035-17474-000A
035-17477-001 Rev. A (801)

Unitary Products Group

 035-17477-001 Rev. A (801)

WIRING DIAGRAM - DOWNFLOW/HORIZONTAL MODELS: P*DH / FG9-DH / G9T-DH

NOTE: THE FURNACE’S CONTROL SYSTEM REQUIRES CORRECT POLARITY OF THE POWER SUPPLY.

Unitary Products Group 39

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 Subject to change without notice. Printed in U.S.A. 035-17477-001 Rev. A (801)
Copyright © by York International Corp. 2001. All rights reserved. Supersedes: 035-17477-000 Rev. A (800)

Unitary 5005 Norman

Product York OK
Group Drive 73069
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