York YP9C

INSTALLATION MANUAL
RESIDENTIAL GAS FURNACE EFFICIENCY

RATING
CERTIFIED
WITH ECM MOTOR

MODELS:
TP9C*C, YP9C*C, CP9C*C, LP9C*C
(Up to 98% Modulating Multi-position) When paired with a
York heat pump
LIST OF SECTIONS
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 COMBUSTION AIR and VENT SYSTEM . . . . . . . . . . . . . . . . . 27
DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . 34
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 NORMAL OPERATION AND DIAGNOSTICS . . . . . . . . . . . . . 39
ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . 41
CONDENSATE PIPING AND FURNACE REPLACEMENT PART CONTACT INFORMATION . . . . . . . . 41
VENTING CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . 21 WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
LIST OF FIGURES
Duct Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Variable Speed Modulating Furnace . . . . . . . . . . . . . . . . . . . . . 18
Combustible Floor Base Accessory . . . . . . . . . . . . . . . . . . . . . . . 6 Thermostat Chart - Single Stage Heat Pump –
Horizontal Application (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Variable Speed Modulating Furnace . . . . . . . . . . . . . . . . . . . . . 19
Typical Attic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Thermostat Chart - Two Stage Heat Pump –
Typical Suspended Furnace / Crawl Space Installation . . . . . . . 7 Variable Speed Modulating Furnace . . . . . . . . . . . . . . . . . . . . . 20
Downflow Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Typical Condensate drain, vertical installation . . . . . . . . . . . . . 22
Vertical Applications (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Typical Combustion Pipe Drain Tee . . . . . . . . . . . . . . . . . . . . . 22
Coil Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Upflow Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Horizontal Right Application (Typical) . . . . . . . . . . . . . . . . . . . . . 8 Downflow Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Horizontal Left Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Horizontal Left Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
PC Series Upflow Coil Installation . . . . . . . . . . . . . . . . . . . . . . . . 8 Horizontal Right Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 26
Horizontal Left or Right application (Right Shown) . . . . . . . . . . . 8 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Home Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Side Return Cutout Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Termination Configuration - 1 Pipe . . . . . . . . . . . . . . . . . . . . . . 30
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Termination Configuration - 2 Pipe . . . . . . . . . . . . . . . . . . . . . . 30
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Termination Configuration - 2 Pipe Basement . . . . . . . . . . . . . 30
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Double Horizontal Combustion Air Intake
and Vent Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Furnace Control Board – Communications Connections . . . . . 13
Double Vertical Combustion Air Intake
Modulating Furnace with Communicating AC or HP . . . . . . . . . 14
and Vent Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Modulating Furnace with Communicating Thermostat and
Downward Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Non-Communicating AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Direct Vent Air Intake Connection and Vent Connection . . . . . . 31
Thermostat Chart - Single Stage Air Conditioner –
Variable Speed Modulating Furnace . . . . . . . . . . . . . . . . . . . . . 15 Combustion Airflow Path Through The Furnace Casing . . . . . . 31
Thermostat Chart - Two Stage Air Conditioner – Outside and Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . 32
Variable Speed Modulating Furnace . . . . . . . . . . . . . . . . . . . . . 16 Attic and Crawl Space Combustion Air Termination . . . . . . . . . 33
Thermostat Chart - Two Stage Air Conditioner with Single Stage Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Thermostat – Variable Speed Modulating Furnace . . . . . . . . . . 17 Furnace Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Thermostat Chart - Single Stage Heat Pump – Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
LIST OF TABLES
Unit Clearances to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . 4 Combustion Air Intake and Vent Connection Size at Furnace (All
Coil Projection Dimensions - PC Series Coils . . . . . . . . . . . . . . . 8 Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Cabinet and Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Recommended Filter Sizes (High Velocity 600 FPM) . . . . . . . . . 9 Unconfined Space Minimum Area . . . . . . . . . . . . . . . . . . . . . . . 32
High Altitude Orifices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Ratings & Physical / Electrical Data . . . . . . . . . . . . . . . . . . . . . 12 Gas Rate (CU FT/HR) at Full Input . . . . . . . . . . . . . . . . . . . . . . 35
Maximum Equivalent Pipe Length . . . . . . . . . . . . . . . . . . . . . . . 27 Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Elbow Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Equivalent Length of Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Blower Performance CFM - Any Position . . . . . . . . . . . . . . . . . 38
681292-UIM-A-0211
681292-UIM-A-0211
The York YP9C is part of a "Hybrid Comfort System" when paired with a which has an external static pressure within the allowable range,
York Heat pump. as specified on the furnace rating plate.
These high efficiency, compact units employ induced combustion, reli- 8. When a furnace is installed so that supply ducts carry air circulated
able hot surface ignition and high heat transfer aluminized tubular heat by the furnace to areas outside the space containing the furnace,
exchangers. The units are factory shipped for installation in upflow or the return air shall also be handled by duct(s) sealed to the fur-
horizontal applications and may be converted for downflow applica- nace casing and terminating outside the space containing the fur-
tions. nace.
9. It is permitted to use the furnace for heating of buildings or struc-
These furnaces are designed for residential installation in a basement, tures under construction where the application and use must com-
closet, alcove, attic, recreation room or garage and are also ideal for ply with all manufacturer’s installation instructions including:
commercial applications. All units are factory assembled, wired and
• Proper vent installation;
tested to assure safe dependable and economical installation and oper- • Furnace operating under thermostatic control;
ation.
• Return air duct sealed to the furnace;
These units are Category IV listed and may not be common vented with • Air filters in place;
another gas appliance as allowed by the National Fuel Gas Code. • Set furnace input rate and temperature rise per rating plate
marking;
SECTION I: SAFETY • Means for providing outdoor air required for combustion;
• Return air temperature maintained between 55ºF (13ºC) and
This is a safety alert symbol. When you see this symbol on
80ºF (27ºC);
labels or in manuals, be alert to the potential for personal • The air filter must be replaced upon substantial completion of
injury. the construction process;
Understand and pay particular attention to the signal words DANGER, • Clean furnace, duct work and components upon substantial
WARNING, or CAUTION. completion of the construction process, and verify furnace-
operating conditions including ignition, input rate, temperature
DANGER indicates an imminently hazardous situation, which, if not
rise and venting, according to the manufacturer’s instructions.
avoided, will result in death or serious injury.
10. When installed in a non-HUD-Approved Modular Home or building
WARNING indicates a potentially hazardous situation, which, if not constructed on-site, combustion air shall not be supplied from
avoided, could result in death or serious injury. occupied spaces.
CAUTION indicates a potentially hazardous situation, which, if not 11. The size of the unit should be based on an acceptable heat loss
avoided may result in minor or moderate injury. It is also used to calculation for the structure. ACCA, Manual J or other approved
alert against unsafe practices and hazards involving only property dam- methods may be used.
age. 12. When moving or handling this furnace prior to installation it is rec-
ommended to leave the doors on the furnace to provide support
and to prevent damage or warping of the cabinet. When lifting the
furnace by the cabinet, support the ends of the furnace rather than
Improper installation may create a condition where the operation of lifting by the cabinet flanges at the return air openings (bottom or
the product could cause personal injury or property damage. sides) or supply air opening.
Improper installation, adjustment, alteration, service or mainte- 13. When lifting the furnace, it is acceptable to use the primary heat
nance can cause injury or property damage. Failure to carefully exchanger tubes as a lifting point provided that the tubes are lifted
read and follow all instructions in this manual can result in fur- at the front of the heat exchangers where attached to the vestibule
nace malfunction, death, personal injury and/or property dam- panel. Do not use the top return bend of the heat exchangers as
age. Only a qualified contractor, installer or service agency should lifting points as the tubes may shift out of position or their location
install this product. brackets/baffles.
SPECIFIC SAFETY RULES AND PRECAUTIONS

1. Only Natural gas or Propane (LP) gas are approved for use with
this furnace. During installation, doors should remain on the furnace when
2. Install this furnace only in a location and position as specified in moving or lifting.
these instructions.
SAFETY REQUIREMENTS
3. A gas-fired furnace for installation in a residential garage must be
installed as specified in these instructions.
4. Provide adequate combustion and ventilation air to the furnace
space as specified in these instructions. This product must be installed in strict compliance with the installa-
5. Combustion products must be discharged outdoors. Connect this tion instructions and any applicable local, state, and national codes
furnace to an approved vent system only, as specified in SEC- including, but not limited to building, electrical, and mechanical
TION VII of these instructions. codes.
6. Test for gas leaks as specified in these instructions.
• Refer to the unit rating plate for the furnace model number, and
then see the dimensions page of this instruction for return air ple-
num dimensions in Figure 13. The plenum must be installed
according to the instructions.
FIRE OR EXPLOSION HAZARD • Provide clearances from combustible materials as listed under
Failure to follow the safety warnings exactly could result in serious Clearances to Combustibles.
injury, death or property damage. • Provide clearances for servicing ensuring that service access is
Never test for gas leaks with an open flame. Use a commercially allowed for both the burners and blower.
available soap solution made specifically for detection of leaks to • These models ARE NOT CSA listed or approved for installation
check all connections. A fire or explosion may result causing prop- into a HUD Approved Modular Home or a Manufactured
erty damage, personal injury or loss of life. (Mobile) Home.
7. Always install the furnace to operate within the furnace’s intended • This furnace is not approved for installation in trailers or recre-
temperature rise range. Only connect the furnace to a duct system ational vehicles.
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681292-UIM-A-0211
• Furnaces for installation on combustible flooring shall not be CODES AND STANDARDS
installed directly on carpeting, tile or other combustible material
Follow all national, local codes and standards in addition to this installa-
other than wood flooring.
tion manual. The installation must comply with regulations of the serv-
• Check the rating plate and power supply to be sure that the elec-
ing gas supplier, local building, heating, plumbing, and other codes. In
trical characteristics match. All models use nominal 115 VAC, 1
Phase, 60-Hz power supply. DO NOT CONNECT THIS APPLI- absence of local codes, the installation must comply with the national
ANCE TO A 50-Hz POWER SUPPLY OR A VOLTAGE ABOVE codes listed below and all authorities having jurisdiction.
130 VOLTS. In the United States and Canada, follow all codes and standards for the
• Furnace shall be installed so the electrical components are pro- following, using the latest edition available:
tected from water.
STEP 1 -Safety
• Installing and servicing heating equipment can be hazardous due
to the electrical components and the gas fired components. Only • US: National Fuel Gas Code (NFGC) NFPA 54/ANSI Z223.1 and
trained and qualified personnel should install, repair, or service the Installation Standards, Warm Air Heating and Air Conditioning
gas heating equipment. Untrained service personnel can perform Systems ANSI/NFPA 90B
basic maintenance functions such as cleaning and replacing the • CANADA: CAN/CGA-B149.1 National Standard of Canada. Natu-
air filters. When working on heating equipment, observe precau- ral Gas and Propane Installation Codes (NSCNGPIC)
tions in the manuals and on the labels attached to the unit and STEP 2 -General Installation
other safety precautions that may apply. • US: Current edition of the NFGC and NFPA 90B. For copies, con-
COMBUSTION AIR QUALITY tact the
(LIST OF CONTAMINANTS) National Fire Protection Association Inc.
Batterymarch Park
The furnace requires OUTDOOR AIR for combustion when the furnace Quincy, MA 02269
is located in any of the following environments.
or for only the NFGC, contact the
• Restricted Environments American Gas Association,
• Commercial buildings 400 N. Capital, N.W.
• Buildings with indoor pools Washington DC 20001
• Furnaces installed in laundry rooms or www.NFPA.org
• Furnaces installed in hobby or craft rooms • CANADA: NSCNGPIC. For a copy contact:
• Furnaces installed near chemical storage areas Standard Sales, CSA International
• Chemical exposure 178 Rexdale Boulevard
Etobicoke, (Toronto) Ontario Canada M9W 1RS
The furnace requires OUTDOOR AIR for combustion when the furnace
is located in an area where the furnace is being exposed to the follow- STEP 3 -Combustion and Ventilation Air
ing substances and / or chemicals. • US: Section 5.3 of the NFGC, air for Combustion and Ventilation
• CANADA: Part 7 of NSCNGPIC, Venting Systems and Air Supply
• Permanent wave solutions
for Appliances
• Chlorinated waxes and cleaners
STEP 4 -Duct Systems
• Chlorine based swimming pool chemicals
• US and CANADA: Air Conditioning Contractors Association
• Water softening chemicals (ACCA) Manual D, Sheet Metal and Air Conditioning Contractors
• De-icing salts or chemicals Association National Association (SMACNA), or American Soci-
• Carbon tetrachloride ety of Heating, Refrigeration, and Air Conditioning Engineers
• Halogen type refrigerants (ASHRAE) 1997 Fundamentals Handbook Chapter 32.
• Cleaning solvents (such as perchloroethylene) STEP 5 -Acoustical Lining and Fibrous Glass Duct
• Printing inks, paint removers, varnishes, etc. • US and CANADA: Current edition of SMACNA and NFPA 90B as
tested by UL Standard 181 for Class I Rigid Air Ducts
• Hydrochloric acid
STEP 6 -Gas Piping and Gas Pipe Pressure Testing
• Cements and glues
• US: NFGC; chapters 2, 3, 4, & 9 and National Plumbing Codes
• Antistatic fabric softeners for clothes dryers
• CANADA: NSCNGPIC Part 5
• Masonry acid washing materials
STEP 7 -Electrical Connections
When outdoor air is used for combustion, the combustion air intake duct
• US: National Electrical Code (NEC) ANSI/NFPA 70
system termination must be located external to the building and in an
• CANADA: Canadian Electrical Code CSA C22.1
area where there will be no exposure to the substances listed above.
These instructions cover minimum requirements and conform to exist-
ing national standards and safety codes. In some instances these
instructions exceed certain local codes and ordinances, especially
those who have not kept up with changing residential and non-HUD
The furnace area must not be used as a broom closet or for any
other storage purposes, as a fire hazard may be created. Never modular home construction practices. These instructions are required
store items such as the following on, near or in contact with the fur- as a minimum for a safe installation.
nace.
1. Spray or aerosol cans, rags, brooms, dust mops, vacuum
cleaners or other cleaning tools.
2. Soap powders, bleaches, waxes or other cleaning com-
pounds; plastic items or containers; gasoline, kerosene, ciga-
rette lighter fluid, dry cleaning fluids or other volatile fluid.
3. Paint thinners and other painting compounds.
4. Paper bags, boxes or other paper products
Never operate the furnace with the blower door removed. To
do so could result in serious personal injury and/or equipment
damage.
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681292-UIM-A-0211
4. Where it will not interfere with proper air circulation in the confined
FOR FURNACES INSTALLED IN THE COMMON- space.
WEALTH OF MASSACHUSETTS ONLY 5. Where the outdoor vent terminal will not be blocked or restricted.
For all side wall horizontally vented gas fueled equipment installed in Refer to “VENT CLEARANCES” located in SECTION VII of these
every dwelling, building or structure used in whole or in part for resi- instructions. These minimum clearances must be maintained in
dential purposes, including those owned or operated by the Com- the installation.
monwealth and where the side wall exhaust vent termination is less 6. Where the unit will be installed in a level position with no more than
than seven (7) feet above finished grade in the area of the venting, 1/4” (6.4 mm) slope side-to-side and front-to-back to provide
including but not limited to decks and porches, the following require- proper condensate drainage.
ments shall be satisfied: Installation in freezing temperatures:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At 1. Furnace shall be installed in an area where ventilation facilities
the time of installation of the side wall horizontal vented gas provide for safe limits of ambient temperature under normal oper-
fueled equipment, the installing plumber or gasfitter shall ating conditions. Ambient temperatures must not fall below 32°F
observe that a hard wired carbon monoxide detector with an (0°C) unless the condensate system is protected from freezing.
alarm and battery back-up is installed on the floor level where
the gas equipment is to be installed. In addition, the installing
plumber or gasfitter shall observe that a battery operated or
hard wired carbon monoxide detector with an alarm is installed Improper installation in an ambient below 32ºF (0°C) could create a
on each additional level of the dwelling, building or structure hazard, resulting in damage, injury or death.
served by the side wall horizontal vented gas fueled equipment.
It shall be the responsibility of the property owner to secure the 2. Do not allow return air temperature to be below 55ºF (13°C) for
services of qualified licensed professionals for the installation of extended periods. To do so may cause condensation to occur in
hard wired carbon monoxide detectors the main heat exchanger, leading to premature heat exchanger
a. In the event that the side wall horizontally vented gas failure.
fueled equipment is installed in a crawl space or an attic, 3. If this furnace is installed in an unconditioned space and an
the hard wired carbon monoxide detector with alarm and extended power failure occurs, there will be potential damage to
battery back-up may be installed on the next adjacent floor the internal components. Following a power failure situation, do
level. not operate the unit until inspection and repairs are performed.
b. In the event that the requirements of this subdivision can
not be met at the time of completion of installation, the
owner shall have a period of thirty (30) days to comply with
Liquid anti-freeze will cause damage to internal plastic parts of this
the above requirements; provided, however, that during
furnace. DO NOT attempt to winterize the furnace using liquid
said thirty (30) day period, a battery operated carbon mon- anti-freeze.
oxide detector with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS. Each car- Clearances for access/service:
bon monoxide detector as required in accordance with the Ample clearances should be provided to permit easy access to the unit.
above provisions shall comply with NFPA 720 and be ANSI/UL The following minimum clearances are recommended:
2034 listed and IAS certified.
1. Twenty-four (24) inches (61 cm) between the front of the furnace
3. SIGNAGE. A metal or plastic identification plate shall be perma- and an adjacent wall or another appliance, when access is
nently mounted to the exterior of the building at a minimum required for servicing and cleaning.
height of eight (8) feet above grade directly in line with the
exhaust vent terminal for the horizontally vented gas fueled 2. Eighteen (18) inches (46 cm) at the side where access is required
heating appliance or equipment. The sign shall read, in print for passage to the front when servicing or for inspection or replace-
size no less than one-half (1/2) inch in size, "GAS VENT ment of flue/vent connections.
DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUC- In all cases, accessibility clearances shall take precedence over clear-
TIONS". ances for combustible materials where accessibility clearances are
4. INSPECTION. The state or local gas inspector of the side wall greater.
horizontally vented gas fueled equipment shall not approve the Installation in a residential garage:
installation unless, upon inspection, the inspector observes car-
A gas-fired furnace for installation in a residential garage must be
bon monoxide detectors and signage installed in accordance
with the provisions of 248 CMR 5.08(2)(a)1 through 4. installed so the burner(s) and the ignition source are located not less
than 18” (46 cm) above the floor, and the furnace must be located or
protected to avoid physical damage by vehicles.
INSPECTION
Table 1: Unit Clearances to Combustibles
As soon as a unit is received, it should be inspected for possible dam-
age during transit. If damage is evident, the extent of the damage Application Upflow Downflow Horizontal
should be noted on the carrier’s freight bill. A separate request for Top 1" 0" 0"
inspection by the carrier’s agent should be made in writing. Also, before Vent 0" 0" 0"
installation, the unit should be checked for screws or bolts which may Rear 0" 0" 0"
have loosened in transit. There are no shipping or spacer brackets Side 0" 0" 1"
which need to be removed from the interior of this unit.
Front1 0" 0" 0"
FURNACE LOCATION AND CLEARANCES Floor Combustible Combustible2 Combustible
The furnace shall be located using the following guidelines: Closet Yes Yes Yes
1. Where a minimum amount of air intake/vent piping and elbows will Line Contact No No Yes
be required.
1. Line contact only permitted between lines formed by the intersection of the
2. As centralized with the air distribution as possible. rear panel and side panel (top in horizontal position) of the furnace jacket
3. Where adequate combustion air will be available (particularly and building joists, studs or framing.
when the appliance is not using outdoor combustion air). 2. For combustible floors only when used with special sub-base.
All furnaces approved for alcove and attic installation.

681292-UIM-A-0211
SECTION II: DUCTWORK On all installations without a coil, a removable access panel is recom-
mended in the outlet duct such that smoke or reflected light would be
DUCTWORK GENERAL INFORMATION observable inside the casing to indicate the presence of leaks in the
The duct system’s design and installation must: heat exchanger. This access cover shall be attached in such a manner
1. Handle an air volume appropriate for the served space and within as to prevent leaks.
the operating parameters of the furnace specifications.
DUCT FLANGES
2. Be installed in accordance of National Fire Protection Association
as outlined in NFPA standard 90B (latest editions) or applicable Four flanges are provided to attach ductwork to the furnace. These
national, provincial, state, and local fire and safety codes. flanges are rotated down for shipment. In order to use the flanges,
3. Create a closed duct system. For residential and non-HUD Modu- remove the screw holding an individual flange, rotate the flange so it is
lar Home installations, when a furnace is installed so that the sup- in the upward position and reinstall the screw then repeat this for all 4
ply ducts carry air circulated by the furnace to areas outside the flanges.
space containing the furnace, the return air shall also be handled If the flanges are not used, they must remain in the rotated down posi-
by a duct(s) sealed to the furnace casing and terminating outside tion as shipped.
the space containing the furnace.
4. Complete a path for heated or cooled air to circulate through the For duct attachment, Factory Installed
air conditioning and heating equipment and to and from the condi- if needed
tioned space.
The cooling coil must be installed in the supply air duct, down-
stream of the furnace. Cooled air may not be passed over the heat
exchanger.
When the furnace is used with a cooling coil, the coil must be installed
parallel with, or in the supply air side of the furnace to avoid condensa-
FIGURE 1: Duct Attachment
tion in the primary heat exchanger. When a parallel flow arrangement is
used, dampers or other means used to control airflow must be ade- DUCTWORK INSTALLATION AND SUPPLY PLENUM
quate to prevent chilled air from entering the furnace. If manually oper- CONNECTION - UPFLOW/HORIZONTAL
ated, the damper must be equipped with means to prevent the furnace
Attach the supply plenum to the furnace outlet. The use of
or the air conditioner from operating unless the damper is in full heat or
an approved flexible duct connector is recommended on all
cool position.
installations. This connection should be sealed to prevent
When replacing an existing furnace, if the existing plenum is not the air leakage. The sheet metal should be crosshatched to
same size as the new furnace then the existing plenum must be eliminate any popping of the sheet metal when the indoor
removed and a new plenum installed that is the proper size for the new fan is energized.
furnace. If the plenum is shorter than 12” (30.5 cm) the turbulent air flow
may cause the limit controls not to operate as designed, or the limit con- FLOOR BASE AND DUCTWORK INSTALLATION -
trols may not operate at all. DOWNFLOW
The duct system is a very important part of the installation. If the duct Installations on combustible material or directly on any
system is improperly sized the furnace will not operate properly. floors must use a combustible floor base shown in Figure 2.
The ducts attached to the furnace plenum, should be of sufficient size Follow the instructions supplied with the combustible floor
so that the furnace operates at the specified external static pressure base accessory. This combustible floor base can be
and within the air temperature rise specified on the nameplate. replaced with a matching cooling coil, properly sealed to
prevent leaks. Follow the instructions supplied with the
cooling coil cabinet for installing the cabinet to the duct con-
nector. Plug intake and vent pipe holes in bottom panel and
The minimum plenum height is 12” (30.5 cm). The furnace will not move grommet to desired vent side exit.
operate properly on a shorter plenum height. The minimum recom-
mended rectangular duct height is 4” (10.2 cm) attached to the ple- Downflow Air Conditioning Coil Cabinet
num. The furnace should be installed with coil cabinet part number specifi-
cally intended for downflow application. If a matching cooling coil is
used, it may be placed directly on the furnace outlet and sealed to pre-
vent leakage. For details of the coil cabinet dimensions and installation
The duct system must be properly sized to obtain the correct airflow requirements, refer to the installation instructions supplied with the coil
for the furnace size that is being installed. cabinet.
Refer to Table 6 or the furnace rating plate for the correct rise range Attach the air conditioning coil cabinet to the duct connector, and then
and static pressures. position the furnace on top of the coil cabinet. The connection to the fur-
If the ducts are undersized, the result will be high duct static pres- nace, air conditioning coil cabinet, duct connector, and supply air duct
sures and/or high temperature rises which can result in a heat must be sealed to prevent air leakage.
exchanger OVERHEATING CONDITION. This condition can result
in premature heat exchanger failure, which can result in personal DOWNFLOW DUCT CONNECTORS
injury, property damage, or death. All downflow installations must use a suitable duct connector approved
by the furnace manufacturer for use with this furnace. The duct connec-
If a matching cooling coil is used, it may be placed directly on the fur-
tors are designed to be connected to the rectangular duct under the
nace outlet and sealed to prevent leakage. If thermoplastic evaporator
floor and sealed. Refer to the instructions supplied with the duct con-
‘A’ coil drain pans are to be installed in the upflow/horizontal configura-
nector for proper installation. Refer to the separate accessory parts list
tion, then extra 2” (5.1 cm) minimum spacing may be needed to ensure
at the end of these instructions for the approved accessory duct con-
against drain pan distortion.
nectors.

681292-UIM-A-0211
Line contact only permissible Supply

between lines formed by the Air Vent (Maintain
intersection of furnace top
required
and two sides and building
FURNACE clearances to
joists, studs or framing
combustibles)
Filter rack
must be a minimum
distance Gas Piping
WARM AIR PLENUM
WITH 1” FLANGES of 18” (45.7 cm)
from the
furnace
FIBERGLASS
INSULATION 30” MIN.
Work Area
FIBERGLASS TAPE Return

UNDER FLANGE Air Sediment
Trap
FIGURE 4: Typical Attic Installation

This appliance is certified for line contact when the furnace is installed
in the horizontal left or right position. The line contact is only permissible
COMBUSTIBLE FLOOR between lines that are formed by the intersection of the top and two
BASE ACCESSORY sides of the furnace and the building joists, studs or framing. This line
may be in contact with combustible material. Refer to Figure 4.
FIGURE 2: Combustible Floor Base Accessory
RESIDENTIAL AND MODULAR HOME UPFLOW

When a furnace is installed in an attic or other insulated space,
RETURN PLENUM CONNECTION keep all insulating materials at least 12” (30.5 cm) away from fur-
Return air may enter the furnace through the side(s) or bottom depend- nace and burner combustion air openings.
ing on the type of application. Return air may not be connected into the
rear panel of the unit.
BOTTOM RETURN AND ATTIC INSTALLATIONS
During installation, doors should remain on the furnace when
Bottom return applications normally pull return air through a base plat- moving or lifting.
form or return air plenum. Be sure the return platform structure or return
air plenum is suitable to support the weight of the furnace. When moving or handling this furnace prior to installation it is recom-
The internal bottom panel must be removed for this application. mended to leave the doors on the furnace to provide support and to
prevent damage or warping of the cabinet. When lifting the furnace,
Attic installations must meet all minimum clearances to combustibles
support the ends of the furnace rather than lifting by the cabinet flanges
and have floor support with required service accessibility.
at the return air openings (bottom or sides) or supply air opening.
HORIZONTAL APPLICATION It is acceptable to use the primary heat exchanger tubes as a lifting
point provided that the tubes are lifted at the front of the heat exchang-
ers where attached to the vestibule panel. Do not use the top return
bend of the heat exchangers as lifting points as the tubes may shift out
of position or their location brackets/baffles.
SUSPENDED FURNACE / CRAWL SPACE

INSTALLATION
FIGURE 3: Horizontal Application (Typical) The furnace can be hung from floor joists or installed on suitable blocks
or pads. Blocks or pad installations shall provide adequate height to
ensure that the unit will not be subject to water damage.
Units may also be suspended from rafters or floor joists using rods, pipe
This furnace may be installed in a horizontal position on either side angle supports or straps. In all cases, the furnace should be supported
as shown above. It must not be installed on its back. with rods, straps, or angle supports at three locations to properly sup-
port the furnace. Place one support at the supply end of the furnace,
ATTIC INSTALLATION one support located approximately in the center of the furnace near the
This appliance is certified for line contact when the furnace is installed blower shelf, and the third support should be at the return end of the fur-
in the horizontal left or right position. The line contact is only permissible nace. Maintain a 6” (15.2 cm) minimum clearance between the front of
between lines that are formed by the intersection of the top and the two the furnace and the support rods or straps.
sides of the furnace and the building joists, studs, or framing. This line All six suspension points must be level to ensure proper and quiet fur-
may be in contact with combustible material. Refer to Figure 4 for nace operation. When suspending the furnace, use a secure platform
details and additional information. constructed of plywood or other building materials secured to the floor
or ceiling joists. Refer to Figure 5 for details and additional information.

681292-UIM-A-0211
COIL INSTALLATION
On all installations without a coil, a removable access panel is rec-

Support ommended in the outlet duct such that smoke or reflected light
Rod would be observable inside the casing to indicate the presence of
leaks in the heat exchanger. This access cover shall be attached in
such a manner as to prevent leaks.
Support COIL/FURNACE ASSEMBLY - MC/FC/PC SERIES

Angle (x3) COILS
Maintain 6” minimum
clearance between support
rods and front of furnace
FIGURE 5: Typical Suspended Furnace / Crawl Space Installation
Furnace
During installation, doors should remain on the furnace when
moving or lifting.
When moving or handling this furnace prior to installation it is recom-

mended to leave the doors on the furnace to provide support and to
Furnace
prevent damage or warping of the cabinet. When lifting the furnace,
support the ends of the furnace rather than lifting by the cabinet flanges
at the return air openings (bottom or sides) or supply air opening.
It is acceptable to use the primary heat exchanger tubes as a lifting
point provided that the tubes are lifted at the front of the heat exchang-
UPFLOW DOWNFLOW
ers where attached to the vestibule panel. Do not use the top return
bend of the heat exchangers as lifting points as the tubes may shift out FIGURE 7: Vertical Applications (Typical)
of position or their location brackets/baffles.
FURNACE ASSEMBLY - MC & FC SERIES COILS
DOWNFLOW APPLICATION These coils are factory shipped for installation in either upflow or down-
To apply the furnace in a downflow position, it will be necessary to flow applications with no conversion.
rotate the vent blower 90° left or right so that the vent pipe passes Position the coil casing over or under the furnace opening as shown in
through the side of the furnace casing rather than the end. See Figure
Figure 7 after configuring coil flanges as required see “Coil Flange” sec-
6.
tion below.
COIL FLANGE INSTALLATION

The coils include removable flanges to allow proper fit up with furnaces
having various inlet and outlet flange configurations. The two flanges
are attached to the top of the coil in the factory during production. For
proper configuration of flanges refer to Figure 8.
ALTERNATE
FLANGE LOCATION
(Used for downflow or
horizontal left
installations)
Rotate vent
blower 90°
either way
FACTORY
LEFT SIDE VENT RIGHT SIDE VENT FLANGE
LOCATION
FIGURE 6: Downflow Venting (Used for upflow
or horizontal
right installations)
FIGURE 8: Coil Flange

681292-UIM-A-0211
FURNACE ASSEMBLY - MC SERIES COILS ONLY

MC coils are supplied ready to be installed in a horizontal position. A
horizontal pan is factory installed. MC coils should be installed in all hor- C
D (Min)
izontal applications with the horizontal drain pan side down.
Mounting Plate
Flexible
Duct Collar
Field
Furnace Fabricated
Ductwork Do not drill
or Screw
Upflow this flange
FIGURE 9: Horizontal Right Application (Typical) Coil
For horizontal left hand applications no conversion is required to an MC Upflow
coil when used with a downflow/horizontal furnace. A mounting plate, Furnace
supplied with every coil should always be installed on the side desig-
Primary Alternate
nated as top side. See Figures 9 & 10. Secondary Drain Location
Drain
Drain
Mounting Plate
FIGURE 11: PC Series Upflow Coil Installation
Table 2: Coil Projection Dimensions - PC Series Coils

Furnace COIL SIZE DIMENSION “C” INCH
PC18 3-1/2
PC24 4-1/2
PC30, PC32, PC35 4-1/2
FIGURE 10: Horizontal Left Application PC42, PC43, PC36, PC37 5-1/2
PC48 6-1/2
FURNACE ASSEMBLY - PC SERIES COILS PC60 9
These upflow coils are designed for installation on top of upflow fur- Dimension “C” should be at least 2/3 of dimension “D”. See Figure 11.
naces only.
If the coil is used with a furnace of a different size, use a 45° transition CRITICAL COIL PROJECTION
to allow proper air distribution through the coil. The coil assembly must be located in the duct such that a minimum dis-
1. Position the coil casing over the furnace opening as shown in Fig- tance is maintained between the top of the coil and the top of the duct.
ure 11. Refer to Table 2.
2. Place the ductwork over the coil casing flange and secure. COIL / FURNACE ASSEMBLY - HC SERIES COILS
3. Check for air leakage between the furnace and coil casing and
These coils are supplied ready to be installed in a right hand position or
seal appropriately.
a left hand position. When used in conjunction with a horizontal furnace
(blow through) application, the coil should be oriented with the opening
of the “A” coil closest to the furnace. See Figure 12.
NOTICE
Do not drill any holes or drive any screws into the front duct
flange on the coil in order to prevent damaging coil tubing. See
Figure 11.
Each coil is shipped with an external tie plate that should be used to
secure the coil to the furnace. It should be installed on the back side
of the coil using the dimpled pilot holes. See Figure 12.
Use tie plate

supplied with coil
Gas Furnace
Air flo
w
FIGURE 12: Horizontal Left or Right application (Right Shown)

681292-UIM-A-0211
LEFT SIDE FRONT RIGHT SIDE

Combustion Air Inlet Combustion Air Inlet
Condensate Drain Gas Pipe

(Downflow) Entry Gas Pipe Condensate Drain
Entry (Downflow)
2” Vent Electrical
Connection Entry Electrical
Entry 2” Vent
Outlet Connection
Condensate
Drain Outlet
33 Condensate 23”
Drain
Thermostat
Wiring Thermostat
Wiring Optional Return Air
Cutout (Either side) 14”
1”
28.5” A 1.5”
29.5”
(For Cladded door add appoximately an additional .75”)
.56”
23.8” 3” 2” Vent
Connection
Outlet
B Combustion B
Air Inlet C
.56” .56” 24.25”

20”
SUPPLY END RETURN END
FIGURE 13: Dimensions

Table 3: Cabinet and Duct Dimensions
BTUH (kW) Nominal Cabinet Cabinet Dimensions (Inches)
Input CFM (m3/min) Size A A (cm) B B (cm) C C (cm)
60 (17.6) 1200 (34.0) B 17 1/2 44.4 16 3/8 41.6 13 1/4 33.7
80 (23.4) 1200 (34.0) B 17 1/2 44.4 16 3/8 41.6 14 3/4 37.5
80 (23.4) 1600 (45.3) C 21 53.3 19 7/8 50.5 16 1/2 41.9
100 (29.3) 1600 (45.3) C 21 53.3 19 7/8 50.5 18 1/4 46.4
100 (29.3) 2000 (56.6) C 21 53.3 19 7/8 50.5 18 1/4 46.4
120 (35.1) 2000 (56.6) D 24 1/2 62.2 23 3/8 59.4 21 3/4 55.2
SECTION III: FILTERS SIDE RETURN

FILTER INSTALLATION Locate the “L” shaped corner locators. These indicate the size of the cut-
out to be made in the furnace side panel. Refer to Figure 14.
All applications require the use of a field installed filter. All filters and
mounting provision must be field supplied. Install the side filter rack following the instructions provided with that
accessory. If a filter(s) is provided at another location in the return air
Filters must be installed external to the furnace cabinet. DO NOT
system, the ductwork may be directly attached to the furnace side panel.
attempt to install filters inside the furnace.
NOTICE Front of
Furnace
Single side return above 1800 CFM is approved as long as the filter
velocity does not exceed filter manufacturer’s recommendation and Side of
a transition is used to allow use on a 20x25 filter.
Furnace
Table 4: Recommended Filter Sizes (High Velocity 600 FPM)
Corner
CFM Cabinet Side Bottom Markings
(m³/min) Size (in) (in)
1200 (34.0) B 16 x 25 16 x 25 FIGURE 14: Side Return Cutout Markings
1600 (45.3) C 16 x 25 20 x 25
2000 (56.6) C (2) 16 x 25 20 x 25
2000 (56.6) D (2) 16 x 25 22 x 25 Some accessories such as electronic air cleaners and pleated
1.Air velocity through throwaway type filters may not exceed 300 feet per minute media may require a larger side opening. Follow the instructions
(91.4 m/min). All velocities over this require the use of high velocity filters. supplied with that accessory for side opening requirements. Do not
2.Do not exceed 1800 CFM using a single side return and a 16x25 filter. For cut the opening larger than the dimensions shown in Figure 13.
CFM greater than 1800, you may use two side returns or one side and the bot-
tom or one side return with a transition to allow use of a 20x25 filter.

681292-UIM-A-0211
Horizontal Filters Main Inlet

Regulator On/Off
Pressure
Adjustment Switch
Tap
All filters and mounting provision must be field supplied. All installa-
tions must have a filter installed. Outlet
Pressure
Any branch duct (rectangular or round duct) attached to the plenum Tap
must attach to the vertical plenum before the filter. The use of straps
and/or supports is required to support the weight of the external filter
box.
Downflow Filters
Downflow furnaces typically are installed with the filters located above
FIGURE 15: Gas Valve
the furnace, extending into the return air plenum or duct. Any branch
duct (rectangular or round duct) attached to the plenum must attach to GAS PIPING INSTALLATION
the vertical plenum above the filter height. Properly sized wrought iron, approved flexible or steel pipe must be
Filter(s) may be located in the duct system external to the furnace using used when making gas connections to the unit. If local codes allow the
an external duct filter box attached to the furnace plenum or at the end use of a flexible gas appliance connection, always use a new listed con-
of the duct in a return filter grille(s). The use of straps and/or supports is nector. Do not use a connector that has previously serviced another gas
required to support the weight of the external filter box. appliance.
SECTION IV: GAS PIPING Some utility companies or local codes require pipe sizes larger than the
minimum sizes listed in these instructions and in the codes. The fur-
GAS SAFETY nace rating plate and the instructions in this section specify the type of
gas approved for this furnace - only use those approved gases. The
installation of a drip leg and ground union is required. Refer to Figure
16.
An overpressure protection device, such as a pressure regulator,
must be installed in the gas piping system upstream of the furnace
and must act to limit the downstream pressure to the gas valve so it
does not exceed 0.5 psig [14" w.c. (3.48 kPa)]. Pressures exceed-
ing 0.5 psig [14” w.c. (3.48 kPa)] at the gas valve will cause damage An accessible manual shutoff valve must be installed upstream of
to the gas valve, resulting in a fire or explosion or cause damage to the furnace gas controls and within 6 feet (1.8 m) of the furnace.
the furnace or some of its components that will result in property
damage and loss of life. The furnace must be isolated from the gas supply piping system by
closing its individual external manual shutoff valve during any pressure
testing of the gas supply piping system at pressures equal to or less
than 0.5 psig (3.5 kPa).
Plan your gas supply before determining the correct gas pipe entry.
Use 90° service elbow(s), or short nipples and conventional 90°
elbow(s) to enter through the cabinet access holes. The gas valve body is a very thin casting that cannot take any
external pressure. Never apply a pipe wrench to the body of the gas
valve when installing piping. A wrench must be placed on the octa-
gon hub located on the gas inlet side of the valve. Placing a wrench
to the body of the gas valve will damage the valve causing improper
operation and/or the valve to leak.
Gas piping may be connected from either side of the furnace using any
of the gas pipe entry knockouts on both sides of the furnace. Refer to
Figure 16.
To Gas NOTE: Ground Union maybe installed inside or outside unit.

To Gas Supply
External
Supply Ground To Gas
External Manual
Union Supply
Manual Shut-off
Ground To Gas
Shut-off Valve
Union Supply
Valve To Gas
Ground Supply
Union Gas Drip Leg
Valve
External Manual
Gas Shut-off Valve
Ground
Pipe
Union
Drip Gas
Drip Leg Ground Valve
Leg Union Gas
Gas To Gas
Valve
Drip Pipe Supply
Gas
Pipe Drip Leg Ground
Upflow Leg Downflow Horizontal Drip Union
FIGURE 16: Gas Piping

681292-UIM-A-0211
GAS CONVERSION FOR PROPANE (LP) 4. Read across that row to the column for the elevation at your loca-
tion. The number listed there is the orifice size that is proper for
This furnace is constructed at the factory for natural gas-fired operation,
your unit.
but may be converted to operate on propane (LP) gas by using a fac-
tory-supplied LP conversion kit. Follow the instructions supplied with Example – You have a 100,000 BTU/H furnace installed at an elevation
the LP kit. of 6,000 feet. You clock the gas meter and find that the furnace is actu-
ally fired at 64,000 BTU/H. Divide 64,000 by 100,000, which gives 0.64
HIGH ALTITUDE NATURAL GAS ORIFICE (64%). The closest number to 64% in the left-hand “Actual Rate” col-
CONVERSION umn is 65. Read across that row to the column for 6,000 feet elevation,
which shows “#43”. You should change from the factory #45 orifices to
The National Fuel Gas Code requires that gas appliances installed larger #43 orifices, which will bring the input rate back up to approxi-
above 2,000 feet elevation have their inputs de-rated by 4% per 1,000 mately 76,000 BTU/H, which is what it should be for that furnace at
feet above sea level. The modulating furnaces automatically de-rate for 6,000 feet.
altitude by measuring the inducer blower pressure and using that to
determine if there is adequate air to support good combustion. If there Table 5: High Altitude Orifices
is not enough combustion air to properly support 100% of the furnace Elevation in Feet Above Sea Level
nameplate input rate, the control will reduce the input to the point that Actual Rate
4,000 5,000 6,000 7,000 8,000 9,000 10,000
there will be good combustion. (percent of
84% 80% 76% 72% 68% 64% 60%
nameplate)
The factory gas orifice sizes are based on a gas heating value of Orifice Drill Size
1030 BTU/cu.ft., so if your gas value is significantly higher or lower 100 48 49 49 50 51 51 52
than that, it may be necessary to change to smaller or larger gas
95 47 48 49 50 50 50 51
orifices.
90 46 47 48 49 49 49 50
85 45 46 47 48 49 49 50
The chart below shows recommended gas orifice sizes to use at vari- 80 45 45 46 47 48 48 49
ous altitudes and at various de-ration levels. To use the chart, follow
75 44 45 45 45 47 47 49
these instructions:
70 43 44 44 45 45 45 48
1. Clock the gas meter and calculate the actual input rate using your
65 42 43 43 44 45 45 47
local gas heating value. See "CALCULATING THE FURNACE
INPUT (NAT. GAS)" in this manual. 60 41 42 42 43 44 45 46
2. Divide that input rate by the input rate shown on the furnace rating 55 40 41 41 32 43 43 44
plate to get the actual de-ration percent. 50 39 40 40 40 43 42 42
3. Read down the left-hand “Actual Rate” column to find the closest
number to your actual de-ration percent.
PROPANE KITS
It is very important to choose the correct kit and/or gas orifices for the altitude and the type of gas for which the furnace is being installed.
Only use natural gas in furnaces designed for natural gas. Only use propane (LP) gas for furnaces that have been properly converted to use pro-
pane (LP) gas. Do not use this furnace with butane gas.
Incorrect gas orifices or a furnace that has been improperly converted will create an extremely dangerous condition resulting in premature heat
exchanger failure, excessive sooting, high levels of carbon monoxide, personal injury, property damage, a fire hazard and/or death.
High altitude and propane (LP) conversions are required in order for the appliance to satisfactory meet the application.
An authorized distributor or dealer must make all gas conversions.
In Canada, a certified conversion station or other qualified agency, using factory specified and/or approved parts, must perform the conversion.
The installer must take every precaution to insure that the furnace has been converted to the proper gas orifice size when the furnace is installed.
Do not attempt to drill out any orifices to obtain the proper orifice size. Drilling out a gas orifice will cause misalignment of the burner flames,
causing premature heat exchanger burnout, high levels of carbon monoxide, excessive sooting, a fire hazard, personal injury, property damage
and/or death.
SECTION V: ELECTRICAL POWER

ELECTRICAL POWER CONNECTIONS
Field wiring to the unit must be grounded. Electric wires that are field Use copper conductors only.
installed shall conform to the temperature limitation for 63°F (35°C) rise
wire when installed in accordance with instructions. Refer to Table 6 in
these instructions for specific furnace electrical data.

681292-UIM-A-0211
Table 6: Ratings & Physical / Electrical Data

Input Output Nominal Air Temp. Rise Air Temp. Rise
BTUH/ Max/Min Max/Min Airflow Max Input Min Input
Cabinet/CFM
MBH kW MBH kW CFM m3/min °F °C °F °C
60B12 60/21 17.6/6.2 58/20 17.0/5.9 1200 34.0 40-70 22-39 20-50 11-28
80B12 80/28 23.4/8.2 77/27 22.6/7.9 1200 34.0 40-70 22-39 20-50 11-28
80C16 80/28 23.4/8.2 78/27 22.8/7.9 1600 45.3 40-70 22-39 20-50 11-28
100C16 100/35 29.3/10.2 97/34 28.4/10.0 1600 45.3 40-70 22-39 20-50 11-28
100C20 100/35 29.3/10.2 97/34 28.4/10.0 2000 56.6 45-75 25-42 25-55 13-31
120D20 120/42 35.1/12.3 116/40 34.0/11.7 2000 56.6 45-75 25-42 25-55 13-31
Max. Outlet Blower Max Min. wire Size Approximate
BTUH Blower AFUE Total Unit
Air Temp Wheel Over-Current (awg) @ 75 ft Operating Wgt.
Cabinet/CFM Amps
°F °C HP Amps Size % Protect one way Lbs (kg)
60B12 170 76.7 1/2 4.8 11 x 8 97.5 15 7.0 14 113 (51)
80B12 175 79.4 1/2 4.8 11 x 8 97.5 15 7.5 14 119 (54)
80C16 175 79.4 3/4 7.5 11 x 10 97.7 15 10.0 14 134 (61)
100C16 175 79.4 3/4 7.5 11 x 10 97.7 15 10.0 14 140 (64)
100C20 180 82.2 1 14.5 11 x 11 97.7 20 12.0 12 143 (65)
120D20 180 82.2 1 14.5 11 x 11 98.0 20 12.0 12 152 (69)
Annual Fuel Utilization Efficiency (AFUE) numbers are determined in accordance with DOE Test procedures.
Wire size and over current protection must comply with the National Electrical Code (NFPA-70-latest edition) and all local codes.
The furnace shall be installed so that the electrical components are protected from water.
SUPPLY VOLTAGE CONNECTIONS 2. 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. In the junc-
tion box there will be 3 wires, a Black Wire, a White Wire. Connect
the power supply as shown on the unit-wiring label on the inside of
Junction
the blower compartment door or the wiring schematic in this sec-
Box
tion. The black furnace lead must be connected to the L1 (hot)
Connect ground wire from the power supply. The white furnace screw must be con-
lead to screw nected to neutral. Connect the power supply ground to the green
Electrical Entry screw (equipment ground) An alternate wiring method is to use a
field provided 2” (5.1 cm) x 4” (10.2 cm) box and cover on the out-
L1-Hot BLK
Neutral WHT side of the furnace. Route the furnace leads into the box using a
protective bushing where the wires pass through the furnace
panel. After making the wiring connections replace the wiring box
cover and screws. Refer to Figure 17.
3. The furnace's control system requires correct polarity of the power
FIGURE 17: Electrical Wiring
supply and a proper ground connection. Refer to Figure 17.
1. Provide a power supply separate from all other circuits. Install
overcurrent protection and disconnect switch per local/national
electrical codes. The switch should be close to the unit for conve-
nience in servicing. With the disconnect or fused switch in the OFF The power connection leads and wiring box may be relocated to the
position, check all wiring against the unit wiring label. Refer to the left side of the furnace. Remove the screws and cut wire tie holding
wiring diagram in this instruction. excess wiring. Reposition on the left side of the furnace and fasten
using holes provided.

681292-UIM-A-0211
CONTROL WIRING In order to use this furnace in full communications (COMM) mode, it
MUST be installed with the matching touch-screen Communicating
This furnace can be connected to the wall thermostat and outdoor A/C
or heat pump using either conventional low voltage (24 VAC) thermo- Control (wall thermostat) and an outdoor air conditioner or heat pump
with a fully communicating control.
stat wiring OR using four-wire digital communications wiring. To use
conventional low voltage wiring, see the section below entitled “Con- This furnace may also be used along with the Communicating Thermo-
ventional Low Voltage Control Wiring”. To use four-wire communica- stat Control and a non-communicating outdoor air conditioner through
tions control wiring, see the section below entitled “Control Wiring using the addition of a communicating Outdoor Aux Control board to the out-
Communicating Controls”. door unit. This system allows full communication between the furnace
The Communicating System consists of several intelligent communicat- and thermostat and limited communication to the outdoor unit. See Fig-
ing components including the Communicating Thermostat Control ure 19.
(touch-screen wall thermostat), modulating variable speed furnace, air This furnace may also be used along with the Communicating Thermo-
conditioner (15 and 18 SEER premium air conditioners) or heat pump stat Control and a non-communicating outdoor air conditioner or heat
(13, 15 and 18 SEER premium heat pumps), which continually commu- pump using COMM between the furnace and thermostat and conven-
nicate with each other via a four-wire connection called the A-R-C-B. tional 24V wiring to the outdoor unit. This system allows full communi-
Commands, operating conditions, and other data are passed continu- cation between the furnace and thermostat but no digital
ally between components over the A-R-C-B. See Figure 18. The result communication with the outdoor unit.
is a new level of comfort, versatility, and simplicity.
CFM Light
Diagnostic Light
FIGURE 18: Furnace Control Board – Communications Connections

681292-UIM-A-0211
CONTROL WIRING USING COMMUNICATING When connecting the Communicating Control (wall thermostat) and fur-
CONTROLS nace control to a non-communicating outdoor A/C or heat pump, use
the wiring diagram in Figure 20. The thermostat and furnace will be con-
Use the wiring diagram below to connect the furnace control, Communi-
nected exactly as shown above, but the conventional 24 volt R, C and
cating Control (wall thermostat) and communicating outdoor unit. Be
Y/Y2 terminals will be used to control the outdoor unit.
sure that all of the “A” terminals are connected together, all of the “B”
terminals are connected together, all of the “GND” or “C” terminals are CONVENTIONAL LOW VOLTAGE CONTROL WIRING
connected together and all of the “R” terminals are connected together. CONNECTIONS
See Figure 19. When using a fully communicating system, the large
Install the field-supplied thermostat by following the instructions that
screw terminals (C, G, R, etc.) on the furnace control are not used. The
come with the thermostat. With the thermostat set in the OFF position
four small screw terminals in the terminal block on the end of the fur-
nace control should be used. and the main electrical source disconnected, connect the thermostat
wiring from the wiring connections on the thermostat to the terminal
Touch Screen Modulating Furnace Air Conditioner/Heat Pump
board on the ignition module, as shown in Figures 21-26. Electronic
Communicating control Communicating control Communicating control thermostats may require the common wire to be connected. Apply
strain relief to thermostat wires passing through cabinet. If air condition-
A+ A+ A+
ing equipment is installed, use thermostat wiring to connect the Y and C
R R R terminals on the furnace control board to the proper wires on the con-
densing unit (unit outside).
C GND or C GND
B- B- B-
LO Set the heat anticipator in the room thermostat to 0.1 amps. Setting
COMP
it lower will cause short cycles. Setting it higher will cause the room
HI
COMP temperature to exceed the set points.
O
DHUM
Y1 Some electronic thermostats do not have adjustable heat anticipa-

tors. They should be set to six cycles per hour. Follow the thermo-
Y/Y2 stat manufacturer's instructions.
W
The 24-volt, 40 VA transformer is sized for the furnace components
R only, and should not be connected to power auxiliary devices such as
humidifiers, air cleaners, etc. The transformer may provide power for an
G air conditioning unit contactor.
C
AIR CONDITIONER CONNECTIONS
This furnace may be used with single-stage or two-stage air condition-
FIGURE 19: Modulating Furnace with Communicating AC or HP ing units.
For Single-Stage A/C - Connect the low voltage wiring as shown in
Touch Screen Modulating Furnace Non-Communicating
Communicating control Communicating control Air Conditioner Figure 21.
For Two-Stage A/C - Use a two-stage thermostat, connect the low volt-
A+ A+
age wiring as shown in Figure 22.
R R For Two-Stage A/C using a Single-Stage Thermostat - connect the
C GND or C
low voltage wiring as shown in Figure 23.
This furnace control board can control a two-stage A/C using only a sin-
B- B-
gle-stage thermostat. In this case, the furnace control switches between
LO high cool and low cool based on the calculated cooling load.
Y
COMP
HI
Y2
COMP
O R
DHUM C
Y1
Y/Y2
FIGURE 20: Modulating Furnace with Communicating Thermostat and

Non-Communicating AC

681292-UIM-A-0211
For additional connection diagrams for all UPG equipment refer to “Low Voltage System Wiring” document available online at www.upgnet.com in the
Product Catalog Section.
ID MODELS
TP9C
YP9C
CP9C
THERMOSTAT LP9C
SINGLE STAGE
MODULATING SINGLE STAGE
*PP11C70224 AIR
FURNACE AIR CONDITIONER
CONDITIONER
MODULATING 1
FURNACE CONTROL
C C
24 – Volt Common 24 – Volt Common
Y1
Y Y
Y
Single
Full Stage Compressor Compressor
Compressor Contactor
Stage Compressor
RH
R
24 – Volt Hot
24 – Volt Hot
(Heat XFMR)
G G
Fan Fan
W
Modulating Heat
RC Y/Y2
24 – Volt Hot Second or Full
(Cool XFMR) Stage Compressor
O
Reversing Valve
Energized in Cool
LO COMP
Single Stage
Compressor (OUT)
HI COMP
Second Stage
Compressor (OUT)
W
Full Stage Heat
DHUM
HM1
Dehumidification-
Humidistat
Open on Humidity Rise
2 External Humidistat
(Optional)
Clipping Jumper W914 for Move HUMIDISTAT

electric heat on thermostat jumper to “YES”
is not necessary if humidistat is to be used.
2 Part Number: Part Numbers: 1

S1-2HU16700124 SAP = Legacy
FIGURE 21: Thermostat Chart - Single Stage Air Conditioner – Variable Speed Modulating Furnace

681292-UIM-A-0211
ID MODELS
TP9C
YP9C
CP9C
THERMOSTAT THERMOSTAT LP9C
MODULATING TWO STAGE

*DN22U00124 *PP32U70124 AIR
FURNACE
CONDITIONER
MODULATING 1
FURNACE CONTROL
C C C C
24 – Volt Common 24 – Volt Common 24 – Volt Common 24 – Volt Common
Y1
Y1 Y1 Y1
Single
First Stage Compressor First Stage Compressor First Stage Compressor
Stage Compressor
R R
R R
24 – Volt Hot 24 – Volt Hot
(Heat XFMR) (Heat XFMR)
G G G
Fan Fan Fan
E/W1 E/W1 W
First Stage Heat Emergency Heat Modulating Heat
W2 AUX
Second Stage Heat Auxiliary Heat
R R Y/Y2
24 – Volt Hot 24 – Volt Hot Second or Full
(Cool XFMR) (Cool XFMR) Stage Compressor
O
Reversing Valve
Energized in Cool
LO COMP
Single Stage
Compressor (OUT)
Y2 Y2 HI COMP Y2
Second Stage Second Stage Second Stage Second Stage
Compressor Compressor Compressor (OUT) Compressor
DHUM
2 External Humidistat Dehumidification-
(Optional) Open on Humidity Rise
Connection of the "C" Connection of the "C" Move HUMIDISTAT

terminal, 24-volt common terminal, 24-volt common jumper to “YES”
is optional when used with is optional when used with if humidistat is to be used.
batteries batteries
Thermostat Installer Setup Thermostat Installer Setup
1-System Type-must 0170-System Type-must
be set to 8-1 Heat/2 Cool be set to 10-1 Heat/2 Cool
Conventional Multistage Conventional
Thermostat Installer Setup
15-Compressor Protection
must be set to 5
Part Numbers: 1
2 Part Number: SAP = Legacy
S1-2HU16700124
FIGURE 22: Thermostat Chart - Two Stage Air Conditioner – Variable Speed Modulating Furnace

681292-UIM-A-0211
ID MODELS
TP9C
YP9C
CP9C
THERMOSTAT LP9C
MODULATING TWO STAGE

*PP11C70224 AIR
FURNACE
CONDITIONER
MODULATING 1
FURNACE CONTROL
C C
24 – Volt Common 24 – Volt Common
Y1
Y Y1
Single
Full Stage Compressor First Stage Compressor
Stage Compressor
RH
R R
24 – Volt Hot
(Heat XFMR)
G G
Fan Fan
W
Modulating Heat
RC Y/Y2
24 – Volt Hot Second or Full
(Cool XFMR) Stage Compressor
O
Reversing Valve
Energized in Cool
LO COMP
Single Stage
Compressor (OUT)
HI COMP Y2
Second Stage Second Stage
Compressor (OUT) Compressor
W
Full Stage Heat
DHUM
HM1
Dehumidification-
Humidistat
(Optional)
Clipping Jumper W914 for Move HUMIDISTAT

electric heat on thermostat jumper to “YES”
is not necessary if humidistat is to be used.
2 Part Number: Part Numbers: 1

FIGURE 23: Thermostat Chart - Two Stage Air Conditioner with Single Stage Thermostat – Variable Speed Modulating Furnace

681292-UIM-A-0211
ID MODELS OD MODELS
TP9C E*R* *RHS
YP9C E*ZD HP*
CP9C E*B* *HGD
THERMOSTAT THERMOSTAT THERMOSTAT LP9C
*BP21H50124
*BN21H00124 MODULATING SINGLE STAGE
*DN22U00124 *DP32H70124
*DP21H40124 FURNACE HEAT PUMP
*DN21H00124
MODULATING 2 DEMAND DEFROST 1

FURNACE CONTROL CONTROL
C C C
24 – Volt Common 24 – Volt Common 24 – Volt Common
Y1
Y1 Y
Single
First Stage Compressor Compressor
Stage Compressor
R R R
24 – Volt Hot 24 – Volt Hot 24 – Volt Hot
G G
Fan Fan
E W W1/66(out)
Emergency Heat Modulating Heat Heat
W2
N/A N/A Third Stage Heat
Y/Y2
Second or Full
Stage Compressor
O O O
Reversing Valve Reversing Valve Reversing Valve
Energized in Cool Energized in Cool Energized in Cool
LO COMP
L X/L
Single Stage
Malfunction Light Malfunction Light
Compressor (OUT)
HI COMP
Y2
Second Stage
Second Stage Compressor
Compressor (OUT)
W1 W
Second Stage Aux. Heat Auxiliary Heat
DHUM
Dehumidification-
(Optional)
Step 1 of Thermostat Move HUMIDISTAT

Installer / Configuration jumper to “YES”
Menu must be set to if humidistat is to be used.
Heat Pump 1
Step 9 of Thermostat
Installer / Configuration
Menu must be set to
Pump OFF
3 Part Number: Part Numbers: 2 Part Numbers: 1

S1-2HU16700124 SAP = Legacy SAP = Legacy
67297 = 031-01975
FIGURE 24: Thermostat Chart - Single Stage Heat Pump – Variable Speed Modulating Furnace

681292-UIM-A-0211
ID MODELS OD MODELS
TP9C YZB
YP9C YMB
CP9C H*3
THERMOSTAT THERMOSTAT THERMOSTAT LP9C
*BP21H50124
*BN21H00124 MODULATING SINGLE STAGE
*DN22U00124 *DP32H70124
*DP21H40124 FURNACE HEAT PUMP
*DN21H00124
MODULATING 2 YORKGUARD VI 1
C C C C C
24 – Volt Common 24 – Volt Common 24 – Volt Common 24 – Volt Common 24 – Volt Common
Y1 Y1
Y1 Y1 Y1
Single Single
First Stage Compressor First Stage Compressor First Stage Compressor
Stage Compressor Stage Compressor
R
R R R R
24 – Volt Hot
24 – Volt Hot 24 – Volt Hot 24 – Volt Hot 24 – Volt Hot
(Heat XFMR)
G G G G
Fan Fan Fan Fan
E E E W W1 OUT
Emergency Heat Emergency Heat Emergency Heat Modulating Heat First Stage Heat
W2 W2 OUT
Third Stage Heat Second Stage Heat
R Y/Y2 Y2 OUT
24 – Volt Hot Second or Full Second
(Cool XFMR) Stage Compressor Stage Compressor
O O O O
O/B
Reversing Valve Reversing Valve Reversing Valve Reversing Valve
Reversing Valve
Energized in Cool Energized in Cool Energized in Cool Energized in Cool
LO COMP
L L L X/L
Single Stage
Malfunction Light Malfunction Light Malfunction Light Malfunction Light
Compressor (OUT)
Y2 Y2 Y2 HI COMP Y2
Second Second Second Second Stage Second
Stage Compressor Stage Compressor Stage Compressor Compressor (OUT) Stage Compressor
AUX W2 W1 W
Auxiliary Heat Second Stage Heat Second Stage Aux. Heat Auxiliary Heat
DHUM
BSG
Dehumidification-
Bonnet Sensor
Open on Humidity Rise Bonnet Sensor
3 External Humidistat (Optional)
(Optional) BS
Thermostat Installer Setup Step 1 of Thermostat Move HUMIDISTAT Change FFuel jumper
B/O Switch on Thermostat Installer / Configuration
1-System Type-must be set jumper to “YES” on the heat pump control
must be in the O position Menu must be set to
to 5 – 2 Heat/1 Heat Pump if humidistat is to be used. to “ON”
Thermostat Installer Setup Heat Pump 1 Change Hot Heat Pump
2-Changeover Valve-must jumper on the heat
be set to 0 – O/B terminal pump control to “ON” if
Energized in Cooling Hot Heat Pump
Operation is desired.
3 Part Numbers:
Part Number: Part Numbers: 2 1
SAP = Legacy
126768 = 031-09137
18395 = 031-01996
340512 = 031-09178
FIGURE 25: Thermostat Chart - Single Stage Heat Pump – Variable Speed Modulating Furnace

681292-UIM-A-0211
ID MODELS OD MODELS
TP9C YZE
YP9C YZH
CP9C H*5
THERMOSTAT THERMOSTAT LP9C H*8
*DN22H00124 MODULATING TWO STAGE

*PP32U70124
*DP22U70124 FURNACE HEAT PUMP
MODULATING 2 YORKGUARD VI 1
C C C C
24 – Volt Common 24 – Volt Common 24 – Volt Common 24 – Volt Common
Y1 Y1
Y Y1
Single Single
First Stage Compressor First Stage Compressor
Stage Compressor Stage Compressor
R
R R R
24 – Volt Hot
24 – Volt Hot 24 – Volt Hot 24 – Volt Hot
(Heat XFMR)
G G G
Fan Fan Fan
E W W1 OUT
Emergency Heat Modulating Heat First Stage Heat
W2 W2 OUT
Second Stage Aux. Heat Second Stage Heat
RC Y/Y2 Y2 OUT
24 – Volt Hot Second or Full Second
(Cool XFMR) Stage Compressor Stage Compressor
O O O
O/B
Reversing Valve Reversing Valve Reversing Valve
Reversing Valve
Energized in Cool Energized in Cool Energized in Cool
LO COMP
L L X/L
Single Stage
Malfunction Light Malfunction Light Malfunction Light
Compressor (OUT)
Y2 Y2 HI COMP Y2
Second Second Second Stage Second
Stage Compressor Stage Compressor Compressor (OUT) Stage Compressor
AUX E/W1 W
Auxiliary Heat First Stage Aux. Heat Auxiliary Heat
DHUM
BSG
Dehumidification-
Bonnet Sensor
External Humidistat
3 (Optional)
(Optional) BS
Thermostat Installer Setup Step 1 of Thermostat Move HUMIDISTAT Change FFuel jumper
0170-System Type- Installer/Configuration jumper to “YES” on the heat pump control
must be set to 12 Menu must be set to “HP2” if humidistat is to be used. to “ON”
3 Heat/2 Heat Pump Selection of GAS/ELEC Change Hot Heat Pump
Thermostat Installer Setup switch on thermostat jumper on the heat
0190-Changeover Valve- not necessary pump control to “ON” if
must be set to 0 Hot Heat Pump
O/B terminal Operation is desired.
Energized in Cooling
Thermostat Installer Setup
0200-Backup Heat Source-
must be set to 1
Heat Pump Backup Heat Part Numbers:
Part Numbers: 2 1
Source is Fossil Fuel SAP = Legacy
SAP = Legacy
Thermostat Installer Setup 126768 = 031-09137
0210-External Fossil Fuel 18395 = 031-01996
Kit- must be set to 1 340512 = 031-09178
Heat Pump Control
is Controlling Heat Pump
Backup Heat
FIGURE 26: Thermostat Chart - Two Stage Heat Pump – Variable Speed Modulating Furnace

681292-UIM-A-0211
ACCESSORY CONNECTIONS TWINNING

The furnace control will allow power-switching control of various acces- These furnaces are not to be twinned. If more than one furnace is
sories. needed in an application, each furnace must have its own complete
duct system and its own wall thermostat.
ELECTRONIC AIR CLEANER CONNECTION
Two 1/4” (6.4 mm) spade terminals (EAC and NEUTRAL) for electronic SECTION VI: CONDENSATE PIPING AND
air cleaner connections are located on the control board. The terminals FURNACE VENTING CONFIGURATION
provide 115 VAC (1.0 amp maximum) during circulating blower opera-
tion. CONDENSATE DRAIN LOCATION
As shipped from the factory:
HUMIDIFIER CONNECTION
• For all 060 & 080K input furnaces the main drain is plumbed
Two 1/4” (6.4 mm) spade terminals (HUM and NEUTRAL) for humidifier
through the casing right-side opening when viewed from the front
connections are located on the control board. The terminals provide 115
of the furnace.
VAC (1.0 amp maximum) during heating system operation.
• For all 100, 120K input furnaces the main drain is plumbed
A mounting hole is provided on the control panel next to the furnace through the casing left-side opening when viewed from the front
control board for mounting a humidifier transformer if read. of the furnace.
HUMIDISTAT CONNECTION The Figures 29-32 show the condensate drain arrangement for the var-
ious possible furnace and vent blower positions.
For better humidity control during cooling operation, an external humidi-
stat may be used. When using a external humidistat, put the HUMIDI- The condensate hoses must slope downwards at all points.
STAT jumper in the YES position. Connect the low voltage wiring as The condensate water will flow to the drain better if an open tee, or
shown in Figures 21-26. short length of pipe is installed in the drain line.
ZONING OPERATION
This furnace may be used in zoning systems, using a separate after-
market zoning control. For use in zoned systems, put the ZONE CON-
The furnace condensate pan is self priming and contains
TROL jumper on the furnace control board in the “YES” position. an internal trap to prevent flue gas leaking. Do not install an
If the Zone jumper is put in the “Yes” position, the heating load logic external condensate trap.
switches to a special algorithm for multi-zone homes.
When drain hose routing changes are required (shown in Figures 29-
1. This algorithm operates at the “low demand” firing rate for 10 min- 32), be sure to cap all un-used openings.
utes and then ramps to high fire within 20 minutes (30 minutes
maximum to get to 100% firing rate). If rerouting hoses - excess length should be cut off so that no sagging
loops will collect and hold condensate - which will cause the furnace to
2. The special zoning algorithm does not have the Run 2 function, so
not operate.
the burners will stop firing as soon as there is no call for heating.
No hose clamps are needed for connecting the condensate pan.
HEAT PUMP OPERATION
This furnace may be used in conjunction with a heat pump in dual fuel
applications. For heat pump applications, put the HEAT PUMP jumper
on the furnace control board in the “YES” position. Connect the low volt- The furnace, evaporator coil, and humidifier drains may be com-
age wiring as shown in Figures 24-26, Thermostat Charts. If a two- bined and drained together. The evaporator coil drain may have an
stage heat pump is to be used, a two-stage thermostat is required. external, field-supplied trap prior to the furnace drain connection to
prevent conditioned air leakage. All drain connections (furnace,
If the Heat Pump jumper is in the “YES” position, it indicates that there evaporator coil, or humidifier) must be terminated into an open or
is a heat pump present and the furnace is used as a secondary heat vented drain as close to the respective equipment as possible.
source. In addition, the “YES” Heat Pump jumper allows the system to Regular maintenance is required on condensate drainage system.
read the presence of the “O” terminal signal. In heat pump operation,
the following special algorithm logic applies:
1. Supplemental Heating - When both a “W” signal and a “Y1” signal
are present, the modulating firing rate will operate as normal, Condensate must be disposed of properly. Follow local plumbing
except there will be no Run 2 function, so the burners will stop fir- or wastewater codes. The drain line must maintain a 1/4" per foot
ing as soon as the “W” signal is removed. (21 mm/m) downward slope to the drain.
2. Defrost Cycle - When both a “W” signal and a “Y2” signal are pres-
ent, the modulating firing rate will operate at a constant 80% firing
rate and there will be no Run 2 function, so the burners will stop fir-
ing as soon as the “W” signal is removed.
If an external vent tee is being installed, then it must have its own
3. Hot Heat Pump - The “hot” heat pump feature will work when the condensate trap before it is disposed into an open or vented drain.
control is wired to a 2-stage thermostat and a 2-stage heat pump. This is not to be considered as a second trap as referenced
4. Hot Heat Pump - The “hot” heat pump feature will not work when elsewhere in this document.
the control is wired to a single-stage thermostat and a 2-stage heat
pump.

681292-UIM-A-0211
Exhaust Pipe
Combustion Air Pipe
Tee with Drain Trap
Trap
Open Stand Pipe

(Anti-siphon air vent) Connect to Drain
5” Min.
Tee
To Open Or
Vented Drain
FIGURE 28: Typical Combustion Pipe Drain Tee
FIGURE 27: Typical Condensate drain, vertical installation CONDENSATE DRAIN TERMINATION
A condensate sump pump MUST be used if required by local codes, or
The condensate will flow to the drain better if an open stand pipe is if no indoor floor drain is available. The condensate sump pump must
installed in the drain line. See Figure 27. be approved for use with acidic condensate.
If evaporator coil or humidifier drains are combined with the furnace
drain, then the open stand pipe could be raised higher, above the 5”
minimum.
DO NOT terminate the condensate drain in a chimney, or where the
NOTICE drain line may freeze. If the drain line will be exposed to tempera-
tures below freezing, adequate measures must be taken to prevent
the drain line from freezing. Failure to provide proper protection
A loop has been added to the pressure switch vacuum hose. How-
from freezing can result in improper operation or damage to the
ever, ensure that all pressure switch hoses are routed such that
equipment and possible property damage. When exposed to tem-
they prevent any condensate from entering the pressure switch.
peratures below freezing, use of a 3 to 6 watt per foot at 115 VAC,
40°F (4.4°C) self-regulating, shielded and waterproof heat tape is
recommended on the drain line outside the furnace.
DO NOT trap the drain line at any other location than at the conden-
sate drain trap supplied with the furnace.
It is possible for condensation to form inside the combustion air
(intake) pipe in the summer months if significant length of combus-
tion air pipe passes through conditioned space. This problem can
be averted by the addition of a simple drain tee, or a drain tee with a
drain on the combustion air pipe as close to the furnace as possi- Liquid anti-freeze will cause damage to internal plastic parts of this
ble, as shown in Figure 28. This is true for all long horizontal vent- furnace. DO NOT attempt to winterize the furnace using liquid
ing in any furnace configuration. This will prevent the condensate anti-freeze.
from entering the furnace.

When drain hose routing changes are required, be sure to cap all un-used openings.
If rerouting hoses - excess length should be cut off so that no sagging loops will collect
and hold condensate, which will cause the furnace to not operate.
FIGURE 29: Upflow Configuration
Johnson Controls Unitary Products

For 060 & 080K input furnaces, the condensate
For 100, 120K input furnaces, the condensate

drain is plumbed toward the left casing outlet from the factory.
Shorten pressure 1 Shorten rain
switch hose 2 gutter hose
drain is plumbed toward the right casing outlet from the factory.
Move rain gutter 1 Condensate drain may exit Re-route and shorten 2
hose to this position cabinet on either side. pressure switch hose
INDUCER ROTATED FOR UPFLOW INDUCER ROTATED FOR

LEFT SIDE VENTING AS RECEIVED RIGHT SIDE VENTING
681292-UIM-A-0211
23
24
681292-UIM-A-0211
AIRFLOW
AIRFLOW
FIGURE 30: Downflow Configuration

1 Move rain
gutter hose
to this position
2 Move pressure switch

hose to this position.
NOTE: May require
the longer hose that
is provided with
wider cabinets
3 Move rain gutter

hose to this position
4 Move condensate drain

(May exit either side
of the cabinet)
DOWNFLOW - INDUCER ROTATED DOWNFLOW - INDUCER ROTATED
FOR LEFT SIDE VENTING FOR RIGHT SIDE VENTING

1 Move rain gutter hose to this
position NOTE: May require hose
extension that is provided with
wider cabinets
HORIZONTAL - LEFT

INDUCER ROTATED
FIGURE 31: Horizontal Left Configuration

AIRFLOW
2 Move pressure switch hose

to this position.
NOTE: May require the longer
hose that is provided with
wider cabinets
1 Move rain gutter
4 Change condensate
drain connection to
3
Move the 90° fitting provided
condensate
drain hose to this position
2
Move pressure switch
AIRFLOW hose to this position.
NOTE: May requirethe longer
hose thatis provided with
wider cabinets
HORIZONTAL - LEFT
INDUCER AS RECEIVED
3
Move rain gutter hose to this position 4 5 Change condensate drain
NOTE: May require hose extension Move condensate connection to the 90° fitting provided
that is provided with wider cabinets drain hose to this position
681292-UIM-A-0211
25
26
681292-UIM-A-0211
1 Move pressure HORIZONTAL - RIGHT

switch hose to INDUCER ROTATED
this position.
FIGURE 32: Horizontal Right Configuration

AIRFLOW
4
Move rain gutter
2 Change condensate
drain connection to Move pressure
1
the 90° fitting switch hose to
provided 3 Move condensate this position.
drain hose to
this position
AIRFLOW
HORIZONTAL - RIGHT
INDUCER AS RECEIVED
2 Change condensate drain

connection to the 90° 4
3 Move condensate Move rain gutter
fitting provided drain hose to this position hose to this position

681292-UIM-A-0211
SECTION VII: COMBUSTION AIR AND 2. The maximum equivalent length listed in Table 7 is for the vent pip-
VENT SYSTEM ing and the air intake piping separately. For example, if the table
allows 65 equivalent feet for a particular model, then the vent can
COMBUSTION AIR AND VENT SAFETY have 65 equivalent feet of pipe, AND the combustion air intake can
This Category IV, dual certified direct vent furnace is designed for resi- have another 65 equivalent feet of pipe.
dential application. It may be installed without modification to the con- 3. Three vent terminal elbows (two for the vent and one for the com-
densate system in a basement, garage, equipment room, alcove, attic bustion air intake) are already accounted for and need not be
or any other indoor location where all required clearance to combusti- included in the equivalent length calculation.
bles and other restrictions are met. The combustion air and the venting 4. All combustion air and vent pipe must conform to American
system must be installed in accordance with Section 5.3, Air for Com- National Standards Institute (ANSI) and American Society for Test-
bustion and Ventilation, of the National Fuel Gas Code Z223.1/NFPA 54 ing and Materials (ASTM) standards D1785 (Schedule 40 PVC),
(latest edition), or Sections 7.2, 7.3 or 7.4 of CSA B149.1, National Gas D2665 (PVC-DWV), F891 (PVC-DWV Cellular Core), D2261
and Propane Codes (latest edition) or applicable provisions of the local (ABS-DWV) or F628 (Schedule 40 ABS). Pipe cement and primer
building code and these instructions. must conform to ASTM Standard D2546 (PVC) or D2235 (ABS). If
ABS pipe is to be used, any joint where ABS pipe is joined to PVC
pipe must be glued with cement that is approved for use with
BOTH materials. Metallic materials must not be used for venting or
air intake.
The “VENT SYSTEM” must be installed as specified in these
instructions for Residential and non-HUD Modular Homes. The 5. If a flexible connector is used in the vent system, it must be made
direct vent system is the only configuration that can be installed in a of a material that is resistant to acidic exposure and to at least
non-HUD Modular Home. 225°F temperature. Flexible connectors are also allowed in the
combustion air pipe.
6. All models are supplied with 2" (5.1 cm) vent connections. When
the pipe must be increased to 3" (7.6 cm) diameter, the transition
from 2" to 3" must be done as close to the furnace as possible. For
This furnace may not be common vented with any other appliance, upflow models, the transition from 2" to 3" should be done immedi-
since it requires separate, properly sized air intake and vent lines. ately above the furnace. For downflow or horizontal models, the
The furnace shall not be connected to any type of B, BW or L vent transition from 2" to 3" pipe should be done immediately after exit-
or vent connector, and not connected to any portion of a factory-
ing the furnace.
built or masonry chimney.
The furnace shall not be connected to a chimney flue serving a sep- 7. In Canada, vents shall be certified to ULC S636, Standard for Type
arate appliance designed to burn solid fuel. BH Gas Venting Systems.
8. In Canada, the first three feet (914 mm) of the vent must be readily
accessible for inspection.
9. For single pipe systems it is recommended to install the combus-
tion air coupling provided and install approximately 18” of PVC
When combustion air pipe is installed above a suspended ceiling or pipe on the furnace.
when it passes through a warm and humid space, the pipe must be 10. Minimum vent length is five feet for all models.
insulated with 1/2” Armaflex or other heat resistant type insulation if
two feet or more of pipe is exposed.
TABLE 7: Maximum Equivalent Pipe Length
Vent piping must be insulated if it will be subjected to freezing tem-
peratures such as routing through unheated areas or through an Maximum
unused chimney. Model Input Pipe Size
Equivalent
BTUH (kW) Inches (cm)
length feet (m)
COMBUSTION AIR/VENT PIPE SIZING
60,000 2 (5.1) 65 (19.8)
The size of pipe required will be determined by the furnace model, the
total length of pipe required and the number of elbows required. 60,000 3 (7.6) 90 (27.4)
60,000 4 (10.2) 150 (45.7)
Table 7 lists the maximum equivalent length of pipe allowed for each
model of furnace. The equivalent length of elbows is shown in Table 9. 80,000 2 (5.1) 65 (19.8)
The equivalent length of the vent system is the total length of straight 80,000 3 (7.6) 90 (27.4)
pipe PLUS the equivalent length of all of the elbows. 80,000 4 (10.2) 150 (45.7)
The following rules must also be followed: 100,000 2 (5.1) 30 (9.1)
100,000 3 (7.6) 90 (27.4)
1. Long radius (sweep) elbows are recommended. Standard elbows
100,000 4 (10.2) 150 (45.7)
may be used, but since they have a longer equivalent length, they
will reduce the total length of pipe that will be allowed. Short radius 120,000 3 (7.6) 90 (27.4)
(plumbing vent) elbows are not allowed. The standard dimensions 120,000 4 (10.2) 150 (45.7)
of the acceptable elbows are shown below.

681292-UIM-A-0211
TABLE 10: Combustion Air Intake and Vent Connection Size at Furnace
A (All Models)
A
FURNACE VENT CONNECTION SIZES
Furnace Input All
Intake Pipe Size 2” (5.1 cm)
Vent Pipe Size 2” (5.1 cm)
A
A
Furnace vent pipe connections are sized for 2” (51 mm). pipe. Any
STANDARD ELBOW LONG (SWEEP) ELBOW pipe size change must be made outside the furnace casing in a ver-
tical pipe section to allow proper drainage of condensate. An offset
FIGURE 33: Dimensions using two 45º (degree) elbows will be required for plenum clear-
ance when the vent is increased to 3” (76 mm).
TABLE 8: Elbow Dimensions
Elbow "A" Dimension
2" Standard 2-5/16"
3" Standard 3-1/16"
Accessory concentric vent / intake termination kits 1CT0302 and
2" Sweep 3-1/4"
1CT0303, and for Canadian applications ICT0302-636 and
3" Sweep 4-1/16" ICT0303-636 are available and approved for use with these fur-
Dimensions are those required in Standard ASTM D-3311. naces. Horizontal sidewall vent terminations kits 1HT0901 &
1HT0902 are also approved for use with these furnaces.
TABLE 9: Equivalent Length of Fittings
COMBUSTION AIR AND VENT PIPING ASSEMBLY
Fitting Equivalent Length
The final assembly procedure for the combustion air and vent piping is
2" 90° sweep elbow 5 feet of 2" pipe
as follows:
2" 45° sweep elbow 2-1/2 feet of 2" pipe
1. Cut piping to the proper length beginning at the furnace.
2" 90° standard elbow 7 feet of 2" pipe
2" 45° standard elbow 3-1/2 feet of 2" pipe 2. Deburr the piping inside and outside.
3" 90° sweep elbow 5 feet of 3" pipe 3. Chamfer (bevel) the outer edges of the piping.
3" 45° sweep elbow 2-1/2 feet of 3" pipe 4. Dry-fit the vent piping assembly from the furnace to the outside ter-
mination checking for proper fit support and slope.
3" 90° standard elbow 7 feet of 3" pipe
3" 45° standard elbow 3-1/2 feet of 3" pipe 5. Dry-fit the combustion air piping assembly checking for proper fit,
support and slope on the following systems:
4" 90° elbow (sweep or standard) 5 feet of 4" pipe
a. Sealed combustion air systems from the furnace to the out-
4" 45° elbow (sweep or standard) 2-1/2 feet of 4" pipe
side termination.
2" corrugated connector 10 feet of 2" pipe
b. Ventilated combustion air systems from the furnace to the
attic or crawl space termination.
Example:
An 80,000 BTUH furnace requires 32 feet of pipe and five 90º elbows.
Using 2" pipe and standard elbows, the total equivalent length will be: Solvent cements are flammable and must be used in well-ventilated
areas only. Keep them away from heat, sparks and open flames.
32 feet of 2" pipe = 32 equivalent feet Do not breathe vapors and avoid contact with skin and eyes.
5 - 90º standard 2" elbows = (5 x 7) = 35 equivalent feet
6. Disassemble the combustion air and vent piping, apply cement
Total = 67 equivalent feet of 2" pipe
primer and the cement per the manufactures instructions. Primer
This exceeds the 65 foot maximum equivalent length of 2" pipe allowed and cement must conform to ASTM D2564 for PVC, or ASTM
for that model and is thus not acceptable. D2235 for ABS piping.
By using sweep elbows, the total equivalent length will be: 7. All joints must provide a permanent airtight and watertight seal.
8. Support the combustion air and vent piping such that it is angled a
32 feet of 2" pipe = 32 equivalent feet minimum of 1/4” per foot (21 mm/m) so that condensate will flow
5 - 90º sweep 2" elbows = (5 x 5) = 25 equivalent feet back towards the furnace. Piping should be supported with pipe
Total = 57 equivalent feet of 2" pipe hangers to prevent sagging.
9. Seal around the openings where the combustion air and / or vent
This is less than the 65 foot maximum equivalent length of 2" pipe
piping pass through the roof or sidewalls.
allowed for that model and is thus acceptable.
Alternatively, using 3" pipe and standard elbows, the total equivalent COMBUSTION AIR / VENTING
length will be:
32 feet of 3" pipe = 32 equivalent feet

5 - 90º standard 3" elbows = (5 x 7) = 35 equivalent feet The vent must be installed with the required clearances, and must
Total = 67 equivalent feet of 3" pipe comply with local codes and requirements.
This is less than the 90 foot maximum equivalent length of 3" pipe
allowed for that model and is thus acceptable.

681292-UIM-A-0211
VENT CLEARANCES
G
V
A
V VENT TERMINAL
D FIXED H
X AIR SUPPLY
E CLOSED B
V B
B I
B X AREA WHERE TERMINAL IS NOT PERMITTED
L V C V M V
V K
X
V V
J FIXED
F V B
CLOSED
B
OPERABLE
FIGURE 34: Home Layout
Direct Vent Terminal Clearances Canadian Installations1,3 US Installation2,3

A. Clearance above grade, veranda, porch, deck, or
12” (30.5 cm) 12” (30.5 cm)
balcony
12” (30.5 cm) for models 100,000 BTUH (30 kW), Two-pipe (direct vent) applications: 12” (30.5 cm)††
B. Clearance to window or door that may be opened
36” (91.4 cm) for models >100,000 BTUH (30 kW). Single-pipe applications: 4 feet (1.2 m).
C. Clearance to permanently closed window 12” (30.5 cm) 12” (30.5 cm)
D. Vertical clearance to ventilated soffit located
12” (30.5 cm) or in accordance with local installation 12” (30.5 cm) or in accordance with local installation
above the terminal within a horizontal distance
codes and the requirements of the gas supplier. codes and the requirements of the gas supplier.
of 2 feet (61 cm) from the center line of the terminal
E. Clearance to unventilated soffit
F. Clearance to outside corner
G. Clearance to inside corner 3 feet (91.4 cm) 3 feet (91.4 cm)
Above a meter/regulator assembly within 3 feet Above a meter/regulator assembly within 3 feet
H. Clearance to each side of center line (91.4 cm) horizontally of the vertical center-line of the (91 cm) horizontally of the vertical center-line of the
extended above meter/regulator assembly regulator vent outlet to a maximum vertical distance of regulator vent outlet to a maximum vertical distance of
15 feet (4.5 m) above the meter/regulator assembly. 15 feet (4.5 m) above the meter/regulator assembly.
3 feet (91.4 cm) or in accordance with local installation
I. Clearance to service regulator vent outlet 3 feet (91.4 cm)
codes and the requirements of the gas supplier.
J. Clearance to non-mechanical air supply inlet to
12” (30.5 cm) for models 100,000 BTUH (30 kW), Two-pipe (direct vent) applications: 12” (30.5 cm)
building or the combustion air inlet to any other
36” (91 cm) for models >100,000 BTUH (30 kW). Single-pipe applications: 4 feet (1.2 m).
appliance
3 feet (91.4 cm) above if within 10 feet (3 m)
K. Clearance to a mechanical supply inlet 6 feet (1.83 m)
horizontally.
L. Clearance above paved sidewalk or paved 7 feet (2.13 m) or in accordance with local installation
7 feet (2.13 m)†
driveway located on public property codes and the requirements of the gas supplier.
12” (30.5 cm) or in accordance with local installation
M. Clearance under veranda, porch, deck, or balcony 12” (30.5 cm)‡
codes and the requirements of the gas supplier.
1. In accordance with the current CSA B149.1-00, Natural Gas and Propane Installation Code.
2. In accordance with the current ANSI Z223.1 / NFPA 54, National Gas Code.
3. In accordance with the current ANSI Z21.47 * CSA 2.3 American National Standard.
† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings.
†† 12” (30.5 cm) up from the bottom edge of the structure for Two-pipe (direct vent) applications per ANSI Z223.1 / NFPA 54, National Gas Code.
‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor and the distance between the top of the vent termina-
tion and the underside of the veranda, porch, or deck is greater than 12” (30.5 cm) as specified in CSA B149.1-00.
A vent shall not terminate less than 12” (30.5 cm) above a grade level.
Any fresh air or make up inlet for dryer or furnace area is considered to be forced air inlet.
Avoid areas where condensate drippage may cause problems such as above planters, patios, or adjacent to windows where steam may cause fogging.
A terminus of a vent shall be fitted with a cap in accordance with the vent manufacturer’s installation instructions, or in accordance with the installation instructions for a
special venting system.
Responsibility for the provision of proper adequate venting and air supply for application shall rest with the installer.
Vent shall extend high enough above building, or a neighboring obstruction, so that wind from any direction will not create a positive pressure in the vicinity of the vent.
Consideration must be given for degradation of building materials by flue gases. Sidewall termination may require sealing or shielding of building
surfaces with a corrosion resistant material to protect against combustion product corrosion. Consideration must be given to wind direction in
order to prevent flue products and/or condensate from being blown against the building surfaces. If a metal shield is used it must be a stainless
steel material at a minimum dimension of 20 inches (51 cm). It is recommended that a retaining type collar be used that is attached to the build-
ing surface to prevent movement of the vent pipe.

681292-UIM-A-0211
VENT SYSTEM
This furnace is certified to be installed with one of two possible vent
12” MIN.
configurations.
1. Horizontal vent system. This vent system can be installed com- 12” Minimum
pletely horizontal or combinations of horizontal, vertical, or offset below overhang
12” MIN.
using elbows. G
AN
12” Minimum
2. Vertical vent system. This vent system can be installed completely R
H separation between
vertical or a combination of horizontal, vertical, or offset using VE bottom of
O
elbows. combustion air
intake and
VENT APPLICATIONS AND TERMINATION bottom of vent
When selecting the location for a horizontal combustion air / vent termi- Maintain 12”
nation, the following should be considered: minimumclearance
above highest
1. Observe all clearances listed in vent clearances in these instruc- anticipated snow
tions. level or grade,
whichever is higher
2. Termination should be positioned where vent vapors will not dam-
age plants or shrubs or air conditioning equipment. FIGURE 37: Termination Configuration - 2 Pipe Basement
3. Termination should be located where it will not be affected by wind
gusts, light snow, airborne leaves or allow recirculation of flue VENTING MULTIPLE UNITS
gases. Multiple units can be installed in a space or structure as either a single
4. Termination should be located where it will not be damaged or pipe configuration or a two-pipe configuration.
exposed to flying stones, balls, etc.
The combustion air side of the single pipe configuration shown in Figure
5. Termination should be positioned where vent vapors are not objec-
35 is referred to in these instructions as ambient combustion air supply.
tionable.
Follow the instructions for ambient combustion air installations, paying
6. Horizontal portions of the vent system must slope upwards and be particular attention to the section on air source from inside the building.
supported to prevent sagging. The vent for a single pipe system must be installed as specified in the
7. Direct vent systems must be installed so the vent and the combus- venting section of these instructions with the vent terminating as shown
tion air pipes terminate in the same atmospheric zone. Refer to in Figure 35. Each furnace must have a separate vent pipe. Under NO
Figures 36 or 37. circumstances can the two vent pipes be tied together.
Maintain 12” minimum clearance The combustion air side of the two-pipe configuration shown in Figure
above highest anticipated snow level. 36 can be installed so the combustion air pipe terminates as described
Maximum 24” above roof. in outdoor combustion air or ventilated combustion air sections in these
instructions. Follow the instructions for outdoor combustion air or venti-
lated combustion air and the instructions for installing the vent system
12” Min. with the vent terminating as shown in Figures 38 or 39. The two-pipe
12” Min.
system must have a separate combustion air pipe and a separate vent
pipe for each furnace. Under NO circumstances can the two combus-
tion air or vent pipes be tied together. The combustion air and vent
pipes must terminate in the same atmospheric zone.
VENT
FIGURE 35: Termination Configuration - 1 Pipe
12” vertical separation

Maintain 12” minimum between combustion air
12” minimum COMBUSTION AIR
clearance above intake and vent.
below overhang
highest anticipated 2”
snow level. 12” minimum MIN.
separation between
bottom of FIGURE 38: Double Horizontal Combustion Air Intake and Vent
combustion air pipe Termination
and bottom of vent.
Maintain 12”
minimum clearance
above highest MIN.
anticipated snow 6”
level or grade,
whichever is higher.
FIGURE 36: Termination Configuration - 2 Pipe

FIGURE 39: Double Vertical Combustion Air Intake and Vent
Termination

681292-UIM-A-0211
DOWNWARD VENTING
In some applications, it may be necessary to run the vent pipe and air
intake downwards. If this is to be done, the following rules must be fol-
NOTICE
An optional plastic birdscreen is shipped in the loose parts bag with
lowed. every furnace. This may be installed in the intake collar to prevent
• A condensate trap hose must be connected to both the air intake any small objects from entering the furnace.
pipe and the vent pipe at the lowest part of the horizontal run.
• The condensate drain trap must have a trap of a minimum of six
Connects to Vent pipe cements
inches. collar on top into socket just
• The total vertical downward distance must not exceed sixteen of burner box above top panel
feet.
• The condensate drain hose must be connected to a condensate
drain pump, a open or vented drain or into the condensate drain
Or vent pipe may be
line from the furnace. clamped into outlet
• The condensate drain lines must not pass through unconditioned of drain coupling
spaces where the temperature may fall below freezing.
• The condensate drain line must be primed at the initial start-up
prior to the start of heating season.
FIGURE 41: Direct Vent Air Intake Connection and Vent Connection
16’ MAX
The combustion air intake pipe should be located either through the
wall (horizontal or side vent) or through the roof (vertical vent). Care
should be taken to locate side vented systems where trees or shrubs
will not block or restrict supply air from entering the terminal.
Also, the terminal assembly should be located as far as possible from a
swimming pool or a location where swimming pool chemicals might be
6” MIN. stored. Be sure the terminal assembly follows the outdoor clearances
listed in Section #1 “Outdoor Air Contaminants.”
Ambient Combustion Air Supply
6” MIN.
This type installation will draw the air required for combustion from
FIGURE 40: Downward Venting within the space surrounding the appliance and from areas or rooms
adjacent to the space surrounding the appliance. This may be from
COMBUSTION AIR SUPPLY within the space in a non-confined location or it may be brought into the
All installations must comply with Section 5.3, Air for Combustion and furnace area from outdoors through permanent openings or ducts. It is
Ventilation of the National Fuel Gas Code, ANSI Z223.1 or Sections not piped directly into the furnace. A single, properly sized pipe from the
7.2, 7.3 or 7.4 of CAN/CGA B149.1 or .2 Installation Code - latest edi- furnace vent connector to the outdoors must be provided. It is recom-
tions. mended that the supplied intake coupling and 18” of pipe be attached to
This furnace is certified to be installed with one of three possible com- the furnace to prevent accidental blockage or combustion air intake.
bustion air intake configurations.
1. OUTDOOR COMBUSTION AIR: This is a direct vent configuration COMBUSTION AIR Vent pipe cements
where the combustion air is supplied through a PVC or ABS pipe into socket just
that is connected to the PVC coupling attached to the furnace and above top panel
is terminated in the same atmospheric zone as the vent. This type
of installation is approved on all models. Refer to Figure 40.
2. AMBIENT COMBUSTION AIR: Combustion air is supplied from Or vent pipe may be
the area surrounding the furnace through openings in the furnace clamped into outlet
casing. The combustion air and the vent pipes are not terminated of drain coupling
in the same atmospheric zone. Refer to Figure 33 for vent termina-
tions. Refer to "Ambient Combustion Air Supply" for proper instal-
lation. Refer to Figure 41.
3. VENTILATED COMBUSTION AIR: Combustion air is supplied
through a PVC or ABS pipe that is connected to the PVC coupling
attached to the burner box and is terminated in a ventilated attic or
crawl space. The combustion air and the vent pipes are not termi- FIGURE 42: Combustion Airflow Path Through The Furnace Casing
nated in the same atmospheric zone. Refer to Figure 43 for attic
and crawl space termination. Only the combustion air intake may
terminate in the attic. The vent must terminate outside.
Outdoor Combustion Air This type of installation requires that the supply air to the appli-
ance(s) be of a sufficient amount to support all of the appliance(s)
Combustion Air Intake/Vent Connections in the area. Operation of a mechanical exhaust, such as an exhaust
This installation requires combustion air to be brought in from outdoors. fan, kitchen ventilation system, clothes dryer or fireplace may cre-
This requires a properly sized pipe (Shown in Figure 40) that will bring ate conditions requiring special attention to avoid unsatisfactory
air in from the outdoors to the furnace combustion air intake collar on operation of gas appliances. A venting problem or a lack of supply
air will result in a hazardous condition, which can cause the appli-
the burner box. The second pipe (Shown in Figure 40) is the furnace
ance to soot and generate dangerous levels of CARBON MONOX-
vent pipe. IDE, which can lead to serious injury, property damage and / or
death.

681292-UIM-A-0211
An unconfined space is not less than 50 ft3 (1.42 m3) per 1,000 BTU/
hr (0.2928 kW) input rating for all of the appliances installed in that
area.
When a Category I furnace is removed or replaced, the original
Rooms communicating directly with the space containing the appli- venting system may no longer be correctly sized to properly vent
ances are considered part of the unconfined space, if doors are fur- the attached appliances.
nished with openings or louvers. An improperly sized vent system can cause CARBON MONOXIDE
A confined space is an area with less than 50 ft3 (1.42 m3) per 1,000 to spill into the living space causing personal injury, and or death.
BTU/hr (0.2928 kW) input rating for all of the appliances installed in that
area. The following must be considered to obtain proper air for combus- Table 12: Unconfined Space Minimum Area
tion and ventilation in confined spaces. Minimum Free Area
BTUH Input Rating
Combustion Air Source From Outdoors Required for Each Opening
The blocking effects of louvers, grilles and screens must be given con- 60,000 60 in2 (387 cm2)
sideration in calculating free area. If the free area of a specific louver or 80,000 80 in2 (516 cm2)
grille is not known, refer to Table 11, to estimate free area. 100,000 100 in2 (645 cm2)
Table 11: Estimated Free Area 120,000 120 in2 (742 cm2)
Wood or Metal Wood 20-25%*
Louvers or Grilles Metal 60-70% * Table 13: Free Area
1/4” (6.4 mm) Minimum Free Area Required for Each Opening
Screens+
mesh or larger 100% BTUH Input Vertical Duct or
Horizontal Duct Round Duct
* Do not use less than 1/4” (6.4 mm) mesh. Rating Opening to Outside
(2,000 BTUH) (4,000 BTUH)
+ Free area of louvers and grille varies widely; the installer should follow (4,000 BTUH)
louver or grille manufacturer’s instructions.
60,000 30 in2 (193 cm2) 15 in2 (97 cm2) 5” (13 cm)
Dampers, Louvers and Grilles (Canada Only) 2
80,000 40 in (258 cm2) 20 in2 (129 cm2) 5” (13 cm)
1. The free area of a supply air opening shall be calculated by sub-
tracting the blockage area of all fixed louvers grilles or screens
100,000 50 in2 (322 cm2) 25 in2 (161 cm2) 6” (15 cm)
from the gross area of the opening. 120,000 2 2 7” (18 cm) 2 2
60 in (387 cm ) 30 in (193 cm )
2. Apertures in a fixed louver, a grille, or screen shall have no dimen- EXAMPLE: Determining Free Area.
sion smaller than 1/4” (6.4 mm). Appliance 1 Appliance 2 Total Input
3. A manually operated damper or manually adjustable louvers are 100,000 + 30,000 = (130,000  4,000) = 32.5 Sq. In. Vertical
not permitted for use. Appliance 1 Appliance 2 Total Input
4. A automatically operated damper or automatically adjustable lou- 100,000 + 30,000 = (130,000  2,000) = 65 Sq. In. Horizontal
vers shall be interlocked so that the main burner cannot operate
unless either the damper or the louver is in the fully open position.
Gas Gas Gas

Gable Vent Gable Vent Vent
Vent Vent
Ventilated Ventilated
Attic Attic
Optional Top Above
Inlet (a) Insulation Top Above
Insulation
Soffit Outlet
Vent Air (a) Soffit Outlet Outlet
Vent Air (b) Air (a)
Furnace
Gas
Water
Furnace
Furnace
Gas Gas
Heater Water Water
Inlet Heater Inlet Inlet Heater
Ventilated Inlet
Air (b) Air (a) Air (b)
Crawl Space Air (a)
FIGURE 43: Outside and Ambient Combustion Air
Air Supply Openings and Ducts 5. A square or rectangular shaped duct shall only be used when the
1. An opening may be used in lieu of a duct to provide to provide the required free area of the supply opening is 9 in2 (58.06 cm2) or
outside air supply to an appliance unless otherwise permitted by larger. When a square or rectangular duct is used, its small dimen-
the authority having jurisdiction. The opening shall be located sion shall not be less than 3” (7.6 cm).
within 12” (30.5 cm) horizontally from, the burner level of the appli- 6. An air inlet supply from outdoors shall be equipped with a means
ance. Refer to “AIR SOURCE FROM OUTDOORS AND VENT to prevent the direct entry of rain and wind. Such means shall not
AND SUPPLY AIR SAFETY CHECK” in these instructions for reduce the required free area of the air supply opening.
additional information and safety check procedure. 7. An air supply inlet opening from the outdoors shall be located not
2. The duct shall be either metal, or a material meeting the class 1 less than 12” (30.5 cm) above the outside grade level.
requirements of CAN4-S110 Standard for Air Ducts.
Combustion Air Source from Outdoors
3. The duct shall be least the same cross-sectional area as the free
area of the air supply inlet opening to which it connects. 1. Two permanent openings, one within 12” (30.5 cm) of the top and
one within 12” (30.5 cm) of bottom of the confined space, Two per-
4. The duct shall terminate within 12” (30.5 cm) above, and within 24”
manent openings, shall communicate directly or by means of ducts
(61 cm) horizontally from, the burner level of the appliance having
with the outdoors, crawl spaces or attic spaces.
the largest input.

681292-UIM-A-0211
2. One permanent openings, commencing within 12” (30.5 cm) of the Ventilated Combustion Air
top of the enclosure shall be permitted where the equipment has
The ventilated attic space or a crawl space from which the combustion
clearances of at least 1” (2.54 cm) from the sides and back and 6”
air is taken must comply with the requirements specified in “AIR
(15.2 cm) from the front of the appliance. The opening shall com-
SOURCE FROM OUTDOORS” in this instruction or in Section 5.3, Air
municate directly with the outdoors and shall have a minimum free
area of: for Combustion and Ventilation of the National Fuel Gas Code, ANSI
Z223.1 (latest edition). This type installation requires two properly sized
a. 1 square in. per 3000 BTU per hour (6.45 cm3 per 0.879 kW) pipes. One brings combustion air from a properly ventilated attic space
of the total input rating of all equipment located in the enclo- or crawl space and a second pipe that extends from the furnace vent
sure. connection (top right of unit) to the exterior of the building. Refer to
b. Not less than the sum of all vent connectors in the confined Table 7 for intake pipe sizing, allowable length and elbow usage. Follow
space. all notes, procedures and required materials in the "COMBUSTION
3. The duct shall be least the same cross-sectional area as the free AIR/VENT PIPE SIZING" section in these instructions when installing
area of the air supply inlet opening to which it connects. the combustion air pipe from the unit and into a ventilated attic space or
4. The blocking effects of louvers, grilles and screens must be given crawl space. DO NOT terminate vent pipe in an Attic or Crawl Space.
consideration in calculating free area. If the free area of a specific Ventilated Combustion Air Termination
louver or grille is not known. Refer to Table 11.
Refer to Figure 43 for required attic termination for the combustion air
intake pipe. For attic termination, use two 90° elbows with the open end
in a downward position. Be sure to maintain 12” (30.5 cm) clearance
above any insulation, flooring or other material.
A crawl space combustion air installation consists of a straight pipe from
the PVC coupling on the burner box that extends into the crawl space
and terminates with a 1/4” (6.4 mm) mesh screen and no elbows.
CARBON MONOXIDE POISONING HAZARD

Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon-
monxide poisoning or death.
The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances
connected to the venting system are not in operation:
1. Inspect the venting system for proper size and horizontal pitch. Determine that there is no blockage, restriction, leakage, corrosion or other
deficiencies, which could cause an unsafe condition
2. Close all building doors and windows and all doors.
3. Turn on clothes dryers and TURN ON any exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum
speed. Open the fireplace dampers. Do not operate a summer exhaust fan.
4. Follow the lighting instructions. Place the appliance being inspected in operation. Adjust thermostat so the appliance shall operate contin-
uously.
5. Test each appliance (such as a water heater) equipped with a draft hood for spillage (down-draft or no draft) at the draft hood relief opening
after 5 minutes of main burner operation. Appliances that do not have draft hoods need to be checked at the vent pipe as close to the
appliance as possible. Use a combustion analyzer to check the CO2 and CO levels of each appliance. Use a draft gauge to check for a
downdraft or inadequate draft condition.
6. After it has been determined that each appliance properly vents when tested as outlined above, return doors, windows, exhaust fans, fire-
place dampers and any other gas burning appliance to their normal condition.
7. If improper venting is observed during any of the above tests, a problem exists with either the venting system or the appliance does not
have enough combustion air (Supply Air from outside) to complete combustion. This condition must be corrected before the appliance can
function safely.
NOTE: An unsafe condition exists when the CO reading exceeds 40 ppm and the draft reading is not in excess of - 0.1” w.c. (-25 kPa) with all
of the appliance(s) operating at the same time.
8. Any corrections to the venting system and / or to the supply (outside) air system must be in accordance with the National Fuel Gas Code
Z223.1 or CAN/CGA B149.1 Natural Gas and Propane Installation Code (latest editions). If the vent system must be resized, follow the
appropriate tables in Appendix G of the above codes or for this appliance.
Specially Engineered Installations
12” minimum The above requirements shall be permitted to be waived where special
between bottom engineering, approved by the authority having jurisdiction, provides an
of air intake and adequate supply of air for combustion and ventilation.
any material below.
12” Min.
Be sure to instruct the owner not to block this intake pipe.
VENT BLOWER ROTATION

For ease of venting, the vent blower may be rotated 90° in either direc-
tion. For upflow installations the vent may exit through the top or either
side of the cabinet. For downflow installations, the vent blower must be
rotated so that the vent exits through either side of the cabinet. See Fig-
ures 29-32 for details.
FIGURE 44: Attic and Crawl Space Combustion Air Termination
681292-UIM-A-0211
SECTION VIII: START-UP AND TEST MODE available that allows the furnace input rate to stay at a
ADJUSTMENTS constant input rate. To access this TEST MODE perform the following
sequence:
The initial start-up of the furnace requires the following additional
procedures: 1. With power to the board on and with no thermostat calls (no call for
heating, cooling or continuous fan), push and hold the TEST but-
ton on the board for one second. The LED on the board will glow
red.
2. Release the TEST button. The LED on the board will flash a rapid
All electrical connections made in the field and in the factory should green signal, indicating that TEST MODE is activated.
be checked for proper tightness.
3. Turn the thermostat to call for heat (R & W signal).
When the gas supply is initially connected to the furnace, the gas piping 4. The furnace will light and operate at high (100%) firing rate. The
may be full of air. In order to purge this air, it is recommended that the furnace firing rate should be checked at this level to confirm that
ground union be loosened until the odor of gas is detected. When gas is the furnace is not overfired or underfired.
detected, immediately retighten the union and check for leaks. Allow 5. To run the furnace at minimum rate (35%), press the ERROR but-
five minutes for any gas to dissipate before continuing with the start-up ton once. The LED will flash one green flash to confirm.
procedure. Be sure proper ventilation is available to dilute and carry 6. To run the furnace at a middle rate (70%), press the ERROR but-
away any vented gas. ton twice within a five-second period. The LED will flash green two
times to confirm.
GAS PIPING LEAK CHECK 7. To again operate the furnace at maximum (100%) rate, press the
ERROR button three times within a five-second period. The LED
will flash green three times to confirm.
8. If the thermostat call for heat is removed, the LED will flash a rapid
green signal, indicating that the furnace is still in TEST MODE.
FIRE OR EXPLOSION HAZARD
9. When startup tests are completed, turning off power to the board
Failure to follow the safety warnings exactly could result in serious
will take the furnace out of TEST MODE and will restore normal
injury, death or property damage.
operation. The furnace will automatically return to normal opera-
Never test for gas leaks with an open flame. Use a commercially tion after 150 minutes if power is not cycled.
available soap solution made specifically for the detection of leaks
to check all connections. A fire or explosion may result causing CALCULATING THE FURNACE INPUT (NAT. GAS)
property damage, personal injury or loss of life.
Burner orifices are sized to provide proper input rate using natural gas
with a heating value of 1030 BTU/Ft3 (38.4 MJ/m3). If the heating value
of your gas is significantly different, it may be necessary to replace the
orifices.
Burner ignition may not be satisfactory on first startup due to resid-
ual air in the gas line or until gas manifold pressure is adjusted. The
ignition control will make three attempts to light before locking out.
NOTICE
It is recommended that when the gas supply is first connected to the DO NOT set manifold pressure less than 3.2” w.c. or more than 3.8”
furnace, the ground union be loosened until the odor of gas is detected. w.c. for natural gas at sea level. If manifold pressure is outside this
When gas is detected, immediately tighten the union and check for gas range, change main burner orifices.
leaks. Allow five minutes for any gas to dissipate before continuing with
NOTICE
the startup procedure. Be sure that proper ventilation is available to
dilute and carry away any vented gas.
With furnace in operation, check all of the pipe joints, gas valve connec- If orifice hole appears damaged or it is suspected to have been
tions and manual valve connections for leakage using an approved gas redrilled, check orifice hole with a numbered drill bit of correct size.
detector, a non-corrosive leak detection fluid or other leak detection Never redrill an orifice. A burr-free and squarely aligned orifice hole
methods. Take appropriate action to stop any leak. If a leak persists, is essential for proper flame characteristics.
replace the faulty component.
The furnace and its equipment shutoff valve must be disconnected from
the gas supply during any pressure testing of that system at test pres-
sures in excess of 0.5 psig (3.45 kPa).
DO NOT bottom out gas valve regulator adjusting screw. This can
The furnace must be isolated from the gas supply piping system by result in unregulated manifold pressure and result in excess over-
closing the equipment shutoff valve during any pressure testing of the fire and heat exchanger failures.
gas supply system.
Verify natural gas input rate by clocking meter.
1. Turn off all other gas appliances and pilots.
2. Run furnace for a minimum of 3 minutes in heating operation.
HOT SURFACE IGNITION SYSTEM
3. Measure time (in sec) for gas meter to complete 1 revolution and
Do not attempt to light this furnace by hand (with a match or note reading. The 2 cubic feet dial provides a more accurate mea-
any other means). There may be a potential shock hazard from surement of gas flow.
the components of the hot surface ignition system. The fur-
4. Refer to Table 14 for cubic feet of gas per hour.
nace can only be lit automatically by its hot surface ignition
system. 5. Multiply cubic feet per hour by heating valve (BTU/ft3) to obtain
input.
SETUP TEST MODE
If clocked rate does not match the input rate from the unit nameplate.
During normal operation, the furnace input rate can vary between 35% follow steps in next section to adjust the manifold pressure. Repeat
and 100% of full nameplate input, making it difficult to check for proper steps 2 - 5 until correct input is achieved.
operation. To help with the furnace startup process, the control has a

681292-UIM-A-0211
HIGH ALTITUDE NATURAL GAS ORIFICE

CONVERSION
The National Fuel Gas Code requires that gas appliances installed
Be sure to relight any gas appliances that were turned off at the above 2,000 feet elevation have their inputs de-rated by 4% per 1,000
start of this input check. feet above sea level. The modulating furnaces automatically de-rate for
altitude by measuring the inducer blower pressure and using that to
determine if there is adequate air to support good combustion. If there
is not enough combustion air to properly support 100% of the furnace
nameplate input rate, the control will reduce the input to the point that
there will be good combustion.
Table 14: Gas Rate (CU FT/HR) at Full Input
Seconds For Size of Test Dial Seconds For Size of Test Dial
1 Revolution 1 Cu Ft 2 Cu Ft 5 Cu Ft 1 Revolution 1 Cu Ft 2 Cu Ft 5 Cu Ft
10 360 720 1800 50 72 144 360
11 327 655 1636 51 71 141 355
12 300 600 1500 52 69 138 346
13 277 555 1385 53 68 136 340
14 257 514 1286 54 67 133 333
15 240 480 1200 55 65 131 327
16 225 450 1125 56 64 129 321
17 212 424 1059 57 63 126 316
18 200 400 1000 58 62 124 310
19 189 379 947 59 61 122 305
20 180 360 900 60 60 120 300
21 171 343 857 62 58 116 290
22 164 327 818 64 56 112 281
23 157 313 783 66 54 109 273
24 150 300 750 68 53 106 265
25 144 288 720 70 51 103 257
26 138 277 692 72 50 100 250
27 133 267 667 74 48 97 243
28 129 257 643 76 47 95 237
29 124 248 621 78 46 92 231
30 120 240 600 80 45 90 225
31 116 232 581 82 44 88 220
32 113 225 563 84 43 86 214
33 109 218 545 86 42 84 209
34 106 212 529 88 41 82 205
35 103 206 514 90 40 80 200
36 100 200 500 92 39 78 196
37 97 195 486 94 38 76 192
38 95 189 474 96 38 75 188
39 92 185 462 98 37 74 184
40 90 180 450 100 36 72 180
41 88 176 439 102 35 71 178
42 86 172 429 104 35 69 173
43 84 167 419 106 34 68 170
44 82 164 409 108 33 67 167
45 80 160 400 110 33 65 164
46 78 157 391 112 32 64 161
47 76 153 383 116 31 62 155
48 75 150 375 120 30 60 150
49 73 147 367

681292-UIM-A-0211
ADJUSTMENT OF MANIFOLD GAS PRESSURE Main Inlet

Inlet and manifold gas pressure may be measured by connecting the Regulator On/Off
Pressure
Adjustment Switch
“U” tube manometer to the gas valve with a piece of tubing. Follow the Tap
appropriate section in the instructions below. Refer to Figure 44 for a
drawing of the locations of the pressure ports on the gas valve.
Outlet
Table 15: Inlet Gas Pressure Range Pressure
Tap
INLET GAS PRESSURE RANGE
Natural Gas Propane (LP)
Minimum* 4.5” w.c. (1.12 kPa) 8.0” w.c. (1.99 kPa)
Maximum 10.5” w.c. (2.61 kPa) 13.0” w.c. (3.24 kPa)
FIGURE 45: Gas Valve
The inlet gas pressure operating range table specifies what the
minimum and maximum gas line pressures must be for the furnace
to operate safely. The gas line pressure MUST BE a minimum of:
• 7” w.c. (1.74 kPA) for Natural Gas If gas valve regulator is turned clockwise, manifold pressure is
increased. If screw is turned counterclockwise, manifold pressure
• 11” w.c. (2.74 kPA) for Propane (LP) Gas
will decrease.
in order to obtain the BTU input specified on the rating plate and/or
The adjustment screw has a range of 16 clicks (about ±0.5” mani-
the nominal manifold pressure specified in these instructions and
fold pressure). There is not a hard stop at the ends of the adjust-
on the rating plate.
ment range. When the limit of the adjustment range is reached, the
next click will start over at the other end of the range. For instance,
if you are increasing pressure and reach the upper limit of adjust-
ment the next click will drop the pressure to the lower limit.
The cap for the pressure regulator must be removed to gain access
8. After the manifold pressure has been adjusted, re-calculate the
to the adjustment screw.
furnace input to make sure you have not exceeded the specified
input on the rating plate. Refer to "CALCULATING THE FURNACE
NOTICE
INPUT (NAT. GAS)".
9. Once the correct BTU (kW) input has been established, turn the
The regulated outlet pressure has been calibrated at the factory. gas valve to OFF and turn the electrical supply switch to OFF; then
Additional pressure adjustment should not be necessary. If adjust- remove the flexible tubing and fittings from the gas valve pressure
ment is necessary, set to the following specifications. After adjust- tap replace the pressure tap plugs.
ment, check for gas leakage. 10. Turn the electrical and gas supplies back on, and with the burners
in operation, check for gas leakage around the gas valve pressure
TABLE 16: Nominal Manifold Pressure port for leakage using an approved gas detector, a non-corrosive
NOMINAL MANIFOLD PRESSURE leak detection fluid, or other leak detection methods.
Natural Gas (Max) 3.5" w.c. (0.87 kPa) ADJUSTMENT OF TEMPERATURE RISE
Natural Gas (Min) 0.5" w.c. (0.15 kPa)
Propane (LP) Gas (Max) 10.0" w.c. (2.49 kPa)
Propane (LP) Gas (Min) 1.6" w.c. (0.40 kPa)
The temperature rise, or temperature difference between the return
Turn gas off at the ball valve or gas cock on gas supply line air and the supply (heated) air from the furnace, must be within the
before the gas valve. Find the pressure ports on the gas range shown on the furnace rating plate and within the application
valve marked Out P and In P. limitations shown in Table 6.
1. The manifold pressure must be taken at the port marked OUT P. The supply air temperature cannot exceed the “Maximum Supply
Air Temperature” specified in these instructions and on the fur-
2. The inlet gas line pressure must be taken at the port marked IN P. nace rating plate. Under NO circumstances can the furnace be
3. Using a 3/16” allen wrench, remove the plugs from the inlet and allowed to operate above the Maximum Supply Air Temperature.
outlet pressure ports. Connect a 1/8” UPT barbed hose fitting to Operating the furnace above the Maximum Supply Air Temperature
each pressure port. will cause premature heat exchanger failure, high levels of Carbon
4. Refer to Figure 44 for location of pressure regulator adjustment Monoxide, a fire hazard, personal injury, property damage, and/or
cap and adjustment screws on main gas valve. death.
5. Turn gas and electrical supplies on and follow the operating After about 5 minutes of operation, determine the furnace temperature
instructions to place the unit back in operation. rise. Take temperature readings of both the return air and the heated air
6. Remove the small plastic cap to gain access to the regulator in the ducts about six feet away from the furnace, where they will not be
adjustment screw. affected by radiant heat. Increase or decrease the temperature rise by
7. Use a small slotted screwdriver to turn the regulator adjustment changing the ATR jumper on the furnace control board. The jumper is
screw. Adjust the pressure by turning the screw one click at a time factory-set to deliver an air temperature rise near the midpoint of the
until desired pressure is reached. Wait a few seconds after each nameplate temperature rise range. If more air is desired (lower temper-
adjustment to allow the pressure to stabilize before making addi- ature rise), move the jumper to the -10 position. If less air is desired
tional adjustments. This is an electronic adjustment screw that (higher temperature rise), move the jumper to the +10 position.
does not require very much force. Application of excessive force to
the adjustment screw will damage the gas valve.

681292-UIM-A-0211
ADJUSTMENT OF FAN CONTROL SETTINGS Tap B is the humid profile. This profile is best-suited for installations
where the humidity is frequently very high during cooling season, such
Cooling - The airflow delivered by the furnace during cooling operation
can be adjusted to match the cooling capacity of the A/C condensing as in the southern part of the country. On a call for cooling, the blower
will ramp up to 50% of full capacity and will stay there for two minutes,
unit. This is done by moving the COOL and ADJ jumper on the control
then will ramp up to 82% of full capacity and will stay there for five min-
board to give the desired airflow.
utes, and then will ramp up to full capacity, where it will stay until the
The COOL jumper has four positions, which will deliver the airflow in wall thermostat is satisfied. In every case, it will take the motor 30 sec-
cooling mode shown in Table 17. onds to ramp from one speed to another.
The ADJ jumper has three positions which can be used to make further Tap C is the dry profile. This profile is best suited to parts of the country
adjustments to the cooling blower airflow. where excessive humidity is not generally a problem, where the sum-
Continuous Fan Operation - The airflow delivered by the furnace dur- mer months are usually dry. On a call for cooling the motor will ramp up
ing continuous fan operation can be adjusted as desired. This is done to full capacity and will stay there until the thermostat is satisfied. At the
my moving the control fan jumper on the control board to give the end of the cooling cycle, the blower will ramp down to 50% of full capac-
desired airflow. ity where it will stay for 60 seconds. Then it will ramp down to zero. In
The jumper has three positions. The "H" position delivers maximum air- every case, it will take the motor 30 seconds to ramp from one speed to
flow, 100% of the blower capacity. Position "M" delivers approximately another.
70% of the blower capacity. And Position "L" delivers minimum airflow, Tap D is the normal profile, best suited for most of the country, where
approximately 40% of the blower capacity. neither excessive humidity nor extremely dry conditions are the norm.
On a call for cooling, the motor will ramp up to 63% of full capacity and
Delay Taps Selection
will stay there for 90 seconds, then will ramp up to full capacity. At the
The set of jumper pins on the control board labeled "DELAY" are used end of the cooling cycle, the motor will ramp down to 63% of full capac-
to set the delay profiles for the furnace. These can be chosen so as to ity and will stay there for 30 seconds, then will ramp down to zero. In
maximize the comfort and sound levels for various regions of the coun- every case, it will take the motor 30 seconds to ramp from one speed to
try. another.
Tap A is the default profile. It provides a 30-second ramp-up from zero Humidistat
airflow to full capacity and a 30-second ramp-down from full capacity
back to zero airflow. Whenever there is a change in airflow mode, such When a humidistat is installed in the system, the “Humidistat con-
as from low heat to high heat, the motor will take 30 seconds to ramp nected?” jumper on the control board should be moved to the “YES”
from one speed to the other. position. The cooling airflow will then be reduced by 15% whenever the
humidistat indicates high humidity.
Cooling Speed EAC Zoning

Humidifier Terminals
Jumper Jumper
Terminals
Heat Pump
Jumper
Humidistat
Jumper
Continuous
Fan Speed
Jumper
Test
Low Button
Diagnostic Voltage Last
Light Terminals Error Button
FIGURE 46: Furnace Control Board

681292-UIM-A-0211
Table 17: Blower Performance CFM - Any Position

High / Low Speed Cooling CFM
060B12 080B12 Jumper Settings
Hi Cool Lo Cool Hi Cool Lo Cool COOL Jumper ADJ Jumper
1305 850 1290 840 H B
1100 715 1090 710 MH B
1065 690 1015 660 H A
1000 650 1000 650 MH A
960 625 960 625 H C
760 495 760 495 ML B
900 585 900 585 MH C
660 430 660 430 L B
690 450 680 445 ML A
600 400 600 400 L A
620 400 620 400 ML C
550 400 540 400 L C
080C16 100C16 Jumper Settings
1670 1085 1655 1075 H B
1295 840 1275 820 MH B
1385 900 1345 875 H A
1175 765 1160 755 MH A
1245 810 1210 785 H C
995 645 1000 650 ML B
1055 685 1045 680 MH C
935 605 955 620 L B
905 590 910 590 ML A
850 550 870 565 L A
815 530 815 530 ML C
765 500 785 510 L C
100C20 120D20 Jumper Settings
2215 1440 2180 1415 H B
1765 1145 1760 1140 MH B
1820 1180 1800 1170 H A
1605 1040 1595 1035 MH A
1635 1060 1620 1050 H C
1270 825 1255 815 ML B
1445 940 1435 935 MH C
1055 685 1050 680 L B
1155 750 1160 755 ML A
960 620 960 615 L A
1040 675 1035 670 ML C
860 560 840 545 L C
All CFM’s are shown at 0.5” w.c. external static pressure.These units have variable speed motors that automatically adjust to provide constant CFM from 0.0”
to 0.6” w.c. static pressure. From 0.6” to 1.0” static pressure, CFM is reduced by 2% per 0.1” increase in static. Operation on duct systems with greater than
1.0” w.c. external static pressure is not recommended.
NOTE: At some settings, LOW COOL airflow may be lower that what is required to operate an airflow switch on certain models of electronic air cleaners.
Consult the instructions for the electronic air cleaner for further details.

681292-UIM-A-0211
SECTION IX: SAFETY CONTROLS LIMIT CONTROLS

CONTROL CIRCUIT FUSE Limit Switch - This furnace is equipped with a high temperature limit
control mounted to the left side of the furnace vestibule panel. This limit
A 3-amp fuse is provided on the control circuit board to protect the 24- switch will open and shut off gas to the burners if it detects excessive air
volt transformer from overload caused by control circuit wiring errors.
temperature in the furnace, which can be caused by any of the following
This is an ATO 3, automotive type fuse and is located on the control
conditions:
board.
1. Dirty filter
BLOWER DOOR SAFETY SWITCH 2. Failure of the circulating blower motor or wheel
This unit is equipped with an electrical interlock switch mounted in the 3. Too many supply or return registers closed or blocked.
burner compartment. This switch interrupts all power at the unit when Temperature Sensor - This furnace is also equipped with a tempera-
the panel covering the blower compartment is removed. ture sensor mounted to the vestibule panel, near the limit switch. This
Electrical supply to this unit is dependent upon the panel that covers the sensor monitors the temperature of the air being supplied to the home.
blower compartment being in place and properly positioned. If the sensor detects air temperature higher than normal, the furnace
control will speed up the circulating blower motor in order to try to
increase the amount of airflow being delivered, thereby reducing the air
temperature.
Main power to the unit must still be interrupted at the main power
disconnect switch before any service or repair work is to be done to
SECTION X: NORMAL OPERATION AND
the unit. Do not rely upon the interlock switch as a main power dis- DIAGNOSTICS
connect. Blower and burner must never be operated without the
NORMAL OPERATION SEQUENCE
blower panel in place.
The furnace control calculates the optimum firing rate each time the
ROLLOUT SWITCH CONTROLS wall thermostat R and W contacts close or open (at the beginning and
These controls are mounted on the burner assembly. If the temperature at the end of each call for heat) based on information from the thermo-
in the area surrounding burner exceeds its set point, the gas valve is stat and past demand. UNLIKE CONVENTIONAL SYSTEMS, THE
de-energized. The operation of this control indicates a malfunction in WALL THERMOSTAT DOES NOT SIMPLY TURN THE FURNACE ON
the combustion air blower, heat exchanger or a blocked vent pipe con- AND OFF. THE FURNACE CONTROL CALCULATES THE DEMAND
nection. Corrective action is required. These are manual reset controls AND MAY CONTINUE TO FIRE THE FURNACE DURING PORTIONS
that must be reset before operation can continue. OF THE THERMOSTAT "OFF" CYCLE.
When the wall thermostat R and W contacts close, indicating a call for
PRESSURE CONTROLS heat, the following sequence occurs:
Pressure Sensor - This furnace is equipped with a pressure sensor in 1. The inducer is energized and ramps up its speed until airflow is
the burner compartment near the combustion blower. This sensor mon- proven by the pressure switch and by the pressure sensor on the
itors combustion airflow through furnace and piping systems. If any of control board.
the conditions listed below are detected by the pressure sensor, the 2. The hot surface ignitor is energized.
control board will prevent a hazardous condition from occurring by
3. After a 17-20 second igniter heat-up, the gas valve opens and the
speeding up the combustion blower motor in order to maintain ade-
burners light.
quate combustion airflow. If the combustion blower is already turning at
4. When the control senses that flame is present, the circulating
full speed, the furnace control will then start reducing the input to the
blower starts at low speed.
furnace in order to maintain proper combustion with the amount of com-
bustion airflow available. If there is not enough combustion air available 5. The furnace fires at 70% of full rate for 30-45 seconds, then drops
to give proper combustion even at the minimum input rate (35%), the to the minimum (35%) firing rate.
control will close the gas valve and shut off the burners. The sensor will 6. The firing rate is automatically adjusted to meet demand, increas-
detect the following conditions. ing gradually to maximum (100%) firing rate if the thermostat is not
satisfied within a defined time.
1. Blockage of vent piping or vent terminal
7. When the thermostat R and W contacts open (thermostat is satis-
2. Failure of combustion air blower motor or blower wheel. fied) the furnace control recalculates the demand and a new firing
3. Blockage of combustion air piping or terminals. rate.
Pressure Switch - This furnace is equipped with a pressure switch a. If demand exceeds the minimum firing rate, the burners will
mounted on the draft inducer. This switch monitors the flow through the continue to fire at a recalculated reduced firing rate, decreas-
vent system. The switch will close at the beginning of each cycle when ing if the thermostat remains off for a defined time.
adequate combustion airflow is established. However, this switch may b. If demand does not exceed the minimum firing rate, the burn-
be open under certain conditions when the burners are lit. The pressure ers will shut off immediately.
sensor is the primary flow sensor.
8. After the burners shut off, the circulating blower will continue to run
Condensate Pressure Switch - This furnace is equipped with a pres- until the temperature sensor detects that the supply air tempera-
sure switch that will shut the furnace burners off if the condensate drain ture has dropped to the desired level, which should take from 30 to
line is blocked so that the water does not drain properly from the fur- 90 seconds.
nace.

681292-UIM-A-0211
TROUBLESHOOTING Three Red Flashes - Pressure switch open with inducer pressure
above pressure switch setpoint (switch is open when it should be
The following visual checks should be made before troubleshooting:
closed). Check pressure switch.
1. Check to see that the power to the furnace and the ignition control
Four Red Flashes - High limit switch open or defective temperature
module is ON.
sensor or 24 volt fuse is open. This may be caused by a dirty air filter,
2. The manual shut-off valves in the gas line to the furnace must be improperly sized duct system, faulty blower motor, restricted circulating
open. airflow an open fuse on the control board.
3. Make sure all wiring connections are secure. Five Red Flashes - Rollout switch or condensate pressure switch
4. Review the sequence of operation. Start the system by setting the open. Check the rollout switch(es) on the burner assembly. It is a man-
thermostat above the room temperature. Observe the system’s ual reset switch. To reset, push the small button in the center of the
response. Then use the troubleshooting section in this manual to switch. If it cannot be reset or if the switch trips again, contact a quali-
check the system’s operation. fied serviceman.
Six Red Flashes - Gas valve communication error.
Seven Red Flashes - Lockout due to no ignition. The control will try
Never bypass any safety control to allow furnace operation. To three times for ignition. If flame cannot be established in three tries, the
do so will allow furnace to operate under potentially hazardous control will lockout for one hour and then will try again to light. Check
conditions. gas supply, ignitor, gas valve, flame sensor.
Do not try to repair controls. Replace defective controls with Eight Red Flashes - Lockout due to too many flame recycles. This
UPG Source 1 Parts. flash code occurs if flame is lost five times during a single heating cycle.
Never adjust pressure switch to allow furnace operation. This could be caused by a faulty gas valve, low gas pressure, or dirty
flame sensor. The control will lock out for one hour and then will try
FURNACE CONTROL DIAGNOSTICS again.
This furnace has built-in self-diagnostic capability. If a system problem Nine Red Flashes - Reversed line polarity or improper grounding.
occurs, a flashing LED shows a fault code. The LED can flash red, Check polarity of the incoming power to the furnace. Check the ground-
green or amber to indicate various conditions. The LED is located on ing of the furnace, including the transformer ground and the L1 and
the furnace control board and can be seen through the clear view port neutral connections.
in the lower door of the furnace. To indicate an error condition, the LED Ten Red Flashes - Gas valve circuit shorted. Check gas valve wiring. If
will turn on for 1/4 second and off for 1/4 second. The pattern will be correct, replace gas valve.
repeated the number of times equal to the flash code. For instance, a
Eleven Red Flashes - Main blower failure - This flash code occurs
"six flash code" will be indicated by the LED turning on and off six times. when the main limit opens and fails to reclose within five minutes, indi-
There will be a two second off period between each set of flashes. The cating that the blower motor or blower wheel has failed.
flash codes and an indication of their likely causes are listed below:
Twelve Red Flashes - ID plug is not present or not connected properly,
STEADY OFF - No 24V power to board. Check the 24 volt control cir- check for loose plug or loose wires in plug.
cuit fuse on the board. Check the circuit breaker or fuse on the 115 volt
Steady On Red - Control fault has been detected or there is 24 volts
supply power to the furnace. Check that the 24 volt transformer.
present without 115 volts. Check that there is 24 volts and 115 volts
One Green Flash - Normal Operation with no call for heat. being supplied to the board. If so, then the board should be replaced.
Two Green Flashes - Indicator for "No error codes in memory". See
Diagnostic Fault Code Storage and Retrieval section below. IGNITION CONTROL FLAME SENSE LEVELS
Normal flame sense current is approximately
Three Green Flashes - Indicator for "Error codes cleared from mem- 3.7 microamps DC (µa)
ory". See Diagnostic Fault Code Storage and Retrieval section below. Low flame signal warning starts at 1.5 microamps.
Rapid Green Flash - Control is in "Factory Speed-up" mode. This Low flame signal control lockout point is
mode is used only during factory run-testing of the furnace. To stop this 0.1 microamps DC (µa)
mode, cycle power to the furnace off and then back on.
DIAGNOSTIC FAULT CODE STORAGE AND
One Amber Flash - Normal operation with call for cooling.
RETRIEVAL
Two Amber Flashes - Normal operation with call for heat.
The control in this furnace is equipped with memory that will store up to
Three Amber flashes - Normal operation, burner is on at end of heat- five error codes to allow a service technician to diagnose problems
ing cycle after wall thermostat has been satisfied. more easily. This memory will be retained even if power to the furnace
Four Amber Flashes - Heating capacity is reduced due to restriction in is lost. Only a qualified service technician should use this feature.
the circulating air system. Check for dirty filter or closed registers. The control stores up to five separate error codes. If more than five
Five Amber Flashes - Heating capacity is reduced due to restriction in error codes have occurred since the last reset, only the five most recent
the combustion air or vent system. Check for blocked vent/air pipe or will be retained. The furnace control board has a button, labeled "LAST
clogged condensate drain. Above 4,000 feet altitude, this may also indi- ERROR" that is used to retrieve error codes. This function will only
cate automatic, normal derating for altitude. See page 7 for additional work if there are no active thermostat signals. So any call for heating,
high altitude information. cooling or continuous fan must be terminated before attempting to
Six Amber Flashes - (Heat Pump applications only) Normal operation retrieve error codes.
with call for heat pump heating. To retrieve the error codes, push the LAST ERROR button. The LED on
Rapid Amber Flash - Low flame sense current. Check for dirty or mis- the control will then flash the error codes that are in memory, starting
located flame sensor rod. with the most recent. There will be a two-second pause between each
flash code. After the error codes have all been displayed, the LED will
One Red Flash - Flame is present with no power being supplied to gas resume the normal slow green flash after a five second pause. To
valve. This can be caused by a gas valve that is slow to close or that repeat the series of error codes, push the button again.
leaks gas through to the burners.
If there are no error codes in memory, the LED will flash two green
Two Red Flashes - Pressure switch closed with inducer pressure flashes. To clear the memory, push the LAST ERROR button and hold it
below pressure switch setpoint (switch is closed when it should be for more than five seconds. The LED will flash three green flashes
open). Check pressure switch.
when the memory has been cleared, then will resume the normal slow
green flash after a five-second pause.

681292-UIM-A-0211
SECTION XI: REPLACEMENT PARTS LIST

DESCRIPTION DESCRIPTION
MOTOR FABRICATED PARTS - Continued
MOTOR, DIRECT DRIVE BLOWER MANIFOLD, GAS
BLOWER, COMBUSTION PAN, BOTTOM
ELECTRICAL PANEL, TOP
CAPACITOR, RUN PANEL, DOOR (2 Req’d)
SWITCH, LIMIT PANEL, BLOCKOFF
CONTROL, FURNACE MISCELLANEOUS
IGNITER ORIFICE, BURNER (Natural #45)
SENSOR, FLAME SIGHT GLASS, OVAL (2 Req’d)
SWITCH, PRESSURE GASKET, FOAM (Door) (1.5 ft req’d)
SWITCH, DOOR PAN, CONDENSATE
TRANSFORMER BRACKET, DOOR
VALVE, GAS HARNESS, WIRING
CONTROL, TEMPERATURE FERRULE (3 Req’d)
AIR MOVING GROMMET (3 Req’d)
HOUSING, BLOWER MOTOR MOUNT
WHEEL, BLOWER TUBING, SILICON
FABRICATED PARTS HOSE, RAIN GUTTER
RESTRICTOR, COMBUSTION BLOWER HOSE, CONDENSATE
BURNER, MAIN GAS PLUG, SEAL, 7/8”
BRACKET, IGNITER PLUG, SEAL, 2-3/8”
SHELF, BLOWER PLUG, VENT PIPE
RAIL, BLOWER (2 Req’d) BAG, PARTS
BRACKET, BLOWER TRACK (2 Req’d) KNOB, QUARTER TURN (4 Req’d)
HEAT EXCHANGER ASS’Y DIAGRAM, WIRING
REPLACEMENT PART CONTACT INFORMATION

This is a generic parts list. To request a complete parts list, refer to the contact information below:
• Visit our website at www.source1parts.com for the following information:
1. Search for a part or browse the catalog.
2. Find a dealer or distributor.
3. Customer Service contact information.
a. Click on the “Brand Links” button
b. Click on the “Customer Service” button
• You can contact us by mail. Just send a written request to:
Consumer Relations
5005 York Drive
Norman, OK 73069

SECTION XII: WIRING DIAGRAM
FIGURE 47: Wiring Diagram
Subject to change without notice. Published in U.S.A. 681292-UIM-A-0211

Copyright © 2011 by Johnson Controls, Inc. All rights reserved. Supersedes: 531518-UIM-C-0110

5005 York Drive
Norman, OK 73069

York YP9C

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INSTALLATION MANUAL

RESIDENTIAL GAS FURNACE EFFICIENCY

WITH ECM MOTOR

SPECIFIC SAFETY RULES AND PRECAUTIONS

2 Johnson Controls Unitary Products

Johnson Controls Unitary Products 3

4 Johnson Controls Unitary Products

Johnson Controls Unitary Products 5

Line contact only permissible Supply

FIBERGLASS TAPE Return

FIGURE 4: Typical Attic Installation

FIGURE 2: Combustible Floor Base Accessory

RESIDENTIAL AND MODULAR HOME UPFLOW

SUSPENDED FURNACE / CRAWL SPACE

6 Johnson Controls Unitary Products

On all installations without a coil, a removable access panel is rec-

Support COIL/FURNACE ASSEMBLY - MC/FC/PC SERIES

FIGURE 5: Typical Suspended Furnace / Crawl Space Installation

When moving or handling this furnace prior to installation it is recom-

COIL FLANGE INSTALLATION

FIGURE 8: Coil Flange

Johnson Controls Unitary Products 7

FURNACE ASSEMBLY - MC SERIES COILS ONLY

Table 2: Coil Projection Dimensions - PC Series Coils

Use tie plate

FIGURE 12: Horizontal Left or Right application (Right Shown)

8 Johnson Controls Unitary Products

LEFT SIDE FRONT RIGHT SIDE

Condensate Drain Gas Pipe

.56” .56” 24.25”

FIGURE 13: Dimensions

SECTION III: FILTERS SIDE RETURN

Johnson Controls Unitary Products 9

Horizontal Filters Main Inlet

To Gas NOTE: Ground Union maybe installed inside or outside unit.

FIGURE 16: Gas Piping

10 Johnson Controls Unitary Products

SECTION V: ELECTRICAL POWER

Johnson Controls Unitary Products 11

Table 6: Ratings & Physical / Electrical Data

12 Johnson Controls Unitary Products

FIGURE 18: Furnace Control Board – Communications Connections

Johnson Controls Unitary Products 13

Y1 Some electronic thermostats do not have adjustable heat anticipa-

FIGURE 20: Modulating Furnace with Communicating Thermostat and

14 Johnson Controls Unitary Products

Clipping Jumper W914 for Move HUMIDISTAT

2 Part Number: Part Numbers: 1

Johnson Controls Unitary Products 15

MODULATING TWO STAGE

Connection of the "C" Connection of the "C" Move HUMIDISTAT

16 Johnson Controls Unitary Products

MODULATING TWO STAGE

Clipping Jumper W914 for Move HUMIDISTAT

2 Part Number: Part Numbers: 1

Johnson Controls Unitary Products 17

MODULATING 2 DEMAND DEFROST 1

Step 1 of Thermostat Move HUMIDISTAT