INSTALLATION MANUAL

1 INSTALLATION MANUAL . residential GAS FURNACE. WITH ECM MOTOR EFFICIENCY. RATING. CERTIFIED. MODELS: ISO 9001. TPLC*C, YPLC*C, CPLC*C, LPLC*C Certified Quality Management System (80% Modulating Multi- position / Low NOx). LIST OF SECTIONS. SAFETY .. 1 START-UP AND ADJUSTMENTS .. 23. DUCTWORK .. 5 SAFETY CONTROLS .. 29. FILTERS .. 9 NORMAL OPERATION AND DIAGNOSTICS .. 30. GAS PIPING .. 10 REPLACEMENT PARTS LIST .. 31. ELECTRICAL POWER .. 11 REPLACEMENT PART CONTACT INFORMATION .. 31. VENT SYSTEM .. 20 WIRING DIAGRAM .. 32. LIST OF FIGURES. Duct Attachment .. 5 Modulating Furnace with Communicating Thermostat Combustible Floor Base Accessory .. 6 and non-Communicating AC .. 13. Horizontal Application (Typical) .. 6 Thermostat Chart - Single Stage Air Conditioner . Typical Attic INSTALLATION .. 6 Variable Speed or PSC Modulating Furnace .. 14. Typical Suspended Furnace / Crawl Space INSTALLATION .

2 7 Thermostat Chart - Two Stage Air Conditioner . Downflow Venting .. 7 Variable Speed or PSC Modulating Furnace .. 15. Vertical Applications (Typical) .. 7 Thermostat Chart - Two Stage Air Conditioner with Single Stage Coil Flange .. 8 Thermostat Variable Speed or PSC Modulating Furnace .. 16. Thermostat Chart - Single Stage Heat Pump . Horizontal Right Application (Typical) .. 8. Variable Speed or PSC Modulating Furnace .. 17. Horizontal Left Application .. 8. Thermostat Chart - Single Stage Heat Pump . PC Series Upflow Coil INSTALLATION .. 8 Variable Speed or PSC Modulating Furnace .. 18. Horizontal Left or Right application (Right Shown) .. 8 Thermostat Chart - Two Stage Heat Pump . Dimensions .. 9 Variable Speed or PSC Modulating Furnace .. 19. Side Return Cutout Markings .. 9 Combustion Air Inducer .. 20. Gas Valve .. 10 Combustion Airflow Path Through The Gas Piping.

3 10 Furnace Casing to the Burner Compartment .. 21. Electrical Wiring .. 12 Outside and Ambient Combustion Air .. 22. Furnace Control Board Communications Connections .. 12 Gas Valve .. 26. Modulating Furnace with Communicating AC or HP .. 13 Furnace Control Board .. 27. Wiring Diagram .. 32. LIST OF TABLES. Unit Clearances to Combustibles .. 4 Unconfined Space Minimum Area .. 21. Coil Projection Dimensions - PC Series Coils .. 8 Free Area .. 21. Cabinet and Duct Dimensions .. 9 Gas Rate (CU FT/HR) at Full Input .. 25. Recommended Filter Sizes (High Velocity 600 FPM) .. 9 Inlet Gas Pressure Range .. 26. High Altitude Orifices .. 11 Nominal Manifold Pressure .. 26. Ratings & Physical / Electrical Data .. 11 Blower Performance CFM - Any position .. 28. Estimated Free Area .. 21. These high efficiency, compact units employ induced combustion, reli- DANGER indicates an imminently hazardous situation, which, if not able hot surface ignition and high heat transfer aluminized tubular heat avoided, will result in death or serious injury.

4 Exchangers. The units are factory shipped for INSTALLATION in upflow or WARNING indicates a potentially hazardous situation, which, if not horizontal applications and may be converted for downflow applica- avoided, could result in death or serious injury. tions. CAUTION indicates a potentially hazardous situation, which, if not These furnaces are designed for residential INSTALLATION in a basement, avoided may result in minor or moderate injury. It is also used to closet, alcove, attic, recreation room or garage and are also ideal for alert against unsafe practices and hazards involving only property dam- commercial applications. All units are factory assembled, wired and age. tested to assure safe dependable and economical INSTALLATION and oper- ation. These units are Category I listed and may be common vented with another gas appliance as allowed by the National Fuel Gas Code.

5 Improper INSTALLATION may create a condition where the operation of SECTION I: SAFETY. the product could cause personal injury or property damage. Improper INSTALLATION , adjustment, alteration, service or mainte- This is a safety alert symbol. When you see this symbol on nance can cause injury or property damage. Failure to carefully labels or in manuals, be alert to the potential for personal read and follow all instructions in this MANUAL can result in fur- injury. nace malfunction, death, personal injury and/or property dam- age. Only a qualified contractor, installer or service agency should Understand and pay particular attention to the signal words DANGER, install this product. WARNING, or CAUTION. 535678-UIM-B-0210. 535678-UIM-B-0210. SPECIFIC SAFETY RULES AND PRECAUTIONS 12. When moving or handling this furnace prior to INSTALLATION , always 1. Only Natural gas or Propane (LP) gas are approved for use with leave the doors on the furnace to provide support and to prevent this furnace.

6 Damage or warping of the cabinet. When lifting the furnace by the cabinet, support the ends of the furnace rather than lifting by the 2. Install this furnace only in a location and position as specified in cabinet flanges at the return air openings (bottom or sides) or sup- these instructions. ply air opening. 3. A gas- fired furnace for INSTALLATION in a residential garage must be 13. When lifting the furnace, it is acceptable to use the primary heat installed as specified in these instructions. exchanger tubes as a lifting point provided that the tubes are lifted 4. Provide adequate combustion and ventilation air to the furnace at the front of the heat exchangers where attached to the vestibule space as specified in these instructions. panel. Do not use the top return bend of the heat exchangers as 5. Combustion products must be discharged outdoors. Connect this lifting points as the tubes may shift out of position or their location furnace to an approved vent system only, as specified in SEC- brackets/baffles.

7 TION VII of these instructions. 6. Test for gas leaks as specified in these instructions. During INSTALLATION , doors must remain on the furnace when moving or lifting. FIRE OR EXPLOSION HAZARD SAFETY REQUIREMENTS. Failure to follow the safety warnings exactly could result in serious injury, death or property damage. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for detection of leaks to check all connections. A fire or explosion may result causing prop- This product must be installed in strict compliance with the installa- erty damage, personal injury or loss of life. tion instructions and any applicable local, state, and national codes including, but not limited to building, electrical, and mechanical 7. Always install the furnace to operate within the furnace's intended codes. temperature rise range.

8 Only connect the furnace to a duct system which has an external static pressure within the allowable range, Refer to the unit rating plate for the furnace model number, and as specified on the furnace rating plate. then see the dimensions page of this instruction for return air ple- 8. When a furnace is installed so that supply ducts carry air circulated num dimensions in Figure 13. The plenum must be installed by the furnace to areas outside the space containing the furnace, according to the instructions. the return air shall also be handled by duct(s) sealed to the fur- Provide clearances from combustible materials as listed under nace casing and terminating outside the space containing the fur- Clearances to Combustibles. nace. Provide clearances for servicing ensuring that service access is 9. It is permitted to use the furnace for heating of buildings or struc- allowed for both the burners and blower.

9 Tures under construction where the application and use must com- These models ARE NOT CSA listed or approved for INSTALLATION ply with all manufacturer's INSTALLATION instructions including: into a HUD Approved Modular Home or a Manufactured Proper vent INSTALLATION ; (Mobile) Home. Furnace operating under thermostatic control; This furnace is not approved for INSTALLATION in trailers or recre- Return air duct sealed to the furnace; ational vehicles. Air filters in place; Furnaces for INSTALLATION on combustible flooring shall not be Set furnace input rate and temperature rise per rating plate installed directly on carpeting, tile or other combustible material marking; other than wood flooring. Means for providing outdoor air required for combustion; Check the rating plate and power supply to be sure that the elec- Return air temperature maintained between 55 F (13 C) and trical characteristics match.

10 All models use nominal 115 VAC, 1. 80 F (27 C); Phase, 60-Hertz power supply. DO NOT CONNECT THIS APPLI- The air filter must be replaced upon substantial completion of ANCE TO A 50 HZ POWER SUPPLY OR A VOLTAGE ABOVE. the construction process; 130 VOLTS. Clean furnace, duct work and components upon substantial Furnace shall be installed so the electrical components are pro- completion of the construction process, and verify furnace- tected from water. operating conditions including ignition, input rate, temperature Installing and servicing heating equipment can be hazardous due rise and venting, according to the manufacturer's instructions. to the electrical components and the gas fired components. Only 10. When installed in a Non-HUD-Approved Modular Home or building trained and qualified personnel should install, repair, or service constructed on-site, combustion air shall not be supplied from gas heating equipment.