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York P*XU/G9D-UP Installation Instruction

Two-stage deluxe high-efficiency gas-fired furnaces tubular heat exchanger series
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INSTALLATION
TWO-STAGE DELUXE
HIGH-EFFICIENCY GAS-FIRED FURNACES
INSTRUCTION
TUBULAR HEAT EXCHANGER SERIES
MODELS: P*XU / G9D-UP (UPFLOW)
60 - 120 MBH INPUT
CONTENTS
GENERAL INFORMATION ...............................................3
SPECIFIC UNIT INFORMATION ......................................4
DUCTWORK .....................................................................5
UPFLOW MODELS ...........................................................7
GAS PIPING .....................................................................8
ELECTRICAL POWER CONNECTION ............................9
ELECTRICAL CONTROL CONNECTIONS ....................10
COMBUSTION AIR AND VENT SYSTEM ......................11
HORIZONTAL VENT APPLICATIONS ...........................18
CONDENSATE PIPING ..................................................19
SAFETY CONTROLS .....................................................19
START-UP AND ADJUSTMENTS ..................................20
ACCESSORY CONNECTIONS ......................................24
FURNACE ACCESSORIES
.........................................25
FILTER PERFORMANCE ...............................................26
OPERATION AND MAINTENANCE ...............................26
TROUBLESHOOTING ....................................................30
FURNACE CONTROL DIAGNOSTICS ..........................30
WIRING DIAGRAM - UPFLOW MODELS ......................32
CAUTION:READ ALL SAFETY GUIDES BEFORE YOU
START TO INSTALL YOUR FURNACE.
SAVE THIS MANUAL
035-17480-000 Rev. A (800)

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Summary of Contents for York P*XU/G9D-UP

  • Page 1 INSTALLATION TWO-STAGE DELUXE HIGH-EFFICIENCY GAS-FIRED FURNACES INSTRUCTION TUBULAR HEAT EXCHANGER SERIES MODELS: P*XU / G9D-UP (UPFLOW) 60 - 120 MBH INPUT CONTENTS GENERAL INFORMATION ..........3 SPECIFIC UNIT INFORMATION ........4 DUCTWORK ..............5 UPFLOW MODELS ............7 GAS PIPING ..............8 ELECTRICAL POWER CONNECTION ......9 ELECTRICAL CONTROL CONNECTIONS ....10 COMBUSTION AIR AND VENT SYSTEM ......11 HORIZONTAL VENT APPLICATIONS ......18...

  • Page 2: Table Of Contents

    035-17480-000 Rev. A (800) TABLE OF CONTENTS GENERAL INFORMATION ..........3 START-UP AND ADJUSTMENTS ........20 DESCRIPTION ................3 IGNITION SYSTEM SEQUENCE ..........20 INSPECTION ................3 CHECKING GAS INPUT ............21 NOTES, CAUTIONS & WARNINGS ........... 3 ADJUSTMENT OF MANIFOLD GAS PRESSURE ....22 VENT SAFETY CHECK PROCEDURE ........

  • Page 3: General Information

    035-17480-000 Rev. A (800) GENERAL INFORMATION DESCRIPTION This Category IV, dual certified direct vent and 1-pipe vent IMPROPER INSTALLATION MAY CREATE A furnace is designed for residential or commercial applica- CONDITION WHERE THE OPERATION OF THE tion. It may be installed without modification to the conden- PRODUCT COULD CAUSE PERSONAL INJURY sate system in a basement, garage, equipment room, alcove, OR PROPERTY DAMAGE.

  • Page 4: Vent Safety Check Procedure

    035-17480-000 Rev. A (800) VENT SAFETY CHECK PROCEDURE Any corrections to the common venting system must be in accordance with the National Fuel Gas Code Z223.1 or CAN/CGA B149.1 or.2 Installation Code (latest edi- tions). If the common vent system must be resized, it should be resized to approach the minimum size as This furnace may not be common vented with any determined using the appropriate tables in Appendix G...

  • Page 5: Clearances To Combustibles

    035-17480-000 Rev. A (800) The size of the unit should be based on an acceptable heat NOTE:In all cases, accessibility clearances shall take prece- loss calculation for the structure. ACCA, Manual J or other dence over clearances for combustible materials where approved methods may be used.
  • Page 6 035-17480-000 Rev. A (800) 6 3/8 3-1/8 1 1/4 2-3/4 4-1/8 6-1/8 8-7/8 Gas Pipe Entry 1 1/4 x 2 1/2 (All gas pipe connections are 1/2" NPT) 7/8 Junction 1-3/4 Box Hole T-Stat Wiring 1-3/4 Optional Side Return 14 -1/2 7/8"...

  • Page 7: Upflow Models

    035-17480-000 Rev. A (800) TABLE 2: UNIT CLEARANCES TO COMBUSTIBLES (ALL DIMENSIONS IN INCHES) All surfaces identified with the unit in an upright configuration LINE LEFT RIGHT FLOOR/ APPLICATION FRONT REAR FLUE CLOSET ALCOVE ATTIC CON- SIDE SIDE BOTTOM TACT UPFLOW MODELS (P*XU / G9D-UP) UPFLOW COMBUSTIBLE...

  • Page 8: Gas Piping

    035-17480-000 Rev. A (800) POSITION WIRE RETAINER (PROVIDED) UNDER FLANGE All installations must have a filter installed. The return duct may be attached to the furnace by S-cleat, FILTER bend tabs or other approved methods. Be sure to seal the (PROVIDED CLIPS duct to the furnace to prevent air leakage.

  • Page 9: Electrical Power Connection

    035-17480-000 Rev. A (800) Some utility companies or local codes require pipe sizes NOTE: An accessible manual shutoff valve must be installed larger than the minimum sizes listed in these instructions and upstream of the furnace gas controls and within 6 feet of the in the codes.

  • Page 10: Electrical Control Connections

    035-17480-000 Rev. A (800) NOTE:The furnace’s control system depends on correct (HOT) polarity of the power supply and a proper ground connection. Refer to the “FURNACE CONTROL DIAGNOSTICS” section : BLK/BLK WIRING INSIDE WHI/WHI JUNCTION BOX on page 30 for symptoms of reversed power supply polarity. GRN/GRN JUNCTION Use copper conductors only.

  • Page 11: Combustion Air And Vent System

    ON TOP OF BURNER BOX the vent system is not allowed. This type connection is allowed in the combustion air pipe near the furnace for air conditioning coil accessibility. FIGURE 9 : Upflow Air Intake/vent Locations (Models P*XU/G9D-UP) Unitary Products Group...
  • Page 12 035-17480-000 Rev. A (800) TABLE 3: INTAKE/VENT PIPING - 2 PIPE SYSTEM VENT CLEARANCES (2-PIPE) U.S. ONLY Dryer Vent........3 ft. Max.
  • Page 13 035-17480-000 Rev. A (800) OVERHANG 12" MINIMUM VENT 12" VERTICAL SEPARATION COMBUSTION AIR BETWEEN COMBUSTION 90° 12" SEPARATION BETWEEN AIR AND VENT BOTTOM OF COMBUSTION AIR VENT AND BOTTOM OF VENT MAINTAIN 12" CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE, WHICHEVER IS GREATER MAINTAIN 12"...

  • Page 14: Method Two: One Pipe System

    035-17480-000 Rev. A (800) Disassemble the piping and apply cement primer and METHOD TWO: ONE PIPE SYSTEM cement per the cement manufacturer's instructions. Primer and cement must conform to ASTM D2564 for This type installation will use combustion air from within the PVC, or ASTM D2235 for ABS piping.
  • Page 15 035-17480-000 Rev. A (800) NOTE: Ducts must have the same cross-sectional area as problems. However, the use of indoor air in most applications the free area in the opening to which they are connected. The is acceptable, except as follows: minimum dimension of rectangular ducts shall be three If the furnace is installed in a confined space it is recom- inches.
  • Page 16 035-17480-000 Rev. A (800) VENT PIPE SIZING (1-PIPE SYSTEM) When selecting the locations for vent termination, the follow- ing should be considered: Refer to Table 5 to select the proper size piping for venting. The size will be determined by a combination of furnace Comply with all clearance requirements.
  • Page 17 035-17480-000 Rev. A (800) Avoid areas where condensate drippage may cause problems such as above planters, patios, or adjacent to windows where steam may cause fogging. NOTE:Consideration must be given for degradation of build- ing materials by flue gases. NOTE:Shaded components of the vent system shown in Fig- VENT ures Figure 17 through Figure 20 are considered to be part of the termination.

  • Page 18: Method Three Two Pipe System Using Combustion Air From A Ventilated Attic Space

    035-17480-000 Rev. A (800) METHOD THREE: TWO PIPE SYSTEM USING VENT PIPE COMBUSTION AIR FROM A VENTILATED ATTIC For vent pipe sizing, allowable length and elbow usage, see SPACE Table 5 on page 16. Follow all notes, installation procedures and required materials in the “METHOD TWO ONE PIPE This type installation requires two properly sized pipes.

  • Page 19: Condensate Piping

    035-17480-000 Rev. A (800) To install the vent drain, complete the following steps: Drain Connection: The following steps apply to all models. Place a tee of the proper diameter for the vent system It is recommended that either 1/2” or 3/4” PVC or equiva- being installed (2"...

  • Page 20: Start-Up And Adjustments

    035-17480-000 Rev. A (800) Rollout Switch Controls: These controls are mounted on START-UP AND ADJUSTMENTS the burner box assembly. If the temperature in the burner compartment exceeds its set point, the igniter control and the The initial start-up of the furnace requires the following addi- gas valve are de-energized.

  • Page 21: Checking Gas Input

    035-17480-000 Rev. A (800) NOTE: :Burner ignition may not be satisfactory on first star- Using the number of seconds for each revolution and the tup due to residual air in the gas line or until gas manifold size of the test dial increment, find the cubic feet of gas pressure is adjusted.

  • Page 22: Adjustment Of Manifold Gas Pressure

    035-17480-000 Rev. A (800) TABLE 6 : GAS RATE (CUBIC FEET PER HOUR) SIZE OF TEST DIAL SECONDS FOR ONE REVOLUTION Be sure to relight any gas appliance that were CUBIC FOOT CUBIC FOOT turned off at the start of this input check. ADJUSTMENT OF MANIFOLD GAS PRESSURE Manifold gas pressure may be measured by two different pro- cedures.

  • Page 23: Adjustment Of Temperature Rise

    035-17480-000 Rev. A (800) To increase outlet pressure, turn the 3/32” socket set You may select a heating speed and a cooling speed. They screw clockwise. To decrease outlet pressure, turn the may be the same speed or a different speed. set screw counterclockwise.

  • Page 24: Accessory Connections

    3.5 IN. WATER COLUMN GAS PRESSURE SHOWN FIGURE 27 : Upflow Models (P*XU/G9D-UP) - Reading Gas Pressure ACCESSORY CONNECTIONS Electronic Air Cleaner Connection Two 1/4” spade terminals (EAC and EAC N) for electronic air cleaner connections are located on the control board. The terminals provide 120 VAC (1.0 amp maximum) during circu-...

  • Page 25: Furnace Accessories

    1CT0303 Concentric Vent 3” vent pipe 1PS0315 High Altitude Pressure Switch Kit (See form 035-14460-000 for proper application) 1PS0316 1PS0317 1PS0318 TABLE 7: AIRFLOW DATA - UPFLOW MODELS: P*XU/G9D-UP EXTERNAL STATIC PRESSURE, INCHES W.C. MODELS: P1XU/ SPEED G9D-UP 0.10 0.20 0.30...

  • Page 26: Filter Performance

    035-17480-000 Rev. A (800) FILTER PERFORMANCE The airflow capacity data published in Table 8 represents NOTE: The filter pressure drop values in Table 8 are typical blower performance WITHOUT filters. To determine the values for the type of filter listed and should only be used as a approximate blower performance of the system, apply the fil- guideline.
  • Page 27 035-17480-000 Rev. A (800) FIGURE 29 : Sequence Timing For 50a51-243 Control Unitary Products Group...

  • Page 28: Intermittent Blower - Cooling

    035-17480-000 Rev. A (800) INTERMITTENT BLOWER - COOLING time. Two retries will be attempted before the control goes into system lockout. On cooling/heating thermostats with fan switch, when the fan If flame is detected, then lost, the 50A51 control will repeat switch is set in the auto position and the thermostat calls for the initial ignition sequence.

  • Page 29: Maintenance

    035-17480-000 Rev. A (800) MAINTENANCE Air Filters The filters must be checked periodically for dirt accumulation. Dirty filters greatly restrict the flow of air and may cause dam- age to the system. Clean the filters at least every three months. On new con- struction, check the filters every week for the first four weeks.

  • Page 30: Vent/Air Intake

    035-17480-000 Rev. A (800) Disconnect wires from flame sensor, rollout switch and TROUBLESHOOTING HSI igniter. Remove igniter carefully, as it is easily bro- ken. The following visual checks should be made before trouble- shooting: Check to see that the power to the furnace and the igni- tion control module is ON.
  • Page 31 035-17480-000 Rev. A (800) All flash code sequences are broken by a 2 second off period. 7 FLASH: This fault code indicates that flame could not be established. This no-light condition occurred 3 times during 50A51-243 IGNITION CONTROL (P/N 031-01290-000) the call for heat before locking out.

  • Page 32: Wiring Diagram - Upflow Models

    NOTE: The furnace’s control system depends on correct polarity of the power supply. Subject to change without notice. Printed in U.S.A. 035-17480-000 Rev. A (800) Copyright © by Unitary Products Group 2000. All rights reserved. Supersedes: 650.78-N1U (899) Unitary 5005 Norman Product York Group Drive 73069...

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