Coleman PxXU-V series Installation Instructions Manual
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Coleman PxXU-V series Installation Instructions Manual

Coleman PxXU-V series Installation Instructions Manual

Two-stage ultra high-efficiency gas-fired variable speed furnaces
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INSTALLATION
INSTRUCTIONS

TABLE OF CONTENTS

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFIC UNIT INFORMATION . . . . . . . . . . . . . . . . . . 3
DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ELECTRICAL POWER CONNECTION . . . . . . . . . . . . 12
ELECTRICAL CONTROL CONNECTIONS . . . . . . . . . 13
COMBUSTION AIR AND VENT SYSTEM . . . . . . . . . . 14
CONDENSATE PIPING . . . . . . . . . . . . . . . . . . . . . . . . 22
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . 24
START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . 25
FURNACE ACCESSORIES . . . . . . . . . . . . . . . . . . . . . 29
AIRFLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
OPERATION AND MAINTENANCE . . . . . . . . . . . . . . . 32
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 35
CAUTION:
READ ALL SAFETY GUIDES BEFORE YOU
START TO INSTALL YOUR FURNACE.
SAVE THIS MANUAL
TWO-STAGE ULTRA
HIGH-EFFICIENCY GAS-FIRED
VARIABLE SPEED FURNACES
MODELS
UPFLOW - P*XU - "V" / G9V-UP
60 To 120 MBH Input
DOWNFLOW/HORIZONTAL - P*XD-V / G9V-DH
80 To 120 MBH Input
EFFICIENCY
RATING
CERTIFIED
035-17468-001 Rev. A (801)

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Summary of Contents for Coleman PxXU-V series

  • Page 1: Table Of Contents

    INSTALLATION TWO-STAGE ULTRA HIGH-EFFICIENCY GAS-FIRED INSTRUCTIONS VARIABLE SPEED FURNACES MODELS UPFLOW - P*XU - “V” / G9V-UP 60 To 120 MBH Input DOWNFLOW/HORIZONTAL - P*XD-V / G9V-DH 80 To 120 MBH Input TABLE OF CONTENTS GENERAL INFORMATION ..... . . 2 SPECIFIC UNIT INFORMATION .

  • Page 2: General Information

    035-17468-001 Rev. A (801) GENERAL INFORMATION DESCRIPTION This Category IV, dual certified direct vent and 1-pipe vent IMPROPER INSTALLATION MAY CREATE A CON- furnace is designed for residential or commercial application. DITION WHERE THE OPERATION OF THE It may be installed without modification to the condensate PRODUCT COULD CAUSE PERSONAL INJURY system in a basement, garage, equipment room, alcove, attic OR PROPERTY DAMAGE.

  • Page 3: Specific Unit Information

    035-17468-001 Rev. A (801) SPECIFIC UNIT INFORMATION VENT SAFETY CHECK PROCEDURE LIMITATIONS & LOCATION This furnace should be installed in accordance with all national and local building/safety codes and requirements, or This furnace may not be common vented with any in the absence of local codes, with the National Fuel Gas other appliance, since it requires separate, properly- Code ANSI Z223.1 or CAN/CGA B149.1 or .2 Installation...
  • Page 4 035-17468-001 Rev. A (801) The furnace shall be located using these guidelines: Where a minimum amount of air intake/vent piping and elbows will be required. Furnaces shall not be installed directly on carpeting, As centralized with the air distribution system as possi- tile or other combustible material other than wood ble.
  • Page 5 035-17468-001 Rev. A (801) 6-3/8 1-1/4 3-1/8 2-3/4 4-1/8 6-1/8 8-7/8 1-3/4 T’STAT WIRING 7/8” K.G. 1-3/4 OPTIONAL SIDE RETURN CUT-OUT (EITHER SIDE) 22-3/4 9-7/8 20-5/8 14-1/2 CONDENSATE 6-7/8 DRAIN 28-1/2 MODELS P*XU -V & G9V-UH 60 / 55 / 1200 /”B” 17-1/2 16-1/4 13-1/8...
  • Page 6 035-17468-001 Rev. A (801) VENT CONNECTION T'STAT WIRING 7/8 K.O. CONDENSATE CONDENSATE DRAIN ACCESS 1-3/4 DRAIN ACCESS 3-1/4 x 3 3-1/4 x 3 5-1/4 16-3/4 18-1/2 AIR INTAKE 3-3/4 AIR INTAKE 3-5/8 x 3-5/8 1-1/4 3-5/8 x 3-5/8 CONN. SIZE/ CONN.

  • Page 7: Ductwork

    035-17468-001 Rev. A (801) DUCTWORK RETURN DUCT CONNECTION Return air may enter the furnace through the side(s) or bot- The duct system's design and installation must: tom depending on the type of application. Return air may Handle an air volume appropriate for the served space not be connected into the rear panel of the unit.
  • Page 8 035-17468-001 Rev. A (801) NOTE: Some accessories such as electronic air cleaners and pleated media may require a larger side opening. Follow the POSITION WIRE RETAINER PROVIDED UNDER FLANGE instructions supplied with the accessory for side opening requirements. FILTER All installations must have a filter installed. PROVIDED CLIPS The return duct may be attached to the furnace by S-cleat,...
  • Page 9 035-17468-001 Rev. A (801) Horizontal Installations FILTER RACK For installation of an air conditioning coil in a horizontal appli- (FACTORY SUPPLIED) cation, the perforations in the wrapper flanges must be bent away from the heat exchanger to create duct flanges so the air conditioning coil can be properly seated on the furnace.
  • Page 10 035-17468-001 Rev. A (801) DOWNFLOW / HORIZONTAL MODELS - HORIZONTAL APPLICATION SUPPLY AIR LINE CONTACT ONLY PERMISSIBLE BETWEEN LINES FORMED BY THE INTERSECTION OF FURNACE TOP AND TWO SIDES AND BUILDING VENT (Maintain JOISTS, STUDS OR FRAMING required clearances to combustibles) SHEET METAL GAS PIPING IN FRONT OF...

  • Page 11: Gas Piping

    035-17468-001 Rev. A (801) An overpressure protection device, such as a pres- sure regulator, which conforms to the National Fuel Gas Code, ANSI Z223.1 (U.S.) or CAN-B149.1 or .2 (Canada) and acts to limit the downstream pressure ANGLE IRON to a value that does not exceed 0.5 PSI (14” w.c.), BRACKET must be installed in the gas piping system upstream SUPPORT...

  • Page 12: Electrical Power Connection

    035-17468-001 Rev. A (801) GND. BLK/BLK (HOT) Compounds used on threaded joints of gas piping WHT/WHT HUM (HOT) GRN/GRN must be resistant to the action of liquefied petroleum LP gases. After connections are made, leak-test all EAC (HOT) pipe connections. WIRING INSIDE After all gas piping connections are completed, leak JUNCTION BOX...

  • Page 13: Electrical Control Connections

    035-17468-001 Rev. A (801) NOTE: The power connection leads and wiring box on upflow units may be relocated to the left side of the furnace. Remove TYPICAL FIELD WIRING - TWO STAGE the screws and cut wire tie holding excess wiring. Reposition on the left side of the furnace and fasten using holes pro- OUTDOOR UNIT...

  • Page 14: Combustion Air And Vent System

    035-17468-001 Rev. A (801) COMBUSTION AIR AND VENT SYSTEM This furnace is certified to be installed with one of VENT PIPE three possible intake/vent configurations. COMBUSTION AIR CEMENTS PIPE PASSES INTO SOCKET THROUGH TOP PANEL Two-pipe with a sealed combustion intake/vent system JUST UNDER TOP PANEL using outdoor combustion air.
  • Page 15 035-17468-001 Rev. A (801) The use of flexible connectors or no hub connectors in Table 4: INTAKE/VENT PIPING - 2 PIPE SYSTEM the vent system is not allowed. This type connection is Max. Elbows vs. One Way Vent allowed in the combustion air pipe near the furnace for Upflow Pipe Length (Ft.)
  • Page 16 035-17468-001 Rev. A (801) NOTE: Shaded components of the combustion air/vent sys- OVERHANG tem shown in the following figures are considered to be part of the vent terminal. These components should not be counted when determining piping limitations. Refer to Figure 12”...
  • Page 17 035-17468-001 Rev. A (801) PIPING ASSEMBLY For upflow models combustion air is brought into the furnace through the unit top panel opening. Do not install a pipe into The final assembly procedure for the vent/combustion air pip- the intake collar on top of the burner box. Refer to Figure 24. ing is as follows: Cut piping to the proper length, beginning at the furnace.
  • Page 18 035-17468-001 Rev. A (801) COMBUSTION AIR 1 sq. in. per 3000 Btu per hr of the total input rating of all equipment located in the enclosure. All installations must comply with Section 5.3, Air for Com- bustion and Ventilation of the National Fuel Gas Code, ANSI Not less than the sum of the areas of all vent con- Z223.1 or Sections 7.2, 7.3 or 7.4 of CAN/CGA B149.1 or .2 nectors in the confined space.
  • Page 19 035-17468-001 Rev. A (801) The following types of installations may require OUT- Table 6: VENT PIPING / 1-PIPE SYSTEM - ALL MODELS DOOR AIR for combustion, due to chemical exposure. Max. Elbows vs. One Way Vent Commercial buildings Length (Ft.) Model Pipe Size 5-40...
  • Page 20 035-17468-001 Rev. A (801) 10 feet from any forced air inlet to the building. Any fresh air or make up inlet as for a dryer or furnace area is con- sidered to be a forced air inlet. Avoid areas where condensate drippage may cause problems such as above planters, patios, or adjacent to windows where steam may cause fogging.
  • Page 21 035-17468-001 Rev. A (801) All joints must be made to provide a permanent, air tight. water tight seal. Support the vent piping such that it is angled 1/4” per lin- Be sure to instruct the owner not to block this intake ear foot so that condensate will flow back towards the pipe.

  • Page 22: Condensate Piping

    035-17468-001 Rev. A (801) HORIZONTAL VENT APPLICATIONS To install the vent drain, complete the following steps: Place a tee of the proper diameter for the vent system If installing a horizontal venting system, it is recommended being installed (2" or 3") in the horizontal run closest to that a vent drain be added to the vent pipe to prevent the the furnace.
  • Page 23 035-17468-001 Rev. A (801) Table 7: HORIZONTAL CONDENSATE DRAIN HOSE SIZES - MODELS P*DH / FG9-DH / G9T-DH CABINET SIZE (IN.) DIM. RIGHT AIRFLOW (INDUCER HIGH) 14-1/2 17-1/2 24-1/2 4-1/2 4-3/4 3-1/2 5-1/4 CONDENSATE TRAP TUBING 7-1/2 10-1/2 17-1/2 13-1/2 16-1/2 23-1/2 LEFT AIRFLOW (INDUCER LOW)

  • Page 24: Safety Controls

    035-17468-001 Rev. A (801) HOSE IDENTIFIER NUMBERS: 1. CONDENSATE PAN TO TRAP “A” DIMENSIONS. RIGHT AIRFLOW (INDUCER HIGH) 2. INDUCER BOTTOM TO TRAP “B” DIMENSIONS. 3. INDUCER OUTLET TO TRAP “C” DIMENSIONS. HOSE IDENTIFIER NUMBERS: LEFT AIRFLOW 1. INDUCER OUTLET TO TRAP USE AS PROVIDED. (INDUCER HIGH) 5.

  • Page 25: Start-Up And Adjustments

    035-17468-001 Rev. A (801) LIMIT CONTROL The ignition module will energize (open) the main gas valve on low fire for seven seconds. There are high temperature limit control(s) located on the fur- After flame is established, the supply air blower will nace vestibule panel near the gas valve.
  • Page 26 035-17468-001 Rev. A (801) CHECKING GAS INPUT (NATURAL GAS) SIZE OF TEST DIAL SECONDS FOR NOTE: Front door of burner box must be secured when 1/2 CUBIC ONE REVOLUTION 1 CUBIC FOOT checking gas input. FOOT Turn off all other gas appliances connected to gas meter. With the furnace turned on, measure the time needed for one revolution of the hand on the smallest dial on the meter.
  • Page 27 035-17468-001 Rev. A (801) ADJUSTMENT OF MANIFOLD GAS PRESSURE High Outlet Pressure Adjustment Turn off all electrical power to the system at main fuse or Manifold gas pressure may be measured by two different pro- circuit breaker. cedures. It may be measured with the burner box cover in place or it may be measured with the burner box cover Attach a manometer to the outlet pressure tap of the removed.
  • Page 28 035-17468-001 Rev. A (801) WITH BURNER BOX COVER IN PLACE WITH BURNER BOX COVER REMOVED BURNER BOX WITH BURNER BOX COVER REMOVED WITH COVER BURNER BOX BURNER BOX PRESSURE PRESSURE REFERENCE REFERENCE HOSE HOSE FITTING OUTLET OUTLET PRESSURE PRESSURE GAS VALVE GAS VALVE 3.5 IN 3.5 IN...

  • Page 29: Furnace Accessories

    035-17468-001 Rev. A (801) FURNACE ACCESSORIES LECTRICAL *ET03700324 Thermostat, One-stage Heat/One-stage Cool, non-programmable *ET03700124 Thermostat, One-stage Heat/One-stage Cool, Deluxe programmable *ET03770010124 Thermostat, Two-stage Heat/Two-stage Cool, non-programmable *ET03700024 Programmable Thermostat, Two-stage Heat/Two-stage Cool, Deluxe programmable ELECTRICAL 1NP0480 Propane Conversion Kit 1SR0302BK External Side Filter Rack (6-Pack) 1BR0317 External Bottom or Horizontal Filter Rack - Cabinet “B”...
  • Page 30 035-17468-001 Rev. A (801) HEATING AIRFLOW Table 8: FAN CONTROL SETTINGS The heating airflow has been preset at the factory to provide IGNITION CONTROL maximum CFM. If a lesser CFM is required for a specific Set Switch To Delay Fan-Off By: HVAC system the “JUMPER”...
  • Page 31 035-17468-001 Rev. A (801) Table 9: AIRFLOW DATA - UPFLOW MODELS HIGH/LOW SPEED COOLING AND HEAT PUMP CFM P1XUB12V05501 P1XUC16V07501 P1XUC20V09501 P1XUD20V11201 JUMPER SETTINGS G9V06012UPB11 G9V08016UPC11 G9V10020UPC11 G9V12020UPD11 High High High High COOL TAP ADJ TAP 1315 1655 2030 1090 2180 1210 1095...

  • Page 32: Operation And Maintenance

    035-17468-001 Rev. A (801) OPERATION AND MAINTENANCE When the first stage of the thermostat is satisfied, the gas valve is de-energized and the heat delay to fan off begins tim- SEQUENCE OF OPERATION ing. The inducer will postpurge for an additional 15 seconds, then the inducer and humidifier will de-energize.
  • Page 33 035-17468-001 Rev. A (801) W2 SIGNAL HIGH INDUCER HIGH STAGE PRESSURE SWITCH AND 2ND STAGE MAIN VALVE CIRCULATOR HIGH HIGH HEAT SPEED HEAT DELAY 30 SEC. CALL HIGH HEAT AFTER LOW HEAT IS ESTABLISHED 2ND STAGE CLOSED HIGH LIMIT OPEN W1 SIGNAL INDUCER CLOSED...
  • Page 34 035-17468-001 Rev. A (801) SINGLE STAGE THERMOSTAT LUBRICATION If a single stage thermostat is used the unit will be controlled Blower and ventor motors in these furnaces are permanently through the CFM Timer board timer adjustment pins (Refer to lubricated and do not require periodic oiling. Figure 13 on Page 13.).

  • Page 35: Troubleshooting

    035-17468-001 Rev. A (801) TROUBLESHOOTING CLEANING THE HEAT EXCHANGER Turn off the main manual gas valve external to the The following visual checks should be made before trouble- furnace. shooting: Turn off electrical power to the furnace. Check to see that the power to the furnace and the igni- Remove the upper access panel and remove the burner tion control module is ON.
  • Page 36 035-17468-001 Rev. A (801) MOTOR STARTS BUT: RUNS ERRATICALLY BLOWER REMOVAL FOR CONTROLLER REPLACEMENT • Check the line voltage for variation. • Refer to BLOWER CARE on Page 34 of this manual for blower removal instructions. • Check low voltage connections at motor, unseated pins in motor harness connectors.
  • Page 37 035-17468-001 Rev. A (801) INSTALLATION OF PSC MOTOR Connect white main harness lead to Line neutral. Install the PSC direct drive motor into motor mount. Connect motor leads to cool, heat lo and heat high per electrical wire diagram table in the Installation manual. Slide motor in motor mount insuring there is no interfer- ence between moving and stationary parts.
  • Page 38 035-17468-001 Rev. A (801) 3 FLASH: This indicates the normally open pressure switch LED ON CONSTANTLY: This indicates an internal fault in the contact did not close at the beginning of the heat cycle. This furnace control discovered during its self-check procedure. could be caused by a number of problems;...
  • Page 39 035-17468-001 Rev. A (801) WIRING DIAGRAM - UPFLOW MODELS NOTE: The furnace’s control system requires correct polarity of the power supply. FIGURE 42 : Upflow Models Unitary Products Group...
  • Page 40 WIRING DIAGRAM - DOWNFLOW/HORIZONTAL MODELS NOTE: The furnace’s control system requires correct polarity of the power supply. FIGURE 43 : Downflow/Horizontal Models Subject to change without notice. Printed in U.S.A. 035-17468-001 Rev. A (801) Copyright © by York International Corp. 2001. All rights reserved. Supersedes: 035-17468-000 Rev.

This manual is also suitable for:

Pxxu-g9v-up seriesPxxd-g9v-dh seriesPxxd-v series

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