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INSTALLATION MANUAL
HIGH EFFICIENCY
TUBULAR HEAT EXCHANGER SERIES
MODELS: PS9*DH / FC9S*DH / FL9S*DH
(Single Stage Downflow/Horizontal)
40 - 120 MBH INPUT
(11.72 - 35.17 KW) INPUT
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Transition Kit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Return Filter Grill and Return Duct Installation . . . . . . . . . . . . . . . . . . . 8
Typical Attic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Typical Suspended Furnace / Crawl Space Installation . . . . . . . . . . . . 9
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Downflow Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Horizontal Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Thermostat Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Accessory Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Typical Twinned Furnace Application . . . . . . . . . . . . . . . . . . . . . . . . 13
Single Stage Twinning Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . 14
Two-Stage Twinning Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 14
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Home Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Downflow/Horizontal Vent Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 18
Termination Configuration - 1 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Termination Configuration - 2 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Termination Configuration - 2 Pipe Horizontal . . . . . . . . . . . . . . . . . . 18
Crawl Space Termination Configuration - 2Pipe . . . . . . . . . . . . . . . . 19
Unit Clearances to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Minimum Duct Sizing For Proper Airflow . . . . . . . . . . . . . . . . . . . . . . . 5
Round Duct Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cabinet and Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Recommended Filter Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electrical and Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Maximum Equivalent Pipe Length . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Equivalent Length of Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Elbow Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SECTION I: SAFETY
This is a safety alert symbol. When you see this symbol on
labels or in manuals, be alert to the potential for personal
injury.
Understand and pay particular attention to the signal words DANGER,
WARNING, or CAUTION.
DANGER indicates an imminently hazardous situation, which, if not
avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation, which, if not
avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation, which, if not
avoided may result in minor or moderate injury. It is also used to
alert against unsafe practices and hazards involving only property dam-
age.
LIST OF SECTIONS
TWINNING AND STAGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
COMBUSTION AIR AND VENT SYSTEM . . . . . . . . . . . . . . . . . . . . .14
CONDENSATE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . .31
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
LIST OF FIGURES
Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Outside and Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . .21
Attic Combustion Air Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Condensate Drain Internal Hose Routing . . . . . . . . . . . . . . . . . . . . . .22
Downflow Condensate Drain Hose Configuration . . . . . . . . . . . . . . .23
Horizontal Left Condensate Drain Hose Configuration . . . . . . . . . . . .24
Horizontal Left Condensate Drain Hose Configuration . . . . . . . . . . . .25
(Option 1 - Front of Casing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
(Option 1 - Front of Casing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
(Option 2 - Back of Casing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
(Option 2 - Back of Casing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Pressure Switch Tubing Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Furnace Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
LIST OF TABLES
(All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Free Area - Outdoor Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Unconfined Space Minimum Area in Square Inches . . . . . . . . . . . . .20
Condensate Drain Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Blower Performance CFM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Filter Performance - Pressure Drop Inches W.C. and (kPa) . . . . . . . .37
Improper installation may create a condition where the operation of
the product could cause personal injury or property damage.
Improper installation, adjustment, alteration, service or mainte-
nance can cause injury or property damage. Refer to this manual
for assistance or for additional information, consult a qualified con-
tractor, installer or service agency.
This product must be installed in strict compliance with the installa-
tion instructions and any applicable local, state, and national codes
including, but not limited to building, electrical, and mechanical
codes.
EFFICIENCY
RATING
CERTIFIED
ISO 9001
Certified Quality
Management System
269441-UIM-A-0407
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Table of Contents
Related Manuals for York PS9 DH Series
Summary of Contents for York PS9 DH Series
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Page 1: Table Of Contents
INSTALLATION MANUAL HIGH EFFICIENCY EFFICIENCY RATING TUBULAR HEAT EXCHANGER SERIES CERTIFIED MODELS: PS9*DH / FC9S*DH / FL9S*DH (Single Stage Downflow/Horizontal) ISO 9001 Certified Quality 40 - 120 MBH INPUT Management System (11.72 - 35.17 KW) INPUT LIST OF SECTIONS SAFETY ..........1 TWINNING AND STAGING . -
Page 2: Safety
269441-UIM-A-0407 SPECIFIC SAFETY RULES AND PRECAUTIONS • Provide clearances from combustible materials as listed under Clearances to Combustibles in Table 1. Only Natural gas or Propane (LP) gas are approved for use with • Provide clearances for servicing ensuring that service access is this furnace. - Page 3 269441-UIM-A-0407 INSPECTION 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 The furnace area must not be used as a broom closet or for any should be noted on the carrier’s freight bill.
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Page 4: Ductwork
269441-UIM-A-0407 When the furnace is used in conjunction with a cooling coil, the coil must be installed parallel with, or in the supply air side of the furnace to avoid condensation in the primary heat exchanger. When a parallel flow arrangement is used, dampers or other means used to control airflow Downflow/Horizontal furnaces for installation on combustible floor- must be adequate to prevent chilled air from entering the furnace. -
Page 5: Minimum Duct Sizing For Proper Airflow
269441-UIM-A-0407 Use the Example below to help you in calculating the duct area to deter- The square inch area for 7 inch round ducts, 38.4 square inch x 2 = 76.8 square inches, mine whether the ducts have sufficient area so that the furnace oper- ates at the specified external static pressure and within the air Then take the 192 square inch from the rectangular duct and add it temperature rise specified on the nameplate. -
Page 6: Transition Kit Assembly
269441-UIM-A-0407 Downflow Air Conditioning Coil Cabinet Horizontal Models The Cooling Coil Cabinet can be used in place of the combustible floor base for downflow installations on combustible materials. The furnace should be installed with the cooling coil cabinet specifically intended for downflow applications. -
Page 7: Filters
269441-UIM-A-0407 T-STAT WIRING 7/8” K.O. T-STAT WIRING 7/8” K.O. HORIZONTAL CONDENSATE HORIZONTAL CONDENSATE DRAIN OPENING 1-3/4” DRAIN OPENING 1-3/4” HORIZONTAL CONDENSATE HORIZONTAL DRAIN OPENING 2” CONDENSATE DRAIN OPENING 1-3/4” JUNCTION BOX HOLE 7/8” JUNCTION BOX HOLE 7/8” GAS PIPE ENTRY 1-1/2” GAS PIPE CONDENSATE DRAIN ENTRY 1-1/2”... -
Page 8: Return Filter Grill And Return Duct Installation
269441-UIM-A-0407 HORIZONTAL APPLICATION Downflow Filters Downflow furnaces typically are installed with the filters located above Horizontal Filters the furnace, extending into the return air plenum or duct. Any branch All filters and mounting provision must be field supplied. Filters(s) may duct (rectangular or round duct) attached to the plenum must attach to be located in the duct system external to the furnace or in a return filter the vertical plenum above the filter height. -
Page 9: Gas Piping
269441-UIM-A-0407 EXTERNAL MANUAL SHUTOFF VALVE TO GAS TO GAS SUPPLY SUPPLY SUPPORT ANGLE IRON BRACKET BRACKET 1” MAX. BETWEEN ROD & FURNACE 6” MIN. BETWEEN GROUNDED JOINT UNION 1” MAX. BETWEEN ROD & FURNACE MAY BE INSTALLED DRIP ROD & FURNACE INSIDE OR OUTSIDE UNIT. -
Page 10: Electrical Power
269441-UIM-A-0407 TABLE 6: Nominal Manifold Pressure Manifold Pressures (in wc) Manifold Pressures (kpa) Altitude (feet) Altitude (m) 0-7999 8000-8999 9000-9999 0-2437 2438-2742 2743-3048 29.8 0.87 0.87 0.87 31.7 0.87 0.87 0.87 33.5 0.87 0.87 0.87 35.4 0.87 0.87 0.81 1000 37.3 0.87 0.80... -
Page 11: Electrical Wiring
269441-UIM-A-0407 SUPPLY VOLTAGE CONNECTIONS IMPORTANT: The power connection leads and wiring box may be relo- BLOWER cated to the left side of the furnace. Remove the screws and cut wire tie COMBUSTION COMPARTMENT holding excess wiring. Reposition on the left side of the furnace and fas- ten using holes provided. -
Page 12: Thermostat Chart
269441-UIM-A-0407 FIGURE 11: Thermostat Chart Unitary Products Group... -
Page 13: Accessory Connections
269441-UIM-A-0407 ACCESSORY CONNECTIONS TWINNING DUCT SYSTEM The furnace control will allow power-switching control of various acces- Twinned furnaces must only be applied on a common duct system. A sories. Refer to Figure 12, for connection details. single air supply plenum must be used for both furnaces and coil(s). Separate plenums and supply ducts systems cannot be utilized. -
Page 14: Single Stage Twinning Wiring Diagram
269441-UIM-A-0407 Single-Wire Twinning Instructions Single-Wire Staging Instructions Connect the control wiring as shown in the Figure 15. Connect the control wiring as shown in the Figure 14. Connect the low voltage wiring from the wall thermostat to the ter- Connect the low voltage wiring from the wall thermostat to the ter- minal strip on the control board of Furnace #1. -
Page 15: Maximum Equivalent Pipe Length
269441-UIM-A-0407 TABLE 8: Maximum Equivalent Pipe Length Maximum Model Input Pipe Size Equivalent This furnace may not be common vented with any other appliance, BTUH (kW) Inches (cm) since it requires separate, properly sized air intake and vent lines. length feet (m) The furnace shall not be connected to any type of B, BW or L vent 40,000 (11.7) 2 (5.1) -
Page 16: Dimensions
269441-UIM-A-0407 COMBUSTION AIR AND VENT PIPING ASSEMBLY The final assembly procedure for the combustion air and vent piping is as follows: Cut piping to the proper length beginning at the furnace. Deburr the piping inside and outside. Chamfer (bevel) the outer edges of the piping. Dry-fit the vent piping assembly from the furnace to the outside ter- mination checking for proper fit support and slope. -
Page 17: Home Layout
269441-UIM-A-0407 VENT CLEARANCES VENT TERMINAL FIXED AIR SUPPLY CLOSED AREA WHERE TERMINAL IS NOT PERMITTED FIXED CLOSED OPERABLE FIGURE 17: Home Layout Direct Vent Terminal Clearances Canadian Installations US Installation A. Clearance above grade, veranda, porch, deck, or 12 inches (30 cm) 12 inches (30 cm) balcony Two-pipe (direct vent) applications: 9 inches (23 cm) -
Page 18: Downflow/Horizontal Vent Assembly
269441-UIM-A-0407 VENT SYSTEM HORIZONTAL VENT ASSEMBLY This furnace is certified to be installed with one of two possible vent Horizontal Left Vent Assembly configurations. Place the 2” (5.08 cm) 45° PVC street elbow on the vent connec- Horizontal vent system. This vent system can be installed com- tion shown in Figure 18. -
Page 19: Crawl Space Termination Configuration - 2Pipe
269441-UIM-A-0407 12” MINIMUM BELOW OVERHANG MIN. 12” MINIMUM 6” SEPARATION BETWEEN BOTTOM OF COMBUSTION AIR PIPE AND BOTTOM OF VENT MAINTAIN 12” MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW FIGURE 24: Double Vertical Sealed Combustion Air and Vent LEVEL OR GRADE, Termination WHICHEVER IS VENT DRAIN... -
Page 20: Combustion Airflow Path Through The Furnace Casing To The Burner
269441-UIM-A-0407 The combustion air intake pipe should be located either through the Combustion Air Source From Outdoors wall (horizontal or side vent) or through the roof (vertical vent). Care The blocking effects of louvers, grilles and screens must be given con- should be taken to locate side vented systems where trees or shrubs sideration in calculating free area. -
Page 21: Outside And Ambient Combustion Air
269441-UIM-A-0407 AIR SUPPLY OPENINGS AND DUCTS GABLE VENT VENT VENT 1. An opening may be used in lieu of a duct to provide to provide the outside air supply to an appliance unless otherwise permitted by the authority having VENTILATED jurisdiction. -
Page 22: Condensate Piping
269441-UIM-A-0407 IMPORTANT: Condensate must be disposed of properly. Follow local plumbing or wastewater codes. The drain line must maintain a 1/4" per 12” MINIMUM BETWEEN BOTTOM OF BELOW AND foot (0.635 cm per meter) slope to the drain. ANY MATERIAL CONDENSATE DRAIN TRAP AND DRAIN FREEZE 12”... -
Page 23: Downflow Condensate Drain Hose Configuration
269441-UIM-A-0407 SPRING CLAMP 1” HOSE #5 HOSE #1 2-3/4” 4-1/2” 3/4” 3/4” PIECE SPRING CLAMP DOGLEG 8-1/8” 9” HOSE #3 HOSE #2 (if drain aligned above the hole in 5/8” SPRING CLAMP furnace top) 1-1/8” 3-3/8” HOSE #4 (with 3/8” barbed nipple) HOSE #2 17-1/2”... -
Page 24: Horizontal Left Condensate Drain Hose Configuration
269441-UIM-A-0407 FIGURE 31: Horizontal Left Condensate Drain Hose Configuration Unitary Products Group... -
Page 25: Horizontal Left Condensate Drain Hose Configuration
269441-UIM-A-0407 FIGURE 32: Horizontal Left Condensate Drain Hose Configuration Unitary Products Group... - Page 26 269441-UIM-A-0407 Horizontal Right Air Flow (Inducer High) Refer to Figures 33-36 Installation with condensate trap bracket (Front of casing): Ensure all condensate hoses are pushed all the way down on the Refer to Figure 33 & 34 condensate trap, barbed fittings, and condensate pan drains. Remove the 2"...
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Page 27: Horizontal Right Condensate Drain Hose Configuration (Option 1 - Front Of Casing)
269441-UIM-A-0407 FIGURE 33: Horizontal Right Condensate Drain Hose Configuration (Option 1 - Front of Casing) Unitary Products Group... -
Page 28: Horizontal Right Condensate Drain Hose Configuration (Option 1 - Front Of Casing)
269441-UIM-A-0407 FIGURE 34: Horizontal Right Condensate Drain Hose Configuration (Option 1 - Front of Casing) Unitary Products Group... -
Page 29: Horizontal Right Condensate Drain Hose Configuration (Option 2 - Back Of Casing)
269441-UIM-A-0407 FIGURE 35: Horizontal Right Condensate Drain Hose Configuration (Option 2 - Back of Casing) Unitary Products Group... -
Page 30: Horizontal Right Condensate Drain Hose Configuration (Option 2 - Back Of Casing)
269441-UIM-A-0407 FIGURE 36: Horizontal Right Condensate Drain Hose Configuration (Option 2 - Back of Casing) Unitary Products Group... -
Page 31: Safety Controls
269441-UIM-A-0407 CONDENSATE DRAIN TERMINATION DO NOT terminate condensate drain in a chimney, or where the drain line may freeze. The line must terminate at an inside drain to prevent freezing of the condensate and possible property damage. DO NOT trap the drain line at any other location than at the condensate drain trap supplied with the furnace. - Page 32 269441-UIM-A-0407 There is an accessory kit (1PK0601) available from Source 1, which IMPORTANT: Burner ignition may not be satisfactory on first startup due to residual air in the gas line or until gas manifold pressure is has the following items: adjusted.
- Page 33 269441-UIM-A-0407 In the USA use the following formula to calculate the furnace input. For natural gas multiply the heat content of the gas BTU/SCF or Default 1030 BTU/SCF (38.4 MJ/m ), times 2 cubic ft. (0.056 m) of gas measured at the gas meter, times a barometric pressure and temperature correction factor of 0.960;...
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Page 34: Gas Valve
269441-UIM-A-0407 Reading the gas pressure with the burner box cover removed - Remove the screws securing the burner box front cover plate. Remove the cover. The gasket and may stick in place. Connect the positive side of the manometer to the gas valve as described in E above. There will Be sure to relight any gas appliances that were turned off at the be no second connection to the manometer, as it will reference atmo- start of this input check. -
Page 35: Reading Gas Pressure
269441-UIM-A-0407 WITH BURNER BOX COVER IN PLACE WITH BURNER BOX COVER REMOVED GAS VALVE FITTING VALVE BURNER BOX PRESSURE BURNER BOX REFERENCE PRESSURE HOSE REFERENCE HOSE 3.5 IN 3.5 IN U-TUBE WATER COLUMN U-TUBE WATER COLUMN MANOMETER GAS PRESSURE MANOMETER GAS PRESSURE SHOWN SHOWN... - Page 36 269441-UIM-A-0407 FURNACE CONTROL DIAGNOSTICS 9 RED FLASHES: Indicates reversed line voltage polarity or grounding problem. Both heating and cooling operations will be affected. Check The furnace has built-in, self-diagnostic capability. If a system problem polarity at furnace and branch. Check furnace grounding. Check that occurs, a blinking LED shows a fault code.
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Page 37: Blower Performance Cfm
269441-UIM-A-0407 TABLE 18: Blower Performance CFM MODELS Airflow with Top Return - without Filters (CFM) Airflow with Top Return - without Filters (m min) Input/ Speed External Static Pressure, Inches W.C. External Static Pressure, Inches (kPa) Airflow/ 0.025 0.050 0.075 0.099 0.124 0.149 0.174 0.199 0.224 0.249 Cabinet High 1635 1590 1535 1480 1415 1340 1280 1185... - Page 38 269441-UIM-A-0407 APPLYING FILTER PRESSURE DROP TO Example: For a 120,000 Btuh furnace operating on high speed blower, DETERMINE SYSTEM AIRFLOW it is found that total system static is 0.58" w.c. To determine the system airflow, complete the following steps: To determine the approximate airflow of the unit with a filter in place, fol- Obtain the airflow values at 0.50"...
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Page 39: Wiring Diagram
269441-UIM-A-0407 SECTION XI: WIRING DIAGRAM FIGURE 41: Wiring Diagram Unitary Products Group... - Page 40 NOTES Subject to change without notice. Printed in U.S.A. 269441-UIM-A-0407 Copyright © by York International Corp. 2007. All rights reserved. Supersedes: 167569-UIM-A-1205 Unitary 5005 Norman Product York Group Drive 73069...