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INSTALLATION MANUAL
HIGH EFFICIENCY
TUBULAR HEAT EXCHANGER SERIES
MODELS: PT9-DH / FC9T-DH / FL9T-DH
(Two Stage Downflow/Horizontal)
60 - 120 MBH INPUT
(17.62 - 35.17 KW) INPUT
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Combustible Floor Base Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Transition Kit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Return Filter Grill and Return Duct Installation . . . . . . . . . . . . . . . . . . . 8
Typical Attic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Typical Suspended Furnace / Crawl Space Installation . . . . . . . . . . . . 8
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Downflow Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Horizontal Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Thermostat Chart - AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Thermostat Chart - HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Accessory Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Twinning Wiring Diagram - 1H/1C Thermostat . . . . . . . . . . . . . . . . . 15
Twinning Wiring Diagram - 2H/1C Thermostat . . . . . . . . . . . . . . . . . 15
Twinning Wiring Diagram - 2H/2C Thermostat . . . . . . . . . . . . . . . . . 15
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Home Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Downflow/Horizontal Vent Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 19
Termination Configuration - 1 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Termination Configuration - 2 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Termination Configuration - 2 Pipe Horizontal . . . . . . . . . . . . . . . . . . 19
Crawl Space Termination Configuration - 2Pipe . . . . . . . . . . . . . . . . 20
Unit Clearances to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Minimum Duct Sizing For Proper Airflow . . . . . . . . . . . . . . . . . . . . . . . 5
Round Duct Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Recommended Filter Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Nominal Manifold Pressure - High Fire . . . . . . . . . . . . . . . . . . . . . . . 10
Nominal Manifold Pressure - Low Fire . . . . . . . . . . . . . . . . . . . . . . . . 10
Electrical and Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Maximum Equivalent Pipe Length . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Equivalent Length of Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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 serio us 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.
TABLE OF CONTENTS
COMBUSTION AIR AND VENT SYSTEM . . . . . . . . . . . . . . . . . . . . .15
CONDENSATE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . .32
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
LIST OF FIGURES
Casing to the Burner Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Outside and Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . .22
Attic Combustion Air Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Condensate Drain Internal Hose Routing . . . . . . . . . . . . . . . . . . . . . .23
Downflow Condensate Drain Hose Configuration . . . . . . . . . . . . . . .24
Horizontal Left Condensate Drain Hose Configuration . . . . . . . . . . . .25
Horizontal Left Condensate Drain Hose Configuration . . . . . . . . . . . .26
(Option 1 - Front of Casing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
(Option 1 - Front of Casing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
(Option 2 - Back of Casing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
(Option 2 - Back of Casing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Pressure Switch Tubing Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Furnace Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
LIST OF TABLES
Size at Furnace (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Unconfined Space Minimum Area in Square Inch . . . . . . . . . . . . . . .21
Condensate Drain Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Blower Performance CFM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Filter Performance - Pressure Drop Inches W.C. and (kPa) . . . . . . . .38
Field Installed Accessories - Non Electrical . . . . . . . . . . . . . . . . . . . .39
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
272314-UIM-A-0407
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Table of Contents
Related Manuals for York PT9-DH
Summary of Contents for York PT9-DH
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Page 1: Table Of Contents
INSTALLATION MANUAL HIGH EFFICIENCY EFFICIENCY RATING TUBULAR HEAT EXCHANGER SERIES CERTIFIED MODELS: PT9-DH / FC9T-DH / FL9T-DH (Two Stage Downflow/Horizontal) ISO 9001 60 - 120 MBH INPUT Certified Quality Management System (17.62 - 35.17 KW) INPUT TABLE OF CONTENTS SAFETY ..........1 COMBUSTION AIR AND VENT SYSTEM . -
Page 2: Specific Safety Rules And Precautions
272314-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 272314-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: Section Ii: Ductwork
272314-UIM-A-0407 Installation in a residential garage: A gas-fired furnace for installation in a residential garage must be installed so the burner(s) and the ignition source are located not less than 18 inches (46 cm) above the floor, and the furnace must be located Downflow/Horizontal furnaces for installation on combustible floor- ing only when installed on the accessory combustible floor base on or protected to avoid physical damage by vehicles. -
Page 5: Combustible Floor Base Accessory
272314-UIM-A-0407 Example: The furnace input is 80,000 BTUH, 1,200 CFM blower Then take the 192 square inch from the rectangular duct and add it requirement. The recommended duct area is 216 sq.in, there are two 8 to the 76.8 square inch of round duct. The total square inch of duct attached to the furnace supply plenum is 268.8 square inches. -
Page 6: Transition Kit Assembly
272314-UIM-A-0407 This transition kit may be installed in one of two ways. The transition kit Horizontal Models may be installed and secured to either the furnace or the cooling coil cabinet by the use of screws and then it must be sealed to prevent leaks. -
Page 7: Recommended Filter Sizes
272314-UIM-A-0407 22-3/4 T-STAT WIRING 7/8” K.O. T-STAT WIRING 7/8” K.O. HORIZONTAL CONDENSATE 13-7/8 DRAIN OPENING 1-3/4” HORIZONTAL CONDENSATE DRAIN OPENING 1-3/4” HORIZONTAL CONDENSATE HORIZONTAL DRAIN OPENING 2” CONDENSATE DRAIN OPENING 1-3/4” JUNCTION BOX HOLE 7/8” JUNCTION BOX 22-3/4 22-3/4 HOLE 7/8” GAS PIPE ENTRY 1-1/2”... -
Page 8: Horizontal Application
272314-UIM-A-0407 If the accessory electronic air cleaner is installed, be sure the air IMPORTANT: In either a horizontal left or right installation, a minimum of 8" (20.3 cm) clearance is required beneath the furnace to allow for cleaner is designed to accommodate the furnace CFM (cm/m) and the the installation of the condensate trap and drain pipe. -
Page 9: Section Iv: Gas Piping
272314-UIM-A-0407 SECTION IV: GAS PIPING MANUAL GAS SAFETY SHUT-OFF VALVE DRIP PIPE GAS BURNERS An overpressure protection device, such as a pressure regulator, must be installed in the gas piping system upstream of the furnace GAS VALVE and must act to limit the downstream pressure to the gas valve so it PIPE does not exceed 0.5 PSI {14"... -
Page 10: Electrical Power Connections
272314-UIM-A-0407 TABLE 5: Nominal Manifold Pressure - High Fire Second Stage Manifold Pressures (in wc) Second Stage 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... -
Page 11: Supply Voltage Connections
272314-UIM-A-0407 TABLE 7: Electrical and Performance Data Input Output Nominal Airflow Cabinet Width Total Unit AFUE Air Temp. Rise (High/Low) (High/Low) Amps °F °C /min 60 / 39 18 / 11 56 / 36 16.1 / 10.6 1200 34.0 17-1/2 44.4 35 - 65 19 - 36... -
Page 12: Thermostat Chart - Ac
272314-UIM-A-0407 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. FIGURE 11: Thermostat Chart - AC Unitary Products Group... -
Page 13: Thermostat Chart - Hp
272314-UIM-A-0407 FIGURE 12: Thermostat Chart - HP Unitary Products Group... -
Page 14: Accessory Connections
272314-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 13, 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 15: Twinning Wiring Diagram - 1H/1C Thermostat
272314-UIM-A-0407 Twinning Operation Heating - On a call for low-stage heat (W1 signal) from the wall thermo- stat, both furnaces will start the ignition sequence and the burners on both furnaces will light and run at low fire. After a short delay, both blow- W1 RELAY ers will come on and operate at the low heat speed. -
Page 16: Dimensions
272314-UIM-A-0407 COMBUSTION AIR/VENT PIPE SIZING TABLE 9: Equivalent Length of Fittings The size of pipe required will be determined by the furnace model, the Fitting Equivalent Length total length of pipe required and the number of elbows required. 2" 90º sweep elbow 5 feet of 2"... -
Page 17: Combustion Air Intake And Vent Connection Size At Furnace (All Models)
272314-UIM-A-0407 Dry-fit the combustion air piping assembly checking for proper fit, TABLE 11: Combustion Air Intake and Vent Connection Size at Furnace support and slope on the following systems: (All Models) Sealed combustion air systems from the furnace to the out- FURNACE VENT CONNECTION SIZES side termination. -
Page 18: Vent Clearances
272314-UIM-A-0407 VENT CLEARANCES VENT TERMINAL FIXED AIR SUPPLY CLOSED AREA WHERE TERMINAL IS NOT PERMITTED FIXED CLOSED OPERABLE FIGURE 18: 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 19: Vent System
272314-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 19. -
Page 20: Venting Multiple Units
272314-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 25: Double Vertical Sealed Combustion Air and Vent LEVEL OR GRADE, WHICHEVER IS Termination VENT DRAIN... -
Page 21: Combustion Airflow Path Through The Furnace Casing To The Burner Box
272314-UIM-A-0407 Also, the terminal assembly should be located as far as possible from a Combustion Air Source From Outdoors swimming pool or a location where swimming pool chemicals might be The blocking effects of louvers, grilles and screens must be given con- stored. -
Page 22: Outside And Ambient Combustion Air
272314-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 23: Section Vii: Condensate Piping
272314-UIM-A-0407 CONDENSATE DRAIN TRAP AND DRAIN FREEZE Specially Engineered Installations PROTECTION The above requirements shall be permitted to be waived where special engineering, approved by the authority having jurisdiction, provides an Special precautions MUST be made if installing furnace in an area, adequate supply of air for combustion, ventilation and dilution of flue which may drop below freezing. -
Page 24: Downflow Condensate Drain Hose Configuration
272314-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 25: Horizontal Left Condensate Drain Hose Configuration
272314-UIM-A-0407 FIGURE 32: Horizontal Left Condensate Drain Hose Configuration Unitary Products Group... -
Page 26: Horizontal Left Condensate Drain Hose Configuration
272314-UIM-A-0407 FIGURE 33: Horizontal Left Condensate Drain Hose Configuration Unitary Products Group... - Page 27 272314-UIM-A-0407 Horizontal Right Air Flow (Inducer High) Refer to Figures 34-37 Installation with condensate trap bracket (Front of casing): Ensure all condensate hoses are pushed all the way down on the Refer to Figure 34 & 35 condensate trap, barbed fittings, and condensate pan drains. Remove the 2"...
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Page 28: Horizontal Right Condensate Drain Hose Configuration (Option 1 - Front Of Casing)
272314-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 1 - Front Of Casing)
272314-UIM-A-0407 FIGURE 35: Horizontal Right Condensate Drain Hose Configuration (Option 1 - Front of Casing) Unitary Products Group... -
Page 30: Horizontal Right Condensate Drain Hose Configuration (Option 2 - Back Of Casing)
272314-UIM-A-0407 FIGURE 36: Horizontal Right Condensate Drain Hose Configuration (Option 2 - Back of Casing) Unitary Products Group... -
Page 31: Horizontal Right Condensate Drain Hose Configuration (Option 2 - Back Of Casing)
272314-UIM-A-0407 FIGURE 37: Horizontal Right Condensate Drain Hose Configuration (Option 2 - Back of Casing) Unitary Products Group... -
Page 32: Pressure Switch Tubing Routing
272314-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 33 272314-UIM-A-0407 TOOLS AND INFORMATION THAT WILL BE REQUIRED IN ORDER TO PROPERLY PERFORM THE FURNACE STARTUP PROCEDURE. FIRE OR EXPLOSION HAZARD Call the local gas supplier to obtain heating value of the natural Failure to follow the safety warnings exactly could result in serious gas.
- Page 34 272314-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 35: Gas Valve
272314-UIM-A-0407 IMPORTANT: The cap for the pressure regulator must be removed entirely to gain access to the adjustment screw. Loosening or tightening the cap does not adjust the flow of gas. Refer to Figure 39 for location of pressure regulator adjustment Be sure to relight any gas appliances that were turned off at the cap and adjustment screw on main gas valve. -
Page 36: Adjustment Of Temperature Rise
272314-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 37: Ignition Control
272314-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. -
Page 38: Blower Performance Cfm
272314-UIM-A-0407 TABLE 18: Blower Performance CFM Models Airflow with Top Return (CFM) Airflow with Top Return (m /min) Input Speed External Static Pressure, Inches W.C. External Static Pressure, Inches (kPa) Airflow/ Cabinet 0.025 0.050 0.075 0.099 0.124 0.149 0.174 0.199 0.224 0.249 High 1687 1652 1631 1595 1557 1511 1456 1382 1313 1211 Med-High... -
Page 39: Field Installed Accessories - Non Electrical
272314-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"... -
Page 40: Section X: Wiring Diagram
SECTION X: WIRING DIAGRAM FIGURE 42: Wiring Diagram Subject to change without notice. Printed in U.S.A. 272314-UIM-A-0407 Copyright © by York International Corp. 2007. All rights reserved. Supersedes: 167801-UIM-B-0806 Unitary 5005 Norman Product York Group Drive 73069...
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