035-20646-001 Rev. A (1004)
HIGH EFFICIENCY
TUBULAR HEAT EXCHANGER SERIES
MODELS: PS9 / FC9S / FL9S
(Single Stage Downflow/Horizontal)
40 - 120 MBH INPUT
(11.72 - 35.17 KW) INPUT
INSTALLATION MANUAL
EFFICIENCY
RATING
CERTIFIED
This product was manufactured
in a plant whose quality system
is certified/registered as being
in conformity with ISO 9001.
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.
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.
TABLE OF CONTENTS
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TWINNING AND STAGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
COMBUSTION AIR AND VENT SYSTEM . . . . . . . . . . . . . . . . . . . . .13
CONDENSATE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
CONDENSATE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . .23
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
LIST OF FIGURES
Transition Kit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Accessory Downflow Filter Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Return Filter Grill and Return Duct Installation . . . . . . . . . . . . . . . . . . . . 7
Typical Attic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Typical Suspended Furnace / Crawl Space Installation . . . . . . . . . . . . . 8
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Downflow Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Horizontal Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Polarity Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Heating and Cooling Thermostat Connections . . . . . . . . . . . . . . . . . . . 11
Accessory Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Typical Twinned Furnace Application . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Single Stage Twinning Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 12
Two-Stage Twinning Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Home Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Downflow/Horizontal Vent Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
External Horizontal Vent Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Termination Configuration - 1 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Termination Configuration - 2 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Termination Configuration - 2 Pipe Horizontal . . . . . . . . . . . . . . . . . . . . 17
Crawl Space Termination Configuration - 2Pipe . . . . . . . . . . . . . . . . . . 17
Double Horizontal Sealed Combustion Air and Vent Termination . . . . . 17
Double Vertical Sealed Combustion Air and Vent Termination . . . . . . . 17
Sealed Combustion Air Intake Connection and Vent Connection . . . . . 18
Combustion Airflow Path Through The Furnace Casing
to the Burner Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Outside and Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Attic Combustion Air Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Condensate Drain Internal Hose Routing . . . . . . . . . . . . . . . . . . . . . . . 20
Downflow Condensate Drain Hose Configuration . . . . . . . . . . . . . . . . . 20
Horizontal Left Condensate Drain Hose Configuration . . . . . . . . . . . . . 21
Horizontal Right Condensate Drain Hose Configuration . . . . . . . . . . . . 22
Pressure Switch Tubing Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Typical Heat/Cool Speed Tap Connections . . . . . . . . . . . . . . . . . . . . . . 27
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
LIST OF TABLES
Unit Clearances to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Minimum Duct Sizing For Proper Airflow . . . . . . . . . . . . . . . . . . . . . . . . . 4
Round Duct Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Filter Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
High Altitude Pressure Switch Application . . . . . . . . . . . . . . . . . . . . . . . 9
High Altitude Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical and Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Combustion Air Intake and Vent Connection Size at Furnace
(All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Combustion Air Supply and Vent Piping . . . . . . . . . . . . . . . . . . . . . . . . 14
Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Unconfined Space Minimum Area in Square Inch . . . . . . . . . . . . . . . . . 18
Condensate Drain Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Blower Performance CFM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Filter Performance - Pressure Drop Inches W.C. and (kPa) . . . . . . . . . 28
