background image

035-20499-001 Rev. B (1004)

HIGH EFFICIENCY
TUBULAR HEAT EXCHANGER SERIES

MODELS: PV9 / FC9V / FL9V

(Two Stage Variable Speed Upflow)

40 - 120 MBH INPUT
(11.7 - 35.1 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  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FILTERS   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
GAS PIPING   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ELECTRICAL POWER   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

COMBUSTION AIR AND VENT SYSTEM . . . . . . . . . . . . . . . . . . . . . .9
CONDENSATE PIPING  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
SAFETY CONTROLS   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . .17
WIRING DIAGRAM   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

LIST OF FIGURES

Dimensions   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Furnace Base Rectangular Blockoff Panel   . . . . . . . . . . . . . . . . . . . . . 6
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Gas Piping  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electrical Wiring  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Line Wiring Connections   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Single Stage Heat Thermostat Connections   . . . . . . . . . . . . . . . . . . . . 9
Single Stage Heating and Two-Stage Cooling 
Thermostat Connections   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Two Stage Heating and Two-Stage Cooling Thermostat Connections  9
Accessory Connections  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Home Layout  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Termination Configuration - 1 Pipe   . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Termination Configuration - 2 Pipe   . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Termination Configuration - 2 Pipe Basement  . . . . . . . . . . . . . . . . . . 12

Double Horizontal Sealed Combustion Air and Vent Termination   . . .13
Double Vertical Sealed Combustion Air and Vent Termination   . . . . .13
External Horizontal Vent Drain  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Sealed Combustion Air Intake Connection and Vent Connection   . . .13
Combustion Airflow Path Through The Furnace Casing to the Burner 
Box  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Outside and Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . .15
Attic and Crawl Space Combustion Air Termination . . . . . . . . . . . . . .16
Condensate Piping  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Pressure Switch Tube Routing  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Gas Valve  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Reading Gas Pressure  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Furnace Control Board  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
CFM / Timer Board  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Wiring Diagram  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

LIST OF TABLES

Unit Clearances to Combustibles  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Minimum Duct Sizing For Proper Airflow  . . . . . . . . . . . . . . . . . . . . . . . 4
Round Duct Size   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Filter Sizes  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inlet Gas Pressure Range  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
High Altitude Conversion  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electrical and Performance Data  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Combustion Air Intake and Vent Connection Size at Furnace 
(All Models)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Combustion Air Supply and Vent Piping . . . . . . . . . . . . . . . . . . . . . . .10
Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Free Area  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Unconfined Space Minimum Area in Square Inch   . . . . . . . . . . . . . . .14
Inlet Gas Pressure Range   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Air Flow Data   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Filter Performance - Pressure Drop Inches W.C. and (kPa) . . . . . . . .23

Summary of Contents for PV9

Page 1: ...des TABLE OF CONTENTS SAFETY 1 DUCTWORK 3 FILTERS 6 GAS PIPING 6 ELECTRICAL POWER 8 COMBUSTION AIR AND VENT SYSTEM 9 CONDENSATE PIPING 16 SAFETY CONTROLS 16 START UP AND ADJUSTMENTS 17 WIRING DIAGRAM...

Page 2: ...tional vehicles Failure to carefully read and follow all instructions in this manual can result in furnace malfunction death personal injury and or property damage Furnaces for installation on combust...

Page 3: ...is required for passage to the front when servicing or for inspection or replacement of flue vent connections In all cases accessibility clearances shall take precedence over clear ances for combustib...

Page 4: ...ABLES 2 AND 3 are to be used as a guide only to help the installer determine if the duct sizes are large enough to obtain the proper air flow CFM through the furnace TABLES 2 and 3 ARE NOT to be used...

Page 5: ...rn End 5 Be sure to seal the furnace to plenum connections to prevent air leakage Refer to Figure 1 for unit and plenum dimensions Attic installations must meet all minimum clearances to combustibles...

Page 6: ...28 27 25 2000 57 C 16 x 25 41 x 64 20 x 25 51 x 64 120 112 2000 35 14 32 80 2000 57 D 2 16 x 25 2 41 x 64 22 x 25 56 x 64 All installations must have a filter installed Toe Plate Removable Rectangula...

Page 7: ...4 National Fuel Gas Code or in Canada CAN CGA B149 1 00 Natural Gas and Propane Installation Code HIGH ALTITUDE PRESSURE SWITCH CONVERSION For installation in locations where the altitude is less than...

Page 8: ...furnace s control system requires correct polarity of the power supply and a proper ground connection Refer to Figure 6 IMPORTANT The power connection leads and wiring box may be relo cated to the le...

Page 9: ...hese instructions IMPORTANT The VENT SYSTEM must be installed as specified in these instructions for Residential and Non HUD Modular Homes The sealed combustion air vent system is the only configurati...

Page 10: ...is as follows 1 Cut piping to the proper length beginning at the furnace 2 Deburr the piping inside and outside 3 Chamfer bevel the outer edges of the piping 4 Dry fit the vent piping assembly from th...

Page 11: ...1 US Installation2 A Clearance above grade veranda porch deck or balcony 12 inches 30 cm 12 inches 30 cm B Clearance to window or door that may be opened 6 inches 15 cm for applications 10 000 Btuh 3k...

Page 12: ...bustion air systems must be installed so the vent and the combustion air pipes terminate in the same atmospheric zone Refer to Figures 13 or 14 VENTING MULTIPLE UNITS Multiple units can be installed i...

Page 13: ...STION AIR Combustion air is supplied through a PVC or ABS pipe that is connected to the PVC coupling attached to the burner box and is terminated in a ventilated attic or crawl space The combustion ai...

Page 14: ...ion smaller than 0 25 6 4 mm 3 A manually operated damper or manually adjustable louvers are not permitted for use 4 A automatically operated damper or automatically adjustable lou vers shall be inter...

Page 15: ...w usage Follow all notes procedures and required materials in the SEALED COMBUS TION AIR SUPPLY section in these instructions when installing the combustion air pipe from the unit and into a ventilate...

Page 16: ...densate sump pump must be approved for use with acidic condensate CONDENSATE DRAIN TRAP AND DRAIN FREEZE PROTECTION Special precautions MUST be made if installing furnace in an area which may drop bel...

Page 17: ...bing 2 pieces of 4 10 cm length x 1 8 0 3 cm diameter tubing 1 5 16 0 8 cm tee 1 5 16 0 8 cm x 1 8 0 3 cm reducing coupling 1 1 8 0 3 cm adapter 1 Dwyer Manometer These items are required in order to...

Page 18: ...ivided by the time it took to measure 2 cubic ft 0 0566 m3 of gas from the gas meter For Propane LP Gas multiply the Heat content of the gas MJ m3 or Default 93 14 times 0 00283 m3 of gas measured at...

Page 19: ...as shown in Figure 24 The procedure below is used to adjust either the high fire manifold pressure or the low fire manifold pressure IMPORTANT The cap for the pressure regulator must be removed entir...

Page 20: ...Heating and Cooling Airflow The heating and the cooling airflows are preset at the factory The heat ing airflow is set to the maximum CFM The cooling airflow is set to pro vide 90 percent of the maxi...

Page 21: ...all for cooling the motor will ramp up to 63 of full capacity and will stay there for 90 seconds then will ramp up to full capacity At the end of the cooling cycle the motor will ramp down to 63 of fu...

Page 22: ...4 1880 1250 53 2 35 4 A C 1560 1010 44 2 28 6 1620 1030 45 9 29 2 C B 1470 940 41 6 26 6 1500 960 42 5 27 2 B C 1370 890 38 8 25 2 1410 880 39 9 24 9 D B 1460 930 41 3 26 3 1490 920 42 2 26 1 C A 125...

Page 23: ...the airflow table i e 0 20 w c 50 Pa 0 60 w c 150 Pa etc the system airflow cor responds to the intersection of the ESP column and Model Blower Speed row TABLE 16 Filter Performance Pressure Drop Inc...

Page 24: ...ed in U S A 035 20499 001 Rev B 1004 Copyright by York International Corp 2004 All rights reserved Supersedes 035 20499 001 Rev A 0904 Unitary 5005 Norman Product York OK Group Drive 73069 SECTION X W...

Reviews: