Installation guide

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HIGH EFFICIENCY

CLAM TUBE HEAT EXCHANGER SERIES

MODELS: UGAA & UGAB

(Single Stage Upflow/Horizontal)

75 - 100 MBH INPUT

(21.98 - 29.31 KW) INPUT

Q _ ]SO 9001

Certified Quality

Management System

TABLE OF CONTENTS

SAFETY ................................................ 1 TWINNING AND STAGING ................................ 12

DUCTWORK ............................................ 4 VENT/COMBUSTION AIR SYSTEM ......................... 14

FILTERS ............................................... 8 SAFETY CONTROLS .................................... 20

GAS PIPING ............................................ 9 START-UP AND ADJUSTMENTS ........................... 20

ELECTRICAL POWER ................................... 11 WIRING DIAGRAM ...................................... 26

LIST OF FIGURES

Dimensions ............................................. 6

Floor Installation .......................................... 6

Platform Installation ....................................... 7

Typical Attic Installation .................................... 7

Typical Suspended Furnace / Crawl Space Installation ............ 8

Side Return Cutout Markings ................................ 8

Horizontal Mount and Filter ................................. 8

Gas Valve ............................................... 9

Upflow Configuration ...................................... 9

Horizontal Gas Piping ..................................... 9

Burner Assembly ........................................ 10

Line Wiring Connections .................................. 11

Heating and cooling Thermostat Connections .................. 12

Two-Stage Heating and Cooling Thermostat Connections ........ 12

Accessory Connections ................................... 12

Typical Twinned Furnace Application ........................ 13

Single Stage Twinning Wiring Diagram ....................... 13

Two-Stage Twinning Wiring Diagram ......................... !4

Vent Termination ........................................ !4

Alternate Air Intake, Air Outlet and Chimney Connections ......... 15

Air Inlet, Outlet and Chimney Connections ..................... 15

Typical Sidewall Vent Application ............................ !6

Typical Sidewall Vent and Termination Configuration ............ 16

Typical Chimney Connections .............................. !6

Horizontal Air Inlet, Outlet and Chimney Connections ............ 16

Home Layout ........................................... !7

Combustion Airflow Path Through The Furnace Casing

to the Burner Box ........................................ !8

Outside and Ambient Combustion Air ......................... 19

Pressure Switch Tubing Routing ............................ 20

Gas Valve .............................................. 23

Reading Gas Pressure .................................... 23

Typical Heat/Cool Speed Tap Connections .................... 24

Wiring Diagram .......................................... 26

LIST OF TABLES

Unit Clearances to Combustibles ............................. 4

Minimum Duct Sizing For Proper Airflow ....................... 5

External Static Pressure Range .............................. 5

Cabinet and Duct Dimensions ............................... 6

Filter Sizes - Upflow ....................................... 8

Inlet Gas Pressure Range .................................. 9

High Altitude Conversion .................................. 1!

Ratings & Physical / Electrical Data - Upflow Models ............ 11

Roof Pitch .............................................. 14

Horizontal Sidewall Venting Clearances ....................... 16

Estimated Free Area ...................................... !8

Free Area .............................................. 18

Unconfined Space Minimum Area in Square Feet ............... 18

Inlet Gas Pressure Range ................................. 23

Nominal Manifold Pressure ................................. 23

Filter Performance - Pressure Drop Inches W.C. and (kPa) ........ 24

Blower Performance - CFM ................................ 25

Field Installed Accessories - Non Electrical .................... 25

Field Installed Accessories - Electrical ........................ 25

SECTION h 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 iniurv.

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 iniurv. It is also used to

alert against unsafe practices and hazards involving only property dam-

age.

_WARNING

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, instafler or service agency.

A CAUTION

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.

66840/035-20003-001 Rev. B (1205)

Summary of content (28 pages)

PAGE 1
HIGH EFFICIENCY CLAM TUBE HEAT EXCHANGER MODELS: SERIES UGAA & UGAB (Single Stage Upflow/Horizontal) Certified Quality Management System 75 - 100 MBH INPUT (21.98 - 29.31 KW) INPUT Q TABLE SAFETY ................................................ DUCTWORK ............................................ FILTERS ............................................... GAS PIPING ............................................ ELECTRICAL POWER ...................................
PAGE 2
66840/035-20003-001 Rev.B(1205) SPECIFIC SAFETY RULES AND PRECAUTIONS 1. Only Natural gas or Propane (LP) gas are approved for use with this furnace. Refer to the furnace rating plate or Section IV d these instructions. 2. Install this furnace only in a location and position as specified SECTION I of these instructions. 3. A gas-fired furnace for installation in a residential garage must be installed as specified in SECTION I of these instructions. 4.
PAGE 3
66840/035-20003-001 Rev.B(1205) SAFETY • • • • • • • • • • REQUIREMENTS Refer to the unit rating plate for the furnace model number, and then see the dimensions page of this instruction for return air plenum dimensions in Figure 1. The plenum must be installed according to the instructions. Provide clearances from combustible materials as listed under Clearances to Combustibles. Provide clearances for servicing ensuring allowed for both the burners and blower.
PAGE 4
66840/035-20003-001 Rev.B(1205) Improper installation in an ambient below 32°t: (0.0 ° C) could create a hazard, resulting in damage, injury or death. 3. If this furnace is installed in an unconditioned space and an extended power failure occurs, there will be potential damage to the internal components. Following a power failure situation, do not operate the unit until inspection and repairs are performed. Clearances for access: Ample clearances should be provided to permit easy access to the unit.
PAGE 5
66840/035-20003-001 Rev. B (1205) Example: Thefurnace input is80,000 BTUH, 1,200 CFM. Therecom- TABLE 3: External Static Pressure Range mended ductareais280sq.in, there aretwo8x14rectangular ducts Ext. Static Pressure attached totheplenum andthere aretwo7inch round ducts attached to Nominal Input Output thefurnace. Air Flow Minimum Maximum 1. Take 8x14,which equals 112 sq.in. X2,which equals 224square MBH kW MBH kW CFM cmm In.W.C kPa In.W.C kPa inch thengotoround ductsizelocated inTable 2. 75 22.0 60 17.
PAGE 6
6840/035-20003-001 Rev.B(1205) 29-3/4 ,7 cm) (75,6 cm_. 31-1/2 (80.0 cm) 13-15/16 (85A cm) (58A cm) FIGURE 1: Dimensions TABLE 4: Cabinet and Duct Dimensions BTUH (kW) Input/Output CFM (m3/min) Cabinet Size /b/6U (22.0/1/.6) /bt6U (22.0/1/.6) 1200 (33.98) !600 (46.31) B C A(in.) 1 / 1/2 21 A(cm) 44.b 53.3 Cabinet Dimension B(in.)* B(cm)* 16 1/2 20 100/80 (29.3/23A) 1600 (45.31) C 21 53.
PAGE 7
66840/035-20003-001 Rev. B (1205) coil, a removable access panel is recommended in the outlet duct such that smoke or reflected light would be observable inside the casing to indicate the presence of leaks in the heat exchanger. This access cover shall be attached in such a manner as to prevent leaks. Mobile Home and Modular Plenum Connections Home Upflow/Horizontal Return The return air duct and the return air plenum is required by the furnace manufacturer.
PAGE 8
66840/035-20003-001 Rev.B(1205) When a furnace is installed in an attic or other insulated space, keep all insulating materials at least 12 inches (30.5 Cm) away from furnace and burner combustion air openings. SUSPENDED FURNACE / CRAWL SPACE INSTALLATION The furnace can be hung from floor joists or installed on suitable blocks or pad. Blocks or pad installations shall provide adequate height to ensure the unit will not be subject to water suspended from rafters or floor joists using straps.
PAGE 9
66840/035-20003-001 Rev.B(1205) SECTION IV: GAS PIPING GAS SAFETY GAS SHUT-OFF VALVE kDANGER _ GAS PIPE PRESSURE GAS VENT -BLOWER This furnace is designed to operate on NATURAL GAS or PROPANE GAS ONLX Do not burn any other fuel in this furnace. Buming any fuel except NATURAL GAS or PROPANE GAS can cause premature heat exchanger burnout, high levels of carbon monoxide, excessive sooting, a fire hazard, personal injury, property damage and/or death.
PAGE 10
66840/035-20003-001 Rev.B(1205) GAS ORIFICE CONVERSION FOR PROPANE (LP) 1. Shut off gas supply at valve upstream from furnace or at meter as required. Refer to Figures 9 and 10. 2. Disconnect 3. Disconnect electrical wires from gas valve, nothing are connected to which terminals. 4. Remove the four screws that attach the gas manifold to the burner support box. See Figure 11. 5. Remove and discard natural gas orifices. 6. Remove LP (Propane) orifices from the bag attached to the gas valve.
PAGE 11
66840/035-20003-001 Rev.B(1205) AkDANGER PROPANE AND HIGH ALTITUDE CONVERSION TABLE 7: High Altitude Conversion KITS It is very important to choose the correct kit and/or gas orifices for the altitude and the type of gas for which the furnace is being installed. Only use natural gas in furnaces designed for natural gas. Only use propane (LP) gas for furnaces that have been properly converted to use propane (LP) gas. Do not use this furnace with butane gas.
PAGE 12
66840/035-20003-001 Rev.B(1205) ELECTRONIC Room Thermostat Furnace Control Condensing Unit Controls _, ...................... ToAir _. Conditioner ...................... Common provide tion. Furnace Control Connections Condensing Unit ...... .......ConO,ti !!!!!!!!!!!!!!!!!!! FIGURE 14: Two-Stage Cooling and Single Stage Heating Thermostat Connections IMPORTANT: Set the heat anticipator in the room thermostat to 0.45 amps. Setting it lower will cause short cycles.
PAGE 13
66840/035-20003-001 TWINNING DUCT SYSTEM TWINNING Twinned furnaces must only be applied on a common duct system. A single air supply plenum must be used for both furnaces and coil(s). Separate plenums and supply ducts systems cannot be utilized. A single return air plenum, common to both furnaces must be used. It is suggested that a return platform be utilized, with bottom air entrance into each furnace.
PAGE 14
66840/035-20003-001 Rev.B(1205) STAGING In applications where more heating capacity or more airflow capacity is needed than what one furnace can deliver, twinning can be used to make two furnaces operate in tandem, using one duct system and one room thermostat. This control can also be used along with a two-stage wall thermostat to stage two twinned furnaces, making them operate like a single two-stage furnace.
PAGE 15
66840/035-20003-001 CATEGORY 1 - 450 F. MAX. VENT TEMR CH IMNEY OR GAS VENT The venting system must be installed in accordance with Section 5.3, Air for Combustion and Ventilation, of the National Fuel Gas Code Z223.1/NFPA 54 (latest edition), or Sections 7.2, 7.3 or 7.4 of CSA B149.1, National Gas and Propane Codes (latest edition) or applicable provisions of the local building code and these instructions.
PAGE 16
66840/035-20003-001 Rev.B(1205) FAN ASSISTED FURNACE FAN ASSISTED CHIMNEY OR GAS VENT L f_ OPENING FIGURE 23: Typical Sidewall Vent Appiication VENT OPENING VENT PIPE \ FLUE FIGURE 25: Typical Chimney Connections BURNER ACCESS PANEL WALL FIGURE 24: Typical Sidewall Vent and Termination VENT PIPING Configuration ASSEMBLY The final assembly procedure for the vent piping is as follows: 1. Cut piping to the proper length beginning at the furnace. 2. Deburr the piping inside and outside. 3.
PAGE 17
66840/035-20003-001 VENT Rev. B (1205) CLEARANCES [] VENT TERMINAL (_) AIR SUPPLY [] AREA WHERE TERMINAL IS NOT PERMITTED FIXED CLOSED OPERABLE FIGURE 27: Home Layout Canadian Installations I A. Clearance above grade, veranda, porch, deck, or balcony 6 inches (15 cm) for applications, B. Clearance to window C.
PAGE 18
66840/035-20003-001 Rev.B(1205) HORIZONTAL VENT APPLICATIONS AND An unconfined TERMINATION When selecting the location for a horizontal combustion air / vent termination, the following should be considered: 1. Observe all clearances listed in vent clearances in these instructions. 2. Termination should be positioned where flue products will not damage plants or shrubs or air conditioning equipment. 3.
PAGE 19
66840/035-20003-001 Rev.B(1205) GAS VENT GAS GABLE VENT OPTIONAL SUPPLY OPENINGS AND DUCTS 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 jurisdiction• The opening shah be located within 12" (30.5 cm) horizontally from, the burner level of the appliance.
PAGE 20
66840/035-20003-001 Rev.B(1205) AWARNING CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death. The following steps shaft be followed for each appliance connected to the venting system being placed into operation, while all other appliances connected to the venting system are not in operation: 1.
PAGE 21
66840/035-20003-001 Rev.B(1205) TOOLS AND REQUIRED FURNACE 1. INFORMATION IN ORDER STARTUP TO THAT WILL PROPERLY BE PERFORM _WARNING THE PROCEDURE. FIRE OR EXPLOSION Call the local gas supplier to obtain heating value of the natural gas. If you cannot obtain the heating valve of the gas from the gas supplier, you may use a default value of 1030 BTU/SCF (38.8 MJ / m3) for natural gas. 2. You will need a thermometer or portable digital thermometer read the supply and return air temperatures.
PAGE 22
66840/035-20003-001 Rev.B(1205) 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, times 2 cubic ft. of gas measured at the gas meter, times a barometric pressure and temperature correction factor of 0.960; times 3600, then divided by the time (in seconds) it took to measure 2 cubic ft. of gas from the gas meter.
PAGE 23
66840/035-20003-001 IMPORTANT: If gas valve regulator is turned in (clockwise), manifold pressure is increased. If screw is turned out (counterclockwise), manifold pressure will decrease. [A CAUTION] Be sure to relight any gas appliances start of this input check. that were turned off at the 8. After the manifold pressure has been adjusted, re-calculate the furnace input to make sure you have not exceeded the specified input on the rating plate. Refer to "CALCULATING THE FURNACE INPUT (NATURAL GAS)".
PAGE 24
66840/035-20003-001 Rev.B(1205) Thetemperature rise,ortemperature difference between thereturn air andtheheated supply airfromthefurnace, mustbewithin therange shown onthefurnace rating plate andwithin theapplication limitations asshown inTable 8. Afterabout 15minutes ofoperation, determine thefurnace temperature rise.Take readings ofboth thereturn airandtheheated airintheducts, about sixfeet(1.83 m)fromthefurnace where theywillnotbeaffected byradiant heat.
PAGE 25
66840/035-20003-001 Rev.B(1205) TABLE 17: Blower Performance - CFM UPFLOW, SINGLE SIDE RETURN (WITHOUT EXTERNAL BTU/H (kW) Input/Output FILTER) STATIC PRESSURE, INCHES WC (kPa) Cabinet Size Speed Tap High 1535 43.5 1470 41.6 1408 399 1343 38.0 1275 36.1 1202 34.0 1115 31.6 1014 28.7 B Medium Low 1215 875 34.4 24.8 1199 874 34.0 24.7 1182 864 33.5 24.5 1151 847 32.6 24.0 1106 827 31.3 23.4 1039 799 29.4 22.6 976 736 27.6 20.8 887 658 25.1 18.6 High 1792 50.
PAGE 26
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PAGE 27
66840/035-20003-001 Rev.
PAGE 28
NOTES 66840/035-20003-001 Rev. B (1205) Supersedes: 035-20003-001 Rev. A (0704) Subject to change without notice. Printed in U.S.A. Copyright st by York International Corp. 2005. All rights reserved.