Hamilton PUR, Installation Instruction

Page 1: ...ND ADJUSTMENTS 26 FURNACE ACCESSORIES 30 OPERATION AND MAINTENANCE 33 TROUBLESHOOTING 36 INSTALLATION INSTRUCTION CAUTION READ ALL SAFETY GUIDES BEFORE YOU START TO INSTALL YOUR FURNACE SAVE THIS MANU...

Page 2: ...ws or bolts which may have loos ened in transit There are no shipping or spacer brackets which need to be removed NOTES CAUTIONS WARNINGS The installer should pay particular attention to the words NOT...

Page 3: ...the National Fuel Gas Code ANSI Z223 1 or CAN CGA B149 1 or 2 Installation Code latest editions local plumbing or waste water codes and other applicable codes Downflow horizontal models when installed...

Page 4: ...mount of air intake vent piping and elbows will be required 2 As centralized with the air distribution as possible 3 Where adequate combustion air will be available partic ularly when installing as 1...

Page 5: ...OUTLET AIR TEMP F BLOWER TOTAL UNIT AMPS MAX OVER CURRENT PROTECT MIN WIRE SIZE AWG 75 FT ONE WAY INPUT MBH OUTPUT MBH NOM CFM HP AMPS SIZE IN 40 37 1000 14 1 2 92 4 35 65 165 1 3 6 2 10 x 6 9 0 20 1...

Page 6: ...200 B 80 75 1600 C 100 95 2000 C 120 112 2000 D Table 2 RATINGS PHYSICAL ELECTRICAL DATA DOWNFLOW HORIZONTAL MODELS MODELS P DH FG9 DH G9T DH CABINET WIDTH AFUE AIR TEMP RISE F MAX OUTLET AIR TEMP F B...

Page 7: ...g cooling coil is used it may be placed directly on the furnace outlet and sealed to prevent leakage Follow the coil instructions for installing the supply plenum On all installations without a coil a...

Page 8: ...overs the cabinet air opening and secure the filter in place at the front of the cabinet by fastening the closed looped end of the retainer wire under the flanged edge of the cabinet When properly ins...

Page 9: ...tion of the coil installation NOTE Duct pliers or other suitable tool can be used to bend perforations To help bend flanges in a straight line scribe a line between the perforations prior to bending H...

Page 10: ...furnace accessories on Page 31 for external filter kit options ATTIC INSTALLATION FIGURE 6 downflow filters FIGURE 7 Combustible Floor Base Accessory NOTE FILTER ACCESS THRU DUCT WORK MUST BE PROVIDED...

Page 11: ...National Fuel Gas Code ANSI Z223 1 latest edition or the CAN CGA B149 1 or 2 Installation Codes latest edition and all applicable local and utility requirements Some utility companies or local codes r...

Page 12: ...power supply and a proper ground connection Refer to the FURNACE CONTROL DIAGNOSTICS on page 36 for symptoms of reversed power supply polarity Connect the power supply as shown on the unit wiring labe...

Page 13: ...is sized for the furnace com ponents only and should not be connected to power auxiliary devices such as humidifiers air cleaners etc The trans former may provide power for an air conditioning unit c...

Page 14: ...vent system using combustion air from the area surrounding the furnace 3 Two pipe intake vent system using combustion air from a ventilated attic space and a vent pipe to the outside Be sure to follow...

Page 15: ...nt termination section These parts are shown shaded For downflow horizontal models the two additional elbows required for the air intake pipe entry into the burner box are also accounted for and shoul...

Page 16: ...cal fresh air intake 1 ft From any door window or non mechanical fresh air or combustion air intake 1 ft Above grade and anticipated snow depth 1 ft Above grade when adjacent to public walkway 7 ft Fr...

Page 17: ...MINIMUM VENT MAINTAIN 12 CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS GREATER 12 SEPARATION BETWEEN BOTTOM OF COMBUSTION AIR AND BOTTOM OF VENT COMBUSTION AIR 90 OVERHANG 12 M...

Page 18: ...his type installation will use combustion air from within the space surrounding the furnace This may be from within the space in a non confined location or it may be brought into the furnace area from...

Page 19: ...where the equipment has clearances of at least 1 inch from the sides and back and 6 inches from the front of the appli ance The opening shall communicate through a vertical or horizontal duct to the o...

Page 20: ...tional Standards Institute ANSI standards and Amer ican Society for Testing and Materials ASTM standards D1785 Schedule 40 PVC D2665 PVC DWV F891 PVC DWV Cellular Core D2241 SDR 21 and SDR 26 PVC D226...

Page 21: ...g NOTE Consideration must be given for degradation of build ing materials by flue gases NOTE Shaded components of the vent system shown in Fig ures 27 through 29 are considered to be part of the termi...

Page 22: ...ires two properly sized pipes One brings combustion air from a properly ventilated attic space and a second pipe from the furnace vent connection top right of unit exits to the outdoors COMBUSTION AIR...

Page 23: ...of excess condensate in the inducer motor during operational cycles refer to Figures 31 or 32 To install the vent drain complete the following steps 1 Place a tee of the proper diameter for the vent s...

Page 24: ...rap must be field supplied using 5 8 I D hose material Refer to Figure 35 and Table 8 for hose placement and sizing Drain Connection The following steps apply to all models For horizontal application...

Page 25: ...bustion air vent piping system These switches de energize the ignition control module and the gas valve if any of the following condi tions are present Refer to Figure 36 for tubing connections 1 Bloc...

Page 26: ...n the field and in the fac tory should be checked for proper tightness IGNITION SYSTEM SEQUENCE 1 Turn the gas supply ON at external valve and main gas valve 2 Set the thermostat above room temperatur...

Page 27: ...ing Using this information locate 26 seconds in the first column of Read across to the column headed 1 Cubic Foot where you will see that 138 cubic feet of gas per hour are consumed by the furnace at...

Page 28: ...st be removed entirely to gain access to the adjustment screw Loosening or tightening the cap does not adjust the flow of gas 3 Refer to Figure 37 on page 27 for location of pressure regulator adjustm...

Page 29: ...SE NOT USED U TUBE MANOMETER 3 5 IN WATER COLUMN GAS PRESSURE SHOWN BURNER BOX WITH COVER REMOVED 6 5 4 3 2 1 0 1 2 3 4 5 6 WITH BURNER BOX COVER IN PLACE WITH BURNER BOX COVER REMOVED FIGURE 39 downf...

Page 30: ...an off setting must be long enough to adequately cool the furnace but not so long that cold air is blown into the heated space The fan off timing may be adjusted by positioning the jumper located on t...

Page 31: ...2285 2205 2145 2080 1995 1905 1820 1715 1610 MED 1950 1915 1870 1830 1780 1710 1640 1560 1475 1375 LOW 1575 1555 1540 1505 1470 1430 1380 1315 1245 1150 120 112 2000 D HIGH 2375 2315 2245 2175 2100 20...

Page 32: ...30 LOW 930 915 895 880 860 835 810 770 695 620 80 75 1600 C HIGH 2030 1980 1925 1870 1830 1755 1675 1600 1515 1435 MED 1505 1490 1475 1460 1440 1420 1380 1340 1280 1215 LOW 1295 1285 1260 1240 1215 11...

Page 33: ...NCE OF OPERATION The following describes the sequence of operation of the fur nace Refer to the schematic wiring diagrams in the back of this manual for component location CONTINUOUS BLOWER On cooling...

Page 34: ...hecked periodically for dirt accumulation Dirty filters greatly restrict the flow of air and may cause dam age to the system Clean the filters at least every three months On new con struction check th...

Page 35: ...rizontal models only remove four top panel screws and lift the top panel enough to disengage and remove the flue chase assembly 4 Remove blower assembly mounting screws and slide the blower assembly o...

Page 36: ...secondary heat exchanger 3 With a stiff wire brush brush out loose scale or soot 4 Vacuum the secondary heat exchanger 5 Finish the cleaning procedure by following steps 10 thru 12 under Cleaning the...

Page 37: ...heat before locking out This may be caused by low gas pressure faulty gas valve faulty hot surface ignitor or burner problem 8 FLASH This fault is indicated if the flame is lost 5 times 4 recycles du...

Page 38: ...AM POWER SUPPLY 115 1 60 SEE NOTE 1 GND DS C NO LS1 C 1LP COM 120V 24V SEC PRI 1T 40VA Y W R G C VENTOR MOTOR IGN R HEAT COOL THERMOSTAT G ON AUTO Y COOL HEAT OFF W NOTES LEGEND ROS1 ROLL OUT SWITCH L...

Page 39: ...035 17477 002 Rev D 1202 Unitary Products Group 39 WIRING DIAGRAM DOWNFLOW HORIZONTAL MODELS P DH FG9 DH G9T DH NOTE THE FURNACE S CONTROL SYSTEM REQUIRES CORRECT POLARITY OF THE POWER SUPPLY...

Page 40: ...ange without notice Printed in U S A 035 17477 002 Rev D 1202 Copyright by York International Corp 2002 All rights reserved Supersedes 035 17477 002 Rev C 1002 Unitary 5005 Norman Product York OK Grou...

Page 41: ...t have been wet or the furnace if deemed necessary FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury death or prop erty damage Do not store or use gasol...

Page 42: ...Examine the furnace casing making sure the physical support is sound without sagging cracks or gaps Examine the furnace base making sure it is physically sound without cracks gaps or sagging and has...

Page 43: ...e any part of the control system and any gas control which has been under water Operating Instructions 1 STOP Read the safety information above 2 Set the thermostat to the lowest setting 3 Turn off al...

Page 44: ...e you install the right size filter for your furnace Dirty filters greatly restrict the flow of air and may cause damage to the moving parts of the furnace If the filters become clogged the heat excha...

Page 45: ...n HEAT and the fan is set on AUTO and there is a call for heat a circuit is completed between terminals R and W of the thermostat When the proper amount of combustion air is being provided the pressur...

Page 46: ...emove burners from the burner assembly 7 Remove the upper cover plate at the top of the furnace Remove the internal baffle 8 The upper portion of the heat exchanger is now exposed 9 With a long flexib...

Page 47: ...s during the heating cycle This could be caused by low gas pres sure or faulty gas valve 9 FLASHES Indicates reversed line voltage polarity Both heating and cooling operations will be affected Check p...

Page 48: ...ARTS LIST C G R W Y HUM EAC XFMR LINE CIR HUM EAC XFMR LINE PARK PARK HEAT COOL 17 18 23 24 30 25 31 32 33 48 20 21 22 26 44 27 28 29 34 36 37 47 52 63 50 51 49 56 59 62 58 60 43 45 38 1 4 2 6 10 11 1...

Page 49: ...HANGER 32 PANEL FRONT Blower 33 PANEL FRONT Burner 34 PANEL TOP 35 SUPPORT BURNER 36 WRAPPER CABINET 37 PANEL VESTIBULE Lower 38 PLUG WINDOW CLEAR 875 MISCELLANEOUS 39 CLIP FILTER RETAINER 2Req d P3U...

Page 50: ...n ALL P3U MODELS 2TH13700424 THERMOSTAT One stage heat Deluxe 24V with heat only sub base does not include fan switch NOTE For one stage cool or one stage heat cool must be used with sub base 2TB17700...

Page 51: ...035 19592 001 Rev C 0204 Unitary Products Group 11 SECTION IV WIRING DIAGRAM FIGURE 9 Wiring Diagram...

Page 52: ...pplies only to products installed in the United States and Canada EXCLUSIONS This warranty does not cover any 1 Shipping labor or material charges 2 Damages resulting from transportation installation...

Page 53: ...n wet or the furnace if deemed necessary FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury death or property damage Do not store or use gasoline or othe...

Page 54: ...ce containing the furnace 4 Examine the furnace casing making sure the physical support is sound without sagging cracks or gaps Examine the furnace base making sure it is physically sound without crac...

Page 55: ...ting 3 Turn off all electric power to the appliance 4 Remove burner access panel 5 Move gas control switch to the OFF position Do not force 6 Wait five 5 minutes to clear out any gas If you then smell...

Page 56: ...How to Clean your Filter High velocity filters may be cleaned with a vacuum cleaner or washed with a garden hose Be sure to shake off excess water and allow filter to completely dry before re installi...

Page 57: ...sensor begins its sensing function The blower motor will energize 30 seconds after the gas valve opens if a flame is detected Normal furnace operation will continue until the thermostat circuit betwee...

Page 58: ...ing a stiff wire brush remove the loose scale or soot from each tube 4 Vacuum the secondary heat exchanger 5 Finish the cleaning procedure by following Steps 5 thru 7 under cleaning the Heat Exchanger...

Page 59: ...gas pressure faulty gas valve faulty hot surface ignitor or burner problem may cause this 8 FLASHES This fault is indicated if the flame is lost 5 times 4 recy cles during the heating cycle This could...

Page 60: ...Unitary Products Group SECTION III REPLACEMENT PARTS LIST 15 16 1 17 3 7A 13 10 11 14 5 8 12 9 2 7 6 6 24 27 26 35 38 34 32 33 25 36 22 37 21 20 28 29 23 31 30 18 19 51 63 43 53 59 57 58 55 39 41 52...

Page 61: ...OP 35 SUPPORT BURNER 36 WRAPPER CABINET Insulated P3D WRAPPER CABINET G9T FG9 37 PANEL VESTIBULE Lower 38 PLUG WINDOW CLEAR 875 MISCELLANEOUS 39 COLLAR AIR INTAKE Burner Box 40 FILTER AIR 2 Req d P3D...

Page 62: ...TS 1CB0324 24 1 2 CABINETS 1BR0314 EXTERNAL FILTER RACK WITH HIGH VELOCITY FILTER FOR HORIZONTAL APPLICATION 14 1 2 CABINETS 1BR0317 17 1 2 CABINETS 1BR0321 21 CABINETS 1BR0324 24 1 2 CABINETS 1NK0301...

Page 63: ...035 19600 001 Rev B 0204 Unitary Products Group 11 SECTION IV WIRING DIAGRAM FIGURE 9 Wiring Diagram...

Page 64: ...warranty does not cover any 1 Shipping labor or material charges 2 Damages resulting from transportation installation or servicing 3 Damages resulting from accident abuse fire flood alteration or act...