035-19624-001 Rev. A (0104)
EFFICIENCY
RATING
CERTIFIED
This product was manufactured
in a plant whose quality system
is certified/registered as being
in conformity with ISO 9001.
HIGH EFFICIENCY
TUBULAR HEAT EXCHANGER SERIES
MODELS: P*XU-”V” / G9V-UP
Two Stage Variable Speed (Upflow)
60 - 120 MBH INPUT
(17.58 - 35.17 KW) INPUT
INSTALLATION MANUAL
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
COMBUSTION AIR AND VENT SYSTEM . . . . . . . . . . . . . . . . . . . . . 9
CONDENSATE DRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . .17
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
LIST OF FIGURES
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Furnace Base Rectangular Perforated Panel . . . . . . . . . . . . . . . . . . . 5
Furnace Filter Slot Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Filter Retainer Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Side Return Cutout Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Line Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Field Wiring for Single Stage Thermostat . . . . . . . . . . . . . . . . . . . . . . 9
Field Wiring for Two Stage Thermostat . . . . . . . . . . . . . . . . . . . . . . . . 9
Accessory Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Home Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Horizontal Vent Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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
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 Tubing Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
White Rodgers Intergrated Control . . . . . . . . . . . . . . . . . . . . . . . . . . .22
CFM / Timer Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Replacement PSC Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Air Flow Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Filter Performance - Pressure Drop Inches W.C. and (kPa) . . . . . . . .24
